TECHNICAL SPECIFICATIONS

OF
11 KV 630 SQ. MM SINGLE CORE XLPE CABLE

DNHDDPCL

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 TECHNICAL SPECIFICATION FOR 11 KV XLPE 630 SQMM SINGLE CORE CABLES

1. SCOPE:

The specification covers the design, testing, supply and delivery in proper packed condition
of different grade of 1 or 3 core, Aluminium Conductor, Cross-linked polyethylene (XLPE)
insulated, FRLS, PVC sheathed, armoured, screened Power Cables.

2. LOCATION:
2.1. The cables may be laid buried directly in ground at a depth of one meter in average,
anywhere in DNHDD and terminate for outdoor connection to a power transformer or to
overhead lines and also indoor connection for indoor switchgear
2.2. The cables may also be laid within covered cable trenches, in cable racks or open-air ladder
trays etc. for certain portion of lengths.

3. SYSTEM DETAILS:

a. Line Voltage (kV) 11kV

b. Highest System Voltage (kV) 12kV

c. Number of Circuits 1

d. Frequency 50Hz

e. Neutral Effectively earthed

f. Short circuit level (KA) 22.77kA, 31.8kA

4. STARDARDS:

4.1. The cable shall conform to the following standards to the extent of DNHDDPCL
requirement is fulfilled.

a. IS 7098 Part 2 : 1985 XLPE insulated PVC sheathed cables For working voltages
from 3.3 kV up to and including 33 kV.
b. IS 5831 : 1984 PVC Insulation and Sheath of electric Cables.
c. IS 8130:1984 Conductors for insulated electric cables and flexible cords.
d. IS 613:1984 Copper rods and bars for electrical purposes.
e. IS 3975:1988 Mild steel wires, formed and tapes for armouring of cable. IS
10810:1984 Method of tests for cables.
f. IS:10810 – 1984, Methods for test for cables
g. IEEE-383:1974 Standard for type test of class IE electric cables, field splices,
and connections for nuclear power generating stations.
h. ASTM-D2843,1993 Standard test method for density of smoke from burning or
decomposition of plastics.
i. ASTM-D2863, 1991 Standard test method for measuring minimum oxygen
concentration to support candle - like combustion of plastics (oxygen index).
j. NEMA-WC5,1992 Thermoplastic Insulated Wire and cable for the transmission
and distribution of Electrical Energy.
k. IEC:754 (Part-1):1994 Test on gases evolved during combustion of electric
cables - Determination of the amount of halogen acid gas evolved during
combustion of polymeric materials taken from cables.

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 l. IEC:332 (Part I):1993 Test on electric cables under fire conditions. Test on a
single vertical insulated wire or cable.
m. IS 3961(Part II):1967 Recommended current rating for cables PVC insulated
and PVC sheathed heavy duty cables.
n. IS 10418:1982 Drums for electric cables.
4.2 The cable, joints, outdoor and indoor termination and their accessories and fittings may
conform to other Indian and/or equivalent standards or important publications to improve
upon their performance, but shall not fall short of the requirement of this specification. The
tenderer shall clearly indicate such standards in their offers.

5.0 ELECTRICAL CHARACTERISTICS & PERFORMANCE:

5.1 General Requirements:

All cables shall be suitable for high ambient, high humid tropical climatic conditions.
Cables shall be designed to withstand the mechanical, electrical and thermal stresses
under the unforeseen steady state and transient conditions and shall be suitable for
proposed method of installation.
Conductor shall be of uniform, of good quality, free from defects Aluminium / copper.
Insulation shall be Cross Linked Polyethylene (XLPE).
For 11 kV cables, conductor screen and insulation screen shall both be extruded, semi-
conducting compound and shall be applied along-with XLPE insulation in a single
operation by triple extrusion process. Method of curing for 11 kV cables it shall be "Dry
curing/ gas curing / Steam curing".
Extruded Semi-conducting screening and metallic screening of copper tape shall be
generally as per IS 7098 (Part-II) with latest amendments. The semi conducting
compound shall be suitable for the operating temperature of the cable and compatible
with the insulating material.
The insulation screen shall be an extruded layer of black semi-conducting compound
and continuously covers the whole area of insulation. The semi-conducting screens
should be effectively cross linked to achieve 90 ᵒ C cable rating. The contact surface
between insulation and insulation screen shall be smooth and free from protrusion
and irregularities.
The interface between insulation and insulation screen shall be free of any voids.
Insulation screen shall be strippable type.
The metallic screen shall consist of a layer of copper cable applied in helical form.

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 5.2 SPECIFIC TECHNICAL REQUIREMENTS

Technical parameters of the cable shall be as follows:

Sl
Particulars Unit 11 KV
No
1 Rated voltage KV 6.35/11
2 Type of insulation - XLPE
3 Single/ three Core - Both Single & three
4 Armoured / Unarmoured - Armoured
Material to IS: 8130,
H4 Grade Aluminium
5 Material of Conductor
Conductor, Stranded
compacted Circular
6 System - 11 KV Earthed
7 Highest System Voltage KV 12
8 Material - Stranded Aluminium
9 Voltage Grade KV 6.35/11 KV
10 Conductor Size Sq. mm 3x240, 1x630
11 Shape of Conductor Circular
30 [for 3x240sq mm
Minimum no. of wires in ],
12 mm
the conductor
53 [1x630 sq mm],
3.15 mm [for 3x240sq
Nominal dimension of Al. mm ],
13 mm
round wire & 2.0 mm [1x630 sq
mm],
Nominal thickness of
14 mm 3.6 mm
XLPE insulation sheath
76.00 mm [ for
Approx overall cable 3x240sq mm],
15 mm
diameter 43.00 mm [ for
1x630 sq mm],
16 Current rating
315 A (3x240sqmm),
A In ground at 300C A
560 A (1x630 sq
mm)
395 A (3x240sqmm),
B In air at 400C A
840 A (1x630 sq
mm)
17 Max. Conductor Temp oC 90 oC at max.
Continuous current
Short Ckt.Current for 1 22.6KA-for240 sq
18 KA
second duration mm,

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 59.4 KA – for 630 sq
mm.
Power Frequency
19 KV rms 28
Withstand Voltage
Lightning Impulse
20 KV rms 75
Withstand Voltage
0.125 for
Max. DC resistance of 3Cx240sqmm
21 ohm/km
conductor at 20 Deg. C 0.046 for
1Cx630sqmm
0.160 for
Max. AC resistance of 3Cx240sqmm
22 ohm/km
conductor at 90 Deg. C 0..060 for
1Cx630sqmm
0.085 for
Reactance of cable at
3Cx240sqmm
23 normal frequency ohm/km
0.092 for
(Approx)
1Cx630sqmm
Electrostatic capacitance microfarad 0.41 for 3Cx240sqmm
24
at normal frequency s per km 0.69 for 1Cx630sqmm
Max. Permissible
emergency overload
25 temp. at 25% overload to 130 oC for one hour
100 hrs. per year or 500 oC
hrs. in life of cable
Continuous Withstand
26 oC 90oC
Temperature
Short Circuit withstand
27
Temperature
oC 250oC for one hour
Extruded, cross linked, semi-conducting
compound of 1.0 mm.
28 Conductor Screening :
thickness for 33 KV and 0.5 mm. thickness for
11 KV
XLPE of thickness, 3.6
29 Insulation :
mm (Nominal)

Annealed copper 0.06

mm (minimum) thick
tape lapping as
metallic part. For 1
A Insulation Screening : core cable, the non-
magnetic metal
Armour will act as
metallic part
insulation screening.

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 Black extruded PVC, Type ST-2 compound for 33
KV and wrapped PVC tape for 11 KV as per ISS.
For 1 core there will be no inner sheath. Min.
30 Inner Sheathing : Thickness for 11kV 3Cx240sqmm shall be
0.70mm and for 11kV 1Cx630sqmm shall be
0.50mm and for 33kV 1Cx630A shall be
0.60mm
Galvanized steel
strips/wire for 11
KV (3 core) as per IS.
31 Armouring : For 1 core, there shall
be round wire
armour made of non-
magnetic metal.
Coloured PVC, type ST-2 compound to IS: 5831,
extruded for both Min. Thickness for 11kV
32 Overall Sheathing : 3Cx240sqmm shall be 2.68mm and for 11kV
1Cx630sqmm shall be 1.88mm

250 metres with a tolerance of ± 5% (for 3

Approx. length of cable in core), 500 metres ± 5% (for 1 core)
33 :
a Drum Note: There shall be no negative tolerance in
the overall itemwise P.O quantity.

34 End Sealing : Heat Shrinkable Caps.

Max. ‘Tan-delta’ at room
A temp. At nominal phase : 0.004
to neutral voltage (Uo):
Max. Increment of ‘tan-
B delta’ between 0.5 Uo to 2 : 0.002
Uo at room temp:
35 Partial discharge value : 20 Pc (Maxm.) at 1.6 Uo.
H.V. Tests between
35kV (rms) as per IS
36 Conductors & :
7098-2
Screen/Armour
37 Oxygen Index : Min 29 (as per ASTMD 2863)
38 Acid Gas Generation : Max 20% ( as per IEC 754-1)
Smoke Density
39 : 60% (As per ASTMD 2843)
Generation
40 Flammability Test : As per Swedish Chimney test

* NB the above parameters are applicable for three core and single core cable, if not
otherwise specified.

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 CABLE CONSTRUCTION:

4.0 XLPE underground cable is to be manufactured in continuous catenaries process at

controlled elevated temperature and pressure in inert atmosphere with use of suitable
materials for XLPE semi-conducting, insulation and XLPE screen. The inner and outer semi-
conducting sheaths and main polyethylene insulation between the sheaths are to be
simultaneously extruded during the Triple Extrusion Process of manufacturing and main
insulation of the Cable is to be extruded unified. The XLPE Cables in this specification does
not have any metal sheath and the short circuit rating of the cable will depend on the
conductivity and continuity of the strands of the armour wires, which shall be ensured by
guarding against corrosion.

4.1 CONDUCTOR SCREENING

A semi-conducting cross-linked polyethylene (XLPE) screening shall be extruded over the
conductor to act as an electrical shield which together with elimination of the so called
“Strand Effect” prevents to a great extent air ionization on the surface of the conductor.

4.2 INSULATION:
The main insulation of the Cable shall be extruded unfilled, chemically cross-linked
polyethylene (XLPE) inert gas cured satisfying the requirement of ISS: 7098 (Part- II)

4.3 INSULATION SCREEN:

The insulation screen shall be an extruded layer of black semi-conducting compound and
continuously covers the whole area of insulation. The semi-conducting screens should be
effectively cross linked to achieve 90deg C cable rating. The contact surface between
insulation and insulation screen shall be smooth and free from protrusion and irregularities.
The insulation screen shall be constructed as per clause no. 29 of the specific technical
parameters. The metal screen shall eliminate tangential stress electrostatic field
surrounding the conductor and uniform electrical stress in the insulation.
The semi conducting polyethylene (XLPE) screen shall be extruded over the main poly
ethylene-insulating wall to prevent partial discharge at the surface of the insulation. The
copper tape shall be wrapped over the semi conducting tape or extrusion as mentioned
earlier for 3 core cables. The metal screen so formed around the cores shall be in contact
with one another as the cores are laid up at triangular configuration. For single core cable,
Aluminium wires armouring shall constitute the metallic part of insulation screen.
Conductor screening, insulation and insulation screening shall be extruded in triple
extrusion processes so as to obtain continuously smooth interfaces.

4.4 The mechanical and chemical properties of the materials for semi conducting screens are
much more important than their electrical properties, but for obtaining the high overall
degree of electrical properties of an E.H.V. cable, the inner and outer semi conducting,
sheaths and the main polyethylene insulation between the sheaths shall be simultaneously

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 extruded during the manufacturing, process known as “triple extrusion”. The advantages
are:
i) The partial discharge level at the surface of the insulation is brought to a minimum.
ii) There will be no displacement of the semi conducting screen and insulation during
expansion and contraction due to load cycles and bending.
iii) The semi conducting screens are easily removable during joining and termination
operations.

Note: Manufacturers not having “triple extrusion” process will be disqualified. The Tenderer
shall have to produce necessary process line at the time of bidding.

4.5 LAYING UP:

The phase identification of the cores shall be either by colour or numerals as per I.S.S. for 3
core cables only.
Core Colour Numeral

Red 1

Yellow 2

Blue 3

The screen cores shall be laid up with interstices filled with PVC fillers and taped a binder
tape as to obtain a reasonably circular cable.

4.6 INNER SHEATH:

The cable core shall be supplied with bedding of PVC (Inner sheath) in the form of extruded
PVC sheath for 33 KV cables. Wrapped PVC tapes shall be used for 11KV thickness as per
relevant IS.

4.7 ARMOUR:

The cable shall be wire armoured /steel strip in case of 33KV and wire/strip armoured
for 11 KV, three core cables to insure an adequate return path for the flow of fault
current and also provide suitable mechanical protection. Steel wires/aluminium wire
/ steel strips of required size in requisite number as per clause 31 of special technical
parameters shall be laid closely in the spiral formation to protect the circumference of
the cable fully and to provide adequate cores section area for flow of maximum fault
current within limits of specified temperature rise and duration of fault. Direction of
the lay of the armour shall be opposite to that of the cable cores in case of single core
cable armour shall be of non-metallic material. Armouring shall be as per relevant IS
and it shall have minimum 90% coverage.

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 4.8 OUTER SHEATH:
A reliable surving shall be necessary for maintaining conductivity of the armour particularly
under corrosive condition in the form of jacket. Cable shall be therefore finished with
extruded PVC over sheath of thickness as per clause 32 of special technical parameters.

The quality of PVC over sheath (jacket) shall be ensured for service reliability against
moisture intrusion and shall confirm to type ST-2 of IS : 5831.It shall be of black colour PVC
with Cable size and Voltage grade embossed on it. Sequential marking shall be at every 1
(one ) Meter distance. Word "FRLS" shall also be embossed on it at every 5 (Five ) meter
distance

The sheaths shall be protected against white ants, vermin and termites by suitable, durable
and reliable measures. The suppliers shall suggest suitable materials for use, in the event of
damage to the over sheath to prevent the passage of moisture along the cable.

4.9 FRLS Properties: All cable shall be Flame Retardant, Low Smoke (FRLS) type. Outer sheath
shall have the following properties –
a) Acid Gas Generation – Max 20% ( as per IEC 754-1)
b) Smoke density rating: 60% (As per ASTMD 2843)
c) Flammability test - As per Swedish chimney test F3 as per SEN 4241475
d) As per IEC 332 part-3 (Category B)
e) Minimum bending radius shall be 10 D
f) Repaired cables shall not be acceptable.

4.10 Current Rating of Cables:

a) Normal current rating shall not be less than as specified in clause 16 of the
Specific Technical Requirements and that covered by IS 3961. Vendor shall
submit data in respect of all cables in the prescribed format.
b) Tables given de-rating factors for various conditions of cable installation
including the following, for all types of cables shall be furnished.
- Variation in ambient air temperature. - Variation in ground temperature.
- Depth of laying.
- Cables laid in the ground - Cables laid in trench
- Cables laid in ducts - Soil resistivity.
- Grouping of cables.
c) The value of short circuit withstand current ratings of all cables shall be indicated
in Clause 18 of the special technical requirements for a short circuit for 1 second
duration and should also specify the maximum temperature during short circuit.
d) The following factors shall also be accounted for, while specifying the maximum
short circuit withstand of the cables.
e) Deformation of the insulation, due to thermo-mechanical forces produced by the
short circuit conditions, can reduce the effective thickness of insulation.

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 f) Conductor and core screens can be adversely affected with loss of screening
effect. Likewise the thermal properties of the outer sheath material can be the
limitation.
g) It is essential that the accessories which are used in the cable system with
mechanical and/or soldered connections are suitable for the temperature
adopted for the cables.
h) Formula for calculating short circuit current for different duration or curve
showing short time current v/s time for different sizes of cables shall be
furnished by vendor.

4.11 CABLE IDENTIFICATION:

The following shall be embossed on the outer sheath for the identification.

a) Manufacturer’s Name or Trade Mark.

b) Voltage Grade.
c) Nominal section and material of conductors and number of cores.
d) Year of manufacture.
e) Inscription of length of cables at 1.0 mtr interval.
f) Name of purchaser APDCL;
g) Marking “Power” shall be embossed throughout the length of the cable at 10
mtr spacing.
h) Type of insulation i.e. XLPE

CEILING OF CABLE ENDS:

The cable ends of the cable in the wooden drum for delivery shall be sealed with
heat shrinkable caps.

5. WOODEN DRUMS:

The cable shall be packed in non-returnable wooden drums.

The following information shall be marked on each drum.
a) Drum identification number.
b) Manufacturer’s name, Trade name / Trade mark, if any.
c) Nominal sectional area of the conductor of the cable.
d) Number of cores
e) Type of cable and voltage grade with cable code
f) Length of cable in cable drum
g) Direction of rotation of drum (by means of an arrow)
h) Appox. Weight: bare: gross:
i) Year and country of manufacture
j) Purchase order number
k) Date of delivery
l) Name of the purchaser.
Drum shall be proofed against attack by white ant or termite conforming to IS: 10418.
The Drums may also be marked with ISI certificate mark, as applicable.

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 Safe pulling force:30 N/mm2 (for conductor).

6. Tests to be performed as per IS:7098 (part II)

Tenderer shall have to submit type test report along with the Bid. The Type test reports shall
not be older than five years from the date of submission of Bid. Bidder will be disqualified for
non-submission of type test reports.
a. Type test of all the test mentioned below are to be made as per details given in
IS:10810
a) Test on conductor
i. Tensile test (For aluminium)
ii. Wrapping test for aluminium
iii. Resistance test.
b) Test for armouring wire strips.
c) Test for thickness of insulation and sheath.
d) Physical test for insulation.
i. Tensile strength and elongation at break
ii. Ageing in air oven.
iii. Hot test
iv. Shrinkage test.
v. Water absorption (Gravimetric)
e) Physical tests for outer sheath
i. Tensile strength and elongation at break
ii. Ageing in air oven.
iii. Shrinkage test.
iv. Hot deformation
v. Heat shock
vi. Loss of mass in air oven
vii. Thermal stability
viii. Thermal Stability
f) Partial discharge test
g) Bending test
h) Dielectric power factor test
i. As a function voltage
ii. As a function of temperature
i) Insulation resistance (volume resistivity) test
j) Heating cycle test
k) Impulse with stand test
l) High voltage test
m) Flammability test

b. The following test on screen cable shall be performed successfully on the same test
sample of completed cable, not less than 10 m. in length between the test
accessories.

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 a) PD test
b) Bending test followed by PD test
c) Di-electric power factor as function of voltage
d) Di-electric power factor as a function of temperature
e) Heating cycle test followed by Di-electric power factor as a function of
voltage and PD test.
f) Impulse withstand test and
g) High voltage test as per para 30 of special technical parameters
If a sample fails in test (g) one more sample shall be taken for this test,
preceded by test (b) and (e)

c. Acceptance test : the following shall constitute acceptance test:

a) Tensile test (For aluminium)

b) Wrapping test for aluminium
c) Conductor resistance test
d) Test for thickness of insulation and sheath
e) Hot set test for insulation
f) Tensile strength and elongation at break test for insulation and outer sheath
g) PD test (Screen enables) only on full drum length
h) High voltage test, and
i) Insulation resistance ( volume resistivity) test
J) Spark test on extruded un-insulated outer PVC sheath as per provision
clause no 3.2 IEC standard (Publication no.229 of 1982)

d. Routine test:

The routine test shall be carried out on all cables manufacturer in accordance with
this specification. The following routine test shall be made on cable length as specified
in ISS.

a) Conductor resistance test

b) Partial discharge test on full drum length
c) High voltage test as per clause 29 of special technical parameters

e. Test witness
a) All tests shall be performed in presence of purchaser representatives if
so desired by the purchaser.
b) The contractor shall give at least 15 days advance notice for witnessing
such tests.

7. Test Certificate.
a. Certified copies of all routine test carried out at work shall be furnished in 6
copies for approval of the Purchaser.
b. The cable shall be dispatched from works only after receipt of
Purchaser’s written approval of shop test report.

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 c. Type test certificates of the cable offered shall be furnished and
should not be older than 5(FIVE) years from the date of
submission of bid.

8. Descriptive literatures test results etc.

The following details for the cable shall be submitted with bid

a) Manufacturers catalogue giving cable construction details and characteristics

b) Manufacturing process in details for cables highlighting the steps of control
i. Contamination
ii. Formation of water trees
iii. Effects of by-products of cross linking
iv. Stress control etc.
c) Cross section drawing of the cable
d) Cable current ratings for different types of installation inclusive of
derating factors due to ambient temperature, grouping etc.
e) Over-load characteristics of the cable without endangering the normal
life and electrical quality of the insulation.
f) Complete technical date of the cables.
g) Type test certificate from government testing units/government
authorized testing units with the quality assurance plan submitted by
the firm, the offer shall be liable for rejection.

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 GUARANTEED TECHNICAL PARTICULARS for 11kV ARMOURED SINGLE CORE XLPE CABLES (Al)

Sl. 11kV 1C
Item Particulars Unit
No. 630sqmm

1 Manufacturers Name & Address

2 Country of manufacturer
3 Type of cable
4 Applicable standards for manufacturing
5 Applicable standards for testing
6 Rated voltage kV
7 Maximum service voltage kV
Maximum continuous current carrying capacity per cable
8 when lain in air at an ambient air temperature of 50 deg. A
(single core cables solid bonded)
Maximum continuous current carrying capacity per cable
when laid in ground at a depth of 1.0 m (ground temp. 40
9 deg. C and soil thermal resistivity of150 deg.c/watt/cm A
max. Conductor temp. 90 deg. C) (single core cables solid
bonded)
Maximum continuous current carrying capacity per cable
10 when drawing into duct./pipes (single core cables solid A
bonded)
Maximum continuous current carrying capacity per cable
when laid in covered RCC trenches at an ambient
11 A
temperature of 50 Deg. C laying conditions to be specified
(single core cables solid bonded)
Short circuit withstand capacities for 1 second of (With a
12
conductor temperature of 90 Deg. C at the commencement
i) Conductor KA
ii) Screen KA
iii) Armour KA
13 Conductor
i) Material & Grade
ii) Nominal cross – sectional area sq.mm
iii) No. of strands
iv) Diameter of each strand (Nominal) mm.
v) Max. DC resistance of conductor at 20 Deg. C ohm/km
vi) Max. AC resistance of conductor at 90 Deg. C ohm/km
14 Reactance of cable at normal frequency (Approx) ohm/km
microfarads
15 Electrostatic capacitance at normal frequency
per km

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16 Charging current
17 Loss tangent at normal frequency at Uo
18 Conductor screen
i) Material
ii) Nominal thickness mm
19 XLPE Insulation
i) Composition
ii) Type of curing
iii) Thickness of insulation (nominal) mm
iv) Tolerance on thickness mm
v) Dielectric constant at normal frequency
vi) Specific insulation resistance at 20 deg. C ohm/k
m
vii) Min. Volume resistivity at 20 deg. C
viii) Min. volume resistivity at 90 deg. C
ix) Min. Tensile strength Kg/sq.
cm.
x) Min. Elongation percentage at rapture %
xi) Identification of cores
20 1.2 / 50 microsecond impulse wave withstand kVp
voltage
21 5 min. power frequency withstand voltage kV
22 Max. Dielectric stress at the conductor kV/c
m
23 Max. Dielectric stress at the conductor screen kV/c
m
24 Insulation screen
i) Material
ii) Extruded/wrapped
iii) Nominal thickness mm
iv) Colour
25 Metallic screen
i) Material / composition
ii) Nominal radial thickness / dia
26 Nominal diameter over metallic screen mm
27 Nominal radial clearance allowed under metal sheath mm
28 Type and material of filler
29 Armour
i) Material and type
ii) Diameter

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 Seal and Sign of Bidder

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 GUARANTEED TECHNICAL PARTICULARS FOR INDOOR/OUTDOOR TERMINATION
& STRAIGHT THROUGH JOINT FOR 6.6KV(UE)/11 KV(E) HEAT SHRINKABKE TYPE
Sr. Particulars 11 KV (E)
No.
1. Name of Manufacturer
2. Applicable Standards IS: 13573- Part 2, 2011
3. Rated Voltage of Cable accessories 6.35/11kV
4. AC / DC Voltage Withstand (Dry) 28.5 kV AC for 5 minute
/ DC 25.4 kV for 15 min
5. AC Voltage 25.4 kV AC for 1 minute
Withstand (Wet) (for
Outdoor
termination)
6. Partial Discharge (Temp of conductor at Less than 10 pC at 11 kV @ ambient and at elevated
Ambient and elevated temp) temp
7. Impulse Voltage (Temp of conductor at 10 impulses of each polarity @75
Ambient and elevated temp)
kVp at Ambient and elevated temp

8. Load Cycle test Total cycle = 60 nos. Duration 8hr per cycle

a. Each cycle heating duration 5 hours (maintain 2 hrs min as steady state)

b. Temperature 100° C
c. Cooling Duration 3 hours
d. Continuous Phase to earth Voltage 15.8kV
withstand
9. Humidity Test 300 hours duration withstand at 8 kV AC

10. Salt Fog Test 1000 hours duration withstand at 8 kV AC

11. Thermal Short Circuit test Two shots As per Cable cross section and material of
conductor
12. Dynamic Short circuit test 2.55 times the thermal short circuit current

13. Method of Stress Control Polyolefin, Heat Shrinkable type High Permittivity

14. Tubing’s & Molded parts Tubing’s are Polyolefin, Heat Shrinkable type
Moulded parts are EVA, Heat Shrinkable type

15. Non Tracking material Confirming as per ASTM D-2303

16. Di-electric strength of insulating material 10 kV/mm min

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 TECHNICAL SPECIFICATIONS
OF
66 KV Transmission Line

DNHDDPCL

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 PART -A TECHNICAL CONDITIONS
SECTION -1
GENERAL INFORMATION AND SCOPE OF THE WORK

1. GENERAL

NOTE :
(A) Technical Specifications for Tower materials, Conductors, Tower hardware fittings and
accessories, Insulators, Foundation of towers, Erection, Commissioning and Testing presented
below are for indicative purpose only and shall be used for reference only.

(B) The intended bidders shall submit GTP based on the item description given in BOQ.

(C) The intended bidders shall strictly follow CEA regulations / GETCO Technical Specifications
with latest amendments only.

(D) The intended bidders shall submit GTP of all relevant materials i.e. Tower materials,
Conductors, Tower hardware fittings and accessories, Insulators etc. used in the proposed
work. The format for GTP shall be as per the recent Technical Specifications of GETCO .

Constructing of 66 kV transmission lines using Multi circuit / Double Circuit / Narrow base towers, dismantling
of existing conductor and towers, wherever required, supplying Towers / TACSR conductor / OPGW with all
accessories, polymeric suspension / tension insulator of approved type and capacity, stringing, supply of spares
as per the specifications and other allied works as per the tower schedule and design as approved by DNHDDPCL
and technical support, up to the full satisfaction of DNHDDPCL on Turnkey Contract Basis. Work also includes
design, proto-fabrication & type-testing 66 KV Multi-circuit / Double Circuit towers as per the details in the
specifications.

2. SCOPE OF THE WORK

a. The following works are included in the scope of the Contract on Turnkey Basis: -

Description Line length

Interconnection with LILO of Khadoli-Rakholi 66 kv D/C Line as to 2.5 kM

form 66 KV Khadoli-Chichpada double circuit & 66 KV Khadoli-
Rakholi circuit.

b. The general scope of work will include the following:

i. Detailed survey, Check survey and tower location marking, soil resistivity
measurement & geotechnical investigation, wherever necessary.

ii. Fabrication and supply of all types of 66 kV transmission line towers fully hot dip
galvanized, with all types of tower accessories like phase plate, circuit plate, number
plate, danger plate, anti-climbing device, Bird guard, earth pipe and counterpoise type
earthing as per approved design by DNHDDPCL including fasteners, anti-theft
fasteners, step bolt, hangers, D-shackles etc.

iii. Supply of Polymeric Insulators, Hardware Fittings, Conductor, OPGW and Accessories,

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 iv. De-stringing & dismantling of towers, earthwire / OPGW, Insulators, Hard- ware & Accessories
including dismantling of tower accessories like phase, danger and number plates, bird guards,
anti-climbing devices etc.

v. Clearing grass & felling of trees, as required.

vi. Proto Fabrication, Assembly and Type Testing (non-destructive type) of a 66KV Multi
circuit/D.C towers.

vii. Soil test, wherever found necessary for ascertaining type of foundation including taking
pits/bore holes, collecting soil samples and testing at approved laboratories as per relevant IS
codes

viii. Verification of the foundation schedule and casting of foundation for tower footings as approved
by DNHDDPCL.

ix. Erection of towers, punching of bolts and nuts, tower earthing including counter poise earthing
if required and measurement of earth resistance (should be less than 10 ohm), fixing of insulator
strings, stringing of conductors and OPGW along with all necessary line accessories.

x. Painting of towers in bands of orange and white (above 45-meter height) and supply & erection
of marker balls, obstruction lights (wherever applicable) for aviation requirements (as
required) as per IS 5613.

xi. Erection of name boards, phase indicator, number plates, danger boards etc. as per standards on
all towers.

xii. Erection, Testing and commissioning of Junction Box and FODP for both ends of substations.

xiii. Testing & commissioning of the erected transmission lines, and other items not specifically
mentioned in this Specification but are required for the successful commissioning of the
transmission line, unless specifically excluded in the Specification.

c. Scope for Supply of Towers

i. The supply of required quantities of fabricated & galvanized steel parts as per specifications
required for towers strictly.

ii. Preparation of fabrication drawings for various types of towers required for project, including
narrow base special multi-circuit towers as per the design approved by DNHDDPCL and proto
fabrication.

iii. Supply of the required quantities of fabricated & galvanized steel parts as per specifications
required for towers, concrete, reinforcement steel for foundation and other items as given in
appropriate price schedule. However, the work shall be executed as per approved construction
drawings.

iv. The Unit rates quoted shall include minor details which are obviously and fairly intended, and
which may not have been included in these documents but are essential for the satisfactory
completion of the various works.

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 v. The unit rate quoted shall be inclusive of all plant equipment, men, material skilled and unskilled
labour etc. essential for satisfactory completion of various works.

vi. All measurements for payment shall be in S.I. units, lengths shall be measured in meters
corrected to two decimal places. Areas shall be computed in square meters & volume in cubic
meters rounded off to two decimals.

d. The Bidder shall submit their offer taking into consideration that the tower and foundation
designs/drawings shall be approved from DNHDDPCL. Bidder shall quote the unit rates for various
items of towers and foundations as per units mentioned in appropriate price schedule. The payment to be
made for towers/foundations shall be worked out based on the unit rates and approved Bill of Materials
(BOM) for towers and quantities/volumes of concrete as per approved tower foundation drawings.

e. This specification also includes the supply of insulators & hardware fittings and all type of accessories for
conductor and OPGW as detailed in the specification. Contractor shall clearly indicate in their offer, the
sources from where they propose to procure these materials. The technical descriptions of these items are
given in technical specifications.

f. All the raw materials such as steel, zinc for galvanizing, reinforcement steel, cement, coarse and fine
aggregates for tower foundation, coke and salt for tower earthing etc. are included in the Contractor’s
scope of supply.

g. Bidder shall also indicate in the offer, the sources from where they propose to procure the fasteners, step
bolts, hangers, D-shackles, tower accessories, Aerial marker balls, aviation signal etc.

h. Stringing

i. The entire stringing work of conductor and earth wire shall be carried out by tension stringing
technique. However, the Bidder having requisite experience has freedom to use helicopter for
stringing. The Bidder intending to use helicopter shall furnish detailed description of the procedure,
type & number of helicopter & accessories etc., to be deployed for stringing operation.

ii. In hilly terrain and thick forest or area with site constraints where deployment of tension stringing
machine is not possible, manual stringing may be adopted after getting approval of supervising
Engineer. The contractor shall deploy appropriate tools/ equipments/ machinery to ensure that the
stringing operation is carried out without causing damage to conductor/OPGW and conductor/ OPGW
is installed at the prescribed sag-tension as per the approved stringing charts.

i. In case of special type pile or well foundations, some suitable execution agency may be engaged by the
contractor for casting of foundations, with the permission of DNHDDPCL. However, the Bidder shall be
responsible for all the necessary co- ordination with the special foundation Contractor including stub-
setting/fixing of base plate with anchor bolt.

j. Details of Transmission Line Routes and Terrain

Bidders may visit the line route to acquaint themselves with terrain conditions and associated details of
the proposed transmission lines.

k. Location Details and Terminal Points

The proposed Transmission lines shall emanate from existing line of 66 Kv to khadoli-Rakholi and end at
respective Sub stations/ Terminal towers. The Contractor shall have to construct 66kV Transmission lines

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 completely up to dead end towers/ termination gantry on either end.

3 TRANSMISSION TOWERS AND LINE DATA

3.1 Tower Data

The complete survey shall be carried out by the executing agency and provide detailed design of
tower, foundations etc and to be approved by DNHDDPCL.

a) Span and clearances

The minimum span and clearances are given in the design and will be provided with detailed
tower schedule and should be strictly followed.

b) Electrical Clearances

The minimum electrical clearance between the lowest power conductors of crossing line
over the crossed line should be as per the regulation 69 of CEA regulations on Safety and
Electricity Supply 2010.

c) Ground Clearance

The minimum ground clearance should be followed as per regulation 58 (4) of CEA
regulations on Safety and Electricity Supply – 2010. An allowance of 150mm shall be
provided to account for errors in stringing.

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4 Electrical System Data for 66 kV lines

GTP / DATA SHEET FOR TACSR 160 sq.mm CONDUCTOR

Sl.No. Description Unit Values

1 Maker's Name, Address

1.1 Code Name - TACSR 160mm 2

1.2 Size / Construction - TAL.30/2.60 mm+ST.7/2.60 mm

1.3 STANDARDS FOR DESIGN

a) Thermal Resistant Aluminium alloy Wires (AT-1) - IEC 62004

b) Extra High Strength Galvanized Steel Wires - IEC 60888

c) Fabrication and testing - IEC 61089

1.4 Cross sectional area of the Conductor mm² 196.4

1.5 Standard Outer Diameter of conductor mm 18.20

2 Thermal Resistant Aluminium alloy strands after stranding (Type AT-1)

2.1 Diameter

a) Nominal mm 2.60

b) Maximum mm 2.63

c) Minimum mm 2.57

2.2 Minimum Tensile Strength

a) Before Stranding N/mm2 169

b) After Stranding N/mm2 161

2.3 % Elongation on 250mm Guage Length % 1.5

2.4 Maximum resistivity of individual Strand at 20°C. Ώ-mm2/Km 28.735

2.5 Wrapping Test - ON 1 X D

2.6 Thermal Resistance Test (Routine) at 23°C for 1 Hour. - Residual strength of the wire shall
not be less than 90% of the
strength measured before heating.

3 Galvanized Steel Strands (Extra High Strength Galvanized steel Wires)

3.1 Diameter

(a) Nominal mm 2.60

(b) Maximum mm 2.64

(c) Minimum mm 2.56

3.2 Minimum Tensile Strength of strand.

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 (a) Before Stranding Mpa 1590

(b) After Stranding Mpa 1510.5

3.3 Stress at 1% Elongation Mpa 1410

3.4 % Elongation on 250mm Guage Length % 2.0

3.5 Galvanising

(a) Minimum mass of zinc coating per sq.m of Uncoated wire gm/m2 230
surface.
(b) Min. no. of twists in a gauge length equal to 100 times Nos. 14
diameter of wire which the strand can withstand in the torsion
test.
3.6 Wrap Test and Adhesion Test - on 4 X D

4 TACSR/EST Stranded Conductor

4.1 Min Breaking Load of Conductor KN 79.3

4.2 D.C. resistance of conductor at 20oC Ohm/Km 0.1846 (max)

4.3 Lay ratio of Conductor -

a) 6+1 Steel wire layer - Max - 26 Min - 16

b) TAL 12 Wire Layer Max - 16 Min - 10

c) TAL 18 Wire Layer Max - 14 Min - 10

4.4 Direction of lay for outside layer - Right Hand

4.5 Co-efficient of linear expansion /°C 19.2 X 10-6

4.6 Final modulus of elasticity Kgf/mm2 8260

4.7 Weight of conductor without grease

a) Standard Kg/Km 731

b) Minimum Kg/Km 716

c) Maximum Kg/Km 745

4.8 Weight of grease in conductor (Steel Core Greased) Kg/Km 6.5 (min)

5 Packing Details

5.1 Standard Length of Conductor m 3000

5.2 Tolerance on standard length of conductor % ± 5%

5.3 No. of standard lengths in one Drum/Reel Nos. 1

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5.4 Net Weight of Conductor in one drum (approx) Kg 2213

5.5 Gross weight of drum (approx) Kg 2613

5.6 Drum/Reel type - Wooden

5.7 Drum/Reel Dimensions (Flange X Barrel X Traverse) mm 1425 X 510 X 875

5.8 Package dimensions for shipping mXmXm 1.501 X 1.501 X 1.027

( length X width X height)

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 Item Specification Requirement
Line Parameters Voltage Class 66 kV (EHV, 3-phase, 50 Hz
Highest System Voltage 72.5 KV
Line Length 3.5 km
Circuit Double Circuit
Source & Termination 66 kv Khadoli S/S – 66 kV Rakholi Line Tapping
Point (Dapada-Chinchpada)
Conductor Type TACSR 160 sqmm (Thermal Alloy Conductor Steel
Reinforced)
Temp. Rating 150°C continuous
Standards IS 398 (Part II/IV), IEC 61089
Insulator Strings Type Polymeric (Composite)
Rating 66 kV, 120 kN mechanical strength
Creepage Distance ≥ 2079 mm (polluted environment) 31.5 mm/kv
Standards IEC 61109, IS 731
Tower Type Lattice steel self-supporting towers (Multi Circuit)
Design Load As per IS: 802 / IEC 60826
Galvanization Hot dip galvanization ≥ 610 g/m² (IS 2629)
Clearances Ground ≥ 6.1 m; Phase-to-phase ≥ 2.1 m; Phase-to-
tower ≥ 1.5 m
Ground Wire / Type OPGW (Optical Ground Wire)
OPGW
Fiber Count 24F / 48F Single Mode (as per requirement)
Standards IEC 60794
Earthing Tower Footing Resistance ≤ 10 ohms
Line Tapping Tapping Tapping of 66 kV Rakholi line at Dapada
Arrangement Chinchpada with required tower modification &
stringing
Hardware Suitable jumpers, tension hardware, polymeric
strings
Survey Deliverables Tower schedule, profile drawings, sag-tension charts

4.1 Climatic & Service Conditions

The materials offered shall be suitable for operation in tropical climate & shall be subject to the sun &
inclement weather and shall be able to withstand wide range of temperature variations. The topography &
climatic conditions in general are as under: -
Maximum ambient temperature of air in Shade
50
(⁰C)
Minimum ambient temperature of air in shade
3.5
(⁰C)
Maximum relative humidity (%) 95
Average number of thunder storm (days/annum) 15
Average number rain fail (cm) 250
Maximum wind pressure (kg / m2) 150
Height above monsoon level (mtr) Not exceeding 100
Moderately hot & humid tropical,
Climate
conducive to rust & fungus growth.
Isokeraunic level 30
Earth quake acceleration (g) 0.08 X 2

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 SECTION-2
GENERAL TECHNICAL CONDITIONS

1.0 GENERAL TECHNICAL CONDITIONS

1.1 General
The following provisions shall supplement all the detailed technical specifications and requirements brought out
herein. The contractor’s proposal shall be based on the use of materials complying fully with the requirements
specified herein.

1.2 Engineering Data

1.2.1 The furnishing of engineering data by the Contractor shall be in accordance with the Schedule as specified in the
Bidding Document. The review of these data by the DNHDDPCL will cover only general conformance of the data
to the specifications and not a thorough review of all dimensions, quantities and details of the materials, or items
indicated, or the accuracy of the information submitted. This review by the DNHDDPCL shall not be considered
by the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations from the
requirements, specified under these specifications.
1.2.2 All engineering data submitted by the Contractor after review by the DNHDDPCL shall form part of the contract
document.
1.3 Drawings
In addition to those stipulated in clause regarding drawings in GCC/SCC, the following also shall apply in respect
of Contractor Drawings.
1.3.1 All drawings submitted by the Contractor including those submitted at the time of Bid shall be with sufficient
details to indicate the type, size, arrangement, dimensions, material description, Bill of Materials, weight of each
component break-up for packing and shipment, fixing arrangement required, the dimensions required for
installation and any other information specifically requested in these specifications.
1.3.2 Each drawing submitted by the Contractor shall be clearly marked with the name of the DNHDDPCL, the
specification title, the specification number and the name of the Project. All titles, noting, markings and writings
on the drawing shall be in English. All the dimensions should be to the scale and in S.I. units.
1.3.3 The drawings submitted by the Contractor shall be reviewed by the DNHDDPCL as far as practicable, within 15
days and shall be modified by the Contractor, if any modifications and/or corrections are required by the
DNHDDPCL. The Contractor shall incorporate such modifications and/or corrections and submit the final
drawings for approval. Any delay arising out of failure by the Contractor to rectify the drawings in time shall not
alter the contract completion date.
1.3.4 The drawings submitted for approval to the DNHDDPCL shall be in quadruplicate. One print of such drawings
shall be returned to the Contractor by the DNHDDPCL marked “approved/approved with corrections”. The
contractor shall there upon furnish the DNHDDPCL additional prints as may be required along with one
reproducible in original of the drawings after incorporating all corrections.
1.3.5 The work shall be performed by the Contractor strictly in accordance with these drawings and no deviation shall
be permitted without the written approval of the DNHDDPCL, if so required.
1.3.6 All manufacturing, fabrication and erection work under the scope of Contractor, prior to the approval of the
drawings shall be at the Contractor’s risk. The contractor may incorporate any changes in the design, which are
necessary to conform to the provisions and intent of the contract and such changes will again be subject to
approval by the DNHDDPCL.
1.3.7 The approval of the documents and drawings by the DNHDDPCL shall mean that the DNHDDPCL is satisfied that:
(a) The Contractor has completed the part of the Works covered by the subject document (i.e. confirmation of
progress of work).
(b) The Works appear to comply with requirements of Specifications.
In no case the approval by the DNHDDPCL of any document does imply compliance with all technical
requirements or the absence of errors in such documents.
If errors are discovered any time during the validity of the contract, then the Contractor shall be responsible for
consequences.
1.3.8 All drawings shall be prepared using AutoCAD software version 2000 or later only. Drawings, which are not
compatible to AutoCAD software version 2000 or later, shall not be accepted. After final approval, all the drawings

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 (structural drawings, BOMs, shop sketches and tower accessories drawings) shall be submitted to the DNHDDPCL
in CDs/pendrive.
A copy of each drawing reviewed will be returned to the Contractor as stipulated herein.
1.3.9 The following is the general list of the documents and drawings that are to be approved by the DNHDDPCL.
a) Work Schedule (Master Network) Plan.
b) Detailed survey report and profile drawings showing ground clearance and tower locations (as applicable).
c) Tower schedule and foundation classification for individual tower locations.
d) Stringing procedure
e) Tower accessories drawings like danger plate, name plate, phase plate, circuit plate, pipe and counter poise
type earthing etc.
f) Quality plans for fabrication and site activities including Quality System, Vendor’s approval, etc.
g) Line material drawings.
h) Type test report for line materials.

