Volume V

MADHYA PRADESH POWER TRANSMISSION CO. LTD.
SHAKTI BHAWAN RAMPUR: JABALPUR
VOLUME V(Part-1)
Technical Book Serial No.
MPPTCL/TECH/PROC/12/JULY13
TECHNICAL SPECIFICATION FOR SUPPLY

OF MATERIALS AND CONSTRUCTION OF
220KV AND 132KV TRANSMISSION
LINES.
O/o CHIEF ENGINEER (PROCUREMENT)

MPPTCL, JABALPUR.
TABLE OF CONTENTS
PART I
Specifications
&
requirements
Transmission Line Materials
for
supply
Section- 1
Common Technical Requirement . 1
Section- 2
Technical Specifications for Towers ..
14
Section- 3
Technical Specifications for Conductor .
33
Section- 4
Technical Specifications for Earth wire .... 45
Section- 5
Technical Specifications for Disc Insulators 52
Section- 6
Technical Specifications for Hardware fittings for

Conductor & Earth wire.....................
70
Section- 7
Technical Specifications for Accessories for Conductor

& Earth wire .
89
Section- 8
Technical Specifications for erection of transmission

lines........................................... 106
Annexure 1
Annexure 2
Annexure 3
Annexure 4
Annexure 6
Technical Particulars of ACSR Conductors & Earth 129

wire
Technical Particulars of Disc Insulators
133
Technical Particulars of Hardware for conductor
135
& Earth wire
Technical Particulars of Accessories for conductor 139
& Earth wire
List of Drawings
142
of
Volume-V (Part-1)
SECTION-1
COMMON TECHNICAL REQUIREMENT
1.01
SCOPE:
1.01.01
The provisions under this section are to
supplement
common
requirements
for
supply
of
Transmission Line Materials and Installation work. Section-2
to Section-8 contains technical specification for all the
Materials to be used for Construction of Transmission Lines.
The bidders shall furnish catalogues, engineering data /
technical information, drawing etc. in conformity with the
technical specification.
1.01.02
The scope of work involves fabrication, galvanizing and
delivery of 220kV & 132kV Double Circuit/ Multi circuit towers, their
body extensions, river/ line crossing structures (Gantries), Hangers,
U bolts, D Shackles, Bolts and Nuts, Spring washers, pack washers,
step bolts, tower accessories (earthing rod with clamps, Danger
Boards, Number plates, Phase plates and Anti-climbing Devices
(including fixing arrangements and barbed wire), ACSR Conductor,
Earth wire, Disc insulators, hardware and accessories for conductor
and Earth wire and complete erection of transmission lines
including, detailed survey/check survey, casting of foundations,
tower erection, stringing etc. and testing & commissioning of the
transmission lines.
Cement and reinforcement steel for
foundation of towers, extensions, river/ line crossing structures and
any
such
materials
required
for
erection
work
shall
also be provided by the successful Bidder. The Bidder is also
required to provide required number of stub setting
templates for each installation work at his own cost.
1.01.03
This
section
also
provides
for
the
Design,
manufacturing, stage testing, inspection and testing before
despatch, packing and delivery of materials for use on 220kV/132kV
transmission lines in the State of Madhya Pradesh.
1.01.04
It is not the intent to specify completely herein all
details of the design and construction of Material. However, the
Material shall conform in all respects to high standards of
engineering, design and workmanship and shall be capable of
performing the duties specified herein. The Material offered shall be
complete with all components necessary for its effective and trouble
free operation. Such components shall be deemed to be within the
scope of Bidders supply, irrespective of whether these are
specifically brought out in this specification or not.
Page 1 of 142
Volume-V (Part-1)
1.01.05
If due to site condition any other type of tower (which is
not envisaged at present) is required to be provided, the same will
also be supplied by the bidder at the same rates terms and
conditions.
1.02
CLIMATIC CONDITION
The equipments and materials shall be suitable for satisfactory

continuous operation under the following climatic conditions:
1
Location in the state of
MADHYA PRADESH
Maximum ambient air temperature

(0C)
50
Minimum temperature in shade (0C )
Maximum relative humidity (%)
95(sometimes
approaches
saturation)
Average daily ambient air

temperature (0C )
32 Centigrade
ISOCERANIC Level (days/year)

(Average number of thunder storm
days)
50
Average rainfall(mm)
1250
Wind Zone as per IS 802(Part-I)1995
Max. Altitudes above mean sea level

(meters)
1000
1
0
Seismic level (Horizontal acceleration)