1.4 Contractor Execution Plan

1.4.1 The time and the date of completion of the Contract as stipulated in the Contract by the Owner without or with
modifications, if any, and so incorporated in the Letter of Award, shall be deemed to be the essence of the Contract.
The Contractor shall so organize his resources and perform his work as to complete it not later than the date
agreed to.
1.4.2 The Contractor shall submit a detailed Work Breakdown Structure in MS Project within the time frame agreed
consisting of adequate number of activities covering various key phases of the work such as design, procurement,
manufacturing, shipment and field erection activities within fifteen (15) days of the date of Notification of Award.
This network shall also indicate the interface facilities to be provided by the Owner and the dates by which such
facilities are needed. The Contractor shall discuss the network so submitted with the Owner and the agreed
network shall form part of the Contract documents. During the performance of the Contract, if in the opinion of
the Engineer, proper progress is not maintained, suitable changes shall be made in the Contractor’s operations to
ensure proper progress without any cost implication to the Owner. The interface facilities to be provided by the
Owner in accordance with the agreed network shall also be reviewed while reviewing the progress of the
Contractor.
1.4.3 Based on the above agreed WBS fortnightly reports shall be submitted by the Contractor as directed by the
Engineer.
1.4.4 Subsequent to the finalization of the network, the Contractor shall make available to the Engineer a detailed
manufacturing programme in line with the agreed Contract network. Such manufacturing programme shall be
reviewed, updated and submitted to the Engineer once every two months thereafter.
1.4.5 The above bar charts/manufacturing programme shall be compatible with the Owner’s computer environment
and furnished to the Owner on such media as may be desired by the Owner.
1.5 Design Improvements
The DNHDDPCL or the Contractor may propose changes in the specification and if the parties agree upon any such
changes, the design shall be modified accordingly.
1.6 Design Co-ordination
The design in the scope of Contractor shall be responsible for the selection and design of appropriate
material/item to provide the best coordinated performance of the entire system. The design of various
components, sub-assemblies and assemblies shall be so done that it facilitates easy field assembly and
maintenance.
1.7 Review Meeting
The contractor will be called upon to attend review meetings with the DNHDDPCL, during the period of Contract.
The contractor shall attend such meetings at his own cost at the Corporate Office of the DNHDDPCL or at mutually
agreed venue as and when required. Such review meeting will be held as and when required.

1.8 Quality Assurance, Inspection & Testing

1.8.1 Quality Assurance
To ensure that the supply and services under the scope of this Contract whether manufactured or performed
within the Contractor’s works or at his Sub- Contractor’s premises or at site or at any other place of work are in
accordance with the specifications. The Contractor shall adopt suitable quality assurance programme to control
such activities at all points necessary. Such programme shall be broadly outlined by the Contractor and shall be
finalised after discussions before the award of Contract. The detailed programme shall be submitted by the
contractor after the award of contract and finally accepted by the DNHDDPCL after discussion. A quality assurance

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 programme of the Contractor shall generally cover but not limited to the following:
(a) His organization structure for the management and implementation of the proposed quality assurance
programme.
(b) Documentation control System.
(c) Qualification data for Contractor’s key personnel.
(d) The procedure for purchase of materials, parts components and selection of sub-Contractor’s services
including vendor analysis, source inspection, incoming raw material inspection, verification of material
purchases etc.
(e) System for shop manufacturing including process controls and fabrication and assembly controls.
(f) Control of non-conforming items and system for corrective action.
(g) Control of calibration and testing of measuring and testing equipment.
(h) Inspection and test procedure for manufacture.
(i) System for indication and appraisal of inspection status.
(j) System for quality audits.
(k) System for authorizing release of manufactured product to the DNHDDPCL.
(l) System for maintenance of records.
(m) System for handling storage and delivery and
(n) A quality plan detailing out the specific quality control procedure adopted for controlling the quality
characteristics relevant to critical and important items of supply.
(o) The Quality plan shall be mutually discussed and approved by the DNHDDPCL after incorporating necessary
corrections by the Contractor as may be required.

1.8.2 Quality Assurance Documents

The Contractor shall be required to submit all the Quality Assurance Documents as stipulated in the Quality Plan
at the time of DNHDDPCL's inspection of equipment/material.

1.8.3 The DNHDDPCL or his duly authorized representatives reserves the right to carry out Quality Audit and quality
surveillance of the systems and procedures of the Contractor's/his vendor's Quality Management and Control
Activities.

1.8.4 Contractors Supervision

The contractor shall appoint, sufficient number of competent and qualified Engineering personnel (graduate and
diploma engineers) as required and approved by the Engineer in-charge for supervision and execution of the
work. The necessary qualified supervisors for work execution/quality/safety/testing etc shall be employed by
the contractor as per actual requirement of the work. The contractor shall intimate the Engineer-in-charge in
writing the names and identity of technical personnel proposed to be engaged on the work.

1.9 Inspection and Tests

1.9.1 Inspection
a) The DNHDDPCL, its duly authorized representative and/or outside inspection agency acting on behalf of the
DNHDDPCL shall have, at all reasonable times, access to the premises and /or works of the contractor and/or
their sub- contractor(s) /sub-vendors and shall have the right, at all reasonable times, to inspect and examine
the materials and workmanship of the product during its manufacture.
b) The Contractor shall give the DNHDDPCL’s Inspector, fifteen (15) days (in case of domestic testing and thirty
(30) days (in case of foreign testing), as the case may be, written notice of any material being ready for
testing. In case of turnkey contract, the turnkey contractor shall give the notice for inspection and shall
associate in the inspection with Employer’s inspector. All such expenses towards inspections shall be to the
Contractor's account. The DNHDDPCL’s inspector, unless witnessing of the tests is waived, will attend such
tests within fifteen (15) days (in case of domestic testing) and thirty (30) days in (in case of foreign testing)
of the date of which the equipment is notified as being ready for test/ inspection or on a mutually agreed
date, failing which the Contractor may proceed with the test in accordance with the technical specification
after informing the DNHDDPCL in writing and he shall forthwith forward to the inspector duly certified
copies of test reports / certificates in triplicate.
c) The DNHDDPCL shall, within fifteen (15) days from the date of inspection, give notice in writing to the

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 Contractor, of any objection to any drawings and all or any equipment and workmanship which in his opinion
is not in accordance with the Contract. The Contractor shall give due consideration to such objections and
shall make the modifications that may be necessary to meet the said objections.
d) In all cases where the Contract provides for test whether at the premises or works of the Contractor or of
any Sub-Contractor, the Contractor except where otherwise specified, shall provide free of charge such item
as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably
demanded by the DNHDDPCL’s inspector or his authorized representative to carry out effectively such tests
of the equipment in accordance with the Contract and shall give facilities to the DNHDDPCL’s Inspector or to
his authorized representative to accomplish testing.
g) i ) The Contractor shall keep the DNHDDPCL informed in advance about the time of starting and of the
progress of manufacture and fabrication of various tower parts at various stages, so that arrangements could
be made for inspection.
ii) The acceptance of any part of items shall in no way relieve the Contractor of any part of his responsibility
for meeting all the requirements of the Specification.
h) The DNHDDPCL or his representative shall have free access at all reasonable times to those parts of the
Contractor’s works which are concerned with the fabrication of the DNHDDPCL’s material for satisfying
himself that the fabrication is being done in accordance with the provisions of the Specification.
i) Unless specified otherwise, inspection shall be made at the place of manufacture prior to dispatch and shall
be concluded so as not to interfere unnecessarily with the operation of the work.
j) Should any member of the structure be found not to comply with the supplied design, it shall be liable to
rejection. No member once rejected shall be resubmitted for inspection, except in cases where the
DNHDDPCL or his authorized representative considers that the defects can be rectified.
k) Defect which may appear during fabrication shall be made good with the consent of, and according to the
procedure proposed by the Contractor and approved by the DNHDDPCL.
l) All gauges and templates necessary to satisfy the DNHDDPCL shall be supplied by the contractor.
m) The specified grade and quality of steel shall be used by the Contractor. To ascertain the quality of steel used,
the inspector may at his discretion get the material tested at an approved laboratory.
1.9.2 Tests
a) The type, acceptance and routine tests and tests during manufacture shall be carried-out on the material and
shall mean as follows:
i. Type Tests shall mean those tests which are to be carried out to prove the process of manufacture and
general conformity of the material to this Specification. These tests shall be carried out on samples prior
to commencement of commercial production against the order.
ii. Acceptance Tests shall mean those tests which are to be carried out on samples taken from each lot
offered for pre-dispatch inspection, for the purposes of acceptance of that lot.
iii. Routine Tests shall mean those tests, which are to be carried out on the material to check requirements
which are likely to vary during production.
iv. Tests during manufacture shall mean those tests, which are to be carried out during the process of
manufacture and end inspection by the Contractor to ensure the desired quality of the end product to
be supplied by him.
b) The norms and procedure of sampling for these tests will be as per the Quality Assurance Programme to be
mutually agreed to by the Contractor and the DNHDDPCL.
c) The standards and norms to which these tests will be carried out are listed against them. Where a particular
test is a specific requirement of this Specification, the norms and procedure of the test shall be as specified
in respective Annexures or as mutually agreed to between the Contractor and the DNHDDPCL in the Quality
Assurance Programme.
d) For all type and acceptance tests, the acceptance values shall be the values specified in this Specification or
guaranteed by the Bidder, as applicable.

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1.10 Guaranteed Technical Particulars (GTP)
The Guaranteed Technical Particulars (GTP) of the various items is given in the relevant schedule of the
specification. The bidder is required to comply with the same in line with technical requirements of the items/
materials as mentioned in part B of volume II.
1.11 Packing
a) All the materials shall be suitably protected, coated, covered or boxed and crated to prevent damage or
deterioration during transit, handling and storage at Site till the time of erection. The Contractor shall be
responsible for any loss or damage during transportation, handling and storage due to improper packing.
b) The Contractor shall include and provide for securely protecting and packing the materials so as to avoid
loss or damage during transport by air, sea, rail and road. All packing shall allow for easy removal and
checking at site. Wherever necessary, proper arrangement for attaching slings for lifting shall be provided.
All packages shall be clearly marked for with signs showing ‘up’ and ‘down’ on the sides of boxes, and
handling and unpacking instructions as considered necessary. Special precaution shall be taken to prevent
rusting of steel and iron parts during transit by sea.
c) The cases containing easily damageable material shall be very carefully packed and marked with appropriate
caution symbols, i.e. fragile, handle with care, use no hook etc. wherever applicable.
d) Each package shall be legibly marked by the Contractor at his expenses showing the details such as
description and quantity of contents, the name of the consignee and address, the gross and net weights of
the package, the name of the Contractor etc.
e) Angle section shall be wire bundled.
f) Cleat angles, gusset plates, brackets, fillet plate, hanger and similar loose pieces shall be tested and bolted
together in multiples or securely wired through holes.
g) Bolts, nuts washers and other attachments shall be packed in double gunny bags accurately tagged in
accordance with the contents.
h) The packing shall be properly done to avoid losses & damages during transit. Each bundle or package shall
be appropriately marked.
2.0 DNHDDPCL’S POLICY AND ITS IMPLEMENTATION
2.1 Basic issues to be kept in mind while carrying out construction activities are to:
i) Apply efficient and safe technology/practices.
ii) Keep abreast of all potential dangers to people’s health, occupational safety and safety of environment and
the respective mitigation measures.
iii) Establish preventive mechanisms to guarantee safety.
iv) Mitigation measures in case of accidents.
v) Avoid unwarranted cutting of trees in forest area.
2.2 While constructing the lines through forest stretches the contractor will provide alternate arrangements to its
employee e.g. working labours/supervisors etc. in order to avoid cutting of forest woods. Contractor will ensure
safety to the wild life, during working/ camping near to the National Park. Contractor during construction of lines
in agricultural fields will ensure minimum damages to the crops, trees, bunds, irrigation etc. If the same is un-
avoidable, the decision of Engineer- in-charge shall be final.
2.3 The waste/excess material/debris should be removed from the construction site including agricultural field,
forest stretches, river etc. immediately after construction work. The Contractor will ensure least disturbance to
the hill slope and natural drainage so as to avoid soil erosion. Natural drainage in plain area if disturbed is to be
restored to the satisfaction of Engineer-in-charge. As far as possible, existing path/kutchcha road/ approach shall
be used for the construction. The Contractor will ensure supply of stone chips/sand from authorized/approved
quarry areas, proper documentation of above, if any.
3.0 STANDARDS
The Indian Standard Specification (IS), British Standards (BS), IEC, ISO, ASTM, CBIP manual etc. relevant to
transmission line design, testing and construction as amended up to date shall be applicable to the materials and
works used in this project.

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 SECTION - 3 SITE ACCESS

1.0 The necessary permission for the removal of obstructions such as trees, houses, etc. and for the permanent
removal or guarding of pipes, telegraph, telephone and power lines will be in the responsibility of the Contractor.
The DNHDDPCL shall assist the Contractor in getting that permission, if required for such works.

2.0 CROSSING OF OBSTACLES

2.1 General
The Contractor shall, at his own expense, make necessary arrangements and take the necessary precautions
where the route crosses buildings, telecommunication, power or pipe lines, orchards, gardens, railways,
antiquities or other obstructions or ground over or across which erection cannot be carried out in the normal
manner or has to be avoided. These arrangements must be submitted to the Engineer.
Where a tower is set across a fence, hedge, bank or wall, the Contractor shall remove and reinstate the fence,
hedge, bank or wall at his own expense and he shall be responsible at his own expense for making good to the
satisfaction of the Engineer, owners and tenants concerned, all land, property, roads, drains, fences, walls, hedges,
gates and the like which he has damaged or disturbed during the execution of tile Contract Works and shall
remove all surplus material after erection. The Contractor shall take proper precautions to prevent the straying
of and damage to livestock until after the backfilling of excavations and permanent reinstatement of fences, walls,
hedges, gates and the like is completed.
2.2 Public Utilities
The Contractor shall ensure that the erection of the Contract Works does not cause damage to or interference
with existing telecommunication, power or pipe lines. Where appropriate Authorities affected deem it
necessary for the protection of their employees, property, or the public or for the assistance of traffic to provide
flagmen and watchmen, the cost of such provision shall be borne by the Contractor. Where required by the
appropriate Authorities, work shall be carried on outside normal hours and at the Contractor's own expense.
The Contractor shall also be liable to make good at least to the original condition or compensate the owners,
operators and users or any public undertaking in respect of any damage however caused to their property, lands
or roads arising, out of or in consequence of the execution of the Works.

3.0 DAMAGE
3.1 General
The Contractor shall take all reasonable precautions to avoid damage to land, property, roads, crops, field drains,
fences walls, hedges, gates, trees and the like and shall ensure that the work is adequately supervised so that any
damage is reduced to the minimum. The Contractor shall pay compensation to the owners/tenants for damages
of crops, trees and houses during the project implementation within the way leaves (right-of-way) which are
unavoidable for construction of the transmission line.
3.2 Contractor's Responsibility
The Contractor's liability for loss or damage shall extend to any such loss or damage resulting from the
employment of a Subcontractor. This does not relieve the Contractor of his liability for all actions of his
Subcontractor.
3.3 Livestock, Dogs
Adequate provision shall be made by the Contractor to prevent the straying of or injury to livestock during the
execution of the Works and until the permanent reinstatement of fences, walls, hedges, gates and the like is
completed.
The Contractor shall not bring any dog on or near the site or suffer or permit any of his employees, representatives
or agents or any Subcontractor to bring any dog on or near the site and shall cause the immediate removal of any
dog which may be on or near the Site in breach of this provision.
The Contractor shall be liable for any injury to or loss of livestock due in the opinion of the Engineer to failure to
comply with the above requirements.

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PART B
TECHNICAL SPECIFICATIONS OF MATERIALS

SECTION - 4
TECHNICAL SPECIFICATIONS OF TOWER & ACCESSORIES

A) GENERAL INFORMATION AND SCOPE

1.0 Scope
The following 66 kV Towers & Materials are included in the scope of the Contractor: -

Sl. No. Item Description

1 66 kV Multi circuit/ Double Circuit Galvanized Lattice towers, Stub & Cleat, Template,
Bolt and Nut and all other accessories complete
2 TACR conductors
3 Dead End Fitting-single
4 Suspension Clamp - single
5 Mid Span Joint
6 Repair Sleeve
7 Pilot Suspension Clamp
8 Vibration Damper
9 90 kN /120 kN Long Rod Composite Insulator
10 Suspension Fitting-single
11 Tension Fitting-single
12 Pilot Suspension Fitting
13 Tee-Taps with Connectors
14 OPGW 24 Pair with accessories
15 Single Tension Dead End Fitting
16 Suspension Clamp
17 Double tension set for pass through location
18 Double tension set for Joint Box location
19 Vibration Damper
20 Down Lead clamp
21 Joint Box 24 Fiber
22 Reinforcing Rod for damper
23 FODP
24 Pipe Earthing Set 3M with all accessories
25 Counterpoise earthing set complete
26 Galvanized Earth Wire
27 Wedge Connector suitable for TACSR/Panther

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2.0 Transmission Tower
2.1 Design and Drawings
2.1.1 The basic drawings for all the towers and their extensions, will be provided by Contractor, which shall include
structural drawings/erection drawings and / or shop fabrication drawings, Bill of Materials for all the towers and
their extensions as well as construction drawings for foundations. Bidder shall include in their offer the following:
a) Proto Fabrication, Assembly and Type Testing (non-destructive type) of 66KV MC/DC towers as per
approved design & drawings by DNHDDPCL complete in all respects as per as per clause 2.2 below.
2.1.2 The tower members can be directly fabricated from the structural/erection drawings wherever the required
fabrication details are provided on the same or shop fabrication drawings. Before taking up mass fabrication, the
Contractor shall arrange for one number proto-assembly for each type of tower and extensions which shall be
inspected by DNHDDPCL. After assembly inspection, the Contractor shall incorporate revisions in the drawings.
The revised drawing shall be submitted in 3 (three) copies for final approval by the DNHDDPCL.
2.1.3 All the drawings shall have a proper name plate clearly displaying the name of DNHDDPCL on right hand bottom
corner. The exact format of the nameplate shall be handed over to the successful bidder for incorporation of the
same on all the drawings.
2.1.4 While submitting the structural drawings, bill of materials, shop drawings and any other drawings pertaining to
the subject transmission line, the Contractor shall clearly indicate on each drawing DNHDDPCL Specification No.,
Name of the specific Transmission line and project, letter reference no. and date on which the submission are
made. The same practice is also to be followed while submitting distribution copies.
2.1.5 The bidder shall submit the tower accessories drawings like number plate, phase plate, Danger plate, bird guard,
circuit plate, step bolt, earthing, etc after endorsing the name of the project. Also drawing of anti-climbing device,
D- shackle etc. shall be prepared by the Contractor and shall be submitted to the DNHDDPCL, in three (3) copies
for approval. This drawing shall be prepared in A4 size only.
2.1.6 The drawings prepared and submitted by the Contractor shall be approved / commented by the DNHDDPCL as
the case may be, within fifteen (15) days of receipt of drawings in his office. If the designs/drawings are
commented by the DNHDDPCL, the Contractor shall submit revised design/drawings duly incorporating all
comments within fifteen (15) days of date of issue of comments. The Contractor shall submit 15 copies of all
approved structural drawings and BOM for tower extensions as well as for tower accessories for further
distribution by the DNHDDPCL.
The mass fabrication shall be taken up from the approved shop drawings. The overall responsibility of fabricating
tower members correctly lies with the Contractor only and the Contractor shall ensure that all the tower members
can be assembled / fitted while erecting without any undue strain on them.

2.2 Materials
2.2.1 Tower Steel Sections
IS Steel Sections of tested quality of conformity with IS:2062:2006 grade E250 (Designated Yield Strength. 250
MPa) and/ or grade E350 (Designated Yield Strength 350 MPa) are to be used in towers, extensions, stubs and
stub setting templates. The Contractor can use other equivalent grade of structural steel angle sections and plates
conforming to latest International Standards. However, use of steel grade having designated yield strength more
than that of EN 10025 grade S355 JR/JO (designated yield strength 355 MPa) is not permitted, unless otherwise
indicated in this specification.

Steel plates below 6mm size exclusively used for packing plates/packing washers produced as per IS 1079 -1994
(Grade -0) are also acceptable. However, if below 6mm size plate are used as load bearing plates viz gusset plates,
joint splices etc. the same shall conform to IS : 2062 / or equivalent standard meeting mechanical strength/
metallurgical properties corresponding to grade E250 or grade E350 (designated yield strength not more than
355MPa), depending upon the type of grade incorporated into design. Flats of equivalent grade meeting
mechanical strength/ metallurgical properties may also be used in place of plates for packing plates/ packing
washers. The chequered plates shall conform to IS: 3502. SAILMA 350HI grade plate can also be accepted in place
of HT plates (EN 10025 grade S355 JR/JO / IS 2062:2006 – grade 350, as applicable) provided SAILMA 350HI
grade plate meet all the mechanical properties of plate as per EN 10025 grade S355 JR/JO (designated yield
strength 355 MPa) / IS 2062:2006 – grade 350.

For designing of towers, preferably rationalised steel sections have been used. During execution of the project, if
any particular section is not available, the same shall be substituted by higher section. Any cost on account of the

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 same shall be borne by the Contractor. However, design approval for such substitution shall be obtained from the
Board before any substitution and records of such substitutions shall be maintained by the Contractor.
2.2.2 Fasteners: Bolts, Nuts and Washers
All tower members shall be joined together with Bolts and nuts. The joints shall be connected with hexagonal
bolts and nuts. All hexagonal bolts and nuts shall conform to IS-12427. They shall have hexagonal head and nuts,
the heads being forged out of the solid, truly concentric, and square with the shank, which must be perfectly
straight. Anti-theft bolts and nuts shall have round tapered heads with hexagonal shear nuts. They shall confirm
to IS: 12427 and IS: 1367 for property class 5.6/5 except for dimensions. All bolts and nuts shall be galvanized as
per IS: 1367 (Part-13)/IS: 2629.
a) The bolt shall be of 16/24 mm diameter and of property class 5.6 as specified in IS: 1367 (Part-III) and
matching nut of property class 5.0 as specified in IS: 1367 (Part-VI).Bolts up to M16 and having length up to
10 times the diameter of the bolt should be manufactured by cold forging and thread rolling process to obtain
good and reliable mechanical properties and effective dimensional control. The shear strength of bolts for
5.6 grade should be 310 MPa minimum as per IS: 12427. Bolts should be provided with washer face in
accordance with IS: 1363 (Part-I) to ensure proper bearing.
b) Nuts for hexagonal bolts should be double chamfered as per the requirement of IS: 1363 Part-III. It should
be ensured by the manufacturer that nuts should not be over tapped beyond 0.4mm oversize on effective
diameter for size up to M 16.
c) Fully threaded bolts shall not be used. The length of bolts shall be such that the threaded portion will not
extend into the place of contact of the members.
d) All bolts shall be threaded to take the full depth of the nuts and threaded for enough to permit firm gripping
of the members, but not further. It shall be ensured that the threaded portion of each bolt protrudes not less
than 3mm and not more than 8mm when fully tightened. All nuts shall fit tight to the point where the shank
of the bolt connects to the head.
e) Flat and tapered washers shall be provided wherever necessary. Spring washers shall be provided for
insertion under all nuts. These washers shall be steel electro galvanised, positive lock type and 3.5 mm in
thickness for 16 mm dia bolt and 4.5 mm for 24 mm bolt.
f) To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect aggregate thickness of
members more than three times its diameter.
g) The bolt positions in assembled towers shall be as per structural drawing.
h) Bolts at the joints shall be so staggered that nuts shall be tightened with spanners without fouling.
i) To ensure effective in-process Quality control it is desirable that the manufacturer should have in house
testing facility for all tests like weight of zinc coating, shear strength and other tests etc. The manufacturer
should also have proper Quality Assurance System which should be in line with the requirement of this
specification and IS: 14000 series Quality System Standard.

3.0 Tower Accessories

Arrangement shall be provided for fixing of all tower accessories to the tower, at a height between 2.5 meters and
3.5 meters above the ground level.
3.1 Step Bolts & Ladders
Each tower shall be provided with step bolts as per specification drawings. The contractor shall submit
distribution copies of the same endorsing the package details (i.e. line name, LOI No. etc). The step bolts
conforming to IS: 10238 of not less than 16mm diameter and 175mm long spaced not more than 450mm apart
and extending from 2.5 meters above the ground level to the top of the tower. However, the head diameter shall
be 50mm. For Double circuit tower the step bolt shall be fixed on two diagonally opposite legs up to top of the
towers. Each step bolt shall be provided with two nuts on one end to fasten the bolt securely to the tower and
button head at the other end to prevent the feet from slipping away.
The step bolts shall be capable of withstanding a vertical load not less than 1.5 KN. For special towers, where the
height of the super structure exceeds 50 meters, ladders along with protection rings shall be provided in
continuation of the step bolts on one face of the tower from 30 meters above ground level to the top of the special
structure. In this case the bidder shall supply the relevant drawings of the ladder to DNHDDPCL for approval.
From 2.5 m to 30m height of super structure step bolts shall be provided. Suitable platform using 6 mm thick
perforated chequered plates along with suitable railing for access from step bolts to the ladder and from the

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 ladder to each cross-arm tip and the ground wire support shall also to be provided. The platform shall be fixed on
tower by using counter-sunk bolts.
3.1.1 Insulator Strings and Earth wire Clamps Attachments
3.1.2 For the attachment of suspension Insulator string, a suitable dimensioned swinging hanger on the tower shall be
provided so as to obtain specified clearances under respective swinging condition of the strings. The hanger,
extensions links, D-shackles etc. as required and considered in the design of the tower shall have minimum
ultimate tensile strength of 90 kN /70 KN for single suspension string and 120 kN/90 KN for double suspension
string for 220/110 KV suspension towers. The design and supply of hanger, D-shackles, strain plate, extension
link etc. are also in the scope of Contractor.
3.1.3 At tension towers, strain plates of suitable dimensions under each cross-arm tip, shall be provided for taking the
hooks or D-shackles of the tension insulator strings. Full details of the attachments shall be provided to the
contractor. To achieve requisite clearances, if the design calls for providing extra D-shackles, link plate etc. before
connecting the insulator string the same shall be supplied by the Contractor.
3.1.4 Earth wire Clamps Attachments
a) Suspension Clamp
Wherever required, the Contractor shall supply U – bolts, D – Shackles, copper bond etc. for attachment of
Suspension clamp to the tower and take DNHDDPCL’s approval for details of the attachments before the mass
fabrication.
b) Tension Clamps
c) Earth wire peaks of tension towers shall be provided with suitable plates to accommodate the shackle of
tension clamps. The contractor shall also supply the U-bolts wherever required and take DNHDDPCL’s
approval for details of the attachments before the mass fabrication.
3.1.5 Anti-climbing Device & Bird Guard
Barbed wire type anti climbing device shall be provided and installed by the Contractor for all towers. The barbed
wire shall conform to IS-278 (size designation A1). The barbed wires shall be hot dip galvanized as per procedure
laid down in IS: 4826. The drawings of ACD shall be approved by DNHDDPCL.
The bird guards for suspension towers shall be made of galvanized iron sheet and shall conform to IS: 5613 (Part-
2/Section-1)-1985. Necessary holes shall be provided on the cross arm of the suspension towers for fixing the
bird guards.
3.1.6 Danger, Number, Circuit and Phase plate
Danger Plates, Phase Plates and Number plates shall be provided and installed by the Contractor. Further Circuit
plates also shall be provided and installed by the contractor for the Double circuit towers. These
Danger/Number/Phase/ circuit Plate shall be as per the drawing enclosed in the section of drawing. The
contractor shall submit distribution copies of the same endorsing the package details (i.e. line name, LOI No. etc)
and installed by the Contractor.
a) Each tower shall be fitted with a danger plate, number plate and a set of phase plates for each circuit. The
transposition towers should have provision of fixing phase plates on both the transverse faces. Circuit plates
shall be provided on all the Multi Circuit towers.
b) The letters, figures and the conventional skull and bones of danger plates shall conform to IS-2551 and shall
be in a signal red on the front of the plate.
c) The corners of the danger, number and circuit plates shall be rounded off to remove sharp edges.
d) The letters of number and circuit plates shall be red enameled with white enameled background.
4.0 Tower Fabrication
The tower members shall be fabricated in accordance with IS: 802(Part –II)- 1978 with the latest revision thereof.
Following important points relevant to work are described as below: -
4.1 All parts of towers shall be fabricated in accordance with the shop drawings prepared from approved detailed
assembly drawings.
4.2 Towers shall have bolted connection. Welding shall not be permitted at any point unless otherwise previously
approved by the DNHDDPCL.
4.3 The tower members shall be accurately fabricated, so that these could be bolted together easily at site without
undue strain on the bolts or members.
4.4 No angle member shall have the two leg flanges brought together by closing the angle.
4.5 The structure shall be such that all parts are accessible for inspection and cleaning. Drain holes shall be provided
at all points where pockets of depression are likely to hold water. It will be ensured that the stressed members
will not have any blank hole after final assembly, except for holes on account of step bolts or planned holes in

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 stubs.
4.6 Fabrication of towers shall be carried out in conformity with the latest practice employed in the manufacture of
transmission line towers by using power driven cropping, punching, shearing and drilling machines. The extent
of various operations shall be governed by relevant Indian standards or any other approved standard
specifications and standard practice followed by such operations.
4.7 All sections before any work is done on them, shall be carefully levelled, straightened and made true to detailed
drawing by methods which will not injure the material so that when assembled, the adjacent matching surface
are in clear contact throughout. The steel sections shall be straightened and trued by pressure and not by
hammering. No rough edge shall be permitted anywhere in the entire structure. The flanges of the angle sections
at the ends of members shall be properly chamfered, if there are even slight chances of its fouling with other
members or if they cause difficulty in proper tightening of bolts. All clippings, back cuts, grindings, bends, holes
etc. shall be as per the detailed drawings and free from burrs.
4.8 Full interchangeability shall be guaranteed.
4.9 No welding, filling or plugging shall be permitted unless previously approved. Welding of two or more pieces to
obtain length of members specified will not be permitted.
4.10 All sections, plates and bars, before any work is done on them, shall be straightened, free from twists, carefully
levelled and made true to detailed drawings by methods, which will not injure the materials so that when
assembled, the adjacent surfaces are in close contact throughout. Hammering shall not be permitted for
straightening or flattening of members.
4.11 Cuttings of members shall be affected by shearing, cropping, flame cutting or sawing. Members preferably over
10 mm thickness shall be sawn, or flame cut followed by grinding. The surface so cut shall be clean, smooth,
reasonably square and free from any distortion.
4.12 Members shall be bent hot, but in case of small bends, the cold bending may be done with the prior approval of
the Engineer, provided no fracture of materials occurs. All the bending operations shall be done by pressure. No
bending of members shall be done for slope above 450.
4.13 When members are spliced by a lap joint, heel of inside angles shall be rounded to the minimum possible radius
consistent with proper fit with the fillet of the outside angle. The thickness of the ground heel shall not be less
than that of leg. Flat heeling will not be allowed.
4.14 The fabrication tolerances shall be as per IS: 7215-1974.

5.0 Drilling and Punching

5.1 Before any cutting work is started, all steel sections shall be carefully straightened and trued by pressure and not
by hammering. They shall again be trued after being punched and drilled.
5.2 Holes in the members shall be either punched or drilled with the help of jigs and fixtures. Drilled holes will be
preferred. However, members up to 12 mm thickness may be punched. Members over 12 mm thickness shall be
drilled. All burrs left after drilling or punching should be removed completely. Holes adjacent to the bend shall be
drilled or punched after bending. Tolerances regarding punch holes are as follows: -
5.2.1 Holes must be perfectly circular and no tolerances in this respect are permissible.
5.2.2 The maximum allowable difference in diameter of the holes on the two sides of plates or angle is 0.8mm. i.e. the
allowable taper in a punched hole should not exceed 0.8mm on diameter.
5.2.3 Holes must be square with the plates or angles and have their walls parallel.
5.3 Holes for bolts shall be circular. Oval or lobbed forms of holes shall not be permitted. The diameter of holes shall
be 1.5 mm more than diameter of bolts.
5.4 The accuracy of location of holes shall be such that for any group when assembled, it shall admit the bolt at right
angles to the plane of connection.
5.5 All burns left by drills or punch shall be removed completely. When the tower members are in position the holes
shall be truly concentric/matching to each other. Drilling or reaming to enlarge holes shall not be permitted.

6.0 Erection mark

6.1 Each individual member shall have erection mark conforming to the component number given to it in the
fabrication drawings. The mark numbers shall be marked with marking dies of 16 mm size before galvanizing and
shall be legible after galvanizing,

7.0 Quantities and weights

7.1.1 The quantities of the following items have been envisaged in Metric Tonne (MT) in the relevant price Schedules
for various types of towers: -
i) Basic Body.

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 ii) Body Extensions.
iii) Leg Extension.
iv) Stubs & Cleats
v) Bolts & Nuts including spring washers and step bolts etc.
7.1.2 During detail engineering, proto assembly of each of the above items shall be inspected and approved by
DNHDDPCL and subsequently shall be released for fabrication and manufacturing as per the Technical
Specification by the Contractor. The manufacturing of the above items shall be taken up in such a manner that the
Equipment/Material offered for inspection to DNHDDPCL are on completed tower basis for each type of tower,
completed Stubs & Cleats set basis so as to facilitate availability of erectable tower of each type and erectable
stubs & cleats set for casting of foundation. After inspection of the offered Equipment/Material by DNHDDPCL
representative(s), MDCC shall be issued only on completed tower basis for each type of tower, on completed tower
extensions basis of each type tower and on completed Stubs & Cleats set basis for each type of tower foundations.
7.1.3 The DNHDDPCL reserves the right to order the final quantities including reasonable quantities of spares for which
the rates quoted in the Bid shall be valid.
7.1.4 The estimated total weight of tower/tower parts as well as bolts & nuts along with spring washers and step bolts
to be supplied by the Contractor under various packages have been envisaged in the relevant Price Schedule.
Though fully galvanised tower parts are to be supplied, the weight of tower shall mean the weight of tower
calculated by using the black sectional (i.e. non-galvanised) weight of steel members of the size indicated in the
approved fabrication drawings and bill of materials, without taking into consideration the reduction in weights
due to holes, notches and level cuts etc. but taking into consideration the weight of the D shackles, hangers, strain
plates, pack plates, gusset plates and pack washers etc.
The weight of stub and cleats also shall be calculated in similar manner. The weight of gusset plates shall mean
the weight of its circumscribing rectangle, without taking into considerations the reductions in weight due to
holes, notches etc. For bolts and nuts along with spring washers and step bolts, the weight per tower shall be
calculated from the bolt schedule applicable to each type of towers and body extensions as per approved B.O.M.
7.1.5 The contractor is permitted to get inspected and supply up to 2.5% extra fasteners to take care of losses during
erection. No payment shall be admissible for these extra supplies.

8.0 Galvanising
8.1 Fabricated Tower Parts & Stubs
8.1.1 The tower parts, stubs and pack washers shall be hot dip galvanized. The galvanization shall be done as per
requirements of IS 4759 after all fabrication work is completed. The contractor shall also take guidelines from the
recommended practices for hot dip galvanizing laid down in IS: 2629 while deciding and implementing
galvanizing procedure. The mandatory requirements however, are specified herein.
8.1.2 Unless otherwise specified, the fabricated tower parts and stubs shall have a minimum overall Zinc coating of 610
gms per sq. m of surface except for plates below 5mm which shall have Zinc coating of 460 gms per sq. m of
surface. The average zinc coating for sections 5 mm & above shall be maintained as 87 microns and that for
sections below 5mm shall be maintained as 65 microns.
8.1.3 The zinc coating shall be adherent, reasonably uniform, smooth, continuous and free from imperfections such as
black/ bare spots, ash rust strains, bulky white deposits / wet storage strains and blisters.
8.1.4 The surface preparation for fabricated tower parts and stubs for hot dip galvanizing shall be carried out as
indicated herein below:
a) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface, wherever required, shall be carried out
in accordance with clause 4.1 of IS: 2629-1985.After degreasing the article shall be thoroughly rinsed.
However, if acidic degreasers are used rinsing is not required.
b) Pickling: Pickling shall be done using either hydrochloric or sulphuric acid as recommended at clause 4.3 of
IS 2629 -1985. The actual concentration of the acids and the time duration of immersion shall be determined
by the Contractor depending on the nature of material to be pickled. Suitable inhibitors also shall be used
with the acids to avoid over pickling. The acid concentration, inhibitors used, and maximum allowable iron
content shall form part of plant standard to be formulated and submitted to employer along with Quality
Assurance Program.
c) Rinsing: After pickling, the material shall be rinsed, preferably in running water to remove acid traces, iron
particles or any other impurities from the surface. Two rinse tanks are preferable, with water cascading from
the second tank to the first to ensure thorough cleaning. Wherever single tank is employed, the water shall

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 be periodically changed to avoid acid contamination, and removal of another residue from the tank.
d) Fluxing: The rinsed article shall be dipped in a solution of Zinc ammonium chloride. The concentration and
temperature of the flux solution shall be standardized by the contractor depending on the article to be
galvanized and individual circumstances. These shall form part of plant standard to be formulated and
submitted to employer along with Quality Assurance Program. The specific gravity of the flux solution shall
be periodically monitored and controlled by adding required quantity of flux crystals to compensate for drag-
out losses. Free acid content of the flux solution also shall be periodically checked and when it is more than
two (2) grams of free acid per litre of the solution, it shall be neutralized. Alternatively, Ph value should be
monitored periodically and maintained between 5.0 to 5.5.
e) Drying: When dry galvanizing is adopted, the article shall be thoroughly dried after fluxing. For the purpose
of drying, the contractor may use hot plate, air oven or any other proven method ensuring complete drying
of the article after fluxing and prior to dipping in the molten zinc bath. The drying process shall be such that
the article shall not attain a temperature at which the flux shall get decomposed. The article thus dried shall
be galvanized before the flux coating picks up moisture from the atmosphere or the flux layer gets damaged
or removed from the surface. The drying procedure, time duration, temperature limits, time lag between
fluxing, drying, galvanizing etc shall form part of plant standard to be formulated and submitted to employer
along with Quality Assurance Program.
f) Quality of Zinc: Any one or combination of the grades of zinc specified in IS 209 or IS 13229 or other
comparable international standard shall be used for galvanizing. The contractor shall declare the grade(s) of
zinc proposed to be used by them for galvanizing. The molten metal in the zinc bath shall contain minimum
98.5 % zinc by mass. It shall be periodically measured and recorded. Zinc aluminum alloy shall be added as
per IS 2629.
g) Dipping Process: The temperature of the galvanizing bath shall be continuously monitored and controlled.
The working temperature of the galvanizing bath shall be maintained at 450 +/ - 10-degree C. The article
should be immersed in the bath as rapidly as possible without compromising on safety aspects. The
galvanizing bath temperature, immersion angle & time, time duration of immersion, rate of withdrawal etc
shall be monitored and controlled depending upon the size, shape, thickness and chemical composition of
the article such that the mass of zinc coating and its uniformity meets the specified requirements and the
galvanized surface is free from imperfections and galvanizing defects.
h) Post Treatment: The article shall be quenched in water. The quench water is to be changed / drained
periodically to prevent corrosive salts from accumulating in it. If water quenching is not done, then necessary
cooling arrangements should be made. The galvanized articles shall be dipped in chromating solution
containing sodium dichromate and sulphuric acid or chromic acid base additive at a predetermined
concentration and kept at room temperature to retard white rust attack. The temperature of the chromate
solution shall not exceed 65-degree C. The articles shall not be stacked immediately after quenching and
dichromating. It shall be ensured that the articles are dry before any further handling operation.
i) Storing, Packing and Handling: In order to prevent white rust formation sufficient care should be exercised
while storing handling and transporting galvanized products. The articles shall be stored in an adequately
ventilated area. The articles shall be stored with spacers in between them and kept at an inclination to
facilitate easy drainage of any water collected on the articles. Similar care is to be taken while transporting
and storing the articles at site.
The Contractor shall prepare a detailed galvanizing procedure including Flow Chart with control parameters
and all plant standards as required above and submit to DNHDDPCL for approval as part of Quality Assurance
Plan.
8.2 Fasteners.
For fasteners, the galvanizing shall conform to IS-1367(Part-13). The galvanizing shall be done with centrifuging
arrangement after all mechanical operations are completed. The nuts, may however be tapped (threaded) or
rerun after galvanizing and the threads oiled. The threads of bolts & nuts shall have a neat fit and shall be such
that they can be turned with finger throughout the length of the threads of bolts and they shall be capable of
developing full strength of bolts. Spring washers shall be electro galvanized as per Grade-IV of IS-1573.

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9.0 Earthing
Each tower shall be earthed. The tower footing resistance shall not exceed 10 ohms. The Contractor shall measure
the tower footing resistance (TFR) of each tower during dry weather after it has been erected and before the
stringing of the earth wire. Pipe type earthing and counter poise type earthing shall be done as required in
accordance with the following standards:
IS: 3043 Code of practice for Earthing.
IS: 5613 Code of practice for Design, Installation and maintenance (Part- II/Section-2) of overhead power lines.
9.1 The drawings and standards for pipe & counterpoise type earthing are as per CBIP manual.
9.2 Pipe Type Earthing
Each earthing arrangement will consist of 50 mm dia, not less than 3000 mm long heavy-duty G.I. pipe driven at
least 3650mm away from the nearest leg of the tower so that the same is outside earthing zone of the tower itself.
50x6 mm G.S. strip 4650 mm long and placed 600 mm below the ground level shall be used to connect the tower
with the pipe. Bolt holes of the leg members joining the bottom most bracing shall be used for connecting the G.S.
strip. The quoted rates will include the supply of these earthing materials complete with necessary bolts and nuts
required for connection of strip with pipe and of the strip with tower.
9.3 Counterpoise Type Earthing
Where necessary, because of difficulties in grounding pipes in rocks or to control excessively high footing
resistance, counterpoise earth shall be provided by the contractor. The counterpoise earth will be of size not less
than 7/9 SWG (3.67 mm) galvanized steel wire having suitable galvanised steel lugs forged at its one end. The
length of each counterpoise earth will not be less than 30 meters.
The contractor shall furnish full details of counterpoise earth and the supply is also included under the scope of
the contractor.

10.0 Standards
10.1 The design, manufacturing, fabrication, galvanising, testing, erection procedure and materials used for
manufacture and erection of towers, design and construction of foundations shall conform to the following Indian
Standards (IS)/International Standards which shall mean latest revisions, with amendments/changes adopted
and published, unless specifically stated otherwise in the Specification.
In the event of supply of material conforming to Standards other than specified, the Bidder shall confirm in his
bid that these Standards are equivalent to those specified. In case of award, salient features of comparison
between the Standards proposed by the Bidder and those specified in this document will be provided by the
Contractor to establish their equivalence.
The material and services covered under these specifications shall be performed as per requirements of the
relevant standard code referred hereinafter against each set of equipment and services. Other internationally
acceptable standards which ensure equal or higher performance than those specified shall also be accepted.

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 SECTION – 5
TECHNICAL SPECIFICATIONS OF CONDUCTORS

1 SCOPE

This section provides the technical details of Conductors for use on this transmission lines package. The
material and services under this specification shall be performed as per the requirements of the latest revisions
and amendments available at the time of placement of order of all the relevant Indian Standards/Codes listed
in Clause-2 STANDARDS here under or equivalent International Standards, except as modified in this document.

The materials covered here under this specification shall be supplied complete in all respects, including all
components, fittings and accessories which are necessary or are usual for their efficient performance and
satisfactory maintenance under the various operating and atmospheric conditions. Such parts shall be deemed
to be within the scope of the Contract, whether specifically included or not in the Specification or in the Contract
Schedules.

2 STANDARDS

Sl. Indian Standard International

Title Standard
No.

1. IS: 209-1992 Specification for zinc BS:3436-1986

IEC:1089- 1991
2. IS: 398-1982 Specification for Aluminium Conductors for Overhead BS:215-
Transmission Purposes 1970

BS;215-1970
3. IS:398-1990 Aluminium Conductor Galvanised Steel Reinforced IEC:1089- 1991
Part-II

IS:398 (Part- IV) IEC: 208-1966 BS-

4. Aluminium Alloy stranded conductor
3242-1970
ISO 6892-
6. IS: 1521-1991 Method of Tensile Testing of Steel Wire
1984
7. IS: 1778-1980 Reels and Drums for Bare Conductors BS:1559-1949
Method of Testing Uniformity of Coating on Zinc
8. IS: 2633-1992 Coated Articles

IEC: 888-1987
9. IS: 4826-1992 Galvanised Coating on Round Steel Wires
BS:443-1969
BS:433-1969 ISO
10. IS: 6745-1990 Methods of Determination of Weight of Zinc Coating of
1460 -
Zinc Coated Iron and Steel Articles
1973

Method of Radio Interference Tests on High Voltage IEC:437-1973

11. IS: 8263-1990 Insulators
NEMA:107-

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 1964 CISPR

IEC 60104-
12. IS: 9997-1988 Aluminium Alloy Redraw Rods
1987

Method of measurement of resistivity of metallic

13. materials IEC:468

Calculating the Current Temperature of Bare IEEE 738-

14. 2006
Overhead Conductors
15. Aluminium-Coated Steel Core Wire for Aluminium
Conductors, Steel Reinforced ASTM B341

3 TECHNICAL DETAILS OF CONDUCTOR

Technical details of conductors are mentioned in clause 4.1, Section 1, Part A of this volume.

3.1 TOLERANCES

Manufacturing tolerances on the dimensions to the extent of one per cent shall be permitted for individual
strands and the complete conductor.

4 TEST ON CONDUCTORS

The following tests should have been conducted for conductor in last five year for which offer is made.

In the event of any discrepancy in the test report (i.e., any test report not applicable due to any design/
material/manufacturing process change including substitution of components or due to noncompliance with
the requirement stipulated in the Technical Specification) the tests shall be conducted by the Contractor at no
extra cost to the DNHDDPCL.

4.1 Type Tests

I) On Complete Conductor

a) DC resistance test on stranded conductor : As per Annexure-5A

b) UTS test on stranded conductor : As per Annexure-5A

c) Stress- Strain test on stranded conductor and core at : IEC 1089

room temperature
d) Stress-strain test on stranded conductor and core at
: As per Annexure-5A
elevated temperature
e) Crush Strength Test : As per Annexure-5A
f) Torsional Ductility & Wrapping Test : As per Annexure-5A
g) Corona Extinction Voltage Test : As per Annexure-5A
h) Radio Interference Voltage Test : As per Annexure-5A
II) On

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 Conductor Strand/ Core

a) Heat resistance test on Aluminium Alloy strands

: As per Annexure-5A

b) Bending test on core : As per Annexure-5A

c) Compression test on core : As per Annexure-5A
d) Coefficient of linear expansion on core/ core strand : As per Annexure-5A

4.2 Acceptance Tests

a) Visual and dimensional check on drum

: As per Annexure-5A

b) Visual check for joints scratches etc. and length : As per Annexure-5A
measurement of conductor by rewinding

c) Dimensional check on steel and aluminium strands : As per Annexure-5A

d) Check for lay-ratios of various layers : As per Annexure-5A

e) Galvanizing test : As per Annexure-5A
f) Aluminium thickness on aluminium clad : As per Annexure-5A
wires (if applicable)
g) Torsion and Elongation tests on core : As per Annexure-5A
strand/composite core
h) Breaking load test on core and Aluminium strands : As per Annexure-5A

i) Wrap test on core & Aluminium strands : IEC: 888 & 889
j) Minimum conductivity test on conductor : IEC: 889
strands.
k) Minimum conductivity test on core Strands : As per Annexure-5A
(if applicable)
l) Procedure qualification test on welded joint of : As per Annexure-5A
Aluminium strands

Note: All the above tests except (j) shall be carried out on aluminium and steel strands after stranding only.

4.3 Routine Test

a) Check to ensure that the joints are as per Specification

b) Check that there are no cuts, fins etc., on the strands.

c) Check that drums are as per Specification

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 d) All acceptance test as mentioned above to be carried out on 10% of drums.

4.4 Tests
During Manufacture

a) Chemical analysis of zinc used for galvanizing (if

: As per Annexure-5A
applicable)
b) Chemical analysis of Aluminum used for making : As per Annexure-5A
Aluminum strands
c) Chemical analysis of core strand : As per Annexure-5A

4.5 Test Reports

4.5.1 Copies of type test reports shall be furnished in at least six copies along with one original. One copy
will be returned duly certified by the Owner only after which the commercial production of the
material shall start.

4.5.2 Record of routine test reports shall be maintained by the Supplier at his works for periodic
inspection by the Owner’s representative.

4.5.3 Test Certificates of tests during manufacture shall be maintained by the Supplier. These shall be
produced for verification as and when desired by the Owner.

4.6 Inspection

4.6.1 The Owner’s representative shall at all times be entitled to have access to the works and all places
of manufacture, where conductor shall be manufactured, and representative shall have full facilities
for unrestricted inspection of the Supplier’s works, raw materials and process of manufacture for
conducting necessary tests as detailed herein.

4.6.2 The Supplier shall keep the Owner informed in advance of the time of starting and of the progress
of manufacture of conductor in its various stages so that arrangements can be made for inspection.

4.6.3 No material shall be dispatched from its point of manufacture before it has been satisfactorily
inspected and tested, unless the inspection is waived off by the Owner in writing. In the latter case
also, the conductor shall be dispatched only after satisfactory testing for all tests specified herein
have been completed.

4.6.4 The acceptance of any quantity of material shall in no way relieve the Supplier of any of his
responsibilities for meeting all requirements of the Specification and shall not prevent subsequent
rejection it such material is later found to be defective.

4.7 Test Facilities

The following additional test facilities shall be available at the Supplier’s works:

Calibration of various testing and measuring equipment including tensile testing machine, resistance
measurement facilities, burette, thermometer, barometer etc.

Standard resistance for calibration of resistance bridges.

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Finished conductor shall be checked for length verification and surface finish on separate rewinding machine
at reduced speed (variable from 8 to 16 meters per minute). The rewinding facilities shall have appropriate
clutch system and free of vibrations, jerks etc. with traverse laying facilities.

5 PACKING

5.1 The conductor shall be supplied in non-returnable, strong, wooden drums provided with lagging
of adequate strength, constructed to protect the conductor against all damage and displacement
during transit, storage and subsequent handling and stringing operations in the field. The Supplier
shall be responsible for any loss or damage during transportation handling and storage due to
improper packing. The drums shall generally conform to IS:1778, except as otherwise specified
hereinafter.

5.2 The drums shall be suitable for wheel mounting and for letting off the conductor under a minimum
controlled tension of the order of 5 KN.

5.3 The Bidder should submit their proposed drum drawings along with the bid.

5.4 For conductor, one standard length shall be wound on each drum.

5.5 All wooden components shall be manufactured out of seasoned soft wood free from defects that
may materially weaken the component parts of the drums. Preservative treatment shall be applied
to the entire drum with preservatives of a quality which is not harmful to the conductor.

5.6 The flanges shall be of two-ply construction with each ply at right angles to the adjacent ply and
nailed together. The nails shall be driven from the inside face flange, punched and then clenched
on the outer face. The thickness of each ply shall not vary by more than 3mm from that indicated
in the figure. There shall be at least 3 nails per plank of ply with maximum nail spacing of 75mm.
Where a slot is cut in the flange to receive the inner end of the conductor the entrance shall be in
line with the periphery of the barrel.

5.7 The wooden battens used for making the barrel of the conductor shall be of segmental type. These
shall be nailed to the barrel supports with at least two nails. The battens shall be closely butted and
shall provide a round barrel with smooth external surface. The edges of the battens shall be
rounded or chamfered to avoid damage to the conductor.

5.8 Barrel studs shall be used for the construction of drums. The flanges shall be holed, and the barrel
supports slotted to receive them. The barrel studs shall be threaded over a length on either end,
sufficient to accommodate washers, spindle plates and nuts for fixing flanges at the required
spacing.

5.9 Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used on the inner
surface of the flanges and the drum barrel shall be counter sunk. The ends of barrel shall generally
be flushed with the top of the nuts.

5.10 The inner cheek of the flanges and drum barrel surface shall be painted with a bitumen-based
paint.

5.11 Before reeling, card board or double corrugated or thick bituminized water-proof bamboo paper
shall be secured to the drum barrel and inside of flanges of the drum by means of a suitable
commercial adhesive material. After reeling the conductor, the exposed surface of the outer layer
of conductor shall be wrapped with water proof thick bituminized bamboo paper to preserve the

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 conductor from dirt, grit and damage during transport and handling.

5.12 A minimum space of 75 mm for conductor shall be provided between the inner surface of the
external protective tagging and outer layer of the conductor.

5.13 Each batten shall be securely nailed across grains as far as possible to the flange, edges with at least
2 nails per end. The length of the nails shall not be less than twice the thickness of the battens. The
nails shall not protrude above the general surface and shall not have exposed sharp, edges or allow
the battens to be released due to corrosion.

5.14 The nuts on the barrel studs shall be tack welded on the one side in order to fully secure them. On
the second end, a spring washer shall be used.

5.15 A steel collar shall be used to secure all barrel studs. This collar shall be located between the
washers and the steel drum and secured to the central steel plate by welding.

5.16 Outside the protective lagging, there shall be minimum of two binders consisting of hoop
iron/galvanised steel wire. Each protective lagging shall have two recesses to accommodate the
binders.

5.17 The conductor ends shall be properly sealed and secured on the side of one of the flanges to avoid
loosening of the conductor layers during transit and handling.

5.18 As an alternative to wooden drum Bidder may also supply the conductors in non- returnable
painted steel drums. After preparation of steel surface according to IS:9954, synthetic enamel paint
shall be applied after application of one coat of primer. Wooden/Steel drum will be treated at par
for evaluation purpose and accordingly the Bidder should quote in the package.

6 MARKING

Each drum shall have the following information stenciled on it in indelible ink along with other essential
data:

(a) Contract/Award letter number.

(b) Name and address of consignee.

(c) Manufacturer’s name and address.

(d) Drum number

(e) Size of conductor

(f) Length of conductor in meters

(g) Arrow marking for unwinding

(h) Position of the conductor ends

(i) Distance between outer-most Layer of conductor and the inner surface of lagging.

(k) Barrel diameter at three locations & an arrows marking at the location of the
measurement.

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 (l) Number of turns in the outer most layer.

(m) Gross weight of drum after putting lagging.

(n) Tear weight of the drum without lagging.

(o) Net weight of the conductor in the drum.

(p) CIP/MICC No.

The above should be indicated in the packing list also.

7 VERIFICATION OF CONDUCTOR LENGTH

The Owner reserves the right to verity the length of conductor after unreeling at least ten (10) percent of the
drums in a lot offered for inspection.

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 GTP-3
GUARANTEED TECHNICAL PARTICULARS OF TENSION HARDWARE FITTINGS

Sl. Description Unit Value guaranteed by the Bidder

1 Name of Manufacturer

2 Address of Manufacturer

3 Drawing enclosed Yes / No

Purity of aluminium used for

4 %
aluminium sleeve
5 Material for steel sleeve

(i) Type of material with chemical composition

(ii) Range of Hardness of material (Brinnel

BHN From …….to ……..
Hardness)
(iii) Weight of zinc coating gm/m2
Aluminium/ Alloy Steel
Outside diameter of sleeve before compression
6 mm

Inside diameter of sleeve before compression

7 mm

8 Length of sleeve before compression

Dimensions of sleeve after

9
compression
(a) Corner to Corner

(b) Surface to Surface

10 Length of sleeve after compression

11 Weight of sleeve

(a) Aluminium / Aluminium Alloy kg

(b) Steel kg

(c) Total kg

Electrical resistance of dead end assembly as a

12 percentage of equivalent length of Conductor %

13 Slip strength of dead end assembly kN

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14 UTS of dead end assembly kN

15 Purity of Zinc used for galvanising %

16 Design calculation of yoke plates and sag Yes / No

adjustment plate enclosed.
19 Maximum permissible continuous operating
temperature of dead end
assembly

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 SCHEDULE -4
GUARANTEED TECHNICAL PARTICULARS OF MID SPAN COMPRESSION JOINT FOR
TACSR CONDUCTOR

Value guaranteed by the

Sl. Description Unit Bidder

1. Name of Manufacturer

2 Address of Manufacturer

3 Drawing enclosed Yes / No

4 Suitable for conductor size mm

Purity of aluminium used for aluminium sleeve

5 %

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/alloy
Outside diameter of sleeve before compression
7 mm

Inside diameter of sleeve before compression

8 mm

9 Length of sleeve before compression

10 Dimensions of sleeve after 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

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 13 Slip strength kN
Resistance of the compressed unit
14 expressed, as percentage of the resistivity of %
equivalent length of bare conductor.
15 Maximum permissible continuous operating Deg. C
temperature of mid span compression joint

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 SCHEDULE -5
GUARANTEED TECHNICAL PARTICULARS OF REPAIR SLEEVE FOR TACSR CONDUCTOR

Sl. Description Unit Particulars/ Value

1. Material
2. Dimension of Aluminum sleeve Before compression
i) Inside diameter mm
ii) Outside diameter mm
iii) Length mm
3. Dimensions of Aluminum Sleeve After compression
i) Outside dimension (Corner to corner) mm
ii) Outside dimension (face to face) mm
4. Minimum corona Extinction voltage kV (rms) kV
under dry condition
5. Maximum Radio Interference Voltage at 1 MHz Micro
for phase to earth voltage of Volts
510 kV (rms) under dry condition ( V)

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 SCHEDULE - 6
GUARANTEED TECHNICAL PARTICULARS OF VIBRATION DAMPER FOR TACSR
CONDUCTOR

Value guaranteed by the

Sl. Description Unit
Bidder
1 Name of Manufacturer
2 Address of Manufacturer
3 Drawing enclosed

(a) Design Drawing YES / NO

(b) Placement Chart YES / NO
4 Suitable for conductor size

5 Total weight of one damper

Right

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

Number of strands in stranded messenger cable

12

13 Lay ratio of stranded messenger cable

Minimum ultimate tensile strength of stranded

14 Kg/mm2
messenger cable
Slip strength of stranded messenger cable (mass pull off)
15 kN

16 Resonance frequencies

(a) First frequency Hz

(b) Second frequency Hz

17 Designed clamping torque Kg-m

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 SCHEDULE - 6

GUARANTEED TECHNICAL PARTICULARS OF VIBRATION DAMPER FOR TACSR

CONDUCTOR

18 Slipping strength of damper clamp

(a) Before fatigue test kN

(b) After fatigue test kN

Magnetic power loss per vibration damper watts for ---

19 Amps, 50 Hz Alternating Current [average continuous watts
operating current]
Maximum permissible continuous operating
20 Deg. C
temperature of Vibration Damper
Percentage variation in reactance after fatigue test in
22 comparison with that. before fatigue %
test
Percentage variation in power dissipation after fatigue
23 test in comparison with that %
before fatigue test

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ANNEXURE-5A TESTS ON CONDUCTORS

1.1 UTS Test on Stranded Conductor

Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of
minimum 5 m length between fixing arrangement suitably fixed by appropriate fittings on a tensile testing
machine. The load shall be increased at a steady rate up to 50% of minimum specified UTS and held for one
minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter the load shall
be increased at steady rate to minimum UTS and held for one minute. The Conductor sample shall not fail during
this period. The applied load shall then be increased until the failing load is reached, and the value recorded.

1.2 Corona Extinction Voltage Test

One sample of conductor of 5m length shall be strung. In case of twin conductor, two samples shall be arranged
with the actual sub-conductor spacing between them. This sample assembly when subjected to power
frequency voltage shall have a corona extinction voltage of not less than 154 KV (rms) for 66 kv system line to
ground under dry condition. There shall be no evidence of corona on any part of sample when all possible
sources of corona are photographed in a darkened room. The test shall be conducted without corona control
rings. The voltage shall be corrected for standard atmospheric conditions. However, small corona rings shall
be used to prevent corona in the end fittings.

1.3 Radio Interference Voltage Test

Under the conditions as specified under (1.2) above, the insulator string along with complete hardware fittings
shall have a radio interference voltage level below 1000 micro volts at one MHz when subjected to 50 Hz AC
voltage of 154kV line to ground under dry condition for 220kV AC line. The test procedure shall be in accordance
with IS: 8263/ IEC: 60437. The Test may be carried out with corona control rings and arcing horns.

1.4 D.C. Resistance Test on Stranded Conductor

On a conductor sample of minimum 5m length two contact-clamps shall be fixed with a predetermined bolt
torque. The resistance shall be measured by a Kelvin double bridge or using micro ohm meter of suitable accuracy
by placing the clamps initially zero meter and subsequently one meter apart. The test shall be repeated at least
five times and the average value recorded. The value obtained shall be corrected to the value at 20⁰C as per IS:
398 (Part-IV)/(Part-V). The resistance corrected at 20deg C shall conform to the requirements of this
Specification.
1.5 Coefficient of linear expansion for core/core strands

The temperature and elongation on a sample shall be continuously measured and recorded at interval of
approximately 15degree C from 15degree C to maximum designed continuous operating temperature
corresponding to rated current as of specification by changing the temperature by suitable means. Coefficient
of linear expansion shall be determined from the measured results.

1.6 Breaking load test on Aluminum Alloy & Core strands and D.C Resistance test on
Aluminum Alloy wire

The above tests shall be carried out as per IEC: 888/889 and the results shall meet the requirements of the
specification.

1.7 Wrap test on Steel Core strand

The wrap test on steel strands shall be meet the requirements of IEC: 888.0. In case of aluminium clad core wire,
the same shall be wrapped around a mandel of diameter of five times that of the strand to form a helix of eight
turns. The strand shall be unwrapped. No breakage of strand shall occur.

1.8 Heat Resistance test on Aluminum Alloy wire (If Applicable)

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Breaking load test as per clause 1.5 above shall be carried out before and after heating the sample in uniform
heat furnace at 280 degC (+5/-3 degC) temperature for one hour. The breaking strength of the wire after heating
shall not be less than the 90% of the breaking strength before heating.

1.9 Chemical Analysis of Aluminum Alloy and Core

Samples taken from the Aluminum and core coils/strands shall be chemically/spectrographically analyzed. The
same shall be in conformity to the particulars guaranteed by the bidder so as to meet the requirements stated in
this Specification.

1.10 Visual and Dimensional Check on Drums

The drums shall be visually and dimensionally checked to ensure that they conform to the approved drawings.

1.11 Visual Check for Joints, Scratches etc.

Conductor drums shall be rewound in the presence of the Owner. The Owner shall visually check for scratches,
joints etc. and that the conductor generally conform to the requirements of this Specification. Ten percent (10%)
drums from each lot shall be rewound in the presence of the Owner's representative.

1.12 Dimensional Check on Core Strands and Aluminium Alloy Strands

The individual strands shall be dimensionally checked to ensure that they conform to the requirement of this
Specification.

1.13 Check for Lay-ratios of Various Layers

The lay-ratios of various layers shall be checked to ensure that they conform to the guaranteed values furnished
by the Contractor.

1.14 Procedure Qualification test on welded Aluminium Alloy strands.

Two Aluminium Alloy wire shall be welded as per the approved quality plan and shall be subjected to tensile
load. The breaking strength of the welded joint of the wire shall not be less than the guaranteed breaking
strength of individual strands.

1.15 Chemical Analysis of Zinc

Samples taken from the zinc ingots shall be chemically/ spectrographically analyzed. The same shall be in
conformity to the requirements stated in the Specification.

1.16 Galvanizing Test

The test procedure shall be as specified in IEC: 888.0. The material shall conform to the requirements of this
Specification. The adherence of zinc shall be checked by wrapping around a mandrel four times the diameter of
steel wire.

1.17 Torsion and Elongation Tests on Core Strands

The test procedures shall be as per clause No. 10.3 of IEC: 888.0. In torsion test, the number of complete twists
before fracture shall not be less than 18 on a length equal to 100 times the standard diameter of the strand. In
case test sample length is less or more than 100 times the stranded diameter of the strand, the minimum
number of twists will be proportioned to the length and if number comes in the fraction then it will be rounded
off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 1.5% for
a gauge length of 250 mm.

1.18 Bending test on conductor core strand

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A sample of conductor core strand measuring 30 cm in length shall be subject to bending with help of a vise.
The vised length of wire should be 5 cm and radius of bend 4.8 mm. The bending should be first 90 degrees left
and 90 degrees right. After this operation the strand should cut at the bending point. There should be no
separation of core and aluminium at the bending point after this operation.

1.19 Compression test on steel strand

A sample of steel core strand 10 mm in length is to be compressed by a plate with a load of 3600 kgs. The
aluminium and core strand should not break.

1.20 Aluminium conductivity test on aluminium clad strand (If Applicable)

Resistivity test as per IEC-468 shall be conducted to confirm minimum conductivity as per specification
requirement.

1.21 Minimum conductivity test on thermal resistant aluminium alloy strands (If Applicable)

Resistivity test as per IEC-468/IEC 889 shall be conducted to confirm minimum conductivity as per
specification requirement.

1.22 Stress-strain test at elevated temperature

Stress-strain test as per IEC-1089 shall be conducted keeping conductor temperature at designed maximum
temperature. The guaranteed Core UTS shall be considered for performing the test.

1.23 High Temperature endurance & creep test

A conductor sample of length equal to at least 100 X d + 2 X a (where, d is the conductor diameter and a is the
distance between the end fitting and the gauge length) shall be strung at tension equal to 25 % of conductor
UTS. The distance, a, shall be at least 25 % of the gauge length or 2 m whichever is the smaller. The conductor
sample shall be subjected to two tests as indicated below:

(i) The conductor temperature shall be maintained at 20 deg C for 1000 hours. The
elongation/creep strain of the conductor during this period shall be measured and recorded
at end of 1 hour, 10 hour, 100 hour and subsequently every 100 hour up to 1000 hours’ time
period.

(ii) The conductor temperature shall be increased to design maximum temperature in steps of 20
deg. C and thermal elongation of the conductor sample shall be measured & recorded at each
step. The temperature shall be held at each step for sufficient duration for stabilization of
temperature. Further, the temperature of the conductor shall be maintained at maximum
designed continuous operating temperature (+10 Deg. C) for 1000 hours. The
elongation/creep strain of the conductor during this period shall be measured and recorded at
end of 1 hour, 10 hour, 100 hour and subsequently every 100 hour up to 1000 hours’ time
period. After completion of the above, the core of the conductor sample shall be subjected to
UTS test where the conductor core should achieve 95% of the guaranteed core UTS. The
supplier shall plot the thermal elongation with temperature. In case of polymer composite core
conductor, the flexural strength & glass transition temperature of the core shall also be evaluated
and the same shall not be degraded by more than 10 % over the initial value. The supplier shall
plot the thermal elongation with temperature.

The supplier shall furnish details of creep characteristic in respect of the conducted based on laboratory test
and other laboratory investigations/ experimental conducted on similar type of conductor and shall indicate
creep strain values corresponding to 1 month, 6 month, 1 year, 10 year & 20 year creep at everyday tension &

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continuous designed temperature as well as room temperature.

1.24 Axial Impact Test

The conductor sample shall be suspended vertically and load applied by dropping a 650 Kg from an elevation of
4 meters above the sample. The impact velocity shall be not be less than 8 m/sec. with an initial pre-tension of
200 kgs. The curve for load vs time shall be recorded and recorded load of failure for core shall not be less than
UTS of core.

1.25 Crush Strength Test

A section of conductor is to be crushed between two six inch steel plates. Load shall be held at 350 Kgs for 1
minute and then released. All the core strands shall be subsequently disassembled and tensile tested. All the core
strands shall exhibit full strength retention

1.26 Torsional Ductility Test

The conductor sample of 10-15m shall be loaded to 20% of UTS and then loaded in increasing steps of +/-180
deg, the core shall withstand at least 16 such rotation for steel core and there shall be no damage to steel core
wires and incase of trapezoidal shaped conductor or composite conductor, after 4 rotations and after separation
of aluminum strands, the aluminum wires shall be cut and removed from the conductor and the exposed core
shall be twisted and shall withstand up to 16 rotations.

1.27 Sheaves Test (if required)

The conductor sample of minimum length of 35 meter shall be tensioned at 22 % of the UTS and shall be passed through
pulleys having diameter of 32 times that of the conductor with angle of 20 deg. between the pulleys. The conductor shall
be passed over the pulleys 36 times a speed of 2 m/sec. After this test UTS test on the conductor shall be carried out.

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 SECTION –6
TECHNICAL SPECIFICATION OF OPGW

1 SPECIFICATION FOR OPGW CABLING AND ASSOCIATED HARDWARE & FITTINGS

The broad scope of this specification includes the design, engineering, manufacturing, supply, transportation,
insurance, delivery at site, unloading, handling, storage, supervision of erection/ installation, installation,
splicing, termination, testing, demonstration for acceptance and commissioning and documentation for:

a) OPGW fibre optic cable including all associated hardware, accessories & fittings

b) Fibre Optic Distribution Panels (FODP) & Joint Box

c) Supply of spares

d) Splicing of fibres

e) Supply of all test equipment

f) All other associated work/items described in the technical specifications.

This section of the technical specification describes the functional and technical specifications of OPGW cabling
and associated hardware and fittings.

1.1 Fibre Optic Cabling

In this section of the technical specification, the functional & technical specifications of OPGW cable, associated
hardware & fittings for the requirements for G.652D Dual-Window Single Mode (DWSM) telecommunications
grade fibre optic cable is mentioned.

All optical fibre cabling including fibre itself and all associated installation hardware shall have a minimum
guaranteed design life span of 25 years. Documentary evidence in support of guaranteed life span of cable &
fibre shall be submitted by the Contractor during detailed engineering.

1.2 Required Optical Fibre Characteristics

The optical fibre to be provided should have following characteristic.

1.3 Physical Characteristic

Dual-Window Single mode (DWSM), G.652D optical fibres shall be provided in the fibre optic cables. DWSM
optical fibres shall meet the requirements defined in Table 6a.

1.4 Attenuation

The attenuation coefficient for wavelengths between 1525 nm and 1575 nm shall not exceed the attenuation
coefficient at 1550 nm by more than 0.05 dB/km. The attenuation coefficient between 1285 nm and 1330 nm
shall not exceed the attenuation coefficient at 1310 nm by more than 0.05 dB/km. The attenuation of the fibre
shall be distributed uniformly throughout its length such that there are no point discontinuities in excess of 0.10
dB. The fibre attenuation characteristics specified in table 6a shall be “guaranteed” fibre attenuation of any &
every fibre reel. The overall optical fibre path attenuation shall not be more than calculated below:

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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 6a: 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 l cc < 1260 nm

1550 nm loss performance As per ITU-T G.652 D

Proof Test Level > 0.69 GPa

@ 1310 nm < 0.35 dB/km & @ 1550

Attenuation Coefficient:
nm < 0.21 dB/km

18 ps/ (nm x km) @ 1550 nm,

Chromatic Dispersion; Maximum: 3.5 ps/ (nm x km) 1288-1339nm
Zero Dispersion Wavelength: Zero 5.3 ps/ (nm x km) 1271-1360nm, 1300 to
Dispersion Slope: 1324nm
0.092 ps/ (nm2 x km) maximum

Polarization mode dispersion

coefficient < 0.2 ps/km^½

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

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 @ 1310 nm (75±2 mm dia Mandrel), 100 turns;
Attenuation Rise < 0.05 dB
Bend 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

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 1.5 Fibre Optic Cable Construction

The OPGW (Optical Ground Wire) cable is proposed to be installed on the 66kV transmission lines. The design
of cable shall account for the varying operating and environmental conditions that the cable shall experience
while in service. The OPGW cable to be supplied shall be designed to meet the overall requirements of all the
transmission lines.

1.6 Optical Fibre Cable Link Lengths

The estimated optical fibre link lengths shall be provided by Contractor for transmission line route length.
However, the Contractor shall supply & install the optical fibre cable as required based on detailed site survey.

For the purpose of payment, the optical fibre link lengths are defined as transmission line route lengths from
Gantry at one terminating station to the Gantry in the other terminating station. The actual cable lengths to be
delivered shall take into account various factors such as sag, service loops, splicing, working lengths & wastage
etc. The unit rate for FO cable quoted in the Bid price Schedules shall take into account all such factors.

1.7 Optical Fibre Identification

Individual optical fibres within a fibre unit and fibre units shall be identifiable in accordance with EIA/TIA 598
or IEC 60304 or Bellcore GR-20 colour-coding scheme.

Colouring utilized for colour coding optical fibres shall be integrated into the fibre coating and shall be
homogeneous. The colour shall not bleed from one fibre to another and shall not fade during fibre preparation
for termination or splicing.

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

1.8 Buffer Tube

Loose tube construction shall be implemented. The individually coated optical fibre(s) shall be 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 for splicing and termination. Each fibre unit shall be individually
identifiable utilizing colour coding. Buffer tubes shall be filled with a water-blocking gel.

1.9 Optical Fibre Strain & Sag-Tension chart

The OPGW cable shall be designed and installed such that the optical fibres experience no strain under all
loading conditions defined in IS 802. Zero fibre strain condition shall apply even after a 25 year cable creep.

For the purpose of this specification, the following definitions shall apply:

• 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.

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

• The cable Maximum Allowable Tension (MAT) is defined as the maximum tension experienced
by the Cable under the worst-case loading condition.

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

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

• The Ultimate /Rated Tensile Strength (UTS/ RTS/ breaking strength) is defined as the maximum
tensile load applied and held constant for one minute at which the specimen shall not break.

• While preparing the Sag-tension charts for the OPGW cable the following conditions shall be
met:

• The Max Allowable Tension (MAT) / max strain shall be less than or equal to the MWT/ Strain
margin of the cable.

• The sag shall not exceed the earth wire sag in all conditions.

• The Max Allowable Tension shall also be less than or equal to 0.4 times the UTS of OPGW.
However, Maximum Allowable Tension up to 0.5 times the UTS of OPGW may be accepted,
subject to no fibre strain.

• The 25-year creep at 25% of UTS (creep test as per IEEE 1138) shall be such that the 25-year
creep plus the cable strain at Max Allowable Tension (MAT) is less than or equal to the cable
strain margin.

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

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

1. 53° C, no wind and no ice

2. 32° C, no wind and no ice

3. 0°C, no wind and no ice

4. 32° C, full wind and no ice

5. 32° C, 75% full wind and no ice

6. 0° C, 2/3rd / 36% of full wind (IS 802)

The above cases shall be considered for the spans from 100 m to 600 m or higher span length in the range of 50
m spans. Max. Vertical sag, max. tension and max sag at 0°C & no wind shall be considered in line with the design
parameter of transmission line. The full wind load shall be considered as the design wind load for all the
specified transmission lines as per relevant IS 802 version and the sag- tension chart shall be submitted
considering the transmission lines. In case of any span higher than 600m, suitable OPGW cable meeting sag-
tension requirement of transmission line shall also be provided by the Contractor. The Contractor shall submit
the stringing chart for review of DNHDDPCL.

1.10 Cable Materials

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

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 1.11 Filling Materials

The interstices of the fibre optic unit and cable shall be filled with a suitable compound to prohibit any moisture
ingress or any water longitudinal migration within the fibre optic unit or along the fibre optic cable. The water
tightness of the cable shall meet or exceed the test performance criteria as per IEC 60794-1-F-5.

The filling compound used shall be a non-toxic homogeneous waterproofing compound that is free of dirt and
foreign matter, non-hygroscopic, electrically non-conductive and non-nutritive to fungus. The compound shall
also be fully compatible with all cable components it may come in contact with and shall inhibit the generation
of hydrogen within the cable.

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

1.12 Metallic Members

When the fibre optic cable design incorporates metallic elements in its construction, all metallic elements shall
be electrically continuous.

1.13 Marking, Packaging and Shipping

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

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

(b) Cable Drums: All optical fibre cabling shall be supplied on sturdy, corrosion resistant, steel
drums suitable for long periods of storage and re-transport & handling. All drums provided
with lagging or PP sheets of adequate strength, constructed to protect the cabling against all
damage and displacement during transit, storage and subsequent handling during installation.
Both ends of 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 with each
drum as required.

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

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

1.14 Optical Ground Wire (OPGW)

OPGW cable construction shall comply with IEEE-1138, 2009. The cable provided shall meet both the
construction and performance requirements such that the ground wire function, the optical fibre integrity and
optical transmission characteristics are suitable for the intended purpose. The cable shall consist of optical fibre
units as defined in this specification. There shall be no factory splices within the cable structure of a continuous
cable length.

The composite fibre optic overhead ground wire shall be made up of multiple buffer tubes embedded in a water
tight aluminium/ aluminium alloy/stainless steel with aluminium coating protective central fibre optic unit

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surrounded by concentric-lay stranded metallic wires in single or multiple layers. In case of central Aluminum tube
type OPGW, each buffer tube shall have maximum 12 no. of fibers and all fibers in single buffer tube is not
acceptable. The dual purpose of the composite cable is to provide the electrical and physical characteristics of
conventional overhead ground wire while providing the optical transmission properties of optical fibre.

1.15 Central Fibre Optic Unit

The central fibre optic unit shall be designed to house and protect multiple buffered optical fibre units from
damage due to forces such as crushing, bending, twisting, tensile stress and moisture. The central fibre optic
unit and the outer stranded metallic conductors shall serve together as an integral unit to protect the optical
fibres from degradation due to vibration and galloping, wind and ice loadings, wide temperature variations,
lightning and fault current, as well as environmental effects which may produce hydrogen.

The OPGW design of dissimilar materials such as stainless-steel tube with aluminum or aluminum–clad-steel
wire strands are not allowed. Central fibre optic unit may be of aluminum or stainless-steel tube with
aluminum protective coating. In case of aluminum protective coating, the coating must completely cover the
tubes leaving no exposed areas of tubing that can make electrical contact either directly or indirectly through
moisture, contamination, protrusions, etc with the surrounding stranded wires. The tube may be fabricated as
a seamless tube, seam welded, or a tube without a welded seam.

1.16 Basic Construction

The OPGW cable construction shall conform to the applicable requirements of this specification, applicable
clauses of IEC 61089 related to stranded conductors. In addition, the basic construction shall include bare
concentric-lay stranded metallic wires with the outer layer having left hand lay. The wires may be of multiple
layers with a combination of various metallic wires within each layer. The direction of lay for each successive
layer shall be reversed. The finished wires shall contain no joints or splices unless otherwise agreed to by the
DNHDDPCL and shall conform 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 wires can be readily regrouped
and then held in place by one hand.

1.17 Breaking Strength

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

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

1.18 Electrical and Mechanical Requirements

“Table 6b” provides OPGW Electrical and Mechanical Requirements for the minimum performance
characteristics. Additionally, the OPGW mechanical & electrical characteristics shall be similar to that of the
earthwire being replaced such that there is no or minimal consequential increase in stresses on towers. For the
purposes of determining the appropriate Max Working Tension limit for the OPGW cable, IS 802 shall be
applied. However, the OPGW installation sag & tension charts shall be based on IS 802 version to which the line
is originally designed. For the OPGW cable design selection and preparation of sag tension charts, the limits
specified in this section shall also be satisfied.

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 TABLE 6b: OPGW ELECTRICAL AND MECHANICAL REQUIREMENTS

1) Everyday Tension < 20% of UTS of OPGW

2) D.C. Resistance at 20ºC: < 1.0 ohm/Km

> 6.32 kA for 1.0 second (for 66 kv & above lines)

3) Short Circuit Current
Short Circuit shall be applicable as per the voltage level
of the line

Ultimate tensile Strength(UTS) The following parameter of the existing earth wire also shall
4) be considered for UTS design

Outer diameter(66kV)
4a) 10.98 mm

4b) UTS (66kV) 68.4 KN

Weight per Km
4c) (66kV) 583 Kgs

1.19 Operating conditions

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

1.20 Installation Hardware

The scope of supply includes all required fittings and hardware such as Tension assembly, Suspension
assembly, Vibration dampers, reinforcing rods, Earthing clamps, Down-lead clamps, splice enclosure etc. The
Bidder shall provide documentation justifying the adequacy and suitability of the hardware supplied. The
quantity of hardware & fittings to meet any eventuality during site installation minimum @ 1% shall also be
provided as part of set/ km for each transmission line without any additional cost to DNHDDPCL.

The OPGW hardware fittings and accessories shall follow the general requirements regarding design, materials,
dimensions & tolerances, protection against corrosion and markings as specified in clause 4.0 of EN 61284:
1997 (IEC 61284). The shear strength of all bolts shall be at least 1.5 times the maximum installation torque.
The OPGW hardware & accessories drawing & GTP (DRS) document shall consist of three parts:

(1) A technical particular sheet

(2) An assembly drawing i.e. level 1 drawing and

(3) Component level drawings i.e. level 2 & lower drawings. All component reference numbers,
dimensions and tolerances, bolt tightening torques & shear strength and ratings such as UTS,
slip strength etc shall be marked on the drawings.

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

(a) Suspension Assemblies: Preformed armour grip suspension clamps and aluminium alloy

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 armour rods/ reinforcing rods shall be used. The suspension clamps shall be designed to
carry a vertical load of not less than 25 KN. The suspension clamps slippage shall occur
between 12kN and 17 kN as measured.

The Contractor shall supply all the components of the suspension assembly including shackles, bolts, nuts,
washers, split pins, etc. The total drop of the suspension assembly shall not exceed 150 mm (measured from the
centre point of attachment to the centre point of the OPGW). The design of the assembly shall be such that the
direction of run of the OPGW shall be the same as that of the conductor.

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

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

(d) Structure Attachment Clamp Assemblies: Clamp assemblies used to attach the OPGW to
the structures, shall have two parallel grooves for the OPGW, one on either side of the
connecting bolt. The clamps shall be such that clamping characteristics do not alter
adversely when only one OPGW is installed. The tower attachment plates shall locate the
OPGW on the inside of the tower and shall be attached directly to the tower legs/cross-
members without drilling 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 corresponding to
wind speed of 1m/s to 7 m/s, shall be used for suspension and tension points in each span.
The Contractor shall determine the exact numbers and placement(s) of vibration
dampers through a detailed vibration analysis as specified in technical specifications.

One damper minimum on each side per OPGW cable for suspension points and two dampers minimum on each
side per OPGW cable for tension points shall be used for nominal design span of 400 meters. For all other ruling
spans, the number of vibration damper shall be based on vibration analysis.

The clamp of the vibration damper shall be made of high strength aluminum alloy of type LM-6. It shall be
capable of supporting the damper and prevent damage or chaffing of the conductor during erection or
continued operation. The clamp shall have smooth and permanent grip to keep the damper in position on the
OPGW cable without damaging the strands or causing premature fatigue failure of the OPGW cable under the
clamp. The clamp groove shall be in uniform contact with the OPGW cable over the entire clamping surface
except for the rounded edges. The groove of the clamp body and clamp cap shall be smooth, free from
projections, grit or other materials which could cause damage to the OPGW cable when the clamp is installed.
Clamping bolts shall be provided with self-locking nuts and designed to prevent corrosion of threads or
loosening in service.

The messenger cable shall be made of high strength galvanised steel/stainless steel. It shall be of preformed
and post formed quality in order to prevent subsequent drop of weight and to maintain consistent flexural
stiffness of the cable in service. The messenger cable other than stainless steel shall be hot dip galvanised in
accordance with the recommendations of IS:4826 for heavily coated wires.

The damper mass shall be made of hot dip galvanised mild steel/cast iron or a permanent mould cast zinc alloy.

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All castings shall be free from defects such as cracks, shrinkage, inclusions and blow holes etc. The surface of the
damper masses shall be smooth.

The damper clamp shall be casted over the messenger cable and offer sufficient and permanent grip on it. The
messenger cable shall not slip out of the grip at a load less than the mass pull-off value of the damper. The
damper masses made of material other-than zinc alloy shall be fixed to the messenger cable in a suitable manner
in order to avoid excessive stress concentration on the messenger cables which shall cause premature fatigue
failure of the same. The messenger cable ends shall be suitably and effectively sealed to prevent corrosion. The
damper mass made of zinc alloy shall be casted over the messenger cable and have sufficient and permanent
grip on the messenger cable under all service conditions.

The contractor must indicate the clamp bolt tightening torque to ensure that the slip strength of the clamp is
maintained between 2.5 kN and 5 kN. The clamp when installed on the OPGW cable shall not cause excessive
stress concentration on the OPGW cable leading to permanent deformation of the OPGW strands and premature
fatigue failure in operation.
The vibration analysis of the system, with and without damper and dynamic characteristics of the damper as
detailed in Technical Specification, shall have to be submitted. The technical particulars for vibration analysis
and damping design of the system are as follows:

Sl No. Description Technical Particulars

Span Length in meters

(i) Ruling design span: 150 meters
1
250 meters
(ii) Maximum span:
70 meters
(iii) Minimum Span:

2 Configuration: As per Specifications

3 Tensile load in each: As per sag tension calculations

Standard preformed armour rods/AGS
4 Armour rods used:

Maximum permissible dynamic strain:

5 5 +/- 150 micro strains

The damper placement chart for spans ranging from 100m to 250m shall be submitted by the Contractor.
Placement charts should be duly supported with relevant technical documents and sample calculations.
The damper placement charts shall include the following
(1) Location of the dampers for various combinations of spans and line tensions clearly indicating
the number of dampers to be installed per OPGW cable per span.

(2) Placement distances clearly identifying the extremities between which the distances are to be
measured.

(3) Placement recommendation depending upon type of suspension clamps (viz Free center
type/Armour grip type etc.)

(4) The influence of mid span compression joints, repair sleeves and armour rods (standard and
AGS) in the placement of dampers.

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 1.21 Fibre Optic Splice Enclosures (Joint Box)

All splices shall be encased in Fibre Optic Splice Enclosures. Suitable splice enclosures shall be provided to
encase the optical cable splices in protective, moisture and dust free environment. Splice enclosures shall
comply with ingress protection class IP 66 or better. The splice enclosures shall be designed for the storage and
protection of required number of optical fibre splices and equipped with sufficient number of splice trays for
splicing all fibres in the cable. Not more than 12 fibres shall be terminated in a single splice tray. They shall be
filled with suitable encapsulate that is easily removable should re-entry be required into the enclosures.
Splice enclosures shall be suitable for outdoor use with each of the cable types provided under this contract.
Splice enclosures shall be appropriate for mounting on transmission line towers above anti-climb guard levels
at about 10 metres from top of the tower and shall accommodate pass-through splicing. Contractor shall be
responsible for splicing of fibres and installation of splice enclosures.
1.22 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 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.

(d) For each link, bi-directional attenuation of single mode fusion splices, shall not average more
than 0.05 dB and no single splice loss shall exceed 0.1 dB when measured at 1550 nm.

(e) For splicing, fibre optic cable service loops of adequate length shall be provided so that all splices
occurring at tower structures can be performed at ground level.

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

(b) Fibre Units Service Loops: For all fibre optic cable splicing, the cable shall be stripped back 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.

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

(d) Fibre Service Loops: At least 0.5 metre of bare fibre service loop shall be provided on
each side of all fibre splices. The bare fibre service loops shall be neatly and safely
installed inside covered splice trays.

2 INSPECTION & TESTING REQUIREMENT

All materials furnished, and all work performed under this Contract shall be inspected and tested. Deliverables
shall not be shipped until all required inspections and tests have been completed, and all deficiencies have been

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corrected to comply with this Specification and approved for shipment by the DNHDDPCL.
Except where otherwise specified, the Contractor shall provide all manpower and materials for tests, including
testing facilities, logistics, power and instrumentation, and replacement of damaged parts. The costs shall be
borne by the Contractor and shall be deemed to be included in the contract price.
The entire cost of testing for factory, production tests and other test during manufacture specified
herein shall be treated as included in the quoted unit price of materials.
Acceptance or waiver of tests shall not relieve the Contractor from the responsibility to furnish material in
accordance with the specifications.
All tests shall be witnessed by the DNHDDPCL and/or its authorized representative (hereinafter referred to as
the DNHDDPCL) unless the DNHDDPCL authorizes testing to proceed without witness.
Should any inspections or tests indicate that specific item does not meet Specification requirements; the
appropriate items shall be replaced, upgraded, or added by the Contractor as necessary to correct the noted
deficiencies at no cost to the DNHDDPCL. After correction of a deficiency, all necessary retests shall be
performed to verify the effectiveness of the corrective action.
The DNHDDPCL reserves the right to require the Contractor to perform, at the DNHDDPCL's expense, any other
reasonable test(s) at the Contractor's premises, on site, or elsewhere in addition to the specified Type,
Acceptance, Routine, or Manufacturing tests to assure the DNHDDPCL of specification compliance.
2.1 Test Plans and Procedures

Test plans and test procedures for both factory and site acceptance tests shall be provided by the Contractor.
Test plans and test procedures shall ensure that each factory and site test is comprehensive and verify all the
features of the equipment to be tested. Test plans and test procedures shall be modular to allow individual test
segments to be repeated upon request.
The Contractor shall give the DNHDDPCL twenty-one (21) days written notice of any material being ready for
testing. Fifteen days prior to the scheduled testing, the DNHDDPCL shall provide written notice to the Contractor
of any drawings, equipment, material, or workmanship in which the DNHDDPCL’s opinion, are not compliant to
the specification. The contractor shall give due consideration to such objections, if valid, effecting the
corrections as necessary or shall prove, in writing, that said modifications are unnecessary for contract
compliance.
2.2 Factory and Site Test Plans

A test plan for factory and site acceptance tests shall be submitted for the DNHDDPCL approval, at least four (4)
weeks before the start of testing. The test plan shall be a single overview document that defines the overall
schedule and individual responsibilities associated with conducting the tests, documenting the test results, and
successfully completing the test criteria.
2.3 Test Procedures

Test procedures for factory and site testing shall be submitted for the DNHDDPCL approval at least four (4)
weeks before each individual test. Testing shall not commence without approved test procedures.
All test equipment and/or instruments shall bear calibration stickers indicating valid calibration on and beyond
the testing date. The time lapsed since last calibration shall not exceed the test equipment/ jig manufacturer
recommended calibration interval or the interval recommended in the test lab’s internal quality procedures.
The Contractor shall ensure that all testing will be performed by qualified testing personnel well experienced
in performing such tests.
2.4 Test Records

Complete and indexed records of all factory and site acceptance tests results shall be maintained and provided
to the DNHDDPCL by the Contractor in hard & soft copy. The records shall be keyed to the steps enumerated in
the test procedures.

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All principle test records, test certificates and performance curves shall be supplied for all tests carried out as
proof of compliance with the specifications and/or each and every specified test. These test certificates, records
and performance curves shall be supplied for all tests, whether or not they have been witnessed by the
DNHDDPCL within the specified duration after the completion of test. Information given on such test certificates
and curves shall be sufficient to identify the material or equipment to which the certificates refer and shall also
bear the Contractor's reference and heading.
2.5 Rejection of Elements

Any item or component which fails to comply with the requirements of this Specification in any respect, at any
stage of manufacture, test, erection or on completion at site may be rejected by the DNHDDPCL either in whole
or part as considered necessary. Material or components with defects of such a nature that do not meet the
requirements of the Specification by adjustment or modification shall be replaced by the Contractor at his own
expense. After adjustment or modification, the Contractor shall submit the items to the DNHDDPCL for further
inspection and/or tests.
2.6 Testing Requirements: Following are the requirements of testing:

1. Type Testing

2. Factory Acceptance Testing

3. Site Acceptance Testing

2.7 Type Testing

"Type Tests" shall be defined as those tests which are to be carried out to prove the design, process of
manufacture and general conformity of the materials to this Specification. Type Testing shall comply with the
following:
(a) All cable & equipment being supplied shall conform to type tests as per technical specification.

(b) The test reports submitted shall be of the tests conducted within last seven (7) years for OPGW
cable prior to the date of proposal/offer submitted. In case the test reports are older than seven
(7) years for OPGW cable on the date of proposal/offer, the Contractor shall repeat these tests
at no extra cost to the DNHDDPCL.

(c) The Contractor shall submit, within 30 days of Contract Award, copies of test reports for all of
the Type Tests that are specified in the specifications and that have previously (before Contract
award) been performed.

These reports may be accepted by the DNHDDPCL only if they apply to materials and equipment that are
essentially identical to those due to be delivered under the Contract and only if test procedures and parameter
values are identical to those specified in this specification carried out at accredited labs and witnessed by third
party / customer’s representatives.
In the event of any discrepancy in the test reports or any type tests not carried out, same shall be carried out by
Contractor without any additional cost implication to the DNHDDPCL.
In case the Type Test is required to be carried out, then following shall be applicable: -
(a) Type Tests shall be certified or performed by reputed laboratories using material and
equipment data sheets and test procedures that have been approved by the DNHDDPCL. The
test procedures shall be formatted as defined in the technical specifications and shall include
a complete list of the applicable reference standards and submitted for DNHDDPCL approval
at least four (4) weeks before commencement of test(s). The Contractor shall provide the
DNHDDPCL at least 30 days written notice of the planned commencement of each type test.

(b) The Contractor shall provide a detailed schedule for performing all specified type tests. These

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 tests shall be performed in the presence of a representative of the DNHDDPCL.

(c) The Contractor shall ensure that all type tests can be completed within the time schedule
offered in his Technical Proposal.

In case of failure during any type test, the Supplier is either required to manufacture a fresh sample lot and
repeat all type tests successfully or repeat that particular type test(s) at least three times successfully on the
samples selected from the already manufactured lot at his own expenses. In case a fresh lot is manufactured for
testing then the lot already manufactured shall be rejected.
2.8 Type Test Samples

The Contractor shall supply equipment/material for sample selection only after the Quality Assurance Plan has
been approved by the DNHDDPCL. The sample material shall be manufactured strictly in accordance with the
approved Quality Assurance Plan. The Contractor shall submit for DNHDDPCL approval, the type test sample
selection procedure. The selection process for conducting the type tests shall ensure that samples are selected
at random. For optical fibres/ Fibre Optic cables, at least three reels/ drums of each type of fibre/cable proposed
shall be offered for selection. For FO cable installation hardware & fittings at least ten (10) samples shall be offered
for selection. For Splice enclosures at least three samples shall be offered for selection.
2.9 List of Type Tests

The type testing shall be conducted on the following items

(a) Optical fibres
(b) OPGW Cable
(c) OPGW Cable fittings
(d) Vibration Damper
(e) Splice Enclosure (Joint Box)
2.10 Type Tests for Optical Fibres

The type tests listed below in Table 6d shall be conducted on DWSM fibres to be supplied as part of overhead
cables. The tests specific to the cable type are listed in subsequent sections.
Table 6d: TYPE TESTS FOR OPTICAL FIBRES

ACCEPTANCE CRITERIA
Sl NO. TEST NAME TEST PROCEDURE

IEC 60793-1-40 Or
1 Attenuation As per Clause-1 of TS
EIA/TIA 455-78A

Attenuation Variation with IEC 60793-1-40 Or

2 Wavelength As per Clause-1 of TS
EIA/TIA 455-78A

Attenuation at Water Peak IEC 60793-1-40 Or

3 As per Clause-1 of TS
EIA/TIA 455-78A

Temp. Cycling IEC 60793-1-52 Or

4 (Temp dependence of As per Clause-1 of TS EIA/TIA 455-3A, 2
cycles
Attenuation)

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 Attenuation with Bending IEC 60793-1-47 Or
5 As per Clause-1 of TS
(Bend Performance) EIA/TIA 455-62A

IEC 60793-1-45 Or
6 Mode Field dia. As per Clause-1 of TS EIA/TIA 455-
164A/167A/174
IEC 60793-1-42 Or
7 Chromatic Dispersion As per Clause-1 of TS EIA/TIA 455-
168A/169A/175A
IEC 60793-1-20 Or
8 Cladding Diameter As per Clause-1 of TS
EIA/TIA 455-176

Point Discontinuities of IEC 60793-1-40 Or

9 As per Clause-1 of TS
Attenuation EIA/TIA 455-59

Core –Clad concentricity error IEC 60793-1-20 Or

10 As per Clause-1 of TS
EIA/TIA 455-176

Fibre Tensile Proof IEC 60793-1-30 Or

11 As per Clause-1 of TS
Testing EIA/TIA 455-31B

2.11 Type Tests for OPGW Cables

The type tests to be conducted on the OPGW cable are listed in Table 6e Type Tests for OPGW Cables. Unless
specified otherwise in the technical specifications or the referenced standards, the optical attenuation of the
specimen, measured during or after the test as applicable, shall not increase by more than 0.05 dB/Km.
Table 6e: TYPE TESTS FOR OPGW CABLE

SR. TEST NAME TEST DESCRIPTION TEST PROCEDURE

NO.
Water IEEE 1138- IEEE 1138- Test duration: 24 hours
Ingress Test 2009 2009(IEC
6074-1-2
1
Method F5 or
EIA/TIA 455-
82B)

Seepage of IEEE 1138- IEEE 1138- Preconditioning period: 72 hours. Test

2 duration: 24 hours.
filling 2009 2009 (EIA/ TIA
compound 455-81B)
Short Circuit IEEE 1138- IEEE 1138- Fibre attenuation shall be
Test 2009 2009 continuously monitored and
recorded through a digital data
logging system or equivalent
means.
A suitable temperature sensor
such as thermocouple shall be

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 used to monitor and record
the temperature inside the
OPGW tube in addition to
3 monitoring & recording the
temperatures between the
strands and between optical
tube and the strand as
required by IEEE 1138.
Test shall be conducted with
the tension clamps proposed
to be supplied. The cable and
the clamps shall be visually
inspected for mechanical
damage and photographed
after the test.
Or IEC60794- Initial temperature during the
4-10/IEC test shall be greater than or
60794-1-2 equal to ambient field
(2003) Method temperature.
H1
Aeolian IEEE 1138- IEEE 1138- Fibre attenuation shall be
Vibration 2009 2009 continuously monitored and
Test recorded through a digital data
logging system or equivalent
4
means.
Or The vibration frequency and
IEC60794-4-10 amplitude shall be monitored
/ and recorded continuously.
IEC 60794-1-2, All fibres of the test cable
Method E19 sample shall be spliced together in
serial for attenuation monitoring.
Test shall be conducted with the
tension/suspension clamps proposed
to be supplied. The cable and the
clamps shall be visually inspected for
mechanical damage and
photographed after the test.

Galloping test IEEE 1138- IEEE 1138- Test shall be conducted with the
2009 2009 tension/suspension clamps
proposed to be supplied. The
cable and clamps shall be
visually inspected for mechanical
5
damage and
photographed after the test.

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 All fibres of the test cable
sample shall be spliced
together in serial for
attenuation monitoring.
Cable Bend Test Procedure 2 in IEC 60794-1-2 The short-term and long-term bend
Method E11 tests shall be conducted in
accordance with Procedure 2 in
IEC60794-1-2 E11 to
determine the minimum acceptable
6 radius of bending without any
increase in attenuation or any other
damage to the fibre optic cable core
such as bird caging,
deformation, kinking and crimping.

Sheave Test IEEE 1138- IEEE 1138- Fibre attenuation shall be continuously
2009 2009 monitored and recorded through a
digital data logging system or
equivalent means.
The Sheave dia. shall be based on the
OR pulling angle and the minimum pulley
dia employed during installation.
7
All fibres of the test cable sample
IEC 60794-1-2 shall be spliced together in serial
(2003) Method E1B for attenuation monitoring.

Crush Test IEEE 1138- IEEE 1138- The crush test shall be carried out on a
8
2009 2009 sample of approximately one (1) metre

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 (IEC 60794-1- long in accordance with IEC 60794-
2, 1-2 E3. A load equal to
Method E3/ 1.3 times the weight of a 400- metre
EIA/TIA 455- length of fibre optic cable shall be
41B) applied for a period of 10 minutes. A
permanent or temporarily increase
in optical attenuation value greater
than 0.1 dB change in sample shall
constitute failure. The load shall be
further increased in small
increments until the measured
attenuation of the optical waveguide
fibres increases and the failure load
recorded along with results.

Impact Test IEEE 1138- IEEE 1138- The impact test shall be carried out in
2009 2009, accordance with IEC 60794-1-2 E4.
Five
(IEC 60794-1-
separate impacts of 0.1- 0.3kgm shall
2 E4/ EIA/TIA be applied. The radius of the
9 455- 25B) intermediate piece shall be the reel
drum radius ± 10%. A permanent or
temporary increase in optical
attenuation value greater than
0.1 dB/km change in sample shall
constitute failure.

Creep Test IEEE 1138- IEEE 1138- As per Aluminium Association

2009 2009 Method, the best-fit straight line
shall be fitted to the recorded creep
data and shall be extrapolated to 25
years.
10 The strain margin of the cable at the
end of 25 years shall be calculated. The
time when the creep shall achieve the
strain margin limits shall also be
calculated.

11 Fibre Strain Test IEEE 1138- IEEE 1138-1994

1994
12 Stress strain Test IEEE 1138- IEEE 1138-2009
2009

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 Cable Cut-off IEEE 1138- IEEE 1138-1994
13
Wavelength 1994
test
14 Temperature IEEE 1138- IEEE 1138-2009 Or
Cycling Test 2009 IEC 60794-1-2, Method F1
Corrosion (Salt EIA/TIA 455-16A/IEEE 1138: 2009
15 Spray)
Test
Tensile IEC 60794-1-2 E1 / EIA/TIA 455- The test shall be conducted on a
Performance 33B sample of sufficient length in
Test accordance with IEC 60794-1- 2 E1.
The attenuation variation shall not
exceed 0.05 dB/Km up to 90% of RTS of
fibre optic cable. The load shall be
increased at a steady rate up to rated
tensile strength and held for one (1)
16 minute. The fibre optic cable sample
shall not fail during the period.
The applied load shall then be
increased until the failing load
is reached, and the value
recorded.

Lightning Test IEC 60794-4-10 / The OPGW cable construction shall be

17 IEC 60794-1-2 (2003) tested in accordance
with IEC 60794-1-2, Method H2 for
Class 1.
DC On a fibre optic cable sample of minimum 1 metre length, two contact clamps
Resistance shall be fixed with a predetermined bolt torque. The resistance shall be measured
Test (IEC by a Kelvin double bridge by placing the clamps initially zero metre and
18 subsequently one metre apart.
60228)
The tests shall be repeated at least five times and the average value recorded
after correcting at 20°C.

2.12 Type Test on OPGW Cable Fittings

The type tests to be conducted on the OPGW Cable fittings and accessories are listed below:
(i) Mechanical Strength Test for Suspension/Tension Assembly

Applicable Standards: IEC 61284, 1997.

SUSPENSION ASSEMBLY
The armour rods /reinforcement rods are assembled on to the approved OPGW using the Installation
Instructions to check that the assembly is correctly fitted and is the same that will be carried out during

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installations.
Part 1:
The suspension assembly shall be increased at a constant rate up to a load equal to 50% of the specified
minimum Failure Load increased and held for one minute for the test rig to stabilize. The load shall then be
increased at a steady rate to 67% of the minimum Failure Load and held for five minutes. The angle between
the cable, the Suspension Assembly and the horizontal shall not exceed 16 o. This load shall then be removed in
a controlled manner and the Protection Splice disassembled. Examination of all the components shall be made
and any evidence of visual deformation shall be documented.
Part 2:
The Suspension clamp shall then be placed in the testing machine. The tensile load shall gradually be increased
up to 50% of the specified Minimum Failure Load of the Suspension Assembly and held for one minute for the
Test Rig to stabilize and the load shall be further increased at a steady rate until the specified minimum Failure
Load is reached and held for one minute. No fracture should occur during this period. The applied load shall
then be increased until the failing load is reached, and the value shall be documented.
TENSION ASSEMBLY
The Tension Assembly is correctly fitted and is the same that will be carried out during installations.
Part 1:
The tension assembly (excluding tension clamp) shall be increased at a constant rate up to a load equal to 50%
of the specified minimum Failure Load increased at a constant rate and held for one minute for the test rig to
stabilize. The load shall then be increased at a steady rate to 67% of the minimum Failure Load and held for five
minutes. This load shall then remove in a controlled manner and the Tension Assembly disassembled.
Examination of the Tension Dead-End and associated components shall be made, and any evidence of visual
deformation shall be documented.
Part 2:
The Tension Dead-End and associated components shall then be reassembled, and bolts tightened as before. The
tensile load shall gradually be increased up shall gradually be increased up to 50% of the specified Minimum
Failure Load of the Tension Assembly and held for one minute for the Test Rig to stabilize and the load shall be
further increased at a steady rate until the specified minimum Failure Load is reached and held for one minute.
No fracture should occur during this period. The applied load shall then be increased until the failing load is
reached, and the value shall be documented.
Acceptance Criteria for Tension/Suspension Assembly:
• No evidence of binding of the Nuts or Deformation of components at end of Part 1 of Test.
• No evidence of Fracture at the end of one minute at the minimum failure load during Part 2 of
the Test.

Any result outside these parameters shall constitute a failure

(ii) Clamp Slip Strength Test for Suspension Assembly

The suspension assembly shall be vertically suspended by means of a flexible attachment. A suitable length fibre
optical cable shall be fixed in the clamps.
Once the Suspension Clamp has been assembled, the test rig is tensioned to 1 kN and the position scale on the
recorder ‘zeroed’. The test rig is then tensioned to 2.5 kN and the relative positions of the Reinforcing Rods,
Armour Rods and Suspension Clamp shall be marked by a suitable means to confirm any slippage after the test
has been completed. The relative positions of the helical Armour Rods and associated Reinforcing Rods at each
end shall be marked and also 2 mm relative position between clamp body and Armour Rods shall be marked on
one side. The load shall be increased to 12 kN at a loading rate of 3 kN/min and held for one minute. At the end
of this one minute period, the relative displacement between clamp body and the armour rods shall be observed.
If the slippage is 2 mm or above, the test shall be terminated. Otherwise, at the end of one minute the position

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of the clamp body and 2 mm. relative positions between clamp body and armour rods shall be marked on the
other side. After the one minute pause, the load shall be further increased at a loading rate of 3 kN/min, and
recording of load and displacement shall continue until either the relative Position displacement between clamp
body and armour rods reaches more than 2 mm or the load reaches the maximum slip load of 17 kN. On reaching
either of the above values the test is terminated. Visual examination of all paint marks shall be recorded, and a
measurement of any displacement recorded in the Table of Results.
Acceptance Criteria:
The Suspension Clamp has passed the Slip Test if the following conditions are met:
No slippage* shall occur at or below the specified minimum slip load.
Definition of no slippage in accordance with IEC 61284, 1997: - Any relative movement less than 2 mm is
accepted. The possible couplings or elongations produced by the cable as a result of the test itself are not
regarded as slippage.
Slippage shall occur between the specified maximum and minimum slip load of 12 - 17 kN.
There shall be no slippage of the Reinforcing Rods over the cable, and no slippage of the Armour Rods over the
Reinforcing Rods.
The relative movement (i.e. more than 2 mm between Armour Rods & Clamp body) between minimum 12 kN
and maximum slip 17 kN, shall be considered as slip.
The Armour Rods shall not be displaced from their original lay or damaged**.
** Definition of no damage in accordance with convention expressed in IEC 61284:1997 no damage, other than
surface flattening of the strands shall occur.
Any result outside these parameters is a failure.
(iii) Slip Strength Test of Tension Clamp

Tension clamps shall be fitted on an 8 m length of fibre optic cable on both ends. The assembly shall be mounted
on a tensile testing machine and anchored in a manner similar to the arrangement to be used in service. A
tensile load shall gradually be applied up to 20% of the RTS of OPGW. Displacement transducers shall be
installed to measure the relative movement between the OPGW relative to the Reinforcing Rods and Tension
Dead –End relative to Reinforcing Rods. In addition, suitable marking shall be made on the OPGW and Dead-End
to confirm grip. The load shall be gradually increased at a constant rate up to 50 % of the UTS and the position
scale of the recorder is zeroed. The load shall then gradually have increased up to 95 % of the UTS and
maintained for one minute. After one minute pause, the load shall be slowly released to zero and the marking
examined and measured for any relative movement.
Acceptance Criteria:
• No movement* shall occur between the OPGW and the Reinforcing Rods, or between the
Reinforcing Rods and the Dead-End assembly.

• No failure or damage or disturbance to the lay of the Tension Dead-End, Reinforcing Rods
or OPGW.

• Definition of no movement as defined in IEC 61284: Any relative movement less than 2 mm
is accepted. The possible couplings or elongations produced by the conductor as a result of
the test itself are not regarded as slippage.

Any result outside these parameters shall constitute a failure

(iv) Grounding Clamp and Structure Mounting Clamp Fit Test

For structure mounting clamp, one series of tests shall be conducted with two fibre optic cables installed, one
series of tests with one fibre optic cable installed in one groove, and one series of tests with one fibre optic cable
in the other groove. Each clamp shall be installed including clamping compound as required on the fibre optic

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cable. The nut shall be tightened on to the bolt by using torque wrench with a torque of 5.5 kgm or supplier's
recommended torque and the tightened clamp shall be held for 10 minutes. After the test remove the fibre optic
cable and examine all its components for distortion, crushing or breaking. Also, the fibre optic cable shall be
checked to ensure free movement within the core using dial callipers to measure the diameter of the core tube.
The material shall be defined as failed if any visible distortion, crushing, cracking or breaking of the core tube
is observed or the fibre optic cable within the core tube is not free to move, or when the diameter of the core
tube as measured at any location in the clamped area is more than 0.5 mm larger or smaller of the core diameter
as measured outside the clamped area.
(v) Structure Mounting Clamp Strength Test

The clamp and mounting assembly shall be assembled on a vertical 200 mm x 200 mm angle and a short length
of fibre optic cable installed. A vertical load of 200 kg shall be applied at the end of the mounting clamp and held
for 5 minutes. Subsequently, the load shall be increased to 400 kg and held for 30 seconds. Any visible
distortion, slipping or breaking of any component of the mounting clamp or assembly shall constitute failure.
2.13 Type Test on Vibration Damper

(a) Dynamic Characteristic Test

The damper shall be mounted with its clamp tightened with torque recommended by the manufacturer on
shaker table capable of simulating sinusoidal vibrations for Critical Aeolian Vibration frequency band ranging
from 0.18/d to 1.4/d – where d is the OPGW cable diameter in meters. The damper assembly shall be vibrated
vertically with a ±1 mm amplitude from 5 to 15 Hz frequency and beyond 15 Hz at 0.5 mm to determine
following characteristics with the help of suitable recording instruments.
(i) Force Vs frequency

(ii) Phase angle Vs frequency

(iii) Power dissipation Vs frequency

The Force Vs frequency curve shall not show steep peaks at resonance frequencies and deep troughs between
the resonance frequencies. The resonance frequencies shall be suitably spread within the Aeolian vibration
frequency-band between the lower and upper dangerous frequency limits determined by the vibration analysis
of fibre optic cable without dampers.
Acceptance criteria for vibration damper:
(i) The above dynamic characteristics test on five dampers shall be conducted.

(ii) The mean reactance and phase angle Vs frequency curves shall be drawn with the criteria
of best fit method.

(iii) The above mean reactance response curve should lie within following limits:

V.D. for OPGW - 0.060 f to 0.357 f kgf/mm* Where f is frequency in Hz.

(iv) The above mean phase angle response curve shall be between 25o to 130o within the
frequency range of interest.

(v) If the above curve lies within the envelope, the damper design shall be considered to
have successfully met the requirement.

(vi) Visual resonance frequencies of each mass of damper is to be recorded and to be

compared with the guaranteed values.

(b) Vibration Analysis

The vibration analysis of the fibre optic cable shall be done with and without damper installed on the span. The

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vibration analysis shall be done on a digital computer using energy balance approach. The following parameters
shall be taken into account for the purpose of analysis.
(i) The analysis shall be done for single fibre optic cable without armour rods. The tension
shall be taken as 25% of RTS of fibre optic cable for a span ranging from 100 m to 1100
m.

(ii) The self-damping factor and flexural stiffness (EI) for fibre optic cable shall be
calculated on the basis of experimental results. The details to experimental analysis
with these data shall be furnished.

(iii) The power dissipation curve obtained from Damper Characteristics Test shall be used
for analysis with damper.

(iv) Examine the Aeolian Vibration level of the fibre optic cable with and without vibration
damper installed at the recommended location or wind velocity ranging from 0 to 30 Km
per hour, predicting amplitude, frequency and vibration energy input.

(v) From vibration analysis of fibre optic cable without damper, antinode vibration
amplitude and dynamic strain levels at clamped span extremities as well as antinodes
shall be examined and thus lower and upper dangerous frequency limits between which
the Aeolian vibration levels exceed the specified limits shall be determined.

(vi) From vibration analysis of fibre optic cable with damper(s) installed at the
recommended location, the dynamic strain level at the clamped span extremities,
damper attachment points and the antinodes on the fibre optic cable shall be
determined. In addition to above damper clamp vibration amplitude and antinodes
vibration amplitudes shall also be examined.

The dynamic strain levels at damper attachment point, clamped span extremities and antinodes shall not exceed
the specified limits. The damper clamp vibration amplitude shall not be more than that of the specified fatigue
limits.
(c) Fatigue Tests

(i) Test Set Up

The fatigue tests shall be conducted on a laboratory set up with a minimum effective span length of 30m. The
fibre optic cable shall be tensioned at 25% of RTS of fibre optic cable and shall not be equipped with protective
armour rods at any point. Constant tension shall be maintained within the span by means of lever arm
arrangement.
After the fibre optic cable has been tensioned, clamps shall be installed to support the fibre optic cable at both
ends and thus influence of connecting hardware fittings are eliminated from the free span. The clamps shall not
be used for holding the tension on the fibre optic cable. There shall be no loose parts, such as suspension clamps,
U bolts, on the test span supported between clamps mentioned above. The span shall be equipped with vibration
inducing equipment suitable for producing steady standing vibration. The inducing equipment shall have
facilities for step less speed control as well as step less amplitude arrangement. Equipment shall be available
for measuring the frequency, cumulative number of cycles and amplitude of vibration at any point along the
span.
(ii) Fatigue Test

The vibration damper shall be installed on the test span with the manufacturer's specified tightening torque. It
shall be ensured that the damper shall be kept minimum three loops away from the shaker to eliminate stray
signals influencing damper movement.
The damper shall then be vibrated at the highest resonant frequency of each damper mass.

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For dampers involving torsional resonant frequencies, tests shall be done at torsional modes also in addition to
the highest resonant frequencies at vertical modes. The resonance frequency shall be identified as the frequency
at which each damper mass vibrates with the maximum amplitude on itself. The amplitude of vibration of the
damper clamp shall be maintained not less than ±25/f mm where f is the frequency in Hz.
The test shall be conducted for minimum ten million cycles at each resonant frequency mentioned above.
During the test, if resonance shift is observed, the test frequency shall be tuned to the new resonant frequency.
The clamp slip test as mentioned herein shall be repeated after fatigue tests without retorquing or adjusting
the damper clamp, and the clamp shall withstand a minimum load equal to 80% of the slip strength for a
minimum duration of one minute.
After the above tests, the damper shall be removed from fibre optic cable and subjected to dynamic
characteristics test. There shall not be any major deterioration in the characteristics of the damper. The damper
then shall be cut open and inspected. There shall not be any broken, loose, or damaged part. There shall not be
significant deterioration or wear of the damper. The fibre optic cable under clamp shall also be free from any
damage.
For purposes of acceptance, the following criteria shall be applied:
(1) There shall not be any resonant frequency shift before and after the test by more than
± 20%

(2) The power dissipation of the damper before and after test at the individual resonant
frequencies do not differ by more than ± 20%

Beside above tests, the type tests listed below in the table shall also be conducted on Vibration Damper

Sl No. Test Name Test Procedure

Visual examination & Dimensional and material IEC 61897 Clause 7.1 &
1
verification 7.2

2 Clamp Slip test IEC 61897 Clause 7.5

3 Clamp bolt tightening test IEC 61897 Clause 7.7

Attachments of weights to messenger cable

4 IEC 61897 Clause 7.8

Attachment of clamps to messenger cable

5 IEC 61897 Clause 7.8

IEC 61897 Clause

6 Damper effectiveness evaluation 7.11.3.2

2.14 Type Tests for Splice Enclosures (Joint Box)

Following Type tests shall be demonstrated on the Splice Enclosure(s) (Splice Enclosure/Box). For certain tests,
lengths of the fibre optic cable shall be installed in the splice box, and the fibres must be spliced and looped in
order to simulate conditions of use. The attenuation of the fibres shall be measured, during certain tests, by
relevant Fibre Optic Test Procedures (EIA/TIA 455 or IEC 60794-1 procedures).
(i) Temperature Cycling Test

FO cable is installed in the splice enclosure and optical fibres spliced and looped. The box must be subjected to
5 cycles of temperature variations of - 40°C to +65°C with a dwell time of at least 2 hours on each extreme.

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Fibre loop attenuation shall be measured in accordance with EIA 455-20 / IEC 60794-1-C10. The variation in
attenuation shall be less than ±0.05dB. The final humidity level, inside the box, shall not exceed the initial level,
at the closing of the box.
(ii) Humid Heat test

The sealed splice enclosure, with fibres spliced and looped inside, must be subjected to a temperature of +55°C
±2°C with a relative humidity rate of between 90% and 95% for 5 days. The attenuation variation of the fibres
during the duration of the test shall be less than ±0.05dB, and the internal humidity rate measured, less than
2%.
(iii) Rain Withstand Test / Water Immersion test

The splice enclosure with optical fibres cable installed and fibres spliced fixed, shall be subjected to 24 hours of
simulated rain in accordance with IEC 60060 testing requirements.
No water seepage or moisture shall be detected in the splice enclosure. The attenuation variation of the fibres
after the test shall be less than ±0.05dB.
(iv) Vibration Test

The splice enclosure, with fibres united inside, shall be subjected to vibrations on two axes with a frequency
scanning of 5 to 50 Hz. The amplitude of the vibrations shall be constant at 0.450mm, peak to peak, for 2 hours,
for each of the vibrations' axes. The variation in attenuation, of the fibres, shall be less than ±0.05dB. The splice
enclosure shall be examined for any defects or deformation. There shall be no loosening or visible damage of
the FO cable at the entry point.
(v) Bending and Torsion test

The splice enclosure, with fibres spliced inside, shall be firmly held in place and be subjected to the following
sequence of mechanical stresses on the cable:
a) 3 torsion cycles of ±180° shall be exercised on the cable. Each cycle shall be less than one
minute.

b) 3 flexure cycles of the cable, of ±180° with one cycle less than one minute.

The variation in the attenuation, of the fibres, shall be less than ±0.05dB. The cables connection ring shall
remain securely fixed to the box with the connection maintained firmly.
No defects/fissures shall be noted on the joint ring or on the splice enclosure
(vi) Tensile test

The splice enclosure with cable fixed to the boxes shall be subjected to a minimum tension of 448 N for a period
of two minutes. No fissure shall be noted in the connections or on the box.
(vii) Drop Test

With 2 lengths of 11 meters of cable fixed to the box, it shall be dropped five times from a height of 10 meters.
There shall be no fissure, at all, of the box, and the connections shall remain tight. The test surface shall be
carried out in accordance with IEC 60068-2-32.
2.15 Factory Acceptance Tests

Factory acceptance tests shall be conducted on randomly selected final assemblies of all equipment to be
supplied. Factory acceptance testing shall be carried out on OPGW Cable and associated hardware & fittings,
Approach Cable, Joint Box, FODP etc. and all other items for which price has been identified separately in the
Bid Price Schedules.
Material shall not be shipped to the DNHDDPCL until required factory tests are completed satisfactorily, all
variances are resolved, full test documentation has been delivered to the DNHDDPCL.

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Successful completion of the factory tests and the DNHDDPCL approval to ship, shall in no way constitute final
acceptance of the system or any portion thereof. These tests shall be carried out in the presence of the
DNHDDPCL's authorised representatives unless waiver for witnessing by DNHDDPCL’s representatives is
intimated to the contractor.
Factory acceptance tests shall not proceed without the prior delivery to and approval of all test documentation
by the DNHDDPCL.
The factory acceptance tests for the supplied items shall be proposed by the Contractor in accordance with
technical specifications and Contractor's (including Sub-Contractor's / supplier's) standard FAT testing
program. In general, the FAT for other items shall include at least: Physical verification, demonstration of
technical characteristics, various operational modes, functional interfaces etc.
For Test equipment FAT shall include supply of proper calibration certificates, demonstration of satisfactory
performance, evidence of correct equipment configuration and manufacturer’s final inspection certificate/
report.
2.16 Sampling for FAT

From each batch of equipment presented by the Contractor for Factory acceptance testing, the DNHDDPCL shall
select random sample(s) to be tested for acceptance. Unless otherwise agreed, all required FAT tests in the
approved FAT procedures, shall be performed on all samples.
The Sampling rate for the Factory acceptance tests shall be minimum 10% of the batch size (minimum 1) for all
items. The physical verification shall be carried out on 100% of the offered quantities as per the approved FAT
procedure. In case any of the selected samples fail, the failed sample is rejected, and additional 20% samples
shall be selected randomly and tested. In case any sample from the additional 20% also fails the entire batch
may be rejected.
For the OPGW cable hardware fittings & accessories, the minimum sampling rate, and batch acceptance criteria
shall be as defined in IS 2486.
The Sampling rate for the Factory acceptance tests shall be 10% of the batch size (minimum 2) for FO cable
drums, FODPs, Joint box and other similar items.
Since FAT testing provides a measure of assurance that the Quality Control objectives are being met during all
phases of production, the DNHDDPCL reserves the right to require the Contractor to investigate and report on
the cause of FAT failures and to suspend further testing/ approvals until such a report is made and remedial
actions taken, as applicable.
2.17 Production Testing

Production testing shall mean those tests which are to be carried out during the process of production by the
Contractor to ensure the desired quality of end product to be supplied by him. The production tests to be carried
out at each stage of production shall be based on the Contractor’s standard quality assurance procedures. The
production tests to be carried out shall be listed in the Manufacturing Quality Plan (MQP), along with
information such as sampling frequency, applicable standards, acceptance criteria etc.
The production tests would normally not be witnessed by the DNHDDPCL. However, the DNHDDPCL reserves
the right to do so or inspect the production testing records in accordance with Inspection rights specified for
this contract.
2.18 Factory Acceptance Tests on Optical Fibre to be supplied with OPGW

The factory acceptance tests listed in table below are applicable for the Optical fibres to be supplied. The listed
tests follow testing requirements set forth in IEEE standard 1138/IEC 60794. The referenced sections specify
the detailed test description. The acceptance norm shall be as specified in the above-mentioned IEEE standards
unless specified otherwise in the technical specifications.
Table 6g: Factory Acceptance Tests for Optical Fibres: Optical Tests

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 Sr. Test Name Acceptance Criteria Test procedure
No.
1 Attenuation Coefficient As per T S EIA/TIA 455- 78A

2 Point Discontinuities of attenuation As per T S EIA/TIA 455-59

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 3 Attenuation at Water Peak As per T S EIA/TIA 455- 78A

4 Chromatic Dispersion EIA/TIA 455-

168A/169A/175A
5 Core – Clad Concentricity Error EIA/TIA 455-/176

6 Cladding diameter EIA/TIA 455-176

7 Fibre Tensile Proof Testing EIA/TIA 455-31B

The test report for the above tests for the fibers carried out by the Fiber Manufacturer and used in the OPGW
cables shall be shown to the inspector during OPGW cable FAT and shall be submitted along with the OPGW
cable FAT report.
2.19 Factory Acceptance Test on OPGW Cable

The factory acceptance tests for OPGW cable specified below in Table follow the requirements set forth in IEEE
standard 1138 / IEC 60794. The FAT shall be carried out on 10% of offered drums in each lot as specified in
technical specifications and the optical tests shall be carried out in all fibres of the selected sample drums. The
Rated Tensile Strength test shall be carried out on one sample in each lot.
Table 6 h: Factory Acceptance Tests on OPGW Applicable standard: IEEE 1138 / IEC
60794

Sr. No. Factory Acceptance Test on Manufactured OPGW

1 Attenuation Co-efficient at 1310 nm and 1550 nm

2 Point discontinuities of attenuation

3 Visual Material verification and dimensional checks as per approved

DRS/Drawings

4 Rated Tensile Strength

5 Lay Length Measurements

2.20 Factory Acceptance Test on OPGW Fittings

The factory acceptance tests for OPGW Fittings as specified below. The sampling plan shall be as per relevant
standard:
Factory Acceptance Tests on OPGW Fittings

S. No. Factory Acceptance Test

Suspension Assembly

1 UTS/ Mechanical Strength of the assembly

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 2 Clamp Slip Test

3 Visual Material verification and dimensional checks as per approved DRS/

Drawings

4 Mechanical strength of each component

5 Galvanizing test

Tension Assembly

6 Clamp Slip Strength test

7 Visual Material verification and dimensional checks as per approved

DRS/Drawings

8 Mechanical strength of each component

9 Galvanizing Test

Vibration Damper

10 Galvanizing test on damper, masses and messenger wires

11 Damper response (resonant frequencies)

12 Clamp Slip test

13 Strength of messenger wires

14 Attachments of weights to messenger cable

15 Attachments of clamps to messenger cable

16 Clamp bolt tightening test

17 Clamp bolt torque test

18 Dynamic characteristic test.

19 Visual Material verification and dimensional checks as per approved

DRS/Drawings

Structure Mounting Clamp

20 Clamp fit test

21 Clamp Strength test

22 Visual Material verification and dimensional checks as per approved

DRS/Drawings

2.21 Factory Acceptance Test on Splice Enclosure (Joint Box) /FODP

The factory acceptance tests for Splice Enclosures/FODP as specified below.

Factory Acceptance Tests on Splice Enclosures (Joint Box)/FODP

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 Sr. No. Factory Acceptance Test

1 Visual check of Quantities and Specific Component Number for each component
of Splice Enclosure/FODP and dimensional checks against the approved
drawings.

2.22 Factory Acceptance Test on Test Equipment & other items

As per technical specification and approved DRS/Documents

2.23 Site Acceptance Tests

The Contractor shall be responsible for the submission of all material & test equipment supplied in this contract
for site tests and inspection as required by the DNHDDPCL. All equipment shall be tested on site under the
conditions in which it will normally operate.
The tests shall be exhaustive and shall demonstrate that the overall performance of the contract works satisfies
every requirement specified. At a minimum Site Acceptance Testing requirement for FO cable etc. is outlined in
following section. This testing shall be supplemented by the Contractor's standard installation testing program,
which shall be in accordance with his quality plan(s) for FO installation.
During the course of installation, the DNHDDPCL shall have full access for inspection and verification of the
progress of the work and for checking workmanship and accuracy, as may be required. On completion of the
work prior to commissioning, all equipment shall be tested to the satisfaction of the DNHDDPCL to demonstrate
that it is entirely suitable for commercial operation.
2.24 Minimum Site Acceptance Testing Requirement for FO Cabling

Prior to installation, every spooled fibre optic cable segment shall be tested for compliance with the Pre-
shipment data previously received from the manufacturer. This requirement will preclude the installation of
out of specification cable segments that may have been damaged during shipment.
2.25 Phases of Site Acceptance Testing

SAT shall be carried out link by link from Tap tower joint enclosure to Gantry side joint enclosure. SAT may be
performed in parts in case of long links.
The tests, checks, adjustments etc conducted by the Contractor prior to offering the equipment for SAT shall be
called Pre-SAT activities. The Pre-SAT activities shall be described in the installation manuals and Field Quality
Plan documents.
Sag and tension of OPGW shall generally be as per approved sag-tension chart and during installation, sag and
tension of OPGW shall be documented. Upon completion of a continuous cable path, all fibres within the cable
path shall be demonstrated for acceptance of the cable path. Fibre Optic cable site testing minimum
requirements are provided in Tables below:
Fibre Optic Cable Pre-Installation Testing

Item Description

1 Physical Inspection of the cable assembly for damage

2 Optical fibre continuity and fibre attenuation with OTDR at 1550 nm

3 Fibre Optic Cable length measurement using OTDR

Fiber Optic Cable Post-Installation Testing (Each section)

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 4 Physical Inspection of the installed OPGW and hardware fittings

5 Optical fiber continuity, fiber attenuation and cable length with OTDR

Fibre Optic Cable Splicing Testing

Item Description

1 Per splice bi-directional average attenuation with OTDR

2 Physical inspection of splice box/enclosure for proper fibre / cable routing

techniques

3 Physical inspection of sealing techniques, weatherproofing, etc.

Fibre Optic Cable Commissioning Testing

Item Description

1 End to End (FODP to FODP) bi-directional average attenuation of

each fibre at 1310 nm and 1550 nm by OTDR.
2 End to End bi-directional average attenuation of each fibre at 1310 nm and
1550 nm by Power meter.

3 Bi-directional average splice loss by OTDR of each splice as well as for all
splices in the link.

4 Proper termination and labelling of fibres & fibre optic cables at as per
approved labeling plan.

3 INSTALLATION OF OPGW CABLING

3.1 OPGW cable installation

The OPGW cable shall be installed at the top of the tower. The OPGW shall be installed generally in accordance
with the IEEE Guide to the Installation of Overhead Transmission Line Conductors (IEEE STD. 524 with latest
revisions), with additional instructions and precautions for fibre optic cable handling. The stringing procedure
shall be submitted by the Contractor prior to stringing for DNHDDPCL’s approval.
The OPGW cable sections shall normally be terminated & spliced only on tension towers. In exceptional
circumstances and on DNHDDPCL specific approval, cable may be terminated on Suspension towers, but in this
case tower strength shall be examined to ensure that tower loads are within safe limits and if required,
necessary tower strengthening shall be carried out by the Contractor.
The stringing shall be carried by the Transmission Line Contractor as per the stringing chart/ procedure
submitted by them and approved by DNHDDPCL. The following shall be under the scope of OPGW Cabling
Package Contractor:
• Supply of OPGW Cable & Hardware Fittings needed to tie the OPGW cable to the
towers/gantries.

• Supervision of stringing of OPGW Cable at sites as per instruction by DNHDDPCL. The

supervision shall include the inspection as per stringing procedure, proper location of drum

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 site, installation of stringing blocks/pulleys, proper sagging, proper installation of hardware,
proper tension as per Sag-Tension chart, provision of service loops of OPGW in jointing
locations

• The Splicing work of OPGW Cable and after that testing of link.

While handing over the OPGW drums, the testing (fibre loss and length measurement using OTDR) of OPGW in
each drum shall be carried out by Fibre Optic Cabling Package Contractor in presence of Tower package
contractor(s) and DNHDDPCL representative. After installation of OPGW cable, the testing of each section shall
be carried out again by the Fibre Optic Cabling Package Contractor in presence of Transmission Line Package
contractor(s) and DNHDDPCL representative. In case of any damage/ high loss in the fibre, the total length of
that particular section of OPGW cable shall be replaced by Transmission Line Package Contractor(s). Fibre Optic
Cabling Package Contractor shall supply new OPGW cable in place of damaged cable. The Contract price shall
be adjusted accordingly.

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 3.2 Installation Hardware

All required hardware's shall be installed along with OPGW Cable.

3.3 Methodology for Installation and Termination

All optical fibre cable termination, installation, stringing and handling plans, guides and procedures, and
engineering analysis (e.g. tension, sag, vibration etc.) shall be submitted to the DNHDDPCL for review and
approval in the engineering/design phase of the project. All installation practices shall be field proven, and ISO
accredited.
All cable segments shall include service loops as specified in this specification. The maximum allowable stringing
tension, maximum allowable torsional shear stress, crush strength and other physical parameters of the cable
shall not be exceeded. The preventative measures to be taken shall be documented in detail and submitted to
DNHDDPCL in advance of installation.
Optical fibre attenuation shall be measured after installation and before splicing. Any increase in attenuation or
step discontinuity in attenuation shall not be acceptable and shall constitute a cable 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 the overhead
transmission/ distribution line towers shall also be carried out by the Contractor. It shall be the Contractors
responsibility to provide adequate communications among all crew members and support staff to ensure safe
and successful installations.
3.4 Cable Raceways

To the extent possible, existing cable raceways shall be utilized. The Contractor is required to provide and install
any additional indoor cable raceways which may be required for proper implementation of the fibre optic cabling
system. This requirement shall be finalized during survey.
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, galvanized iron
or anodized sheet metal or any other suitable material approved by the DNHDDPCL. Suitable
anticorrosion measures shall be provided. Steel fabricated raceways shall be finished inside
and out, treated to resist rust and to form a metal-to- paint bond.

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

Expected Contents & Structure of FO Cable Installation Manual for Overhead FO cable

Sl no. Chapters Description

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 1 Installation procedure Description of activities of installation gangs: Preparation &
Setting up, Stringing, sagging, attaching hardware, attaching
down lead clamps & cable routing on the tower, securing
cable ends (for protection before work by jointing gang).
Precautions for preventing cable damage shall be highlighted.

2 Safety Instructions Instructions & procedures related to ensuring installation

crew safety: personnel grounding & safety, installation
equipment safety, Safety for power system & environment
(viz preventing accidental tripping, precaution for railway
crossings etc)

3 Description of Installation Sketches, drawings, photographs, safe working ratings of

Equipment installation equipment, tools & tackles etc., handling
instructions & precautions.

4 Cable routing Illustrations of the positions of tower attachment clamps

(down lead clamps), routing of FO cable on the tower, service
loop(s), joint box position.
References to other related documents covering the test

5 References installation, jointing & testing, such as SAT administrative &

functional test plans & procedures

Jointing Procedures
Field Quality Plan & Field Quality Audit Storage & Handling
Instructions

FO cable & hardware drawings, technical parameters, DRS

etc.

DNHDDPCL & Statutory safety rules, safety manuals,

standards, codes of practices etc.

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 DRS Form 1

DATA REQUIREMENTS SHEETS FOR OVERHEAD FIBRE OPTIC CABLE OPTICAL GROUND WIRE
(OPGW) – 24 Fibre

Manufacturer:

Part:

Configuration:

CABLE CONSTRUCTION

Sr. As per Technical As per Bidder

Parameter Specification Offering
No.
1 No. of Fibres
24
Dual Window Single-Mode:
2 Buffer Type: Loose Tube

3 Buffer Tube material As applicable

4 No. of Buffer Tubes: As applicable

5 No. of Fibers per Buffer Tube: As applicable

6 Expected Cable Life 25 Year

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DATA REQUIREMENTS SHEETS FOR OPTICAL FIBRE DUAL-WINDOW SINGLE MODE

(DW-SM)

OPTICAL PARAMETERS

Sr. Parameter As per Technical As per Bidder

No. Specification Offering

1 Fibre manufacturer(s)/Type:

2 Attenuation Coefficient
@ 1310 nm: < 0.35 dB/km
@ 1550 nm: < 0.21 dB/km

3 Point discontinuity
@ 1310nm: @ 1550nm: < 0.05 dB
< 0.05 dB

4 Nominal Mode Field Diameter

@ 1310 nm: 8.6 to 9.5 μm (± 0.6μm)
@ 1550 nm:

5 Chromatic Dispersion Coefficient

@ 1310 (1288-1339) nm: 3.5 ps/ (nm x km)
@ 1310 (1271-1360) nm: 5.3 ps/ (nm x km)
@ 1550 nm: 18 ps/ (nm x km)

6 Zero dispersion wavelength: 1300 to 1324 nm

7 Cutoff wavelength: <1260 nm

PHYSICAL AND MECHANICAL PROPERTIES

8 Bend Performance:
(37.5 mm radius, 100 turns) @1310 < 0.05 dB
nm (30 mm radius, 100 turns) @1550 < 0.05 dB
nm < 0.50 dB
(16mm radius, 1 turn) @1550nm

9 Cladding Diameter
(nominal ± deviation): 125.0 μm ± 1 μm

Polarization mode dispersion coefficient < 0.2 ps/km1/2

10

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 11 Proof test level > 0.69 GPa

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PART – III GUARANTEED TECHNICAL PARTICULARS FOR OPTICAL GROUND WIRE (OPGW) &
ACCESSORIES

The following sets of GTP are required to be filled up by the bidders to aid in the evaluation process. The
response shall be brief and to the point and shall be supported by the printed product description and
other literature. The same GTP format duly filled and the relevant drawings shall also be submitted during
the detailed engineering along with the relevant technical brochures.

The bidder shall fill in the guaranteed technical particulars in the Proforma given in this section and
submit the same with his tender, without which bid will not be considered.)

TABLE OF CONTENTS
Sl. No. Sample Form

GTP- 1 GTP of Optical Ground Wire (OPGW)

GTP– 2 GTP of Dual-Window Single Mode (DWSM)

GTP– 3 GTP of Hardware and Accessories

GTP- 4 GTP of Splice Enclosures (Joint Box) for Overhead FO cable

GTP- 5 GTP of Fibre Optic Distribution Panels (FODPs)

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GTP-1 GUARANTEED TECHNICAL PARTICULARS OF OPTICAL GROUND WIRE (OPGW)

Manufacturer:
Model Name:
GENERAL PARAMETERS
Sl.
Parameter Units Particulars
No
Fibre Manufacturer
1
Dual Window Single-Mode
No. of Fibres
2 each
Dual Window Single-Mode:
3 Buffer Type
4 Buffer Tube Diameter mm
5 Buffer Tube material
6 No. of Buffer Tubes each
7 No. of Fibers per Tube each
Identification/numbering of
8 individual
tubes
9 No. of empty tubes (If any)
10 Filling material
Filling material compliant with technical
11
specifications?
12 Strength member(s)
13 Binding yarn/ tape
14 Describe Central Core Design
Aluminum Clad steel wire
15 Diameter Number mm each

Aluminum alloy wires

16 Diameter Number mm each

17 Aluminum tube inner diameter mm

18 Aluminum tube outside diameter mm
Cable Diameter (nominal ±
19 mm
deviation)
20 Cable cross-section area (Nominal) mm2
21 Cable cross-section area (Effective) mm2
22 Fully Compliant with IEEE 1138 Yes/No

Mechanical Properties of Cable

Max. breaking load/ Ultimate Tensile Strength

23 kN
(UTS)

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24 Fibre strain margin %
25 Zero fibre strain up to load kN
26 Weight kg/km

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27 Crush strength kg/mm
28 Equivalent Modulus of elasticity KN/mm2
Minimum Bending Radius without
29 mm
microbending
Maximum Bending
30 Radius:ShortTerm:Long Term mm
(Continuous)
31 Tensile proof test (Screening) level KN/mm2

32 Maximum permissible tensile stress KN/mm2

33 Permissible CTS. tensile stress KN/mm2

Maximum sag at maximum temperature and
34 design span with no wind mm

% of UTS
35 Everyday tension at 32ºC, no wind

Maximum tension at Every day condition

36 Kg
with full wind pressure

Thermal Properties of Cable

37 Coefficient of linear expansion per °C

Coefficient of expansion
38 Cladding : per °C per
Core : °C
Nominal operating temperature range
39 °C

SC current transient peak

40 °C
temperature
Maximum allowable temperature for lightning
41 °C
strike

CABLE SPOOL and DRUM

Available length per spool
42 Maximum Nominal : m
:
43 Size of drum : m
44 Weight of empty drum : kg
Weight of drum with cable spooled :
45 kg

Will drum length scheduling be practiced

46 to match transmission line Yes/No
span lengths?
47 Describe Drum materials :

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 Describe cable end capping and protection
48 against abrasion etc.
:

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 INSTALLATION

Splice Loss
49 Maximum : dB dB
Average :
Operating Temperature Range
50 °C
:
51 Rated Isokeraunic No.
52 Expected Cable Life : Years
Installation rate per team
53 km/day
:
No. of persons per team
54 no.
:
Max. possible span for specified operating
55 conditions M
:
Midspan sag at 0°C with no wind loading :
56 Mm

Midspan sag at max temp. with no wind

57 loading Mm
:

Midspan sag at max temp. and wind loading

58 Mm

Cable swing angles

59 Worst Case :
Everyday :

Describe Installation method(s)

60
:
Sag tension chart parameters like sag and tension at various spans and applicable wind and ice load
conditions shall be submitted along with the DRS. The cable
parameters like coefficient of liner expansion, modulus of elasticity shall also be indicated.

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 GTP- 2
GUARANTEED TECHNICAL PARTICULARS OF DUAL-WINDOW SINGLE MODE (DWSM)

OPTICAL PARAMETERS
Sl.
No. Parameter Unit Particulars
Fiber manufacturer(s)/Type
1
:
Fiber production method
2
:
Attenuation Coefficient @
1310 nm : dB/km
3
@ 1550 nm : dB/km

Attenuation Variation with Wavelength (±25

4 nm) : dB/km

5 Attenuation at water peak : dB/km

Point discontinuity @ @ 1310nm : dB dB
6
1550nm :
Temperature dependence (induced
7 dB
attenuation)
Nominal Mode Field Diameter
8 @ 1310 nm : μm
@ 1550 nm :
Mode Field Diameter Deviation
9 @ 1310 nm : μm
@ 1550 nm :
Mode field non-circularity
10 %
:
Chromatic Dispersion Coefficient
11 @ 1310 (1288-1339) nm : Ps/nm.km
@ 1310 (1271-1360) nm :
@ 1550 nm :
12 Zero dispersion wavelength : nm

ps/nm2.k m
13 Zero dispersion Slope :

14 Cut-off wavelength : nm

15 Refractive Index

16 Refractive Index profile :

17 Cladding Design :

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18 Numerical aperture :

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 PHYSICAL and MECHANICAL PROPERTIES

Sl.
Parameter Unit Particulars
No.
Bend Performance :
(37.5 mm radius, 100 turns) @1310 nm
19 (30 mm radius, 100 turn) @1550 nm dB dB
(16mm radius, 1 turn) @ 1550nm

20 Core Diameter (nominal± deviation) : μm

21 Core non-circularity : %
Cladding Diameter (nominal ±
22 μm
deviation)
23 Core- Clad concentricity Error : μm
24 Cladding non-circularity : %
25 Fibre cut-off wavelength μm
Protective Coating type & material
26 Primary :
Secondary :
Protective Coating Diameter (nominal ±
27 μm
deviation)
28 Protective Coating removal method :
29 Coating Concentricity μm
Polarisation mode dispersion coefficient
30 ps/km1/2

31 Proof test level kpsi

Colour coding scheme compliant with
32 EIA/TIA 598 or IEC 60304 or Yes/No
Bellore GR-20.

Colouring material compliant with technical

33 Yes/No
specs?

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 GTP- 3
GUARANTEED TECHNICAL PARTICULARS FOR HARDWARE AND ACCESSORIES

Suspension Clamp Assembly

Manufacturer:

Type:

Drawing No.

Sl.
Parameter Unit Particulars
No.

1 Minimum vertical Strength kN

2 Maximum Slip Strength kN

3 Minimum Slip Strength kN

4 Length (nominal) mm

5 Weight (nominal) kg

Total Drop (maximum) including shackles

6 mm

7 Tightening torque (nominal) Nm

8 Details of Armour Rod Set

No. of rods per clamp

Direction of Lay

Overall length mm
Diameter of each Rod mm

e) Tolerances
±%
(i) Diameter of each rod ±%
(ii) Length of each rod
Material of manufacture

UTS of each Rod kN

Weight kg

9 Details of Protection Splice Set (Reinforcing

Rods)

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 i) No. of rods per clamp

j) Direction of Lay

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 k) Overall length mm

l) Diameter of each Rod mm

m) Tolerances
±%
(i) Diameter of each rod ±%
(ii) Length of each
n) Material of manufacture

o) UTS of each Rod kN

p) Weight kg

Dead End Clamp Assembly

Manufacturer:

Type:

Drawing No.:

1 Minimum Slip Load kN

2
Length (nominal)

a) Reinforcing Rods mm

b) Dead end mm

3
Weight (nominal)

a) Reinforcing Rods kg

b) Dead end kg

4 Breaking strength (minimum) kN

5
Wire Size

a) Reinforcing Rods mm

b) Dead end mm

Vibration Damper

Manufacturer:

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Type:

Drawing No.:

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 Total Weight Kg
1
Weight of each Damper
2
Material of Damper Weight
3
Clamp Material
4
Clamp bolt tightening torque Nm
5
Clamp bolt material
6
Messenger Cable Material
7
No. of Strands in Messenger Cable
8
Breaking Strength of Messenger Cable
kN
9
Resonance Frequencies
10
First Frequency Hz

Second Frequency Hz

Third Frequency Hz
Forth Frequency Hz

Minimum Slip Strength of Damper Clamp

11
a) Before Fatigue Test kN
b) After fatigue Test kN

Down Lead Clamp /Fastening Clamp

Manufacturer:

Type:

Drawing No.:

Material:
1
Suitable for OPGW (range) :
2 mm
Tightening torques
3 Nm
Vertical load
4 kN
Filler details :
5

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 Material

diameter
mm
Tower attachment arrangement
6

Earth lead assembly

Manufacturer:

Type:

Drawing No.:
Weight
1 kg
Material
2
length
3 mm
Short circuit current
4 KA

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 GTP- 4
GUARANTEED TECHNICAL PARTICULARS FOR SPLICE ENCLOSURES (JOINT BOX) FOR OVERHEAD
FO CABLE

Splice Enclosures (Joint Box)

Manufacturer:

Type:

Drawing No.:
1 Dimensions H * W * D : cm
2 Weight : Kg
3 Colour and Finish :
4 Cable Glanding& Fixing
Construction materials &
5
Gauge
6 Locking arrangements :
Installation Clearances :
Front Access : Rear
7 Access :
Top * Bottom * Sides : cm
8 IP Protection Class
Total number of optical couplings
9
ea
Provision of pass through
10
splicing Yes/No
Whether filled with suitable
11
encapsulant Yes/No
Method(s) for mounting with the
12
tower :

Optical Fibre Cable Accommodations

13 Cable Glanding :
Maximum number of cables that
14
can beaccommodated :

Diameter(s) of cables that can be

15 each
accommodated :

16 Describe Cable entries :

Cable Termination Splice Accommodations

Details of Splice Trays :

Dimension :

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17 Material/Gauge :
Weight : kg

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 Colour & Finish
Method of mounting
Maximum number of splice trays
18
ea
19 Number of splices per tray ea
20 Provision of Splice organisors
Do splice trays require a
separate
enclosure? If so Yes/No
Manufacturer
21 Dimensions H * W * D cm
Weight: Kg
Colour and Finish:
Method(s) of Mounting:
Construction materials &
Gauge:
Locking arrangements:
Installation Clearances
Front Access :
22 Rear Access :
Top * Bottom * Sides : m
Excess length of fibre service
loops

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 GTP- 5
GUARANTEED TECHNICAL PARTICULARS FOR FIBRE OPTIC DISTRIBUTION PANELS (FODPs)

Manufacturer :

Model :

Sl. No. Parameter Unit Particulars

1 Dimensions H * W * D :
cm
2 Weight :
kg
3 Colour and Finish :

4 Cable Glanding& Fixing :

5 Construction materials & Gauge

6 Locking arrangements :

Installation Clearances:
Front Access :
7 Rear Access :
Top * Bottom * Sides : cm

8 IP Protection
Class
9 Total number of optical couplings
ea
10 Provision of pass through splicing
Yes/No
Whether filled with suitable encapsulant Yes/No
11

12 Method(s) for mounting

Optical Fibre Cable Accommodations

13 Cable Glanding :

Maximum number of cables that can be

14
accommodated :
Diameter(s) of cables that can be
15 each
accommodated :
Describe Cable entries :
16

Cable Termination Splice Accommodations

Details of Splice Trays :

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17 Dimension :

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 Material/Gauge :

Weight : kg
Colour & Finish

Method of mounting

18 Maximum number of splice trays ea

19 Number of splices per tray ea

20 Provision of Splice organizers

Do splice trays require a separate enclosure? If

Yes/No
so
Manufacturer

Dimensions H * W * D cm
21
Weight Kg

Colour and Finish

Method(s) of Mounting

Construction materials & Gauge

Locking arrangements

Installation Clearances
22 Front Access m
Rear Access :
Top * Bottom * Sides : Excess length of
fibre service loops

SECTION 7

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 TECHNICAL SPECIFICATIONS OF POLYMERIC INSULATORS TABLE OF CONTENT

1.0 SCOPE

This specification covers design, manufacturing, testing, inspection, packing and supply of Silicon
Rubber housed composite Insulators for satisfactory operation on various transmission lines and
Substations situated in any part of UT of DNH & DD.

These insulators are to be used as insulating part of Multi circuit tower structures single/double
suspension & tension (dead end) for 66kV MC transmission lines. The configuration on structure
may be single or double insulators per phase at required locations.

The materials covered here under this specification shall be supplied complete in all respects,
including all components, fittings and accessories which are necessary or are usual for their efficient
performance and satisfactory maintenance under the various operating and atmospheric
conditions. Such parts shall be deemed to be within the scope of the Contract, whether specifically
included or not in the Specification or in the Contract Schedules.

2.0 STANDARDS

2.1 Unless otherwise specified elsewhere in this specification, the rating as well as performance &
testing of the Polymer Insulators shall conform but not limited to the latest revision & amendments
available at the time of placement of order of all the relevant standards as listed hereunder, except
as modified in this document.

International
Sr. no. Indian standard Title
standard
1. IS:209 Specification for Zinc BS:3436

2. IS:406 Method for Chemical Analysis of Slab BS:3436

Zinc
Porcelain insulators for overhead
power lines with a nominal voltage
3. IS:731 IEC:61109-1992
greater than 1000V
IS:2071 Part I, II,
4. Method of High Voltage Testing IEC:60060-1
III
IS:2486 Specification for insulator fittings for
overhead power lines with a nominal
voltage greater than 1000V- General IEC-60575 IEC-
Part-I Part-II
5. Requirements, Tests, Dimensional 60120 IEC:60372
Part-III
Requirements, Locking Devices
6. IS:2629 Recommended practice for Hot Dip ISO:1461(E)
Galvanization for iron & steel
IS:2633 Testing for Uniformity of Coating of
7.
Zinc coated articles
IS: 3203 Methods of testing of local thickness of ISO: 2178
8.
electroplated coatings
IS: 4699 Specification for refined secondary
9.
zinc
Hot dip zinc coatings on structural ISO: 1459,
10.
IS: 4759 steel & other allied products ISO: 1461

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 Determination of Weight of Zinc BS:443-1969 ISO
11. coating on Zinc coated iron and steel
IS:6745 1460-1973
articles
12. IS: 8263 Methods of RIV Test of HV Insulators IEC:60487
IS:8269 Methods for Switching impulse test on IEC:60506
13.
HV insulators
IS:13134 Guide for the selection of insulators in IEC: 60815
14.
respect of polluted conditions
Standard for insulators– Composite - ANSI C29 13-
15.
Distribution Dead end type 2000
Standard specification for glass fiber ASTM D 578-05
16.
strands
Standard test method for ASTM E 1131-03
17. compositional analysis by Thermo
gravimetry
Characteristics of string insulator IEC: 60433
18.
units of the long rod type
Verification of Dimensions of Polymer IEC:61109
19.
Insulators
20. Hydrophobicity classification guide STRI guide 1.92/1
Tests on insulators of Ceramic material IEC:60383
21. or glass or glass for overhead lines
with a nominal voltage greater than
1000V
Salt Fog Pollution Voltage Withstand IEC:60507
22.
Test
Thermal Mechanical Performance test
23. and mechanical performance test on IEC: 60575
string insulator units
Electrical Insulating materials used
24. under severe ambient conditions –Test IEC 60587
methods for evaluating resistance to
tracking and erosion
Selection and dimensioning of high
25. voltage insulators intended for use in IEC:60815-3
polluted conditions: Polymer
Insulators for AC systems
Composite insulators for A.C.
26. Overhead lines with nominal voltage IEC 61109
greater than 1000V – Definitions, test
methods and acceptance criteria
Composite string insulator units for
overhead lines with a nominal voltage
above 1000V :
27.
i) Standard strength classes and end
IEC 61466-1
fittings Dimensional and electrical
characteristics IEC 61466-1

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 Polymeric insulators for indoor and
outdoor use with nominal voltage IEC 62217
28. greater than 1000V- General
definitions, tests, methods and
acceptance criteria.

2.2 Material meeting with the requirements of other authoritative standards, which ensure equal or
better performance than the standards mentioned above, shall also be considered. When the
material offered by the bidder conforms to other standards, salient points of difference between
standards adopted & the standards specified in this specification shall be clearly brought out in the
relevant schedules. Three copies of such standards with authentic translation in English shall be
furnished along with the bid.

3.0 ELECTRIC SYSTEM DATA & SITE CLIMATIC CONDITIONS

Electrical system data and site climatic conditions are furnished in clause 4, section 1, part A of
volume II.

4.0 DETAILS OF CONDUCTOR

Details of conductors are furnished in clause 4.1, section 1, part A of volume II.

5.0 DETAILS OF COMPOSITE POLYMER INSULATORS

5.1 The technical specifications of composite polymer insulators are furnished in clause 4.1, section 1,
part A of this volume

5.2 The Composite Polymer insulator shall be suitable for a three phase 50 Hz, effectively earthed 66kV
transmission systems in a moderately polluted atmosphere.

5.3 The specified values and dimensions, impulse and power frequency voltages, electromechanical
strength [EMS] of Polymer insulators are as under. The values given are minimum which apply to
all cases. Specified withstand and flashover voltages are referred to standard atmospheric
condition.

5.4 Composite Polymer Insulators shall have sheds with good self-cleaning properties. Insulator shed
profile, spacing, projection etc., and selection in respect of polluted conditions shall be generally in
accordance with the recommendation of IEC-60815/IS: 13134

5.5 Dimensional Tolerance of Composite Insulators

The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as
follows in line with IEC 61109:

± (0.04d + 1.5) mm when d≤300mm

± (0.025d+6) mm when d>300mm

Where, “d” being the dimensions in millimeters for diameter, length or creepage distance as the case
may be.

However, no negative tolerance shall be applicable to creepage distance

6.0 GENERAL TECHNICAL REQUIREMENTS

6.1 CORE

The core shall be glass-fiber reinforced epoxy resin rod (FRP) of high strength. Both, glass fiber and

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 resin shall be optimized in the FRP rod. Glass fibers with low content in 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 interface between matrix and fibers is to be
considered as design parameter to prevent brittle fracture. The FRP rod should be void free and
shall be manufactured through Pultrusion process.

6.2 HOUSING (SHEATH)

The core of the Polymer insulator shall be completely covered by a continuous housing consisting
of a sheath-weathershed. For moulding of entire weathershed structure on to the rod in a one shot
moulding process to be employed to avoid multiple interfaces.

Hardware i.e. metal fittings may be installed on the rod prior to moulding of the shed controlling
moulding lines. The base polymer shall be 100% Silicon Rubber prior to the addition of reinforcing
fillers. The thickness of compounding material on core should be minimum 3 mm.

Manufacturer should furnish a description of its Quality Assurance Programme including

fabrication, testing and inspection for any material (i.e. rubber), components (i.e. rod) or hardware
(i.e. end fittings). The manufacturer has had fabricated by others should also be included.
Manufacturing methods and material composition documentation will be a part of Technical Bid to
be submitted along with offer. Insulator should have hermetically sealed structure in which the
housing material is moulded to cover the interface between the end fittings and the FRP Prod. This
seal should never be broken during testing or otherwise.

6.3 END FITTINGS

The Polymer insulators shall be socket and ball type with the necessary coupling arrangement such
that pin shall move freely in the socket but do not get disengaged while in service under various
operating and atmospheric conditions.

The socket & ball type metal end fittings shall be designed to transmit the mechanical load to the
core & the end fittings shall maintain uniform and consistent mechanical strength Material and
methods used in the fabrication of metal parts shall be selected to provide good toughness and
ductility. Metal end fittings shall be made from a quality malleable cast iron or forged steel or
Spheroidal Graphite Iron (SGI) and shall be hot dipped galvanized in accordance with IS 2629. Metal
end fittings shall be uniform and without sharp edges or corners and shall be free of cracks, flakes,
slivers, slag, blow-holes shrinkage defects and localized porosity.

The attachment to the FRP rod shall be performed with a symmetrically controlled crimping
method control by acquistic method that compresses the metal radically onto the rod without
damage to the rod fibers or resin matrix while providing a strength equal to or greater than the
defined and specified ultimate strength to the insulator. The material used in fittings shall be
corrosion resistant.

Nominal dimensions of the pin, ball and socket interior shall be in accordance with the standard. No
joints in ball & socket or pin will be allowed. Outer portion of ball or socket should be Zinc sleeved
with minimum 99.95% purity of electrolytic high-grade Zinc. The finished surface shall be smooth
and shall have a good performance. The surface shall not crack or get chipped due to ageing effect
under normal and abnormal service conditions or while handling during transit or erection. The
design of the fittings and the insulators shall be such that there is no local corona formation or
discharges likely to cause the interference to either sound or vision transmission.

6.4 GRADING RINGS

Grading rings shall be provided when system voltages are equal to or greater than 220kV. For 220kV

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 transmissions, grading ring is to be provided at the energized end only.

All grading rings and brackets shall be designed as an integral part of the insulator assembly with a
positive mounting system that allows mounting in one position. The design of the grading ring shall
be such that ring can only be mounted with its orientation towards the weather sheds for maximum
RIV and Corona control. Grading rings shall be designed in such a manner that the rings can be
readily installed and removed with hot line tools without disassembling any other part of the
insulator assembly.

Grading ring height (is the distance from the end of the end fitting to the top of corona ring) should
be so selected that maximum field minimizes and uniformly distributed along the insulator.
Manufacturer should provide reports of successful electric field modeling testing for the specific
insulator design. The EFM should be three dimensional with result containing drawing depicting
the electric field in various colours, each of a different voltage level. The result of this study should
show that the voltage field surrounding the polymer insulators is optimum along the entire length
of the insulator, with the effected hot end of the insulator being a critical location. The threshold at
which corona may or may not be present should be defined as a figure in KV/mm for the designed
insulator.

6.5 VERIFICATION OF HOUSING MATERIAL

The manufacturer should provide written verification about housing material, for which base
polymer shall be 100% Silicon Rubber prior to the addition of reinforcing fillers considered will
provide satisfactory performance in the particular environment It shall meet following
requirements Be homogenous, impermeable, with no fissures, bubbles and strange materials
inclusions. Be designed in order to avoid formation of localized discharges and to prevent interfaces
humid penetration. Be resistant to corona, UV radiation, ozone, atmospheric contamination, water
penetration and power arcs.

6.6 BALL AND SOCKET DESIGNATION

The dimensions of the Ball and Socket shall be 16mm designation for 70KN and 90KN Polymer
insulators and 20 mm & 24 mm designation for 120 KN and 160 KN Polymer insulators in
accordance with the standard dimensions stated in IEC:60120/IS:2486(Part-II)

6.7 MARKINGS:

6.7.1 Each insulator shall be legibly and indelibly marked with the following details as per IEC – 61109.

a. Name or trademark of the manufacturer.

b. Voltage and Type.

c. Month and year of manufacturing.

d. Minimum failing load / guaranteed mechanical strength in kilo Newton followed by the word ‘KN’
to facilitate easy identification.

e. Country of manufacture

6.7.2 One 10 mm thick ring of suitable quality of paint shall be marked on the end fitting of particular
strength for easy identification of Polymer insulators. The paint shall not have any deteriorating
effect on the insulator performance.

Following codes shall be used as identification mark:

For 90KN Polymer insulator : Blue

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 For 120KN Polymer insulator : Yellow

6.8 BID DRAWINGS

6.8.1 The Bidder shall furnish full description and illustration of the material offered.

6.8.2 The Bidder shall furnish along with the bid the outline drawing of each insulator unit along with
grading rings including a cross sectional view of the long rod insulator unit. The drawing shall
include but not limited to the following information:

(a) Major Dimensions with manufacturing tolerances

(b) Minimum Creepage distance with positive tolerance

(c) Protected creepage distance

(d) Unit mechanical and electrical characteristics

(e) Size and weight of ball and socket parts

(f) Weight of composite long rod units

(g) Materials

6.8.3 After placement of award, the Manufacturer/contractor shall submit full dimensioned insulator
drawings containing all the details as given in Clause No. 6.8.2 above, in four (4) copies to
DNHDDPCL for approval. After getting approval from DNHDDPCL and successful completion of all
the type tests, the Manufacturer/contractor shall submit 10 more copies of the same drawing along
with a soft copy to the DNHDDPCL for further distribution and field use at DNHDDPCL’s end.

6.8.4 After placement of award the Manufacturer/contractor shall also submit fully dimensioned
insulator crate drawing for different type of insulators.

7.0 MATERIAL DESIGN AND WORKMANSHIP

7.1 GENERAL

(i) All raw materials to be used in the manufacture of these insulators shall be subject to strict raw
material quality control and to stage testing/quality control during manufacturing stage to
ensure the quality of the final end product. Manufacturing shall conform to the best engineering
practices adopted in the field of high voltage transmission. Bidders shall therefore offer
insulators as are guaranteed by them for satisfactory performance on 66Kv Transmission lines.

(ii) The design, manufacturing, process and material control at various stages be such as to give
maximum working load, highest mobility, best resistance to corrosion, good finish, elimination
of sharp edges and corners to limit corona and radio interference voltages.

7.2 GALVANISING

All ferrous parts shall be hot dip galvanized in accordance with the latest edition of IS: 2629. The
zinc to be used for galvanizing shall conform to grade Zn 99.5 as per IS: 209. The Zinc coating shall
be uniform, smoothly adherent, reasonably bright, continuous and free from impurities such as flux,
ash, rust stains, bulky white deposits and blisters. Before ball fittings are galvanized, all die flashing
on the shank and on the bearing surface of the ball shall be carefully removed without reducing the
designed dimensional requirements.

7.3 INTERCHANGEABILITY

The Polymer insulators inclusive of the ball and socket fittings shall be of standard design suitable

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 for use with hardware fittings of any make conforming to relevant Indian Standards.

7.4 CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) PERFORMANCE

All surfaces shall be even, smooth, without cuts, abrasions or projections. No part shall be subjected
to excessive localized pressure. The metal parts shall not produce any noise generating corona
under all operating conditions.

7.5 SUITABILITY FOR LIVE LINE MAINTENANCE

7.5.1 The Polymer insulators shall be compatible for use with hot line or live line maintenance techniques
so that usual hot line operations can be carried out with ease, speed and safety.

7.5.2 Suppliers shall indicate the methods generally adopted in routine hot and cold line maintenance of
EHV lines for similar Polymer insulators supplied by them. Suppliers shall also indicate the
recommended periodicity of such maintenance.

8.0 TEST ON INSULATORS

The following tests shall be carried out on the Composite Polymer insulator:

8.1 TYPE TESTS

This shall mean those tests which are to be carried out to prove the design, process of manufacture
and general conformity of the material and product with the intents of this specification. These tests
shall be conducted on a representative number of samples prior to commencement of commercial
production.

8.2 ACCEPTANCE TESTS

This shall mean those tests which are to be carried out on samples taken from each lot offered for
pre-dispatch inspection for the purpose of acceptance of the lot.

8.3 ROUTINE TESTS

This shall mean those tests, which are to be carried out on each Polymer insulator to check the
requirements, which are likely to vary during production.

8.4 STAGE TESTS DURING MANUFACTURE

Stage tests during manufacture shall mean those tests, which are to be carried out during the
process of manufacture to ensure quality control such that the end product is of the designed quality
conforming to the intent of this specification.

8.5 TEST VALUES

For all type and acceptance tests, the acceptance values shall be the value guaranteed by the
Supplier in the guaranteed technical particulars or the acceptance value specified in this
specification or the relevant standard whichever is more stringent for that particular test.

8.6 TEST PROCEDURES AND SAMPLING NORMS

The norms and procedure of sampling for the above tests shall be as per the relevant Indian
Standard or other internationally accepted standards. This will be discussed and mutually agreed
to between the successful Supplier and Purchaser before placement of order. The standards and
norms according to which these tests are to be carried out are listed against each test. Where a
particular test is a specific requirement of this specification the norms and procedure for the same
shall be as mutually agreed to between the successful supplier and purchaser in the quality
assurance programme. The supplier shall offer at least three times the quantity of material required

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 for conducting all the type tests for sample selection.

Before sample selection, the supplier shall be required to conduct the entire acceptance test
successfully in presence of purchaser’s representative.

8.6.1 TYPE TESTS

(A) The following type tests shall be conducted on all types of the Polymer insulator with hardware
fittings:

a) Power frequency voltage flash over test with corona control rings and arcing horn under
(dry/wet) conditions

b) Power frequency voltage flash over test without corona control rings and arcing horn under
(dry/wet) conditions

c) Switching surge voltage withstand test under wet condition.

d) Impulse voltage withstand test under dry condition.

e) Voltage Distribution test

f) Impulse voltage flash over test under dry condition

g) Corona and RIV Test under dry condition.

h) Mechanical strength test

i) Vibration test.

j) Power Arc Test

k) Salt fog pollution withstand Test

(B) On composite Insulator Unit: -

1. Tests on interface and connection of metal fittings

(a) Dry Power Frequency Voltage Test

(b) Sudden Load Release Test

(c) Thermal Mechanical Test

(d) Steep Front Impulse Voltage Test

(e) Dry Power Frequency Voltage Test

2. Assembled Core Load Time Test

(a) Determination of the Average failing load of the core of the assembled unit

(b) Control of slope of the strength time curve of the insulator

3. Accelerated Ageing Test of 5000 hours

4. Flammability Test

5. Recovery of Hydrophobic Test

6. Mechanical Load Time Test

7. Brittle Fracture resistance test

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 8. Test of Housing, Tracking and Erosion Test

9. Test for the Core Material

- Dye Penetration Test

- Water Diffusion Test

8.6.2 ACCEPTANCE AND ROUTINE TESTS

On Polymer Insulators following Acceptance & Routine tests shall be conducted:

(A) Acceptance tests:

a) Verification of dimensions IEC: 61109-1992

b) Verification of Locking System -

c) Galvanizing test IS-731

d) Verification of specified Mechanical Load IEC: 575

e) Recovery of Hydrophobicity As per annex-A

(B) Routine tests:

a) Visual Inspection IS-731

b) Mechanical routine test IS-731

c) Electrical routine test IEC: 383

8.6.3 TESTS DURING MANUFACTURE (STAGE TESTS)

On all components as applicable

a) Chemical analysis of Zinc used for galvanizing

b) Chemical analysis, mechanical and metallographic test and magnetic particle inspection for
malleable castings

c) Chemical analysis, hardness test and magnetic particle inspection for forgings

d) Crack detection test for metal parts

8.6.4 ADDITIONAL TESTS

The purchaser reserves the right for carrying out any other tests of a reasonable nature at the works
of the Supplier/laboratory or at any other recognized laboratory / research institute in addition to
the above-mentioned type, acceptance and routine tests at the cost of the Purchaser to satisfy that
the material complies with the intent of this specification.

8.6.5 COORDINATION FOR TESTING:

For polymer insulator strings, the Supplier is required to produce type test reports to the
satisfaction of the Purchaser. However, in case the Purchaser desires, the Supplier shall conduct all
the type tests on the complete string with relevant hardware fittings. Responsibility of arranging
required hardwares for the purpose of type testing will remain with the insulator Supplier.

8.7 TEST SCHEDULE

8.7.1 TYPE TESTS

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 The material offered shall be fully type tested as per this specification and the Supplier shall furnish
four sets of type test reports along with the offer. These tests must not have been conducted earlier
than five years.

For any change in the design/type, already type tested and the design/type offered against this bid,
the purchaser reserves the right to demand repetition of some or all type tests without any extra
cost.

8.7.2 ACCEPTANCE AND ROUTINE TESTS

All Acceptance and Routine tests as stipulated herein shall be carried out by the Supplier in the
presence of Purchaser’s representative.

8.7.3 Immediately after finalization of the programme of acceptance/ routine testing, the Supplier shall
give sufficient advance intimation to the Purchaser, to enable him to depute his representative for
witnessing the test.

8.8 INSPECTION

i) Purchaser and its representatives shall at all times be entitled to have access to the works and
to all places of manufactures where insulators are manufactured, and the successful Supplier
shall afford all facilities to them for unrestricted inspection of the works, inspection of material,
inspection of manufacturing process of insulators and for conducting necessary tests as
specified herein.

ii) The successful Supplier shall keep the Purchaser informed in advance of the time of starting
and progress of manufacture of insulators in its various stages so that arrangements could be
made for inspection.

iii) No material shall be dispatched from its point of manufacture unless the material has been
satisfactorily inspected and tested.

iv) The acceptance of any quantity of insulators shall in no way relieve the successful Supplier of
his responsibility for meeting all the requirement of this specification and shall not prevent
subsequent rejection, if such insulators are later found to be defective.

8.9 QUALITY ASSURANCE PLAN

8.9.1 The Supplier hereunder shall invariably furnish following information alongwith his offer, failing
which the offer shall be liable for rejection. Information shall be separately given for individual type
of material offered.

i) Statement giving list of important raw materials, names of sub-suppliers for the raw material,
list of standards according to which the raw material are tested, list of tests, normally carried
out on raw material in presence of Supplier’s representative, copies of test certificates.

ii) Information and copies of test certificates as in (i) above in respect of bought out items.

iii) List of manufacturing facilities available.

iv) Level of automation achieved and list of areas where manual processing exists.

v) List of areas in manufacturing process, where stage inspections are normally carried out in
quality control and details of such test and inspections.

vi) Special features provided in Polymer insulators to make it maintenance free.

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 vii) List of testing equipment available with the Supplier for final testing of Polymer insulators
specified and test plant limitation, if any, vis-a-vis the type, special, acceptance and routine tests
specified in the relevant standards.

8.9.2 The successful Supplier shall within 30 days of placement of order submit the following information
to the Purchaser.

i) List of raw material as well as bought out accessories and the name of material as well as bought
out accessories and the names of sub-suppliers selected from those furnished along with the
offer.

ii) Type test certificates of the raw material and bought out accessories.

iii) Quality assurance plan (QAP) withhold points for Purchaser’s inspection. The QAP and
Purchaser’s hold points shall be discussed between the Purchaser and the Supplier before the
QAP is finalized.

The successful Supplier shall submit the routine test certificates of bought out items and raw
material at the time of routine testing of the insulator.

8.10 DOCUMENTATION

The Supplier shall furnish full description and illustrated catalogues of insulators offered, along
with the bid. The supplier shall also furnish along with the bid the outline drawing of Polymer
insulator unit including cross-sectional view. The drawing shall include the following information:

i) Shed diameter and unit spacing with manufacturing tolerance.

ii) Creepage distance.

iii) Unit mechanical and electrical characteristics for the complete string- suspension and tension.
Unit

iv) Size and weight of ball and socket part.

v) Weight of Polymer unit.

vi) Materials for the cap and pin.

vii) Identification mark.

viii) Manufacturer’s catalogue number.

ix) Brief installation instructions.

x) Relevant technical details of significance.

8.11 TEST REPORTS

i) Four copies of type test reports shall be furnished to the Purchaser within one month of
conducting the tests. One copy will be returned duly certified by the Purchaser to the Supplier
within three weeks thereafter and on receipt of the same Supplier shall commence with the
commercial production of the Polymer insulators.

ii) Four copies of acceptance test reports shall be furnished to the Purchaser. One copy will be
returned, duly certified by the Purchaser and only thereafter shall the materials be dispatched.

iii) All records of routine test reports shall be maintained by the Supplier at his works for periodic
inspection by the Purchaser.

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 iv) All test reports of tests conducted during manufacture shall be maintained by the Supplier.
These shall be produced for verification as and when requested for by the Purchaser.

8.12 GUARANTEED PARTICULARS AND PERFORMANCE GUARANTEE:

(i) The bidder shall furnish all relevant technical guaranteed particulars of the long rod Polymer
Insulators offered. Offers without such details may not be considered.

(ii) The Polymer Insulators shall be guaranteed for satisfactory performance for a period of 24
months from the date of commissioning of line. Any defect due to faulty material or
workmanship found during guarantee period shall be rectified free of cost to the DNHDDPCL.
The replacement will have to be organized expeditiously and within one month from the date
of intimation.

(iii) The contractor must ensure that the material supplied from specific vendor also guaranteed for
the period specified in the bid against the manufacturing defect.

9.0 PACKING & FORWARDING

i) All Polymer insulators shall be packed in suitable PVC/Plastic tubes/any other suitable packing.
The packing shall provide protection against rodents. The supplier shall furnish detailed design
of the packing. For marine transportation crates shall be paletted.

ii) The packing shall be of sufficient strength to withstand rough handling during transit, storage
at site and subsequent handling in the field.

iii) Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent
damage or deformation during transit and handling.

iv) All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and avoid the possibility of goods being lost or wrongly dispatched on account of
faulty packing and faulty or illegible markings.

Each case/crate shall have all the markings stenciled on it in indelible ink.

The supplier shall guarantee the adequacy of the packing and shall be responsible for any loss
or damage during transportation handling, storage and installation due to improper packing
indelible ink.

10.0 GUARANTEED TECHNICAL SPECIFICATIONS OF POLYMERIC INSULATORS & ACCESSORIES

(The following sets of GTP are required to be filled up by the bidders to aid in the evaluation process.
The response shall be brief and to the point and shall be supported by the printed product
description and other literature. The same GTP format duly filled and the relevant drawings shall
also be submitted during the detailed engineering along with the relevant technical brochures. The
bidder shall fill in the guaranteed technical particulars in the Proforma given in this section and
submit the same with his tender, without which bid will not be considered.)

TABLE OF CONTENTS

Sr. no. Sample from

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 GTP 1 66 kv 120KN Tension Type Silicone Rubber Housed long rod

composite polymer insulator

GTP 2 66 kv 90KN Suspension Type Silicone Rubber Housed long rod

composite polymer insulator

GTP-1

66 kV 120KN Tension Type Silicone Rubber Housed long rod composite polymer insulator

Sr. no. Description Unit 66kv:120KN To be filled

Tension type by the bidder

1. Manufacturer

2. Country of Origin India

3. Insulator type Origin 66kV:120KN

Tension type
composite long rod
insulators

4. Standard according to which the IEC – 61109

insulators will be manufactured and
tested

5. Name of material used in Silicone Rubber

manufacture of insulator with class/
grade

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 6a. Material of core (FRP rod) ECR boron free

i) E-glass of ECR glass

ii) Boron content

6b. Material of Housing & weather – Silicon Rubber

sheds (Silicon content by weight) (40%)

6c. Material End Fitting MCI/SGI/Forged

steel

6d. Sealing compound for end fittings Silicon Sealant

6e. Colour Yellow

7. Electrical Characteristic

7a. Nominal system voltage kV 66

7b. Highest system voltage kV 72.5

7c. Dry power frequency withstand kV 160

voltage (rms)

7d. Wet power frequency withstand kV 140

voltage (rms)

7e. Dry Flashover Voltage kV

(rms)

7f. Wet Flashover voltage kV

(rms)

7g. Dry lighting impulse withstand kV

voltage (rms)

I) Positive 350

ii) Negative 350

7h. RIV at 1 MHz when energised at kV < 500 micro volts

10kV/30kV/110kV (rms under dry (rms)
condition

7i. Creepage Distance (Minimum) mm/kV 31 mm/kV

8. Mechanical Characteristics

8a. Minimum failing load kN

9. Dimensions of insulators

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 9a. Weight kgs

9b. Diameter of FRP rod mm

9c. Length of FRP rod mm

9d. Dia Weather – Shed mm

9e. Thickness of Housing mm

9f. Dry arc distance mm

10. Method of fixing of sheds to housing

i) Single mould

ii) Modular construction (injection

moulding /compression moulding)

11. No of weather sheds Nos.

12. Type of sheds

12a. Aerodynamic

12b. With under-rubs

13. Packing details

13a. Type of packing

13b. No of insulator in each pack

13c. Gross weight of package Kgs.

14. Dimensioned drawings of the

insulator (including weight with
tolerance in weight)

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 GTP-2

66 kV 90KN Tension Type Silicone Rubber Housed long rod composite polymer insulator

Sr. no. Description Unit 66kv:120KN To be filled

Tension type by the bidder

1. Manufacturer

2. Country of Origin India

3. Insulator type Origin 66kV:90KN

Tension type
composite long rod
insulators

4. Standard according to which the IEC – 61109

insulators will be manufactured and
tested

5. Name of material used in manufacture Silicone Rubber

of insulator with class/ grade

6a. Material of core (FRP rod) ECR boron free

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 i) E-glass of ECR glass

ii) Boron content

6b. Material of Housing & weather – sheds Silicon Rubber

(Silicon content by weight) (40%)

6c. Material End Fitting MCI/SGI/Forged

steel

6d. Sealing compound for end fittings Silicon Sealant

6e. Colour Blue

7. Electrical Characteristic

7a. Nominal system voltage kV 66

7b. Highest system voltage kV 72.5

7c. Dry power frequency withstand kV 160

voltage (rms)

7d. Wet power frequency withstand kV 140

voltage (rms)

7e. Dry Flashover Voltage kV

(rms)

7f. Wet Flashover voltage kV

(rms)

7g. Dry lighting impulse withstand kV

voltage (rms)

I) Positive 350

ii) Negative 350

7h. RIV at 1 MHz when energised at kV < 1000 micro volts

10kV/30kV/110kV (rms under dry (rms)
condition

7i. Creepage Distance (Minimum) mm/kV 31 mm/kV

8. Mechanical Characteristics

8a. Minimum failing load kN

9. Dimensions of insulators

9a. Weight kgs

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 9b. Diameter of FRP rod mm

9c. Length of FRP rod mm

9d. Dia Weather – Shed mm

9e. Thickness of Housing mm

9f. Dry arc distance mm

10. Method of fixing of sheds to housing

i) Single mould

ii) Modular construction (injection

moulding /compression moulding)

11. No of weather sheds Nos.

12. Type of sheds

12a. Aerodynamic

12b. With under-rubs

13. Packing details

13a. Type of packing

13b. No of insulator in each pack

13c. Gross weight of package Kgs.

14. Dimensioned drawings of the

insulator (including weight with
tolerance in weight)

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 ANNEXURE-7A

TESTS ON COMPLETE COMPOSITE INSULATOR WITH HARDWARE FITTINGS

1.0 MECHANICAL STRENGTH TEST

The complete insulator string along with its hardware fitting excluding arcing horn, corona control
ring, grading ring and suspension assembsly/dead end assembly shall be subjected to a load equal
to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a
steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then
removed. After removal of the load, the string components shall not show any visual deformation
and it shall be possible to disassemble them by hand. Hand tools may be used to, remove cotter pins
and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the
load shall be further increased at a steady rate till the specified minimum UTS and held for one
minute. No fracture should occur during this period. The applied load shall then be increased until
the failing load is reached, and the value recorded.

4.0 VIBRATION TEST

The suspension string shall be tested in suspension mode, and tension string in tension mode itself
in laboratory span of minimum 30 meters. In the case of suspension string, a load equal to 600 kg
shall be applied along the axis of the suspension string by means of turn buckle. The insulator string
along with hardware fittings and the each sub-conductor (each tensioned at 35KN for 220kV) shall
be secured with clamps. The system shall be suitable to maintain constant tension on each sub-
conductor throughout the duration of the test. Vibration dampers shall not be used on the test span.
All the sub-conductors shall be vertically vibrated simultaneously at one of the resonance
frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment.
The peak to peak displacement in mm of vibration at the antinode point, nearest to the string, shall
be measured and the same shall not be less than 1000/f1.8 where f is the frequency of vibration in

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 cycles/sec. The insulator string shall be vibrated for not less than 10 million cycles without any
failure. After the test, the insulators shall be examined for looseness of pins and cap or any crack.
The hardware shall be examined for looseness, fatigue failure and mechanical strength test. There
shall be no deterioration of properties of hardware components and insulators after the vibration
test. The insulators shall be subjected to the Mechanical performance test followed by mechanical
strength test as per relevant standards.

5.0 SALT - FOG POLLUTION WITHSTAND TEST

This test shall be carried out in accordance with IEC-60507. The salinity level for composite long
rod insulators shall be 80 Kg/m3 NACL.

6.0 COMPOSITE LONG ROD INSULATOR UNITS

6.1 BRITTLE FRACTURE RESISTANCE TEST

Assembled core load time test with container that contains in HNO3 concentric acid this is applied
at the naked FRP rod. The rod should be held at 80% of SML for the duration of the test. The rod
should not fail within the 96-hour test duration.

6.2 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 the sample surface

(ii) Treat the surface with corona discharges to destroy the hydrophobicity. This can be done
utilizing a high frequency corona tester. Holding the electrode approximately 3 mm 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 maximum output.

(iii) Immediately after the corona treatment, spray the surface with water and record the HC
classification. The surface should be hydrophilic with an HC value of 6 to 7. If not, dry the surface
and repeat the corona treatment for a longer time until an HC of 6 or 7 is obtained. Dry the
sample surface.

(iv) Allow the sample to recover and repeat the Hydrophobicity measurement at several time
intervals. Silicone rubber should recover to HC 1 – HC 2 within 24 to 48 hours, depending on the
material and the intensity of the corona treatment

6.3 SILICONE CONTENT TEST

Minimum content of silicone as guaranteed by supplier shall be verified through FT-IR spectroscopy
& TGA analysis or any other suitable method mutually agreed between Owner & Supplier in Quality
Assurance Programme.

7.0 HIGH PRESSURE WASHING TEST

If applicable, washing of a complete insulator of each E&M rating is to be carried out at 3800 KPa
with nozzles of 6mm diameter at a distance of 3m from nozzles to the insulator. The washing shall
be carried out for 10minutes. There shall be no damage to the sheath or metal fitting to housing
interface. The verification shall be 1 minute wet power frequency withstand test at 460 kV r.m.s for
220KV.

8.0 TORSION TEST

Three complete insulators of each E&M rating shall be subjected to a torsional load of 55Nm. The
torsional strength test shall be made with test specimen adequately secured to the testing machine.
The torsional load shall be applied to the test specimen through a torque member so constructed

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 that the test specimen is not subjected to any cantilever stress. The insulator after torsion test must
pass the Dye Penetration Test as per IEC 61109.

9.0 TESTS ON ALL COMPONENTS (AS APPLICABLE)

9.1 CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING

Samples taken from the zinc ingot shall be chemically analyzed as per IS 209- 1979. The purity of
zinc shall not be less than 99.95%.

9.2 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 test will be as discussed and mutually
agreed to by the Supplier and Owner in Quality Assurance Programme.

9.3 TESTS ON CASTINGS

The chemical analysis, mechanical and metallographic tests and magnetic, particle inspection for
castings will be as per the internationally recognized Procedures for these tests. The samplings will
be based on heat number and heat treatment batch. The details regarding test will be as discussed
and mutually agreed to by the Supplier and Owner in Quality Assurance Programme.

10.0 POWER ARC TEST:

Three insulators 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 the insulator by means of a Copper
shorting fuse wire. The arc shall burn 15 to 30 cycles and its current magnitude is determined by
ampere- time product (IxT) equal to a minimum of 150kA 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.

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 SECTION - 8

TECHNICAL SPECIFICATION OF HARDWARE & ACCESSORIES FOR CONDUCTOR, INSULATOR & EARTH
WIRE

1.0 SCOPE

This section provides the technical details of Hardware fittings & Accessories suitable for Insulator
string, Conductor and Earth wire for use on 66kV Multi circuit transmission lines. The material and
services under this specification shall be performed as per the requirements of the latest revisions
and amendments available at the time of placement of order of all the relevant Indian
Standards/Codes listed in Clause-2 STANDARDS here under or equivalent International Standards,
except as modified in this document.

The materials covered here under this specification shall be supplied complete in all respects,
including all components, fittings and accessories which are necessary or are usual for their efficient
performance and satisfactory maintenance under the various operating and atmospheric
conditions. Such parts shall be deemed to be within the scope of the Contract, whether specifically
included or not in the Specification or in the Contract Schedules.

2.0 STANDARDS

Sr. no. Indian standard Title

1. IS:206 Tee and Strap Hinges
IS:209 Specification for Zinc
2.

3. IS:1367 Technical supply conditions for threaded fasteners

4. IS:1385 Phosphor Bronze Rods & Bar Sheet and Strips and Wire
IS:1570 Schedules for wrought steels for general engineering
5.
(part-I) purposes steel specified by tensile and/or yield properties
6. IS:1573 Electroplated coatings of zinc on iron and steel
IS:2002 Steel plates for pressure vessels for intermediate and high
7.
temperature
IS:2004 Specification for carbon steel forgings the general
8.
engineering purposes
9. IS 2062-2011 Specification for steel for general purpose
10. IS:2071 Method of high voltage testing
IS:2121 Specification of conductors and earthwire accessories for
11.
(all parts) over-head power lines
IS:2486 Specification for insulator fittings for overhead power lines
12.
(all parts) with nominal voltage greater than 1000V
13. IS:2629 Recommended practice for Hot Dip galvanizing of iron & steel
IS:2633 Methods of testing uniformity of coating on zinc coated
14.
articles
15. IS:3138 Hexagon Bolts and Nuts
16. IS:3188 Characteristic of String Insulators Units

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 IS:4759 Hot Dip Zinc Coatings on Structural Steel and other Allied
17.
Products
18. IS: 4826-1979 Hot Dip Galvanised Coating on Round Steel Wires
19. IS 6639 Specification for Hexagonal bolts for steel structures
IS:6745 Methods of Determination of Weight of Zinc Coating of Zinc
20.
Coated Iron and Steel Articles
21. IS:7814-1985 Phosphor Bronze Sheet and Strip
IS: 8263 Method of Radio Interference Tests on High Voltage
22.
Insulators
23. IS: 9708 Stockbridge Vibration Dampers for Overhead Power lines.
IS:10162 Spacers and Spacer Dampers for twin horizontal bundle
24.
Conductors.
BS:970 General Instructions and Testing Procedures Specific
25. Requirements for Carbon and Carbon Manganese Alloy and
(Part-I)
Stainless Steels.
26. Ozone test on Elastomer
Composite string insulator units for overhead lines with a
27. nominal voltage above 1000V:
• Standard strength classes and end fittings
• Dimensional and electrical characteristics

The standards mentioned above are available from:

3.0 LINE REQUIREMENT

3.1 INSULATOR STRING CHARACTERISTICS

Insulator string characteristics are furnished in clause 4.1, section 1, part A of volume II.

3.2 CONDUCTORS CHARACTERISTICS

Conductor characteristics are furnished in clause 4.1, section 1, part A of volume II.

3.3 OPGW CHARACTERISTICS

OPGW characteristics are furnished in clause 4.1, section 1, part A of volume II.

4.0 TECHNICAL DESCRIPTION OF HARDWARE FITTINGS

4.1 General

The Hardware fittings & Accessories shall meet the technical requirement as per standards.
Hardware fittings & Accessories shall be suitable for single/double suspension V-string Insulator
and single/double tension Insulator strings.

Each Hardware fitting shall be supplied complete in all respect and shall include all components,
which are required for making complete set.

The hardware fittings shall be suitable for use with Composite Long Rod insulators having ball and
socket fittings.

Corona control rings/grading ring with fittings for attachment to line side yoke plate.

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 Sag adjustment plate for Double tension hardware fittings and turn buckle for single tension
hardware fittings.

Suspension and dead-end assembly to suit conductor size as detailed in clause 4.6 & 4.7 hereinafter.

Other necessary fittings viz D-shackles, eye links, extension links, ball clevis, socket clevis, clevis eye,
U clevis and chain link etc. to make the hardware fittings complete.

The fittings shall be suitable for attachment to suspension and tension insulator strings along with
hardware fittings and shall include 2.5 % extra fasteners, Aluminium filler plugs & retaining rods.
Indicative drawings of complete insulator strings along with hardware fittings as well as indicative
drawings for suspension clamps and dead end clamps are enclosed in Section-VII of this
specification. The supplier shall be responsible for satisfactory performance of complete conductor
system along with fittings offered by them for continuous operation at the maximum temperature
specified by them for the conductor.

4.2 Interchangeability

The hardware for insulator strings with Composite long rod insulators together with ball and socket
fittings shall be of standard design, so that these hardware are inter- changeable with each other
and suitable for use with insulators of any make conforming to relevant Indian/International
Standard.

4.3 Corona and RI Performance

Sharp edges and scratches on all the hardware fittings shall be avoided. All surfaces must be clean,
smooth, without cuts and abrasions or projections. The Supplier shall be responsible for satisfactory
corona and radio interference performance of the materials offered by him.

4.4 Maintenance

The hardware fittings offered shall be suitable for employment of hot line maintenance technique
so that usual hot line operations can be carried out with ease, speed and safety. The technique
adopted for hot line maintenance shall be generally bare hand method & hot stick method. The
Bidder should clearly establish in the bid, the suitability of his fittings for hot line maintenance.

The line side yoke plate shall have a notch & a working hole of suitable size. The design of corona
control rings/grading ring shall be such that it can be easily replaced by employing hot line
maintenance technique.

4.5 Split Pins

Split pins shall be used with bolts & nuts.

4.6 SUSPENSION ASSEMBLY

4.6.1 The suspension assembly shall be suitable for the TACSR 160 Sq. mm conductor

4.6.2 The suspension assembly shall include either free centre type suspension clamp along with
standard preformed armour rods or armour grip suspension clamp.

4.6.3 The suspension clamp along with standard preformed armour rods set shall be designed to have
maximum mobility in any direction and minimum moment of inertia so as to have minimum stress
on the conductor in the case of oscillation of the same.

4.6.4 The suspension clamp suitable for various type of Conductor along with standard preformed

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 armour rods/armour grip suspension clamp set shall have a slip strength between 8% to 15% of
ultimate strength of conductor.

4.6.5 The suspension clamp shall be designed for continuous operation at the temperature according to
the temp of required conductor.

4.6.6 The suspension assembly shall be designed, manufactured and finished to give it a suitable shape,
so as to avoid any possibility of hammering between suspension assembly and conductor due to
vibration. The suspension assembly shall be smooth without any cuts, grooves, abrasions,
projections, ridges or excrescence which might damage the conductor.

4.6.7 The suspension assembly/clamp shall be designed so that it shall minimise the static & dynamic
stress developed in the conductor under various loading conditions as well as during wind induced
conductor vibrations. It shall also withstand power arcs & have required level of Corona/RIV
performance.

4.6.8 Free Centre Type Suspension Clamp

For the Free Centre Suspension Clamp seat shall be smoothly rounded and curved into a bell mouth
at the ends. The lip edges shall have rounded bead. There shall be at least two U-bolts for tightening
of clamp body and keeper pieces together.

4.6.9 Standard Preformed Armour Rod Set

4.6.9.1 The Preformed Armour Rods Set shall be used to minimize the stress developed in the sub-
conductor due to different static and dynamic loads because of vibration due to wind, slipping of
conductor from the suspension clamp as a result of unbalanced conductor tension in adjacent spans
and broken wire condition. It shall also withstand power arcs, chafing and abrasion from suspension
clamp and localized heating effect due to magnetic power losses from suspension clamps as well as
resistance losses of the conductor.

4.6.9.2 The preformed armour rods set shall have right hand lay and the inside diameter of the helics shall
be less than the outside diameter of the conductor to have gentle but permanent grip on the
conductor. The surface of the armour rod when fitted on the conductor shall be smooth and free
from projections, cuts and abrasions etc.

4.6.9.3 The pitch length of the rods shall be determined by the Bidder but shall be less than that of the outer
layer of conductor and the same shall be accurately controlled to maintain uniformity and
consistently reproducible characteristic wholly independent of the skill of linemen.

4.6.9.4 The tolerance in length of the rods in complete set should be within 13 mm between the longest and
shortest rod. The ends of armour rod shall be parrot billed.

4.6.9.5 The number of armour rods in each set shall be eleven. Each rod shall be marked in the middle with
paint for easy application on the line.

4.6.9.6 The armour rod shall not lose their resilience even after five applications. The conductivity of each
rod of the set shall not be less than 40% of the conductivity of the International Annealed Copper
Standard (IACS).

4.6.10 Armour Grip Suspension Clamp

4.6.10.1 The armour grip suspension clamp shall comprise of retaining strap, support housing, elastomer
inserts with aluminium reinforcements and AGS preformed rod set.

4.6.10.2 Elastomer insert shall be resistant to the effects of temperature up to maximum conductor
temperature guaranteed by the bidder corresponding to peak current, Ozone, ultraviolet radiations

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 and other atmospheric contaminants likely to be encountered in service. The physical properties of
the elastomer shall be of approved standard. It shall be electrically shielded by a cage of AGS
performed rod set. The elastomer insert shall be so designed that the curvature of the AGS rod shall
follow the contour of the neoprene insert.

4.6.10.3 The length of the AGS preformed rods shall be such that it shall ensure sufficient slipping strength
and shall not introduce unfavorable stress on the conductor under all operating conditions.

4.7 DEAD END ASSEMBLY

4.7.1 The dead-end assembly shall be suitable for the TACSR 160 sqmm conductor.

4.7.2 The dead-end assembly shall be of compression type with provision for compressing jumper
terminal at one end. The angle of jumper terminal to be mounted should be 30° with respect to the
vertical line. The area of bearing surface on all the connections shall be sufficient to ensure positive
electrical and mechanical contact and avoid local heating due to I2R losses.

The resistance of the clamp when compressed on Conductor shall not be more than 75% of the
resistance of equivalent length of Conductor.

4.7.3 Die compression areas shall be clearly marked on each dead-end assembly designed for continuous
die compressions and shall bear the words ‘COMPRESS FIRST’ suitably inscribed near the point on
each assembly where the compression begins. If the dead-end assembly is designed for intermittent
die compressions it shall bear identification marks ‘COMPRESSION ZONE’ and ‘NON-
COMPRESSION ZONE’ distinctly with arrow marks showing the direction of compressions and
knurling marks showing the end of the zones. Tapered aluminium filler plugs shall also be provided
at the line of demarcation between compression & non-compression zone. The letters, number and
other markings on the finished clamp shall be distinct and legible. The dimensions of dead end
assembly before & after compression along with tolerances shall be shall be guaranteed in the
relevant schedules of the bid and shall be decided by the manufacturer so as to suit the conductor
size & conform to electrical & mechanical requirement stipulated in the specification.

4.7.4 The assembly shall not permit slipping of, damage to, or failure of the complete conductor or any
part thereof at a load less than 95% of the ultimate tensile strength of the conductor.

4.8 OTHER HARDWARE FITTINGS

4.8.1 BALL AND SOCKET

The Ball and Socket for Hardware fittings shall necessarily conform to the dimensions as stipulated
in the Indian Standards. The Ball and Socket dimensions of the Hardware sets to be used with 90KN
Electro Mechanical strength of Polymeric Insulators shall be of 16mm. The Ball and Socket
dimensions of the Hardware sets to be used with 120KN Electro Mechanical strength of Polymeric
Insulators shall be of 20mm. The Bidder shall offer full detail of locking device in accordance with
IS 2486:(Part-III) or equivalent International Standard along with test reports, gauges and
adherence to Standards for Tests on Locking Devices in line with IS:2486 (Part-IV) or equivalent
International Standard.

4.8.1.1 Ball fittings

Ball fittings shall be made of class IV steel as per IS:2004 or steel of equivalent grade and shall be
forged in one piece. They shall be normalized to achieve the minimum breaking strength specified
on the respective drawings. Before galvanization of ball fittings, all die flashing on the shank and on
the bearing surface of the ball shall be carefully removed without reducing the dimensions below
the requirements.

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4.8.1.2 Socket fittings

Socket fittings shall be made of class IV steel as per IS:2004 or steel of equivalent grade and shall be
forged in one piece. They shall be normalized to achieve the minimum breaking strength specified
on the respective drawings.

4.8.1.3 Security clips for socket fittings

Socket fittings shall be provided with R-shaped security clip in accordance with IS:2486 (parts III &
IV) to provide positive locking against unintentional disengagement of socket from the ball of the
insulator. The security clip shall be humped to maintain the clip in the locked position and shall have
both prongs spread to prevent template withdrawal from the socket. The clip end shall not project
outside the recess of socket when the clip in locked position.

The hole for the security clip shall be on the side of the socket opposite to the socket opening. The
hole for the clip shall be counter sunk. The clip eye shall be of such design that the same may be
engaged by a hotline clip puller to provide for disengagement under energized conditions.

The security clip shall be made of stainless steel of type AISI 302 or 304 or phosphor bronze as per
IS:7814.

4.8.2 YOKE PLATE/LINK PLATE

The strength of yoke plates shall be adequate to withstand the minimum ultimate tensile strength
suits to Insulators mentioned in Section 7 of Volume II.

The plates shall be either triangular or rectangular in shape as may be necessary. The design of yoke
plate shall take into account the most unfavorable loading conditions likely to be experienced as a
result of dimensional tolerances for Composite insulators as well as components of hardware
fittings within the specified range. The plates shall have suitable holes for fixing corona control
rings/grading ring/arcing horn. All the corners and edges should be rounded off with a radius of
atleast 3 mm. Design calculations i.e. for bearing & tensile strength, for deciding the dimensions of
yoke plate shall be furnished by the bidder.

The yoke plate/link plate shall be made of steel plate as per IS: 226 or equivalent standards.
Shearing/cutting of the plate shall be clean without drawn or ragged edges. If the plates are flame
cut, mechanical guides shall be used. It shall be ensured that the grain flow of the yoke plate shall
be in the direction of the tensile load.

Holes shall be cylindrical, clean cut and perpendicular to the plane of the material. The periphery of
the holes shall be free from burrs.

4.8.3 ANCHOR SHACKLE

Anchor shackle shall be made of forged steel complete with G.I. rivets and stainless-steel split pin,
minimum breaking strength shall be 240KN for double tension string.

4.8.4 BALL CLEVIS, SOCKET CLEVIS

The Ball clevis shall be made of forged steel and socket clevis from malleable cast iron complete
with G.I. rivet and stainless-steel split pins. Ball and socket clevis shall be suitable for insulator string
for appropriate fitting to which they are connected. All ball and clevis shall be a minimum breaking
strength of 120KN.

4.8.5 CLEVIS – CLEVIS

Clevis fittings shall be made of malleable cast iron, complete with G.I. rivet and stainless-steel split
pins. Clevis shall be suitable for connecting to yoke plate on sub-station structure side. Minimum

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 breaking strength of the clevis shall be 120KN

4.8.6 TURN BUCKLE

The turn buckle is to be provided with single tension hardware fitting. The threads shall be of
sufficient strength to remain unaffected under the specified tensile load.

It shall be made of forged steel. The minimum adjustment in the movement facilitated by the turn
buckle shall be 175mm. The minimum breaking strength of the turn buckle shall be 160KN and
requisite locking arrangement shall be provided for safe guarding shearing of threads under
working conditions. The same shall be specifically indicated in the drawings.

4.8.7 SAG ADJUSTMENT PLATE

The Sag adjustment plate shall be made of steel plate as per IS:226 or equivalent standards.
Shearing/cutting of the plate shall be clean without drawn or ragged edges. If the plates are flame
cut, mechanical guides shall be used.

Sag adjustment plate for Dead End Assembly having adjustment of upto 150mm minimum at the
interval of 6 mm.

The sag-adjustment plate to be provided with the Double tension hardware fitting shall be of three
plate type. The sag adjustment plate shall be provided with a safety locking arrangement. The device
shall be of such design that the adjustment is done with ease, speed and safety.

Design calculations for deciding the dimensions of sag adjustment plate shall be furnished by bidder

4.8.8 ARCING HORN

66kV Insulator strings for transmission line shall be provided with Arcing Horns of different type at
suitable position for each insulator. In case of 66kV Insulator strings, the Arcing Horn shall be
provided on both line side & tower side. The dimension of the Arcing Horn shall be as per standard.
However, the height of the Arcing Horn may be changed depending upon the length of Socket Eye,
Yoke Plate etc. The arrangement for fixing of Arcing Horn shall be such that they do not get loose
while in service. To achieve this, they should have proper seat for the Arcing Horn and heat-treated
Belleville washers should be provided with the bolts.

5.0 PARTICULARS OF HARDWARE FITTINGS

Each Hardware fitting for the transmission line shall be complete in all respect and Bidder should
furnish complete drawings and technical particulars of the items of hardware fittings. The Hardware
fittings should normally comprise items mentioned below:

5.1 SINGLE SUSPENSION V-STRING HARDWARE FITTING

Single suspension Hardware string shall comprise of one Ball Hook, one Socket Eye Horn holder,
one-line side Arcing Horn and one Suspension Clamp of AGS type with armour rod suitable for
respective sizes of Conductors. The Complete string shall have ultimate breaking strength of not less
than 90KN for 66 kV.

5.2 SINGLE TENSION STRING HARDWARE FITTINGS

Single tension string Hardware shall comprise of one `D’ Shackle, one Ball Link, one Forged Steel
Socket, Socket Clevis Horn holder, Arcing Horn and one Tension Clamp of compression type. The
Complete string shall have ultimate breaking strength of not less than 90KN for 66kV.

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5.3 DOUBLE TENSION STRING HARDWARE FITTINGS

The double tension string Hardware shall comprise of two `D’ shackle, one chain link one top yoke
plate, two ball clevis, two socket clevis, one bottom yoke plate, Arcing horn, one clevis and a
compression type dead-end Clamp. The Complete string shall have ultimate breaking strength of
not less than 180KN for 66kV.

6.0 GENERAL SPECIFICATIONS

6.1 All the materials shall be of the latest design and conform to the best modern practice adopted in
the extra high voltage field. The manufacturer shall supply only such material as guaranteed by him
to be satisfactory and suitable for 66kV Transmission lines.

6.2 The design, manufacturing process and quality control of all the materials shall be such as to give
maximum factor of safety, maximum possible working load, highest mobility, elimination of sharp
edges and corners, best resistance to corrosion and a good finish.

6.3 All ferrous parts shall be hot dip galvanised, after all machining has been completed. Nuts may,
however, be tapped (threaded) after galvanizing and the threads oiled. Spring washers shall be
electro galvanised. The bolts threads shall be undercut to take care of increase in diameter due to
galvanizing. Galvanizing shall be done in accordance with IS:2629-1990 or equivalent International
Standard and satisfy the tests mentioned in IS:2633- 1992 or equivalent International Standard.
Fasteners shall withstand four dips while spring washers shall be guaranteed to withstand at least
six dips each lasting one minute under the standard preece test for galvanizing.

6.4 The Zinc coating shall be perfectly adhere, of uniform thickness, smooth, reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky while deposits and
blisters. The Zinc used for galvanizing shall be grade Zn. 99.95 as per IS: 209-1992 or equivalent
International Standard.

6.5 In case of castings, the same shall be free from all internal defects like shrinkage, inclusion,
blowholes, cracks etc.

6.6 All current carrying parts shall be so designed and manufactured that contact resistance is reduced
to minimum.

6.7 No item which would produce high electrical and mechanical stresses in normal working shall have
sharp ends or edges, abrasions or projections and shall not cause any damage to the Conductor in
any way during erection or during continuous operation. The design of adjacent metal parts and
mating surfaces shall be such as to prevent corrosion of the contact surface and no maintain good
electrical contact under service conditions.

6.8 Particular care shall be taken during manufacturing and subsequent handling to ensure smooth
surface free from abrasion or dents.

6.9 The fasteners shall conform to the requirement of IS: 6639-1972 or equivalent International
Standard. All fasteners and clamps shall have locking arrangements to guard against vibration
loosening.

7.0 BID DRAWINGS

7.1 The Bidder shall furnish full description and illustrations of materials offered.

7.2 Fully dimensioned drawings of the complete insulator string hard wares and their component parts
showing clearly the following arrangements shall be furnished along with the bid. Weight, material
and fabrication details of all the components should be included in the drawings.

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 (i) Attachment of the hanger or strain plate.

(ii) Suspension or dead-end assembly.

(iii) Arcing horn attachment to the string as specified in clause 4.8.8 of this technical Specification.

(iv) Yoke plates

(v) Hardware fittings of ball and socket type for inter connecting units to the top and bottom Yoke
plates.

(vi) Corona control rings/grading ring attachment to conductor and other small accessories.

(vii) Links with suitable fittings.

(viii)Details of balancing weights and arrangements for their attachment in the single suspension
pilot insulator string.

7.3 All drawings shall be identified by a drawing number and contract number. All drawings shall be
neatly arranged. All drafting & lettering shall be legible. The minimum size of lettering shall be 3
mm. All dimensions & dimensional tolerances shall be mentioned in mm.

The drawings shall include:

(i) Dimensions and dimensional tolerance.

(ii) Material, fabrication details including any weld details & any specified finishes & coatings.
Regarding material designation & reference of standards are to be indicated.

(iii) Catalogue No.

(iv) Marking

(v) Weight of assembly

(vi) Installation instructions

(vii) Design installation torque for the bolt or cap screw.

(viii)Withstand torque that may be applied to the bolt or cap screw without failure of component
parts.

(ix) The compression die number with recommended compression pressure.

(x) All other relevant terminal details.

7.4 After placement of award, the Contractor/Manufacturer shall submit fully dimensioned drawing
including all the components in four (4) copies to the DNHDDPCL for approval. After getting
approval from the DNHDDPCL and successful completion of all the type tests, the
Contractor/Manufacturer shall submit thirty (30) more copies of the same drawings to the
DNHDDPCL for further distribution and field use at DNHDDPCL’s end.

8.0 DIMENSIONS & TOLERANCES:

8.1 The dimensions and tolerances of pin balls and socket ends shall conform to IS 2486 Part-II/IEC-
120 and shall be checked by the gauge therein after galvanizing.

8.2 The pin balls shall be checked with the applicable “GO” gauges in at least two directions, one of
which shall be across the line of die flashing and the other 90 deg. to this line. “NO GO” gauges shall
not pass in any direction.

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8.3 The bearing surfaces of balls and machined sockets, before galvanizing shall not have surface
roughness more than 250 micro inches.

8.4 The bearing surface of socket ends shall be uniform about the entire circumference without
depressions or high spots. The internal contour of the socket ends shall be concentric with the axis
of fittings. The axis of the bearing surface of socket ends shall be coaxial with the axis of fittings with
no appreciable tilting.

9.0 IMPORTANT CONDITIONS:

9.1 All Hardware items shall be complete with minor items such as security clip, bolts, nuts, washer,
split pins and inners etc.

9.2 The Contractor shall be responsible for satisfying him that the Insulator fittings offered are entirely
suitable for the proposed attachments and for the sizes of the Conductor specified.

9.3 All ferrous fittings (except those specified otherwise) shall be hot dip galvanized, after all machining
and fitting has been completed, in accordance with relevant Indian Standard. All Hardware items
(other than clamps) and those specified otherwise should be made of Drop Forged Steel. Socket
items in forged steel must be forged. All forgings supplied should be stress relieved and this
treatment should be done at the Contractor works. Forgings, which are not stress relieved, will not
be acceptable. The items like Yoke Plate, Arcing Horn, Bolts and Nuts shall be of mild steel and rest
of the items shall be of forged steel.

9.4 All Bolts, Nuts and Screw heads shall have only wide worth standard thread and of sizes indicated
in the enclosed drawing. Bolts head and Nuts shall be hexagonal. Where required, nuts shall be
locked in approved manner. The thread in Nuts shall be over tapped after galvanizing and shall be
cut before galvanizing. The threads shall not be undercut. The Nuts should be tapped such that they
are fit on the bolt threads i.e. these should not have loose fitting.

9.5 Compression Markings

Die compression areas shall be clearly marked on each equipment designed for continuous die
compressions and shall bear the words ‘COMPRESS FIRST’ ‘suitably inscribed on each equipment
where the compression begins. If the equipment is designed for intermittent die compressions, it
shall bear the identification marks ‘COMPRESSION ZONE’ and ‘NONCOMPRESSION ZONE’ distinctly
with arrow marks showing the direction of compression and knurling marks showing the end of the
zones. The letters, number and other markings on finished equipment shall be distinct and legible.

10.0 GALVANISING:

10.1 Hot dip galvanizing shall conform to Indian Standard specification IS-2633 or equivalent
International Standard.

10.2 Galvanizing shall be uniform, free from blisters, and shall not peel off due to abrasion, Zinc coating
shall be thick enough to withstand 6 one minute dips in Copper Sulphate solution (preece test) for
all ferrous parts except for threaded portions which shall withstand at least 4 one minute dips.

10.3 The Contractor must emboss/engrave their name in each forged steel item and Aluminium castings
such as Ball Hook, Yoke Plate, Socket Clevis, Clevis Eye, Clevis- Clevis, Anchor Shackle/D-Shackle,
Chain Link, Suspension Clamps of AGS type, Tension Clamps and Arcing Horns.

11.0 TESTS

11.1 All the specified type tests on Hardware Fittings and Accessories for Conductors offered by the
bidder shall not be required to be carried out if valid test certificate is available i.e., tests conducted
within last five years from the date of bid opening in an accredited laboratory or witnessed by the

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 representative (s) of a Utility.

11.2 In the event of any discrepancy in the test report (i.e., any test report not applicable due to any
design / material/manufacturing process change including substitution of components or due to
non-compliance with the requirement stipulated in the Technical Specification) the tests shall be
conducted by the Contractor at no extra cost to the DNHDDPCL. The hardware fittings offered shall
be type tested as per the relevant standards. Further the acceptance, routine tests and tests during
manufacture shall be carried out on the conductor.

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

11.4 Routine tests shall mean those tests which are to be carried out on each and every product so as to
check with requirements which are likely to vary during production.

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

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

11.7 For all type and acceptance tests, the acceptance values shall be the values guaranteed by the
Contractor in the “Technical Questionnaire” or the acceptance value specified in this specification,
whichever is more stringent for that particular test.

11.8 Type Tests (Type tests should have been completed during last five years)

11.8.1 On Suspension Clamp

a) Magnetic power loss test : As per Annexure-8A

b) Clamp slip strength Vs torque test : As per Annexure-8A

c) Ozone Test on elastomer : As per Annexure-8A

11.8.2 On Dead End Tension Assembly

a) Electrical resistance test for dead end Assembly: As per IS:2486- (Part-I)

b) Heating cycle test for dead end Assembly : As per IS:2486-(Part-I)

c) Slip strength test for dead end assembly : As per IS:2486-(Part-I)

d) Ageing test on filler (if applicable) : As per Annexure-8A

11.8.3 Mid Span Compression Joint for Conductor

a) Chemical analysis of materials : As per Annexure-8A

b) Electrical resistance test : As per IS: 2121(Part-II)

c) Heating cycle test : As per IS: 2121(Part-II)

d) Slip strength test : As per Annexure-8A

e) Corona extinction voltage test (dry) : As per Annexure-8A

f) Radio interference voltage test (dry) : As per Annexure-8A

Note: Tests mentioned at (c), (e) & (f) are not applicable to mid span compression joints for earth wire

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11.8.4 Repair Sleeve for Conductor

a) Chemical analysis of materials : As per Annexure-8A

b) Corona extinction voltage test (dry) : As per Annexure-8A

c) Radio interference voltage test (dry) : As per Annexure-8A

11.8.5 Connector for Conductor

a) Chemical analysis of materials : As per Annexure-8A

b) Electrical resistance test : As per IS: 2121(Part-II) Clause 6.5 & 6.6

c) Heating cycle test : As per IS: 2121 (Part-II)

d) Axial tensile load test on welded portion : As per Annexure-8A

e) Corona extinction voltage test (dry) : As per Annexure-8A

f) Radio interference voltage test (dry) : As per Annexure-8A

11.8.6 Vibration Damper for Conductor

a) Chemical analysis of materials : As per Annexure-8A

b) Dynamic characteristics test* : As per Annexure-8A

c) Vibration analysis : As per Annexure-8A

d) Clamp slip test : As per Annexure-8A

e) Fatigue tests : As per Annexure-8A

f) Magnetic power loss test : As per Annexure-8A

g) Corona extinction voltage test (dry) : As per Annexure-8A

h) Radio interference voltage test (dry) : As per Annexure-8A

i) Damper efficiency test : As per IS: 9708

* Applicable for 4 R stock bridge dampers. For alternate type of vibration dampers (permitted as per clause
2.5.2), as an alternative to dynamic characteristic test, damper efficiency test as per IEEE-664 Power
Manual may be proposed/ carried out by the supplier.

11.8.7 Acceptance Tests

On Both Suspension Clamp and Tension Assembly

a) Visual Examination : As per IS: 2486-(Part-I)

b) Verification of dimensions : As per IS: 2486-(Part-I)

c) Galvanising/Electroplating test : As per IS: 2486-(Part-I)

d) Mechanical strength test of each component: As per Annexure-8A

e) Mechanical Strength test of welded joint : As per Annexure-8A

f) Mechanical strength test for corona

control ring/ grading ring and arcing horn : BS:3288 - (Part-I)

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 g) Test on locking device for ball and

socket coupling : As per IEC:372 (2)

h) Chemical analysis, hardness tests,

grain size, inclusion rating & magnetic

particle inspection for forgings/castings : As per Annexure-8A

On Suspension Clamp only

a) Clamp Slip Strength Vs Torque test

for suspension clamp : As per Annexure-8A

b) Shore hardness test of elastomer

cushion for AG suspension clamp : As per Annexure-8A

c) Bend test for armour rod set : As per IS: 2121(Part-I),

Clause 7.5,7,10 &7.11

d) Resilience test for armour rod set : As per IS: 2121(Part-I),

Clause 7.5,7,10 & 7.11

e) Conductivity test for armour rods set : As per IS: 2121(Part-I),

Clause 7.5,7,10 & 7.11

On Tension Hardware Fittings only

a) Slip strength test for dead end assembly : As per IS: 2486 (Part-I)

Clause 5.4

b) Ageing test on filler (if applicable) : As per Annexure-8A

On Mid Span Compression Joint for Conductor & Earth wire

a) Visual examination and dimensional verification: As per IS: 2121 (Part-II),

Clause 6.2, 6.3 7 6.7

b) Galvanizing test : As per Annexure-8A

c) Hardness test : As per Annexure-8A

d) Ageing test on filler (if applicable) : As per Annexure-8A

Connector for Conductor

a) Visual examination and dimensional verification: As per IS:2121 (Part-II)

b) Axial tensile load test for welded portion : As per Annexure-8A

Repair Sleeve for Conductor

a) Visual examination and dimensional verification: As per IS:2121(Part-II)

Clause 6.2, 6.3

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 Vibration Damper for Conductor

a) Visual examination and dimensional verification: As per IS: 2121(Part-II) Clause 6.2, 6.3 7 6.7

b) Galvanizing test : As per Annexure-8A

i) On damper masses : As per Annexure-8A

ii) On messenger cable : As per Annexure-8A

c) Verification of resonance frequencies : As per Annexure-8A

d) Clamp slip test : As per Annexure-8A

e) Clamp bolt torque test : As per Annexure-8A

f) Strength of the messenger cable : As per Annexure-8A

g) Mass pull off test : As per Annexure-8A

h) Dynamic characteristics test* : As per Annexure-8A

* Applicable for 4R Stockbridge dampers. For alternate type of vibration dampers (permitted as per
clause 2.5.2), as an alternative to dynamic characteristic test, damper efficiency test as per IEEE-
664 Power Manual may be proposed/ carried out by the supplier.

Routine Tests

For Hardware Fittings

a) Visual examination : IS:2486-(Part-I)

b) Proof Load Test : As per Annexure-8A

For Conductor

a) Visual examination and dimensional : As per IS: 2121(Part-II)

verification Clause 6.2, 6.3 7 6.7

Tests During Manufacture on all components as applicable

a) Chemical analysis of Zinc used for galvanizing: IS:2486-(Part-I)

b) Chemical analysis mechanical metallographic test and magnetic particle inspection for

malleable castings : As per Annexure-8A

c) Chemical analysis, hardness tests and

magnetic particle inspection for forging : As per Annexure-8A

12.0 TESTING EXPENSES

12.1 In case of failure in any type test, the Bidder whose material has failed is either required to modify
the design of the material & successfully carryout all the type tests as has been detailed out in Clause
11 of this specification or to repeat that particular type test at least three times successfully at his
own expenses.

12.2 In case of type test on the complete insulator string, the Contractor/Manufacturer has to arrange
similar insulators at his own cost.

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12.3 Bidder shall indicate the laboratories in which they propose to conduct the type tests. They shall
ensure that adequate facilities for conducting the tests are available in the laboratory and the tests
can be completed in these laboratories within the time schedule guaranteed by them in the
appropriate schedule.

12.4 The entire cost of testing for acceptance and routine tests and tests during manufacture specified
herein shall be treated as included in the quoted Ex- works/CIF Price.

12.5 In case of failure in any type test, repeat type tests are required to be conducted, then, all the
expenses for deputation of Inspector/DNHDDPCL’s representative shall be deducted from the
contract price. Also, if on receipt of the Contractor/Manufacturer's notice of testing, the
DNHDDPCL's representative/Inspector does not find 'plant' to be ready for testing the expenses
incurred by the DNHDDPCL for re-deputation shall be deducted from contract price.

12.6 The Contractor/Manufacturer shall intimate the DNHDDPCL about carrying out of the type tests
along with detailed testing programme at least 3 weeks in advance (in case of Domestic
Contractor/Manufacturer and at least 6 weeks advance in case of Foreign
Contractor/Manufacturer) of the scheduled date of testing during which the DNHDDPCL will
arrange to depute his representative to be present at the time of carrying out the tests.

12.7 Sample Batch for Type Testing

12.7.1 The Contractor/Manufacturer shall offer material for sample selection for type testing only after
getting Quality Assurance Programme approved by the DNHDDPCL. The Contractor/Manufacturer
shall offer at least three times the quantity of materials required for conducting all the type tests for
sample selection. The sample for type testing will be manufactured strictly in accordance with the
Quality Assurance Programme approved by the DNHDDPCL.

12.7.2 Before sample selection for type testing the Contractor/Manufacturer shall be required to conduct
all the acceptance tests successfully in presence of DNHDDPCL's representative.

12.8 Schedule of Testing and Additional Tests

12.8.1 The Bidder has to indicate the schedule of following activities in their bids

(a) Submission of drawing for approval.

(b) Submission of Quality Assurance programme for approval.

(c) Offering of material for sample selection for type tests.

(d) Type testing.

12.8.2 The DNHDDPCL reserves the right of having at his own expense any other test(s) of reasonable
nature carried out at Manufacturer’s premises, at site, or in any other place in addition to the
aforesaid type, acceptance and routine tests to satisfy himself that the material complies with the
specifications.

12.8.3 The DNHDDPCL also reserves the right to conduct all the tests mentioned in this specification at his
own expense on the samples drawn from the site at Manufacturer’s premises or at any other test
center. In case of evidence of noncompliance, it shall be binding on the part of
Contractor/Manufacturer to prove the compliance of the items to the technical specifications by
repeat tests, or correction of deficiencies, or replacement of defective items, all without any extra
cost to the DNHDDPCL.

13.0 TEST REPORTS

13.1 Copies of type test reports shall be furnished in at least six copies along with one original. One copy

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 shall be returned duly certified by the DNHDDPCL, only after which the commercial production of
the concerned material shall start.

13.2 Copies of acceptance test report shall be furnished in at least six copies. One copy shall be returned,
duly certified by the DNHDDPCL, only after which the materials will be dispatched.

13.3 Record of routine test report shall be maintained by the Manufacturer at his works for periodic
inspection by the DNHDDPCL 's representative.

13.4 Test certificates of tests during manufacture shall be maintained by the Manufacturer. These shall
be produced for verification as and when desired by the DNHDDPCL.

14.0 INSPECTION

14.1 The Owner’s representative shall at all times be entitled to have access to the works and all places
of manufacture, where the material and/or its component parts shall be manufactured, and the
representatives shall have full facilities for unrestricted inspection of the Contractor’s, sub-
Contractor’s works raw materials. Manufacturers of all the material and for conducting necessary
tests as detailed herein.

14.2 The material for final inspection shall be offered by the Contractor only under packed condition.
The engineer shall select samples at random from the packed lot for carrying out acceptance tests.

14.3 The Contractor shall keep the Owner informed in advance of the time of starting and of the progress
of manufacture of material in its various stages so that arrangements could be made for inspection.

14.4 Material shall not be dispatched from its point of manufacture before it has been satisfactorily
inspected and tested unless the inspection is waived off by the Owner in writing. In the latter case
also, the material shall be dispatched only after all tests specified herein have been satisfactorily
completed.

14.5 The acceptance of any quantity of material shall in no way relieve the Contractor of his
responsibility for meeting all the requirements of the Specification, and shall not prevent
subsequent rejection, if such material is later found to be defective.

15.0 PACKING AND MARKING

15.1 All material shall be packed in strong and weather resistant wooden cases/crates. The gross weight
of the packing shall not normally exceed 200 Kg to avoid handling problems.

15.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage at
site and subsequent handling in the field.

15.3 Suitable cushioning, protective padding, dunnage or spacers shall be provided to prevent damage
or deformation during transit and handling.

15.4 Bolts, nuts, washers, cotter pins, security clips and split pins etc. shall be packed duly installed and
assembled with the respective parts and suitable measures shall be used to prevent their loss.

15.5 Each component part shall be legibly and indelibly marked with trade mark of the manufacturer
and year of manufacture.

15.6 All the packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly dispatched on account of
faulty packing and faulty or illegible markings. Each wooden case/crate shall have all the markings
stenciled on it in indelible ink.

15.7 Each consignment shall be accompanied by a detailed packing list showing following details: -

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 (i) The name of the consignees

(ii) Details of consignment.

(iii) Destination.

(iv) Total weight of consignment.

(v) Handling and unpacking instrumentation.

(vi) Bill of material indicating content of each package.

16.0 QUALITY ASSURANCE PROGRAM

The contractor shall submit the Quality Assurance Programme. A copy of the accepted Quality
Assurance Plan must be available at the manufacturer’s works of the Plant for reviewing by
inspecting officer of the DNHDDPCL.

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 ANNEXURE - 8A

TESTS ON HARDWARE FITTINGS

1.1 Magnetic Power Loss Test for Suspension Assembly

Two hollow aluminium tubes of 32 mm diameter for the conductor shall be placed 450 mm apart
respectively. An alternating current over the range of 1500 to 2000 amps shall be passed through
each tube. The reading of the wattmeter with and without suspension assemblies alongwith line
side yoke plate, clevis eye shall be recorded. Not less than three suspension assemblies shall be
tested. The average power loss for suspension assembly shall be plotted for each value of current.
The value of the loss corresponding to 2456 amperes per phase shall be read off from the graph and
the same shall not be more than the value guaranteed by the supplier.

1.2 Galvanizing/Electroplating Test

The test shall be carried out as per Clause no. 5.9 of IS:2486-(Part-1) except that both uniformity of
zinc coating and standard preece test shall be carried out and the results obtained shall satisfy the
requirements of this specification.

1.3 Mechanical Strength Test of Each Component

Each component shall be subjected to a load equal to the specified minimum ultimate tensile
strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The
load shall be held for five minutes and then removed. The component shall then again be loaded to
50% of UTS and the load shall be further increased at a steady rate till the specified UTS and held
for one minute. No fracture should occur. The applied load shall then be increased until the failing
load is reached, and the value recorded.

1.4 Mechanical Strength Test of Welded Joint

The welded portion of the component shall be subjected to a Load of 2000 kgs for one minute.
Thereafter, it shall be subjected to die-penetration/ultrasonic test. There shall not be any crack at
the welded portion.

1.5 Mechanical Strength Test for Suspension/Tension Hardware Fittings

The complete string without insulators excluding arcing horn, corona control rings/grading ring
and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of the
specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67%
of the minimum UTS specified. This load shall be held for five minutes and then removed. After
removal of the load, the string component shall not show any visual deformation and it shall be
possible to disassemble them by hand. Hand tools may be used to remove cotter pins and loosen the
nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be
further increased at a steady rate till the specified minimum UTS is reached and held for the one
minute. No fracture should occur during this period. The applied load shall then be increased until
the failing load is reached, and the value recorded.

1.6 Clamp Slip Strength Vs Torque Test for Suspension Clamp

The suspension assembly shall be vertically suspended by means of a flexible attachment. A suitable
length of conductor shall be fixed in the clamp. The clamp slip strength at various tightening torques
shall be obtained by gradually applying the load at one end of the conductor. The Clamp slip strength
vs torque curve shall be drawn. The above procedure is applicable only for free centre type
suspension clamp. For AG suspension clamp only, clamp slip strength after assembly shall be found

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 out. The clamp slip strength at the recommended tightening torque shall be more than 20 KN but
less than 29 KN.

1.7 Heating Cycle Test

Heating cycle test shall be performed in accordance with IS 2486 (Part-I) with following
modifications: -

i) Temperature of conductor during each cycle: 40 deg. C above designed maximum operating
temperature of the conductor.

ii) Number of cycle: 100 Slip strength tests shall also be carried out after heating cycle test.

1.8 Shore Hardness Test for Elastomer Cushion for AG Suspension Assembly

The shore hardness at various points on the surface of the elastomer cushion shall be measured by
a shore hardness meter and the shore hardness number shall be between 65 to 80.

1.9 Proof Load Test

Each component shall be subjected to a load equal to 50% of the specified minimum ultimate tensile
strength which shall be increased at a steady rate to 67% of the UTS specified. The load shall be held
for one minute and then removed. After removal of the load the component shall not show any visual
deformation.

1.10 Tests for Forging Casting and Fabricated Hardware

The chemical analysis, hardness test, grain size, inclusion rating and magnetic particle inspection
for forging, castings and chemical analysis and proof load test for fabricated hardware shall be as
per the internationally recognized procedures for these tests. The sampling will be based on heat
number and heat treatment batch. The details regarding test will be as in the Quality Assurance
programme.

1.11 Ozone Test for Elastomer

This test shall be performed in accordance with ASTM D-1171 by the Ozone chamber exposure
method (method B). The test duration shall be 500 hours and the ozone concentration 50 PPHM. At
the test completion, there shall be no visible crack under a 2 x magnification.

2.0 TESTS ON ACCESSORIES FOR CONDUCTOR

2.1 Mid Span Compression Joint for Conductor

(a) Slip Strength Test: The fitting compressed on conductor shall not be less than one meter in
length. The test shall be carried out as per IS:2121 (Part-ii)-1981 clause 6-4 except that the load
shall be steadily increased to 95% of minimum ultimate tensile strength of conductor/earth wire
and retained for one minute at this load. There shall be no movement of the conductor/ earth wire
relative to the fittings and no failure of the fit tings during this one minute period.

2.2 Connector for Conductor

Axial Tensile Load Test for Welded Portion: - The sleeve portion of the T-Connector shall be
compressed on conductor. The compressed portion shall be held rigidly on some fixtures and axial
load shall be applied along with the jumper terminal the load shall be increased gradually till
breaking of welded joint occurs. The breaking load should be above 30 KN.

2.3 Vibration damper for conductor

Clamp Slip and Fatigue Tests

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 (i) Test Set Up: The clamp slip and fatigue tests shall be conducted on a laboratory set up with a
minimum effective span length of 30 m. The conductor shall be tensioned at tension corresponding
to 0 deg & no wind condition and ruling span 400 from sag –tension calculation and shall not be
equipped with protective armour rods at any point. Constant tension shall be maintained within the
span by means of lever arm arrangement. After the conductor has been tensioned, clamps shall be
installed to support the conductor at both ends and thus influence of connecting hardware fittings
are eliminated from the free span. The clamps shall not be used for holding the tension on the
conductor. There shall be no loose parts, such as suspension clamps, U bolts on the test span
supported between clamps mentioned above. The span shall be equipped with vibration inducing
equipment suitable for producing steady standing vibration. The inducing equipment shall have
facilities for step less speed control as well as step less amplitude arrangement. Equipment shall be
available for measuring the frequency, cumulative number of cycles and amplitude of vibration at
any point along the span.

(ii) Clamp Slip test: The vibration damper shall be installed on the test span. The damper clamp,
after lightning with the manufacturer’s specified tightening torque, when subjected to a longitudinal
pull of 2.5 KN parallel to the axis of conductor for a minimum duration of one minute shall not slip
i.e. the permanent displacement between conductor and clamp measured after removal of the load
shall not exceed 1.0 mm. The load shall be further increased till the clamp starts slipping. The load
at which the clamp slips shall not be more than 5 KN.

2.4 Mechanical Strength Test for Earth wire Suspension/Tension Clamp

(a) The suspension assembly/tension assembly (excluding tension clamp) shall be subjected to a
load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be
increased at a steady rate to 67% of the minimum UTS specified. This load shall be held for five
minutes and then removed. After removal of the load, the components shall not show any visual
deformation and it shall be possible to disassemble them by hand. Hand tools may be used to loosen
the nuts initially. The assembly shall then be reassembled and loaded to 50% of UTS and the load
shall be further increased at a steady rate till the specified minimum UTS is reached and held for
one minute. No fracture should occur during this period. The applied load shall then be increased
until the failing load is reached, and the value recorded.

(b) Clamp Slip Strength Vs Torque Test for Suspension Assembly: The suspension assembly shall be
vertically suspended by means of a flexible attachment. A suitable length of Earth wire shall be fixed
in the clamps. The clamp slip strength at various tightening torques shall be obtained by gradually
applying the load at one end of the earth wire. The clamp slip strength Vs torque curve shall be
drawn. The clamp slip strength at the recommended tightening torque shall be as per the values
stipulated in the Standard Technical Particulars.

(c) Slip Strength Test of Tension Clamp: Tension clamps shall be compressed on a 5 m length of earth
wire on both ends. The assembly shall be mounted on a tensile testing machine and anchored in a
manner similar to the arrangement to be used in service. A tensile load of 50% of the specified
breaking load of the earth wire shall be applied & the sample shall be marked in such a way that
movement relative to the fitting can easily be detected. Without any subsequent adjustment of the
fitting, the load shall be steadily increased to 95% of the specified breaking load and maintained for
one minute. There shall be no movement of the earth wire relative to the fitting during this one
minute period and no failure of the fitting also.

(d) Electrical Resistance Test of Tension Clamp: The tension clamp and the jumper shall be
compressed on two suitable lengths of earth wire. The electrical resistance shall be measured
between points on earth wire near the clamp and near the jumper mouth keeping 25 mm clearance
of the fitting and should not exceed 75% of the measured resistance of equivalent length of earth

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 wire. The test shall be conducted with direct current. The current connections shall be at a distance
not less than 50 times the diameter of earth wire from the fitting and shall be made so that effective
contact is ensured with all those strands of the earth wire which would be taken into account in
calculating its equivalent resistance. The test shall be repeated with the polarity reversed and the
average of the two results considered as the measured value.

2.5 Chemical Analysis Test

Chemical analysis of the material used for manufacture of items shall be conducted to check the
conformity of the same with Technical Specification and approved drawing.

3.0 TESTS 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. The purity 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 test will be as discussed
and mutually agreed to by the Contractor and Owner in Quality Assurance Programme.

3.3 Tests on Castings: The chemical analysis, mechanical and metallographic tests and magnetic
particle inspection for castings will be as per the internationally recognized procedures for these
tests. The samplings will be based on heat number and heat treatment batch. The details regarding
test will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance
Programme.

ANNEXURE-8B ACCEPTANCE TESTS

1 Mid Span Compression Joint for Conductor

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 Hardness Test: - The Brinnel hardness at various points on the steel sleeve of conductor core and
tension clamp shall be measured.

2 Connector for Conductor

Axial Tensile Load Test for Welded Portion: - Same as clause 2.2 of Annexure – 8A

3 Vibration Damper for Conductor

a) Verification of Resonance Frequencies: - The damper shall be mounted on a shaker table and
vibrate at damper clamp displacement of +/-0.5 mm to determine the resonance frequencies. The
resonance shall be visually identified as the frequency at which damper mass vibrates with
maximum displacement on itself. The resonance frequency thus identified shall be compared with
the guaranteed value. A tolerance of ± 1 Hz at a frequency lower than 15 Hz and ± 2 Hz at a frequency
higher than 15 Hz only shall be allowed.

b) Clamp Slip Test: - Same as Clause 2.3 (ii) of Annexure – 8A.

c) Clamp Bolt Torque Test: - The clamp shall be attached to a section of the conductor/earth wire.
A torque of 150 percent of the manufacturer’s specified torque shall be applied to the bolt. There
shall be no failure of component parts. The test set up is as described in Clause 2.4 (c), Annexure-
8A.

d) Strength of the Messenger Cable: - The messenger cable shall be fixed in a suitable tensile
testing machine and the tensile load shall be gradually applied until yield point is reached.
Alternatively, each strand of messenger cable may be fixed in a suitable tensile testing machine and
the tensile load shall be gradually applied until yield point is reached. In such a case, the 95% of
yield strength of each wire shall be added to get the total strength of the cable. The load shall be not
less than the value guaranteed by the Contractor

e) Mass Pull off Test: - Each mass shall be pulled off in turn by fixing the mass in one jaw and the
clamp in the other of a suitable tensile testing machine. The longitudinal pull shall be applied
gradually until the mass begins to pull out of the messenger cable. The pull off loads shall not be
less than the value guaranteed by the Contractor.

PART C EXECUTION OF THE PACKAGE

SECTION - 9

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 TOWER FOUNDATION, ERECTION, STRINGING AND INSTALLATION OF LINE MATERIALS

PART – I TOWER FOUNDATION

(A) SCOPE OF WORK

This section covers the scope of the work to be executed for various items of works coming under
foundations of self-supporting galvanized lattice towers for 66kV Multi / DC circuit Transmission
Lines under the scope of this contract.

The contractor shall complete the works as per the detailed design and drawings furnished by
DNHDDPCL for foundations for all types of normal towers with extensions as detailed in the design
drawings.

The execution of works for foundation shall be as per relevant IS and in accordance with the CBI&P
Publication No. 323 (Transmission Line Manual). Reference to any code/publication shall always
mean reference to the latest revised edition of the code/publication including all its amendments
upto date, unless otherwise specified. In the event of any conflict between the requirements of this
specification and those of the referred codes, the former shall govern.

1.0 GEOTECHNICAL INVESTIGATION:

1.1. Item Description: Soil test, wherever found neccessary for asertaining type of foundation including
taking pits/bore holes, collecting soil samples and testing at approved laboratories as per relevant
IS codes, including cost of testing, all labour and transportion charges etc. as directed by DNHDDPCL
Officers complete in all respects as per scope & technical specifications of following types: Except
in River/Lake.

This item is applicable for all locations wherever soil testing is required to be carried out as directed
by the engineer in charge. The Contractor shall perform a detailed soil investigation to arrive at
sufficiently accurate conclusion regarding general as well as specific information about the soil
profile and the necessary soil parameters of the site, in order to design and construct the foundation
of the structures safely and rationally wherever required by the Engineer-in-charge. The procedures
and result submissions as in compliance to the IS 1892 and CPWD manuals. A report by a qualified
Geo-technical engineer to the effect shall be submitted by the Contractor for DNHDDPCL’s specific
approval giving details re- garding data proposed to be utilized for the design. The Contractor shall
submit the detailed report as specified in IS: 1892 wherein information regarding the geological
detail of the site, summarised observations and test data, bore logs, and conclusions and
recommendations on the type of foundations with supporting calculations for the
recommendations. Initially the Contractor shall submit draft report and after the draft report is
approved, the final report in five (5) copies shall be submitted. The site test data shall bear the
signatures of the Investigation Agency, Vendor and also site representative of DNHDDPCL.

2.0 Earthwork Excavation

2.1 Item Description: Excavation by mechanical means (Hydraulic excavator) / manual means in
foundation trenches or drains (not exceeding 1.5m in width or 10 sqm on plan), including dressing
of sides and ramming of bottoms, lift upto 1.5 m, including disposal of surplus excavated soil as
directed, including pumping out water from all sources wherever necessary within a lead of 50m.

This item is applicable for excavation works of not exceeding 1.5m in width or 10 sqm on plan under
various soil classification as detailed below

2.1.1 CLASSIFICATION OF SOILS

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 The earthwork shall be classified under the following categories and measured separately for each
category:

(a) All kind of soils: Generally any strata, such as sand, gravel, loam, clay, mud, black cotton moorum,
shingle, river or nallah bed boulders, siding of roads, paths etc. and hard core, macadam surface of
any description (water bound, grouted tarmac etc.), lime concrete mud concrete and their mixtures
which for excavation yields to application of picks, showels, jumper, sacrifiers, ripper and other
manual digging implements.

(b) Ordinary rock: Generally any rock which can be excavated by splitting with crow bars or picks and
does not require blasting, wedging or similar means for excavation such as lime stone, sand stone,
hard laterite, hard conglomer- ate and un-reinforced cement concrete below ground level. If
required light blasting may be resorted to for loosening the materials but this will not in any way
entitle the material to be classified as ‘Hard rock’.

(c) Hard rock: Generally any rock or boulder for the excavation of which blasting is required such as
quartzite, granite, basalt, reinforced cement concrete (re- inforcement to be cut through but not
separated from concrete) below ground level and the like.

2.2 Item Description: Excavation by mechanical means (Hydraulic excavator) / manual means over
areas (exceeding 30cm in depth. 1.5 m in width as well as 10 sqm on plan) including disposal of
excavated earth, lead upto 50m and lift as specified, including pumping out water from all sources
wherever necessary disposed earth to be levelled and neatly dressed.

This item is applicable for excavation works of exceeding 30cm in depth. 1.5 m in width as well as
10 sqm on plan under various soil classification as detailed above.

2.3 Item Description: Excavation in hard rock using non explosive agent (Chemical) without resorting
to the use of conventional explosive materials etc in all lifts and conveying and depositing the
excavated rock etc. at places with in a distance of 50m including pumping out water from all sources
wherever necessary.

This item is applicable for excavation works of any width or area where blasting is not possible by
the conventional methods and breaking of rock to be resorted using chemical. The locations where
chemical blasting is to be carried out will be as directed by the Engineer in charge and the decision
of the Engineer in charge shall be final. The quantity under removal by ‘Chemical blasting’ shall be
restricted to the minimum as decided by the Engineer in charge.

3.0 Protection of excavated side slopes

3.1 Item Description: Close timbering in trenches including strutting, shoring and packing cavities
(wherever required) complete. (Measurements to be taken of the face area timbered) complete in
all respects as per scope & technical specifications:

This item is applicable for protection of the sides of excavated earth and to be executed on specific
direction from the Engineer-in-charge.

3.2 Item Description: Open timbering in trenches including strutting and shoring complete
(measurements to be taken of the face area timbered). Complete in all respects as per scope &
specification of work & technical specifications:

This item is applicable for protection of the sides of excavated earth and to be executed on specific
direction from the Engineer-in-charge.

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4.0 Pumping

4.1 Item Description: Pumping out water caused by springs, tidal or river seepage, broken water mains
or drains and the like. Complete in all respects as per scope & specification of work & technical
specifications.

This item is applicable for pumping water that may accumulate in locations where no excavation is
required to be executed as decided by the engineer-in charge during the progress of the work from
springs, tidal or river seepage, bro- ken water mains or drains (not due to the negligence of the
contractor), and seepage from subsoil aquifer shall be bailed, pumped out or otherwise removed
and to be executed on specific direction from the Engineer-in-charge.

5.0 Earthwork excavation under water

5.1 Item Description: Extra for Earth work in excavation in soil (Under water) by mechanical means
(Hydraulic excavator) / manual means over areas (exceeding 30cm in depth, 1.5 m in width as well
as 10 sqm on plan) including disposal of excavated earth, lead upto 50m and lift as specified,
disposed earth to be levelled and neatly dressed, in or under water and/or liquid mud, including
pumping out water as required, complete in all respects as per scope & technical specifications:

This item is applicable for excavation works coming in fully submerged soil conditions like paddy
fields, wet land etc as decided by the Engineer-in-charge. No pumping will be paid separately on
these locations. The contractor shall take ad- equate measures for bailing and/or pumping out
water from excavations and/or pumping out water from excavations and construct diversion
channels, bunds, sumps, coffer dams etc. as may be required.

6.0 Concreting

6.1 Item Description: Providing and laying in position plain/reinforced cement concrete of specified
grade excluding the cost of centering and shuttering up to plinth level complete in all respects as
per scope & specification of work & technical specifications including dewatering wherever
required.

Concreting works are to be carried out at tower locations as per design drawings. Cement content
considered in each item is as per DSR specifications. Cement content considered in the specific item
is mentioned. Excess/less cement used as per design mix is payable/recoverable separately.
Generally design mix/ Ready mix concrete is preferred for the work. In exceptional cases where the
ac- cess is limited engineer-in-charge may permit usage of the item of 1:1.5:3. The method of
concreting is decided soley by the Engineer-in-charge. Concreting works in pile foundations also
comes under this item except for the River/lake location. The cement content considered in this
item is specified. Ex- cess/less cement used as per design mix is payable/recoverable separately as
per rates quoted for the item for providing extra cement. The quoted rate is inclusive of cost of
admixtures in recommended proportions as per IS : 9103 to accelerate/ retard setting of concrete,
improve workability without impairing strength and durability for the specified mix. Additional
payment will be made on account of variation in cement content only and not for the
admixture/other contents.

6.2 Item Description: Steel reinforcement for R.C.C. work including straightening, cutting, bending,
placing in position and binding all complete above plinth level with Thermo-Mechanically Treated
bars.

This item to be carried as per approved barbending schedule and drawings.

6.3 Item Description: Centering and shuttering including strutting, propping etc. and removal

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 following complete in all respects as per scope & technical specifications:

This item to be executed as per design drawings.

7.0 Revetment

7.1 Item Description: Random rubble masonry with hard stone in foundation and superstructure at
all levels with cement mortar 1:6 ( 1 cement : 6 coarse sand) complete in all respects as per scope
& technical specifications:

Rubble masonry used for the protection of sides of tower locations will come under this item.

7.2 Item Description: Flush/ Ruled pointing on stone work with cement mortar 1:3 (1 cement : 3 fine
sand)

This item is applicable for the pointing works coming in rubble masonry works.

7.3 Item Description: 12 mm cement plaster of mix 1:4 (1 cement: 4 fine sand)

Plastering works wherever required as specifically ordered by the Engineer-in- charge will come
under this category.

8.0 Back Filling

8.1 Item Description: Filling available excavated earth (excluding rock) in trenches, plinth, sides of
foundations etc. in layers not exceeding 20cm in depth, consolidating each deposited layer by
ramming and watering, lead up to 50 m and in all lifts complete in all respects as per scope &
technical specifications.

The available excavated earth to be used for backfilling the foundation trenches

8.2 Item Description: Supplying and Filling good quality earth brought from outside in the revetment
and pits of towers in layers for consolidation including stacking for measurements watering,
ramming, etc, complete as directed.

If earth available is not sufficient the contractor has to bring earth from outside and fill in the tower
locations including all leads and lifts.

9.0 Demolishing

9.1 Item Description: Demolishing stone rubble masonry in cement mortar manually/by mechanical
means including stacking of serviceable material and disposal of unserviceable material within 50
metres lead as per direction of DNHDDPCL engineer complete in all respects as per scope &
technical specifications.

When existing revetments/any nearby structure as specifically ordered by Engineer-in-charge are

required to be demolished this item will be used.

9.2 Item Description: Demolishing R.C.C. work manually/ by mechanical means including stacking of
steel bars and disposal of unserviceable material within 50 metres lead as per direction of
DNHDDPCL.

When existing structure as specifically ordered by Engineer-in-charge are re- quired to be

demolished this item will be used.

10.0 Bunds

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10.1 Item Description: Construction of earthen ring bunds for bailing out water for excavation and stub
setting with coconut cadjan and bamboos etc complete in all respects as per scope & technical
specifications (provisional qty)

For the construction of revetments this item will be executed wherever necessary. This item will not
be included for works in fully submerged soil conditions.

11.0 Piling

11.1 Item Description: Boring and installation bored cast-in-situ reinforced cement concrete piles of
specified grade of specified diameter and length below the pile cap, to carry a safe working load not
less than specified, excluding the cost of steel reinforcement and cost of concrete but including the
cost of boring with bentonite solution and temporary casing of appropriate length for setting out
and removal of same and the length of the pile to be embedded in the pile cap etc. by percussion
drilling using Direct mud circulation (DMC) or Bailer and chisel technique by tripod and mechanical
Winch Machine all complete, including removal of excavated earth with all its lifts and leads (length
of pile for payment shall be measured up to bottom of pile cap). Note: Truck Mounted
rotary/TMR/Tubewell boring machine shall not be used . For all diameters of pile including charges
for structural design of piles, all costs towards shifting , making ring bunds, access bunds,
dewatering etc complete except for piles in river/lake as per the direction of DNHDDPCL Engineer
complete in all respects as per scope & technical specifications.

Piling process has been split into two items boring & installation and concreting. Since the diameter
of pile can be ascertained only after detailed geo-technical investigation contractor has to submit
the calculations and approval of pile diameter to DNHDDPCL. Contractor has to execute the pile in
the specified diameter and to the specified depth in this item. The rate quoted by the contractor is
inclusive of structural design of piles, all costs towards shifting, making ring bunds, access bunds,
dewatering etc complete for all diameter of piles. All piling coming in weak soil, fully submerged
locations, partially submerged locations, dry land will come under this item except for piling in
river/lake.

11.2 Item Description: Hire charges for providing floating platform required for piling, concreting etc
(Pontoon in steel work using 2 Nos. x 12.00 x 5.55x1.75 meter size one for providing machineries
and the other for handling materials for form work etc, fabricating and hoisting in position with MS
plate 6mm thick for bottom and sides, 10mm for top and stiffening both ways with 65mm x 65mm
x 6mm Ms angle at 50cm c/c supporting over by ISMB - 150 200mm & 3 Nos., 6m long MS pipe is
used for supporting the pontoon. 1 meter dia circular barrels having length 6.40 meter and 5.00
meter each is used on either side and 3.75 meter long is used in front side) or of equivalent size and
approved materials. Necessary charges are included for sot and hire charges of anchorages,
pontoon, mobilization charges including painting with iron primer etc. complete for piling works in
river/lake as per the directions of the departmental officers at site.

This item is applicable for arranging a floating platform anchored at the middle of the river/lake
with approximate water depth of 12m. The platform provided should be of sufficient size and
strength so as to carry out boring, concreting works of piles and pile cap. The platform provided
should be able to accommodate excavated earth and the bentonite solution mixture as per
requirement. Further the platform should be kept in place for all operations required to complete
the erection, stringing, testing and commissioning of the line and no separate/additional
payment for the other works will be given on account of removal of platform. The platform provided
should in no way cause disturbance to the navigational/fishing activities currently undergoing. The
waterway is under the control of Inland waterways authority and all statutory clearances required
will be taken care of by DNHDDPCL. However contractor has to abide by the rules and regulations
set forth by Inland waterway authority for the work. Rates include the erection, anchoring,

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 providing warning signs, removal after completion etc complete.

11.3 Item Description: Fabricating, casing pipe of specified diameter with specified thick MS plate used
for cast in situ pile including cost and conveyance of all materials, all related charges for fixing
anchorages etc with all leads and lifts etc. complete for piles in river/lake according to the
specification and as directed by the departmental officers complete in all respects as per scope &
technical specifications.

This item is required for the permanent casing required for the piles coming in lake/river. Internal
diameter of pile casing will be the diameter of pile. Rate shall be inclusive of the design of the casing
pipe.

11.4 Item Description: Conveying pre-fabricated, casing pipe of specified diameter with specified
thickness MS plate used for cast in situ pile and erecting at site in lines and levels and driven down
into a required depth including cost and conveyance of all materials, all related charges for
anchoring etc with all leads and lifts etc. complete for piles in river/lake according to the
specification and as directed by the departmental officers.

This item is required for the permanent casing for the piles coming in lake/river. Rates shall be
inclusive of conveyance to site, driving, welding at site etc complete.

11.5 Item Description: Boring and installation of cast-in-situ reinforced cement concrete piles of
specified grade of specified diameter and length below the pile cap, to carry a safe working load not
less than specified, excluding the cost of steel reinforcement and cost of concrete but including the
cost of boring with bentonite solution and the length of the pile to be embedded in the pile cap etc.
by percussion drilling using Direct mud circulation (DMC) or Bailer and chisel technique by tripod
and mechanical Winch Machine all complete, including removal of excavated earth with all its lifts
and leads and disposal of earth as per local regulations for Piles and pile cap coming in
river/lake(away from water bodies) (length of pile for payment shall be measured up to bottom of
pile cap). Note: Truck Mounted rotary/TMR/Tubewell boring machine shall not be used. For all
diameters of pile including charges for structural design of piles and pile cap, all costs towards
shifting, making ring bunds, access bunds, dewatering etc complete as per the direction of
DNHDDPCL Engineer complete in all respects as per scope & technical specifications.

This item is applicable for Boring and installation of cast-in-situ reinforced cement concrete piles
coming in river/lake. Disposal of excavated earth and bentonite mixture shall be disposed off away
from the water body as per the prevailing local regulations. The work to be carried out on the
working platform set for the purpose.

11.6 Item Description: Conveyance to site and driving precast vertical specified grade R.C.C. Piles
(Guard piles) excluding cost of cement concrete and Reinforcement complete as per Drawing and &
Technical Specification Size of pile as specified in river/lake. For all diameters / size of pile including
charges for structural design of piles, all costs towards shifting, driving, jointing wherever required,
etc complete as per the direction of DNHDDPCL Engineer complete in all respects as per scope &
technical specifications.

This item is applicable for the conveyance, driving of precast RCC piles with necessary jointing for
guard piles around the tower foundation coming in river/lake. The cement concrete required for
precast piles will be measured in the item of concreting for piles coming in submerged/ground
locations. The quoted rate shall be inclusive of cost of structural design of piles, all costs towards
shifting, driving, jointing wherever required. Rate shall further include painting, providing warning
signs etc as per Inland waterway authority specifications.

11.7 Item Description: Providing and laying in position ready mixed specified grade concrete for
reinforced cement concrete work, using cement content as per approved design mix, manufactured

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 in fully automatic batching plant and transported to site of work in transit mixer for all leads, having
continuous agitated mixer, manufactured as per mix design of specified grade for reinforced cement
concrete work, including pumping of R.M.C. from transit mixer to site of laying and with necessary
floating arrangements to keep the pipes floating, excluding the cost of centering, shuttering finishing
and reinforcement, including cost of admixtures in recommended proportions as per IS : 9103 to
accelerate/ retard setting of concrete, improve workability without impairing strength and
durability as per direction of DNHDDPCL for Piles and pile cap coming in river/lake, complete in all
respects as per scope & technical specifications.(Note :- Cement content considered in this item is
@ 400 kg/cum. Excess/less cement used as per design mix is payable/recoverable separately)

This item is applicable for concreting works for piles coming in river/lake. The cement content
considered in this item is 400 kg/m3. Excess/less cement used as per design mix is
payable/recoverable separately as per rates quoted for the item for providing extra cement. The
quoted rate is inclusive of cost of admixtures in recommended proportions as per IS : 9103 to
accelerate/ retard set- ting of concrete, improve workability without impairing strength and
durability for the specified mix. Additional payment will be made on account of variation in cement
content only and not for the admixture/other contents.

12.0 Cement content

12.1 Item Description: Add for using extra cement in the items of design mix over and above the
specified cement content therein. (This rate will be used for making deductions in case of usage of
lesser cement content as directed)

Cement content is fixed based on relevant IS codes and standards. Excess/less cement used as per
design mix or if directed by Engineer-in-charge is payable/recoverable separately as per rates
quoted for this item.

13.0 Under Reamed piles

13.1 Item Description: Boring with hydraulic piling rigs with power units, and installing cast in situ
single under reamed piles of specified diameter and length below pile cap in cement concrete, to
carry a safe working load not less than specified, excluding the cost of steel reinforcement and
concrete but including the cost of boring with bentonite solution and the length of the pile to be
embedded in pile cap etc. (Length of pile for payment shall be measured up to the bottom of pile
cap) For all diameters of pile including charges for structural design of piles, all costs towards
shifting, making ring bunds, access bunds, dewatering etc complete as per the direction of
DNHDDPCL Engineer complete in all respects as per scope & technical specifications.

13.2 Under-reamed piling process has been split into two items boring & installation and concreting.
Since the diameter of pile can be ascertained only after detailed geo-technical investigation
contractor has to submit the calculations and approval of pile diameter to DNHDDPCL. Contractor
has to execute the pile in the specified diameter with single bulb and to the specified depth in this
item. The rate quoted by the contractor is inclusive of structural design of piles, all costs towards
shifting, making ring bunds, access bunds, dewatering etc complete for all diameter of piles. All
under-reamed piling coming in weak soil, fully submerged locations, partially submerged locations,
dry land will come under this item. The cement concrete required for under-reamed piles will be
measured in the item of concreting for piles coming in submerged/ground locations. The quoted
rate shall be inclusive of cost of structural design of piles and pile cap, all costs towards shifting,
driving, etc.

13.3. Item Description: Extra for providing additional bulb in under reamed piles.

If the structural design specifies more than one bulb for the under reamed pile this item will be
operated for boring and installation. Concreting quantity will be given as specified in the item for

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 under reamed pile with single bulb.

14.0 Pile load tests

14.1 Item Description: Vertical load testing of piles in accordance with IS 2911 (Part IV) including
installation of loading platform by Kentledge/Anchor piles method and preparation of pile head or
construction of test cap and dismantling of test cap after test etc. complete as per specification &
the direction of Engineer in-charge for Single pile of various tone capacities. Initial test (Test Load
2.5 times the Safe capacity) Note: 1. Initial and Routine Load Test shall not be carried out by
Dynamic method of testing. Note: 2. Testing agency shall submit the design of loading platform for
DNHDDPCL approval complete in all respects as per scope & technical specifications:

This item is applicable for testing of piling works coming in various locations. Initial and routine
test to be carried out as per IS specifications. Various loads at which tests are to be conducted are
specified and contractor has to quote all inclusive rate for each type of test.

14.2 Item Description: Integrity testing of Pile using Low Strain/ Sonic Integrity Test/ Sonic Echo Test
method in accordance with IS 14893 including surface preparation of pile top by removing soil,
mud, dust & chipping lean concrete lumps etc. and use of computerised equipment and high skill
trained personal for conducting the test & submission of results, all complete at all locations as per
direction of Engineer-in-charge.

This item is applicable for testing of piling works coming in various locations. This is to check the
quality of piling like concreting, diameter of pile, depth of pile, etc

14.3 Item Description: High-Strain Dynamic Testing of pile using method in accordance with ASTM D
4945 including surface preparation of pile top by removing soil, mud, dust & chipping lean concrete
lumps etc. and use of computerised equipment and high skill trained personal for conducting the
test & submission of results, except in river/lake all complete as per direction of Engineer-in-
charge.

This item is applicable for testing of piling works coming in various locations. Based on the
measurements from strain or force, and acceleration, velocity, or dis- placement transducers, this
test method obtains the force and velocity induced in a pile during an axial impact event. The
Engineer-in-charge may analyze the acquired data using engineering principles and judgment to
evaluate the integrity of the pile, the performance of the impact system, and the maximum
compressive and tensile stresses occurring in the pile and to estimate the ultimate axial static
compression capacity of the pile. Rate quoted shall be inclusive of all works associated with the test
for the successful interpretation of the axial bearing capacity of the pile.

15.0 Anchoring in hard rock foundations

Item Description: Boring holes of dia 100mm or nearest size dia on hard rock where anchoring is
found necessary to accommodate anchor bars including hire charges of machinery, T&P, pilot
vehicle to carry other materials, grouting charg- es etc. Complete in all respects as per scope &
technical specifications.

This item is applicable for making anchoring for foundations coming entirely on hard rock Rates
shall be inclusive of drilling, including hire charges of machinery, T&P, pilot vehicle to carry other
materials, grouting charges etc. but excluding cost of anchor bars to be placed.

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16.0 CLASSIFICATION OF FOUNDATIONS

Depending on the location of water table and the presence of surface water, the following types of
foundation designs shall be used for each type of tower:

(i) Normal dry type:

To be used for locations in normal cohesive or non-cohesive soils; where water table is expected to
be below foundation level.

(ii) Wet type:

To be used for locations in normal cohesive or non-cohesive soil and

1. Where sub-soil water is met at 1.5 m or more below the ground level at or above foundation
level.

2. Which are in surface water for long period with water penetration not exceeding one meter
below the ground level e.g. the paddy fields.

(iii) Fully submerged type:

To be used at locations in normal cohesive or non-cohesive soil and where sub-soil water is met at
or less than 0.75 m below the ground level.

(iv) Wet Black Cotton Soil

To be used at locations where soil is clayey type, not necessarily black in colour, which shrinks when
dry and swells when wet, resulting in differential movement. For designing the foundation for such
locations, where sub-soil water is met between 1.5 meters and the depth of foundation below the
ground level.

(v) Fissured – Rock

To be used at locations, where decomposed or fissured rock, hard gravel, kankar, limestone, laterite
or any other soil of similar nature is met. Under cut type foundation is to be used for fissured rock
locations.

In case of fissured rock locations, where water table is met at 1.5M or more below ground level, wet
fissured rock foundations shall be adopted. Where fissured rock is encountered with subsoil water
table less than 1.5 meter below ground level, submerged fissured rock foundations shall be adopted.
In case of dry locations dry fissured rock foundations shall be adopted.

(vi) Hard Rock

The locations where chiseling, drilling and blasting is required for excavation for monolithic rock
for a particular leg/tower, hard rock type foundations are to be used. For these locations rock
anchoring is to be provided to resist uplift forces.

The contractor shall be paid for the actual volume of concrete, excavation and weight of
reinforcement executed as per Schedule of prices.

In addition to the above, depending on the site conditions more varieties of foundations may be
introduced for suitable intermediate conditions under the above classifications to affect more
economy.

The relevant characteristics of various types of soils are as given under this section. It shall be the
responsibility of the contractor to draw the attention and obtain approval of DNHDDPCL for any
departure necessitated in these design data, based on geotechnical investigation at tower location,

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 results of trial pits, etc.

(B) TECHNICAL SPECIFICATION FOR FOUNDATION OF TOWERS

The Technical specification and measurement of various items under this contract, unless otherwise
mentioned hereunder specifically, will be governed by the CPWD specifications 2009 vol. 1&2 and
latest amendments thereafter published by Director General of works, CPWD, Nirman Bhawan, New
Delhi.

A. GEOTECHNICAL INVESTIGATION

The Contractor shall perform a detailed soil investigation to arrive at sufficiently accurate
conclusion regarding general as well as specific information about the soil profile and the necessary
soil parameters of the site, in order to design and construct the foundation of the structures safely
and rationally wherever required by the Engineer-in-charge. The procedures and result
submissions as in compliance to the IS 1892 and CPWD manuals. A report by a qualified Geo-
technical engineer to the effect shall be submitted by the Contractor for DNHDDPCL’s specific
approval giving details regarding data proposed to be utilized for the design. The Contractor shall
submit the detailed report as specified in IS: 1892 wherein information regarding the geological
detail of the site, summarised observations and test data, bore logs, and conclusions and
recommendations on the type of foundations with supporting calculations for the
recommendations. Initially the Contractor shall submit draft report and after the draft report is
approved, the final report in five (5) copies shall be submitted. The site test data shall bear the
signatures of the Investigation Agency, Vendor and also site representative of DNHDDPCL.

1. EARTH WORK EXCAVATION

This item of work to be executed as per CPWD specifications and includes dewatering from all
sources wherever necessary. Dewatering to be executed as per CPWD specifications without any
additional claims.

2. EARTH WORK EXCAVATION IN BLASTING PROHIBHITED LOCATIONS

Excavation in hard rock or rock boulders of size more than 0.5m3 in volume to be carried out by
wedging, barring, picking using rock drills, hammer, rock breaking tools attached to excavator etc.
without resorting to the use of conventional explosive methods at locations where such excavation
is specifically ordered by the Engineer in charge in lifts as specified and conveying and depositing
the excavated rock etc. at places with in a distance of 50m as directed by the Engineer in Charge.

3. ROCK EXCAVATION USING NON-EXPLOSIVE AGENTS (CHEMICAL)

Excavation in hard rock or rock boulders of size more than 0.5m3 in volume by use of non-
explosives methods using specified chemical without resorting to the use of conventional explosive
methods at locations where such excavation is specifically ordered by the Engineer in charge in all
lifts and conveying and depositing the excavated rock etc. at places with in a distance of 50m as
directed by the Engineer in Charge. Necessity of usage of chemical will be decided by Engineer-in-
charge. The location where the rock excavation is to be carried out by non- explosives methods
(Chemical) will be decided by the Engineer in charge depending upon site conditions.

4. CONCRETING

This item of work to be executed as per CPWD specifications and includes dewatering from all
sources wherever necessary.

5. EARTHERN BUNDS

Putting up ring bund as per approved shape using empty gunny/polythene bags filled with earth

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 placed in 2 rows at 0.6m apart and filled in between with puddle clay to form bund for an average
height as specified including labour dismantling the bund after completion of the work etc.
complete.

6. PILING

Piling process has been split into two items boring & installation and concreting. Since the diameter
of pile can be ascertained only after detailed geo-technical investigation contractor has to submit
the calculations and approval of pile diameter to DNHDDPCL. Contractor has to execute the pile in
the specified diameter and to the specified depth in this item. The rate quoted by the contractor is
inclusive of structural design of piles, all costs towards shifting, making ring bunds, access bunds,
dewatering etc complete for all diameter of piles. The work has to be carried out as per latest IS
specifications/ CPWD specifications.

7. CONSTRUCTION AND INSTALLATION OF RCC BORED/ Driven CAST-IN-SITU / Pre-cast PILES

Following LIST OF BUREAU OF INDIAN STANDARD CODES are to be followed for the Design,
construction and installation of RCC bored cast in situ piles.

1. IS-1200 (Part 23) Method of measurement of building and Civil Engineering Works – Piling.

2. IS-2911 (Part 1/Sec. 1) Code of practice for Design and Construction of pile foundation.
Driven cast-in-situ piles.

3. IS-2911 (Part 1/Sec. 2) Code of practice of Design and Construction of pile foundation. Bored
Cast-in-situ piles.

4. IS-2911 (Part 1/Sec. 3) Code of practice for Design and Construction of pile foundation.
Driven pre-cast concrete piles.

5. IS-2911 (Part 1/Sec. 4) Code of practice for Design and Construction of pile foundation. Bored
pre-cast concrete piles.

6. IS-2911 (Part 3) Code of practice for Design and Construction of pile foundation. Under
reamed piles.

7. IS-2911 (Part 4) Code of practice for design and Construction of pile foundation. Load test on
piles.

8. IS-5112 Safety Code for piling and other deep foundations.

9. IS-6426 Specification for pile driving hammer.

10. IS-6427 Glossary of terms relating to pile driving.

11. IS-6428 Specification for pile frame.

12. IS-9716 Guide for lateral dynamic load test on piles.

13. IS-14362 Pile boring equipments. General requirements.

The work has to be carried out in accordance with CPWD specifications Volume-2 20.0 to 20.5.5.6

The design of pile foundations and pile cap as per the relevant IS codes is in contractor’s scope. The
rated quoted shall be inclusive for all diameters of pile including charges for structural design of
piles, all costs towards shifting, making ring bunds, access bunds, dewatering etc complete as per
the direction of Engineer-in-charge.

8. VERTICAL LOAD TESTING OF PILES

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 The bearing capacity of a single or group of piles shall be determined from test loading. It is most
direct method for determining safe load on pile and it is more reliable on account of its being in-situ
test. The load test on a concrete pile shall not be carried out earlier than 28 days of its casting. Initial
test shall be carried on test pile which is not used as working pile and Routine tests shall be carried
out as a check on working pile. Routine test shall be one-half percent to two percent of total number
of piles or as specified, applicable to vertical and lateral load. Load Test shall generally conform to
provision made in IS 2911 (Part IV) which provides guidelines for determination of safe loads and
conducting of different types of tests.

9. MEASUREMENT AND PAYMENT

9.1 In general an average lead of 50m is considered for depositing spoil/excavated earth but in rare
cases if the situation at site warrants additional lead the contractor has to execute the work without
any additional financial commitment to DNHDDPCL.

9.2 The locations where chemical blasting is to be carried out will be as directed by the Engineer in
charge and the decision of the Engineer in charge shall be final. The quantity under removal by
‘Chemical blasting’ shall be restricted to the minimum as decided by the Engineer in charge.

9.3 The quoted rates for excavation of respective items in the schedule shall include cost of removal,
handling and the disposal of all excavated materials wet or dry as the case may be. The rates shall
further include hire and operational charges of all machinery involved, fencing, protection, care and
diversion works, conveyance of excavated soil to dump yard and all other operations and incidental
works necessary for the execution of works. The rates in the schedule shall include the entire cost
of transporting the materials directly or indirectly from the excavation to the points of the final
disposal including temporary stock piling and re-handling, if required.

9.4 Measurement for excavation by chemical blasting will be based on the actual quantity of rock in
solid removed by the process. The unit rate will include all cost of excavation and of conveying and
depositing the spoil at site pointed out by the Engineer in charge including all lifts.

9.5 The payment will be made at the agreed rate for the relevant items in the accepted schedule.

(C) CONSTRUCTION OF TOWER FOUNDATION

1. SETTING OF STUBS

The stubs shall be set correctly and precisely in accordance with approved method at the exact
location, alignment and levels with the help of stub setting templates and levelling instruments.
Minimum clearance between chimney concrete level and ground level shall be ensured as per
foundation drawing. Stubs setting shall be done in the presence of DNHDDPCL’s representative
available at site where required and for which adequate advance intimation shall be given to
DNHDDPCL by Contractor. Tolerances as per provisions of IS: 5613 shall be allowed for stub setting.

Setting of stubs at each location shall be approved by DNHDDPCL.

However, towers with unequal leg extensions for Multi circuit tower, Extensions for raised chimney
foundations, for river crossing towers, Anchor tower and for foundations in highly collapsible soils,
props may be used with complete accuracy and high skilled supervision, subject to prior approval
from DNHDDPCL. No recovery shall be made on account of using Props for stub setting.

2. STUB SETTING TEMPLATES

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 Stub setting templates shall be arranged by the Contractor at his own cost for all heights of towers
as per DNHDDPCL’s supplied drawings. Stub templates shall be of adjustable type. Stub templates
should be painted.

The Contractor shall deploy sufficient number of templates for timely completion of the line without
any extra cost to DNHDDPCL.

However, the number of template to be deployed shall depend upon type of terrain condition,
number & type of towers etc. Hence the quantity of template to be deployed for timely completion
of the line shall be finalized in consultation with site in-charge without any extra cost to the
DNHDDPCL. One set of stubs setting template (if used) shall be supplied to the DNHDDPCL, on
completion of the project, at no extra cost to DNHDDPCL.

3. BENCHING

When the line passes through hilly / undulated terrain, levelling the ground may be required for
casting of tower footings. All such activities shall be termed benching and shall include cutting of
excess earth and removing the same to a suitable point of disposal as required by DNHDDPCL.
Benching shall be resorted to only after approval from DNHDDPCL. Volume of the earth to be cut
shall be measured before cutting and approved by DNHDDPCL for payment purposes. Further, to
minimize benching, unequal leg extensions shall be considered and provided if found economical.
If the levels of the pit centres be in sharp contrast with the level of tower centre, suitable leg
extensions may be deployed as required. The proposal shall be submitted by the Contractor with
detailed justification to the DNHDDPCL.

4. PROTECTION OF TOWER AND TOWER FOOTING

Tower shall be spotted such that the quantity of revetment is optimum. For tower locations in
undulated terrain such as hill / mountain slopes, options like use of unequal leg extensions for
towers, unequal chimney extensions etc. shall be explored by the contractor for optimizing the need
for revetment & benching.

The work shall include all necessary stone revetments, concreting and earth filling above ground
level, the clearing from site of all surplus excavated soil, special measures for protection of
foundation close to or in small water streams (Nalas), river bank / bed, undulated terrain, protection
of uphill / downhill slopes required for protection of tower etc., including suitable revetment or
galvanized wire netting and meshing packed with boulders. Contractor shall recommend protection
at such locations wherever required. Details of protection of tower/tower footing are given in
drawing enclosed with these specifications for reference purpose only.

In protection of tower footings works the back filling shall generally be done using soil excavated at
site unless deemed unsuitable for back filling. In the latter case, back filling shall be done with
contractor's earth for which provision is given in the tender schedule. The unit rate for back filling
quoted in Price Schedules shall include the required lead and consolidation and levelling of earth
after back filling.

The provisional quantities for protection work of foundations are furnished in Price Schedule of Bid.
The unit rates shall also be applicable for adjusting the actual quantities of protection works done.
These unit rates shall hold good for protection work carried out on down hills or up hills slopes
applicable for the tower locations.

No deduction shall be made for the volume enclosed by weep holes. The locations where both
benching and protection of tower footing are envisaged, an economy got to be established against
providing unequal leg extension.

PART - II TOWER ERECTION, STRINGING AND INSTALLATION OF LINE MATERIALS

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2.0 GENERAL

2.0.1 The scope of erection work shall include the cost of all labour, tools and plant such as tension
stringing equipment and all other incidental expenses in connection with erection and stringing
work. The stringing equipment shall be of sufficient capacity to string the bundle conductors of
specified size.

2.0.2 The Contractor shall be responsible for transportation to site of all the materials to be supplied by
the Contractor as well as proper storage and preservation of the same at his own cost, till such time
the erected line is taken over by the Owner. Similarly, the Contractor shall be responsible for
transportation, proper storage, safe custody, and loss or damage of all Owner’s supplied items for
incorporation in the lines and shall maintain and render proper account of all such materials at all
times. The Contractor shall reimburse the cost of any of the materials lost or damaged during
storage and erection.

2.0.3 Contractor shall set up required number of stores along the line and the exact location of such stores
shall be discussed and agreed upon with the Owner.

Owner supplied items shall be dispatched to the railway stations situated nearest to the stores set
up by the Contractor. From the railway stations, receipt, unloading and transportation to the stores
shall be the entire responsibility of the Contractor.

2.0.4 Payment for stringing shall be done on the basis of per kilometer and irrespective of number of
tension/suspension towers. However, stringing for river crossing spans have been given separately
in the BPS. The units of measurement for tower erection and other line materials, like, earth wire,
Hard ware fittings and Accessories for conductor & earth wire are indicated in the BPS.

2.0.5 TREATMENT OF MINOR GALVANISATION DAMAGE

Minor defects in hot-dip galvanised members shall be repaired by applying zinc rich primer and two
coats of enamel paint to the satisfaction of the Owner before erection.

2.1 TOWER ERECTION

2.1.1 The towers shall be erected on the foundations not less than 14 days after concreting or till such
time the concrete has acquired sufficient strength. The towers are erected as per the erection
drawings furnished by the designer to facilitate erection.

2.1.2 For the convenience of assembling the tower parts during erection operations, each member is
marked in the factory to correspond with a number shown in the erection drawing. Any damage to
the steel and injuring of galvanizing shall be avoided. No member shall be subjected to any undue
over stress, during erection

2.1.3 The contractor shall give complete details of the erection procedures. The method for the erection
of towers shall ensure the following:

a) Straining of the members shall not be permitted for positioning. It may, however, be
necessary to match hole positions at joints using tommy bars not more than 450mm in
length;

b) Prior to erection of an upper section, the lower sections shall be completely braced, and all
bolts provided tightened adequately in accordance with approved drawings to prevent any
mishap during tower erection;

c) All plan diagonals, oblique bracings etc for relevant section of tower shall be in place prior to
assembly of an upper Section;

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 d) The bolt positions in assembled towers shall be as per IS-5613 (Part II/Section 2);

e) Tower shall be fitted with number, danger and phase plates as well as anti- climbing device,
as described;

f) After complete erection of the tower, all blank holes, if any, are to be filled by bolts and nuts
of correct size.

g) Before starting erection of an upper section, the lower section shall be completely braced and
all bolts provided in accordance with approved drawings.

2.1.4 The contractor shall be entirely responsible for correct erection for all towers as per the approved
drawings and their correct setting on the alignment finally approved by the purchaser. The towers
must be truly vertical after erection, the permitted tolerance in verticality being 1 in 360 of the
tower height. No straining will be permitted to make the towers vertical.

2.1.5 A reasonable amount of drifting as permissible in IS:5613 (Part 3, section-2)-1989 shall be allowed
in assembling but reaming for correction of mismatched holes due to shop errors will not be
permitted. If any shop errors are discovered, the contractor shall notify the purchaser, who will
decide whether the errors may be corrected in the field or members returned to tower fabricator
for correction or replacement.

All galvanized surfaces damaged as a result of correction shall be made good to the satisfaction of
the department.

2.1.6 Tower shall be fitted with number plate, danger plate, phase plates, circuit plates and anti-climbing
device as described. After complete erection of tower, all blank holes, if any, are to be filled by Bolts
and nuts of correct size. Suspension towers shall be fitted with Bird guards.

2.1.7 TIGHTENING OF BOLTS AND NUTS

2.1.7.1 All nuts shall be tightened properly using correct size spanner and torque wrench. Before
tightening, it will be verified that filler washers and plates are placed in relevant gap between
members, bolts of proper size and length are inserted, and one spring washer is inserted under each
nut. In case of step bolts, spring washers shall be placed under the outer nuts. The tightening shall
progressively be carried out from the top downwards, care being taken that all bolts at every level
are tightened simultaneously. The threads of bolts projecting outside the nuts shall be punched at
their position on the diameter to ensure that the nuts are not loosened in course of time. If, during
tightening, a nut is found to be slipping or running over the bolt threads, the bolt together with the
nut shall be replaced.

2.1.7.2 The threads of all the bolts except for Anti-theft bolts projected outside the nuts shall be welded at
two diametrically opposite places, the circular length of each welding shall be at least 10mm. The
welding shall be provided from ground level to waist level for single circuit towers and to bottom
cross arm for double circuit towers. However, for towers, with +18-meter, +25 meter extensions and
river crossing towers, the welding shall be provided from ground level to 30m height from stub
level. After welding zinc-rich primer having approximately 90% zinc content shall be applied. to the
welded portion. At least two coats of the paint shall be applied. The surface coated with zinc rich
primer shall be further applied with two finish coats of high build enamel of the grade
recommended by the manufacturer of the zinc rich primer. The cost of welding and paint including
application of paint shall be deemed to be included in the erection price.

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 STRINGING OF CONDUCTORS AND EARTH WIRE

2.2 INSULATOR HOISTING

Suspension insulator strings shall be used on Suspension towers (A/DA) and tension insulator
strings on angle and dead-end towers. These shall be fixed on all the towers just prior to the
stringing. Damaged insulators and strings, if any, shall not be employed in the assemblies. Prior to
hoisting, all insulators shall be cleaned in a manner that will not spoil, injure or scratch the surface
of the insulator, but in no case shall any oil be used for that purpose. For checking the soundness of
insulators, IR measurement using 10kV (DC) Meager shall be carried out on 100% insulators.
Corona control rings/arcing horn shall be fitted in an approved manner. Torque wrench shall be
used for fixing various line materials and components, such as suspension clamp for conductor and
earth wire, etc., whenever recommended by the manufacturer of the same.

2.3 HANDLING OF CONDUCTOR AND EARTH WIRE

2.3.1 RUNNING OUT OF THE CONDUCTORS

2.3.1.1 The conductors shall be run out of the drums form the top in order to avoid damage. The Contractor
shall be entirely responsible for any damage to tower or conductors during stringing.

2.3.1.2 A suitable braking device shall be provided to avoid damaging, loose running out and kinking of the
conductors. Care shall be taken that the conductors do not touch and rub against the ground or
objects which could scratch or damage the strands.

2.3.1.3 The sequence of running out shall be from the top down i.e. the earth wire/OPGW shall be run out
first followed in succession by the conductors. Unbalanced loads on towers shall be avoided as far
as possible. Inner phase of line conductors shall be strung before the stringing of the outer phases
is taken up.

2.3.1.4 The Contractor shall take adequate steps to prevent clashing of sub conductors until installation of
the spacers/spacer dampers. Care shall be taken that sub conductors of a bundle are from the same
Contractor and preferably from the same batch so that creep behavior of sub conductors remains
identical. During sagging, care shall be taken to eliminate differential sag in sub-conductors as far
as possible. However, in no case shall sag mismatch be more than 25mm.

2.3.1.5 Towers not designed for one sided stringing shall be well guyed and steps taken by the Contractor
to avoid damage. Guying proposal along with necessary calculations shall be submitted by the
Contractor to Owner for approval. All expenditure related to this work is deemed to be included in
the bid price and no extra payment shall be made for the same.

2.3.1.6 When the transmission lines runs parallel to existing energised power lines, the Contractor shall
take adequate safety precautions to protect personnel; from the potentially dangerous voltage built
up due to electromagnetic and electrostatic coupling in the pulling wire, conductors and earth wires
during stringing operations.

2.3.1.7 The Contractor shall also take adequate safety precautions to protect personnel from potentially
dangerous voltage build up due to distant electrical storms.

2.3.2 RUNNING BLOCKS

2.3.2.1 The groove of the running blocks shall be of such a design that the seat is semicircular and larger
than the diameter of the conductor/earth wire and it does not slip over or rub against the slides.
The grooves shall be lined with hard rubber or neoprene to avoid damage to conductor and shall be
mounted on properly lubricated bearings.

2.3.2.2 The running blocks shall be suspended in a manner to suit the design of the cross- arm. All running

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 blocks, especially at the tensioning end will be fitted on the cross-arms with jute cloth wrapped over
the steel work and under the slings to avoid damage to the slings as well as to the protective surface
finish of the steel work.

2.3.3 REPAIRS TO CONDUCTORS

2.3.3.1 The conductor shall be continuously observed for loose or broken strands or any other damage
during the running out operations.

2.3.3.2 Repairs to conductor if accidentally damaged, shall be carried out with repair sleeve with the
permission of the Engineer in charge.

2.3.3.3 Repairing of the conductor surface shall be carried out only in case of minor damage, scuff marks,
etc. The final conductor surface shall be clean, smooth and free from projections, sharp points, cuts,
abrasions, etc.

2.3.3.4 The Contractor shall be entirely responsible for any damage to the towers during stringing.

2.3.4 CROSSINGS

Derricks or other equivalent methods ensuring that normal services need not be interrupted, nor
damage caused to property shall be used during stringing operations where roads, channels,
telecommunication lines, power lines and railway lines have to be crossed. However, shut down
shall be obtained when working at crossings of overhead power lines. The Contractor shall be
entirely responsible for the proper handling of the conductor, earth wire and accessories in the field.
The shutdown schedule and number of days will be intimated at the time of execution after
consulting with Load Dispatch Center. The shutdown will be arranged by the DNHDDPCL as per
requirement.

2.4 STRINGING OF CONDUCTOR AND EARTH WIRE

2.4.1 The stringing of the conductor shall be done by the control tension method. The equipment shall be
capable of maintaining a continuous tension per bundle such that the sag for each conductor is
about twenty percent greater than the sags specified in the stringing sag table.

2.4.2 The bidder shall give complete details of the stringing methods he proposes to follow. Prior to
stringing the Contractor shall submit the stringing charts for the conductor and earth wire showing
the initial and final sags and tension for various temperatures and spans alongwith equivalent spans
in the lines for the approval of the Owner.

2.4.3 A controlled stringing method suitable for simultaneous stringing of the sub conductors shall be
used. The two conductors making up one phase bundle shall be pulled in and paid out
simultaneously. These conductors shall be of matched length. Conductors or earth wires shall not
be allowed to hang in the stringing blocks for more than 96 hours before being pulled to the
specified sag.

Conductor creep are to be compensated by over tensioning the conductor at a temperature of 26°C
lower than the ambient temperature or by using the initial sag and tensions indicated in the tables.

2.5 JOINTING

2.5.1 When approaching the end of a drum length at least three coils shall be left in place when the
stringing operations are stopped. These coils are to be removed carefully, and if another length is
required to be run out, a joint shall be made as per the specifications.

2.5.2 Conductor splices shall not crack or otherwise be susceptible to damage in the stringing operation.
The Contractor shall use only such equipment/methods during conductor stringing which ensures

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 complete compliance in this regard.

2.5.3 All the joints on the conductor and earth wire shall be of the compression type, in accordance with
the recommendations of the manufacturer, for which all necessary tools and equipment like
compressors, dies etc., shall be obtained by the Contractor. Each part of the joint shall be cleaned by
wire brush till it is free of dust or dirt etc. and be properly greased with anti-corrosive compound.
If required and as recommended by the manufacturer, before the final compression is carried out
with the compressors.

2.5.4 All the joints of splices shall be made at least 30 meters away from the tower structures. No joints
or splices shall be made in spans crossing over main roads, railways, power lines and small river
spans up to 650m. Not more than one joint per sub conductor per span shall be allowed. The
compression type fittings shall be of the self centering type or care shall be taken to mark the
conductors to indicate when the fitting is centered properly. During compression or splicing
operation; the conductor shall be handled in such a manner as to prevent lateral or vertical bearing
against the dies. After compressing the joint the aluminium sleeve shall have all corners rounded,
burrs and sharp edges removed and smoothened.

2.5.5 During stringing of conductor to avoid any damage to the joint, the Contractor shall use a suitable
protector for mid span compression joints in case they are to be passed over pulley blocks/aerial
rollers. The pulley groove size shall be such that the joint along with protection can be passed over
it smoothly.

2.6 TENSIONING AND SAGGING OPERATIONS

2.6.1 The tensioning the sagging shall be done in accordance with the approved stringing charts or sag
tables. The “initial” stringing chart shall be used for the conductor and final stringing chart for the
earth wire. The conductors shall be pulled up to the desired sag and left in running blocks for at
least one hour after which the sag shall be rechecked and adjusted, if necessary, before transferring
the conductors from the running blocks to the suspension clamps. The conductor shall be clamped
within 96 hours of sagging in.

2.6.2 The sag will be checked in the first and the last section span for sections up to eight spans, and in
one additional intermediate span for sections with more than eight spans. The sag shall also be
checked when the conductors have been drawn up and transferred from running blocks to the
insulator clamps.

2.6.3 The running blocks, when suspended from the transmission structure for sagging, shall be so
adjusted that the conductors on running blocks will be at the same height as the suspension clamp
to which it is to be secured.

2.6.4 At sharp vertical angles, conductor and earth wire sags and tensions shall be checked for equality
on both sides of the angle and running block. The suspension insulator assemblies will normally
assume verticality when the conductor is clamped.

2.6.5 Tensioning and sagging operations shall be carried out in calm whether when rapid changes in
temperature are not likely to occur.

2.6.6 CLIPPING IN

2.6.6.1 Clipping of the conductors into position shall be done in accordance with the manufacturer’s
recommendations.

2.6.6.2 Jumpers at section and angle towers shall be formed to parabolic shape to ensure maximum
clearance requirements. Pilot suspension insulator strings shall be used, if found necessary, to
restrict jumper swing to design values.

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2.6.6.3 Fasteners in all fittings and accessories shall be secured in position. The security clip shall be
properly opened and sprung into position.

2.7 FIXING OF CONDUCTORS AND EARTH WIRE ACCESSORIES

Conductor and earth wire accessories including spacers, spacer dampers (for bundle conductor)
and vibration dampers shall be installed by the Contractor as per the design requirements and
manufacturer’s instruction within 24 hours of the conductor/earth wire clamping. While installing
the conductor and earth wire accessories, proper care shall be taken to ensure that the surfaces are
clean and smooth and that no damage occurs to any part of the accessories or of the conductors.
Torque wrench shall be used for fixing the Dampers/Spacer Dampers, Suspension Clamps etc. and
torque recommended by the manufacturer of the same shall be applied.

2.8 AERIAL MARKER BALLS & AVIATION SIGNAL

The line route shall be at a sufficient distance from the aerodromes / airports so that clearance from
the aerodrome / airport authorities is not required or, otherwise, can be obtained easily. Aviation
obstruction fixtures / lights / painting have been provided, if required.

Aircraft warning sphere/ aerial marker ball will be provided wherever required, is designed to
provide daytime visual warning or nighttime visual warning if comes with reflective tape, for
electricity transmission line and overhead wire for aircraft pilots, especially cross river high voltage
transmission lines. An aircraft warning marker should be of one color such as aviation orange, white
and red. Generally, the marking spheres are placed on the highest line. Where there is more than
one line at the highest level, white and red, or white and orange spheres should be displayed
alternately. This alternating color scheme provides the most conspicuity against all back ground.

2.9 REPLACEMENT

If any replacement is to be affected after stringing and tensioning or during maintenance, leg
member and bracing shall not be removed without first reducing the tension on the tower by proper
guying techniques or releasing of the conductor. For replacement of cross arms, the conductor shall
be suitably tied to the tower at tension points or transferred to suitable roller pulleys at suspension
points.

2.10 PERMITTED EXTRA CONSUMPTION OF LINE MATERIALS

2.10.1 The quantity of conductor and earth wire to be incorporated in the line shall be worked as per the
following norms.

Quantity of Conductor = Line length as per detailed survey x 3 phases x Nos. of

conductor per bundle (for Single Circuit Line)

= Line Length as per detailed survey x 3 phases x Nos. of conductor per bundle x 2 (for Double
Circuit Line)

Quantity of Earth wire = Line length as per detailed survey x nos. of ground wires

- For calculation of conductor & Earth wire requirement in hilly stretches, inclined distance between
the towers may be considered instead of horizontal distance (considered for line length).

2.10.2 The Contractor shall make every effort to minimize breakage, losses and wastage of the line
materials during erection. However, the Contractor shall be permitted and extra consumption of line
materials up to the limits specified in Table 2.10.2.1 and shall be permitted to dispose of the scrap,
if any at the end.

Table 2.10.2.1 Permitted extra consumption of line materials

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 Item % of permitted extra consumption

Conductor & earth wire 1

Insulators 1

2.10.3 In case of conductor and earth wire, the permitted extra consumption limit of one percent is
inclusive of sag, jumpering, damage, loss and wastage etc.

2.10.4 The Contractor shall not be required to return to the Owner empty conductor and earth wire drums
and shall dispose of the same at his cost.

2.10.5 Any conductor and earth wire drum which has been opened by the Contractor shall not be taken
back by Board and the unused conductor or earth wire in such drums may be treated as waste
permissible within the overall limits specified in Table 2.10.2.1.

2.10.6 The Contractor shall return to the Board all Board supplied material not incorporated in the works,
except those permitted by Board as scrap in terms of Table 2.10.2.1. Otherwise, the Contractor shall
pay in respect of such excess materials which he is unable to return at rates corresponding to the
actual cost of procurement plus 15% for OSM procured under domestically funded packages. The
“cost of procurement” for the above purpose shall be F O R destination site cost of OSM as per LOA
of the respective packages plus taxes & duties plus price variation (if positive) applicable as on the
date of issuance of TOC for Tower Package.

2.10.7 For calculation of conductor & earth wire consumption in hilly (mountainous) stretches inclined
distance between towers may be considered, instead of horizontal distance between them.

2.10.8 The quantities of line materials to be supplied by the contractor (i.e. earth wire, Hardware fittings
& accessories) as indicated in the bill of quantities are provisional and the actual quantity shall
depend upon detailed survey.

Contractor shall be responsible for regulating the supplies of contractor supplied materials in the
basis of actual requirements. The Owner shall have right, not to take any surplus contractor supplied
line materials.

2.11 FINAL CHECKING, TESTING AND COMMISSIONING

2.11.1 After completion of the works, final checking of the line shall be carried out by the Contractor to
ensure that all foundation works, tower erection and stringing have been done strictly according to
the specifications and as approved by the Owner. All the works shall be thoroughly inspected in
order to ensure that:

a) Sufficient back filled earth covers each foundation pit and is adequately compacted;

b) Concrete chimneys and their copings are in good condition and finely shaped.

c) All tower members are used strictly according to final approved drawing and are free of any
defect or damage whatsoever.

d) All bolts are properly tightened, punched, tack welded and painted with zinc rich paint;

e) The stringing of the conductors and earth wire has been done as per the approved sag and
tension charts and desired clearances are clearly available;

f) All conductor and earth wire accessories are properly installed;

g) All other requirements for completion of works such as fixing of danger plate, phase plate,
number plate, anti-climbing device, Aerial marker balls, aviation signal have been fulfilled.

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 h) Wherever required, that proper revetment (erosion protection) is provided;

i) The original tracings of profile and route alignment as well as tower design, structural
drawings, bill of material and shop drawings of all towers are submitted to the Owner for
reference and record.

j) The insulation of the line as a whole is tested by the Supplier through provision of his own
equipment, labour etc., to the satisfaction of the Owner.

k) All towers are properly grounded.

l) The line is tested satisfactorily for commissioning purpose.

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 PART D DOCUMENTATION AND DELIVERABLES

(To be submitted with the proposal of vendor approval by the successful bidder after
placement of order)

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 PART D DOCUMENTATION AND DELIVERABLES

This section describes the documentation requirements and provides a list of deliverable that the
Contractor shall provide to the DNHDDPCL. Complete documentation necessary for the operation and
maintenance of the fibre optic cabling system is required. All the documentation shall be provided in hard
copy and also on CD-ROMs in full compliance with the specification. Conditions pertaining to Document
Review and Approval Rights and Document Submission Scheduling are specified in this section.

The documentation shall include the following:

(a) Detailed list of the deliverables

(b) Description of the products

(c) Technical particulars

(d) Installation manuals

(e) Maintenance manuals

(f) Quality assurance manuals, Manufacturing Quality Plan (MQP) & Field Quality Plan (FQP)

(g) Tests documentation

1. System Documentation

A detailed documentation plan and document submission schedule shall be prepared and
submitted for approval. The guidelines specified in table 5-1 & table 5-2 shall be followed.

2. Supplementary Documentation

While performing maintenance during the warranty period, the DNHDDPCL determines that
additional information is required to perform the maintenance function, the Contractor and/or its
subcontractors shall provide the specific supplemental information necessary to perform the
maintenance function. This information shall be documented in a form suitable for incorporation
into the appropriate maintenance document.

3. Test Documentation

The Contractor shall provide documentation for all Type tests, Factory Acceptance tests and site
tests (SAT).

The test documentation shall include the following:

a. Type test Documents (Procedures & Reports)

b. Factory Acceptance Test Documents (Procedures & Reports)

c. Site Acceptance Test Documents (Procedures & Reports)

Drawings

All drawings submitted by the Contractor including those submitted at the time of bid shall be in
sufficient detail to indicate the type, size, arrangement, dimensions, material description, Bill of
Materials, weight of each component, break-up for packing and shipment, shipping arrangement
required, the dimensions required for installation and any other information specifically requested
in the Specifications.

Each drawing submitted by the Contractor shall be clearly marked with the DNHDDPCL name, the
unit designation, the specification title, the specification number and the name of the Project. All

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 titles, notes, markings and writings on the drawing shall be in English. All the dimensions should
be to the scale and in metric units. The drawing revision level/ issue no, issue date shall be marked
on each drawing and the drawing shall carry issue history information and appropriate signatures
(eg: originator, checker and approving authority).

4. Drawing and Document Approval Procedure

The drawings/documents submitted by the Contractor shall be reviewed by the DNHDDPCL as far
as practicable within stipulated duration and shall be modified by the Contractor if any
modifications and/or corrections are required by the DNHDDPCL in compliance with the
Specifications. The Contractor shall incorporate such modifications and/or corrections and submit
the final drawings for approval. Any delays arising out of failure by the Contractor to rectify the
drawings in good time shall not alter the contract completions date.

The drawings/documents submitted for approval to the DNHDDPCL shall be in quadruplicate. One
print of such drawings shall be returned to the Contractor by the DNHDDPCL marked with one of
the categories as listed below: -

Category Inference

Cat I Approved/Released for implementation.

Cat II Approved/Released for implementation subject to incorporation of
comments. Revised drawing required
Cat III To be resubmitted for approval after incorporating comments.
Cat IV For information and record.

The approval of the drawing/document conveyed vide above marked copy shall neither relieve the
Contractor of its contractual obligations and its responsibilities towards weights, qualities, design
details, assembly fits, performance particulars and conformity of supplies with the Indian Statutory
Laws as may be applicable, nor shall it limit DNHDDPCL’s and/or DNHDDPCL’s right under the
contract.

Depending upon the category of approval the Contractor shall resubmit the drawings/documents
for review by DNHDDPCL after incorporating all corrections.

Further work by the Contractor shall be strictly in accordance with the Cat-I, Cat-II or Cat-IV
approved drawings and no deviation shall be permitted without the written approval of the
DNHDDPCL.

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

5. Final Documentation

Final documentation shall consist of all the documents approved in Cat I and Cat IV. The documents
will be used by the DNHDDPCL personnel for operating and maintaining the equipment after
acceptance.

Until acceptance of the equipment by the DNHDDPCL, the Contractor shall be responsible for
supplying documentation revisions or changes necessitated by inaccuracies, installation
requirements, omissions determined by usage, and design or production alterations to the

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 equipment. All changes shall be issued in the form of replacements for the affected drawings,
diagrams, charts, graphs, tables, lists, and pages in the various documentation such that all
documentation describes the equipment "as delivered".

For all the documents listed in Table D.1 (except Type, FAT & SAT related), five(5) sets of the final
approved documentation shall be provided for the engineering office of the DNHDDPCL in CD-ROM
and two (2) sets in hard copy.

All final Contractor-supplied documentation shall be easily reproducible by the DNHDDPCL.

Table D-1: Documentation Plan

Applicable Approval
Sr. no. Document Brief Description
Equipment’s/Item Category
This document shall
contain the list of all
documents to be
Documentation Plan
1. submitted for approval Cat-I
and Schedule
and their
submission/approval
schedule.
Survey guidelines & As per technical
2. Cat-I
formats specifications.
These document(s)
For each and every
shall describe all the
item to be supplied
technical parameters of
including fibre,
the item being offered.
OPGW cable,
The formats for some
Data Requirement approach cable, joint
items provided in the
Sheets (DRS) and box, FODP, All FO Cat - I (for
appendices shall be
Guaranteed cable Hardware & DRS) & Cat –
3. used, which may be
Technical fittings IV (for
expanded as required.
Parameters & (suspension clamp brochure)
The GTP shall be
Drawings assembly, tension
submitted for all items.
clamp assembly,
The GTP shall be
vibration damper
supported by technical
etc.), test
brochures / product
equipment.
manuals.
Shall accompany the
4. Sag tension charts For OPGW cable Cat-I
DRS
For all items for
which type testing is
Shall be complete in all
required. (fibre,
respect including all
Previous type test OPGW cables, Acceptance
5. test graphs, curves,
reports Hardware & fittings Letter
calculations,
for OPGW cable,
photographs etc.
approach cable, joint
box,)
Manufacturing For all items to be Refer technical Cat- IV
6.
Quality Plan supplied specifications.
Line wise survey Cat- I (for
reports, indicating Drum
tower schedules, drum Schedule)
Survey reports & schedules, crossing and Cat-IV for
7. engineering analysis For FO cable link details, hardware & other
fitting requirements etc. detailed
Shall include line wise report
sag-tension charts and
other engineering

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 analysis etc.
Link and survey For each Fibre Link wise survey reports
8. reports & Optic link and site as per specifications, Cat- I
engineering analysis link calculations etc.
Must include
Numbering, numbering, marking,
Marking, labelling As applicable. labelling and naming Cat- I
9. Document conventions for
channels, cables,
connectors, sub racks,
cubicles etc
Line wise survey
reports, indicating
tower schedules, drum
schedules, crossing
details, Hardware &
fitting requirements etc.
Shall include line wise Cat- I
10.
For each item and sag- tension charts and
Bill of Quantities each line other engineering
analysis such as tower
strengthening analysis
etc. Shall include site
wise detailed quantities
of each equipment
This document shall
include the list of
Factory acceptance
Factory Acceptance For all items to be tests, the administrative Cat- I
tests: test plan, supplied & functional test plans,
11.
procedures and test procedures and
report format formats for recording &
reporting factory
acceptance
test results.
This document shall
Factory acceptance For all Factory provide all factory Cat- IV
12. test report acceptance tests acceptance reports for
all materials used in this
project.
This document shall
describe the procedures
& precautions to be
observed during
overseas & inland Cat- IV
transportation, cable &
13. Transportation & For OPGW cable cable drum handling
Handling Procedures during transport,
storage & pre-
installation. It shall also
include drum details
and drum labelling
details.
This document shall
For each type of FO describe the installation
Jointing Manual cable/ joint box to of joint box (In line Cat- I
14.
be supplied splice enclosures) and
other
jointing gang activities

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 The expected content of
Installation For OPGW cable & this document are Cat- IV
15.
procedure joint box presented in table D-2
below.
This document shall
include the list of Site
Site Acceptance tests acceptance tests, the
(SAT) test plan, System document administrative &
16. procedures and functional test plans, Cat- I
report format test procedures and
formats for recording &
reporting site
acceptance test results.
Field Quality Plan shall
describe the quality
control to be exercised
during the field
activities. This
document can include
the following
information:
(a.) The list of
performance & safety
checks applied to
installation equipment, Cat- I
tools & tackles, checks,
One Document with check on physical health
17.
Field Quality Plan multiple & training records of
subdocuments if installation crew etc.
required (b.) The list of Site
Acceptance tests
(including statement of
acceptance criteria).
The inclusion of list of
site acceptance tests in
FQP is analogous to the
inclusion of list of FAT in
the MQP. The formats for
recording & reporting
Site acceptance tests can
also be reproduced.

Field Safety Plan Safe Execution Instructions and Cat- I

18.
procedures Procedures for safe
practices at site.
Approach Cable & To describe the layout of
FODP layout For each site approach cable at each Cat - I
19.
document – site and the floor plan of
site wise the FODP.
Site test
records as per Per Link and per
20.
approved SAT Location *
procedures

* To be reviewed & approved by the Site

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 Table D-2: Expected Contents & Structure of FO Cable / Equipment Installation Manual

Sr. no. Document Applicable Equipment’s/Item

Description of activities of installation gangs: Preparation &
Installation Setting up, Stringing, sagging, attaching hardware, attaching
1. procedure down lead clamps & cable routing on the tower, securing cable
ends (for protection before work by jointing gang).
Precautions for preventing cable damage shall be highlighted.
Instructions & procedures related to ensuring installation
crew safety: personnel grounding & safety, installation
Safety Instructions equipment safety, Safety for power system & environment (viz
2.
preventing accidental tripping, precaution for railway
crossings etc)

Description of Sketches, drawings, photographs, safe working ratings of

Installation installation equipment, tools & tackles etc., handling
3.
Equipment instructions & precautions.

Illustrations of the positions of tower attachment clamps

4. Cable routing (down lead clamps), routing of FO cable on the tower, service
loop(s), joint box position.
References to other related documents covering the
installation, jointing & testing, like: SAT administrative &
functional test plans & test procedures, Jointing Procedures,
5. References Field Quality Plan & Field Quality Audit, Storage & Handling
Instructions, FO cable & hardware drawings, technical
parameters, GTP etc. DNHDDPCL & Statutory safety rules,
safety manuals, standards, codes of practices etc.

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