(g)
0.3
NOTE: Moderately hot and humid tropical climate conducive to rust

and fungus growth. The climatic conditions are also prone to
wide variations in ambient conditions. Smoke is also present
in the atmosphere. Heavy lightening also occurs during June
to October.
1.03
STANDARDS:
1.03.01
Bidders may please note that all offered materials shall
be manufactured, tested and supplied with all guaranteed technical
particulars generally conforming to meet the requirement of
technical specification as brought out in various Sections and latest
revisions of relevant standards of international electro technical
commission or equivalent national standards of India with latest
amendments of relevant standards rules and codes. The lists of
standards are specified in relevant Sections of bid document.
Page 2 of 142
Volume-V (Part-1)
1.03.02
The works covered by the specification shall be
designed,
engineered,
manufactured,
built,
tested
and
commissioned in accordance with the Acts, Rules Laws and
Regulations of India.
1.03.03
The Contractor shall also note that list of standards
presented in this specification is not complete. Wherever necessary
the list of standards shall be considered in conjunction with specific
IS/IEC.
1.03.04
When the specific requirements stipulated in the
specifications exceed or differ than those required by the applicable
standards, the stipulation of the specification shall take precedence.
1.04
ACCEPTANCE OF OTHER AUTHORITATIVE

STANDARDS :
1.04.01
The lists of Indian standards are specified in individual
sections for various materials and Installation work of bid
document. However, the Material and Installation work meeting any
other authoritative International Standard, which ensures equal or
better quality than the Standards mentioned in bid document, shall
also be acceptable. Material for which Indian Standards are
not available, any equivalent International Standards will be
applicable. Please attach photocopy of all such Standards
according to which the material and Installation work have
been offered.
1.04.02
If the material offered by the Bidder conform to any
other standards, salient points of comparison between the
standards adopted and the specific standards shall be clearly
brought out in relevant schedule of deviation. It will be sole
responsibility of Bidder to prove that the salient features of offered
materials are equivalent or better than Indian standards as
indicated in Section-2 to Section- 8 of Volume-V(Part-1) of bid
document.
1.04.03
The Material and Installation work conforming to
standards other than specified in individual sections for various
Material and Installation work shall be subject to Employers
approval.
1.05
TYPE TESTS:
1.05.01
Type tests shall mean those tests, which are to be
carried out to prove the process of manufacture and general
conformity of the Material.
Page 3 of 142
Volume-V (Part-1)
1.05.02
The offered Material (except Towers & Tower
Accessories) should be fully type tested as per the relevant
standards. Bidder shall invariably furnish type test reports from the
reputed and approved national/international laboratory/Government
approved test houses to prove that specifications of Material to be
supplied conform to the relevant standard. Test certificates shall
clearly indicate the type and other details etc., so that relevant
details of offered Material could be verified. While submitting the bid
the details and type etc., shall be clearly indicated. Type test
reports so furnished should not pertain to the period earlier than
five years from the date of opening of Bid. In case the type tests
were carried out earlier than five years, the manufacturer will have
to conduct these tests without any extra cost to the Employer. In
both the above cases type test certificate must be submitted with
the offer. The Bidders have to submit one complete set of Test
reports for the offered Material. Further, for any change in the
design/type already type tested and the design/type offered against
this specification, the Employer reserves the right to demand
repetition of tests without any extra cost.
1.06
DISCREPANCY IN TECHNICAL PARTICULARS:
The bidders will have to furnish confirmation in regard to

compliance of our entire technical requirement. The bid should
clearly describe various technical particulars of the material as per
this specification.
1.07
MANUFACTURER'S AUTHORISATION:
The bidders shall have to submit the documentation from the

manufacturer of the Material on the format specified in this volume
that they are authorised to supply the material indicated in their
bids in the employer's country
1.08
SCHEDULE OF QUANTITIES:
1.08.01
The requirements of various Materials and Installation
work are indicated in Price Schedules. In these schedules short
description of material has been given. The details of all such
description are given in relevant sections of Volume-V(Part-1) of bid
document. The bidder shall refer these detailed descriptions for
clarity.
1.08.02
Although all the quantity of Material and Installation
work have been included in the bid as mentioned in Price
Schedules.
However there may be requirement of some minor
nature items required for successful erection / commissioning of
transmission line work covered under this Bid.
Bidder should
Page 4 of 142
Volume-V (Part-1)
include all such items in the bid proposal sheets which are not
specifically mentioned but are essential for the execution of the
contract. The cost of supply of such item which explicitly may not
appear in various schedules and are required for successful
commissioning of transmission line shall deemed to be inclusive in
the bid price and shall be provided at no extra cost to Employer.
1.09
PERFORMANCE GUARANTEE PERIOD:
All the Material & its accessories and Installation work covered
under the Bid shall guaranteed for performance and quality for a
period of 24 months from the date of completion of facilities (or
any part thereof). In case after commissioning of transmission line,
any operational problem is observed in any Material/ installation
work because of which any major rectification or replacement work
is done, then the guarantee for such Material / installation work
shall be extended by a period equal to the period during which the
facilities or such part can not be used by the EMPLOYER.
1.10
WORKMANSHIP:
All Material shall be of the best class and quality most suitable for
the conditions of operation under the climate conditions as per
clause no. 1.02 above for supply of Material. The workmanship shall
be of the best grade and the entire construction in accordance with
the best modern practice.
1.11
DRAWINGS AND DOCUMENTS:
1.11.01
In addition to those stipulated in Vol. I of bidding
document, the following also shall apply in respect of Contractor
drawings.
1.11.02
With in one month from the award of contract, the
contractor shall submit the drawing of all Material for approval. Each
drawing submitted by the Contractor shall be clearly marked with
the name of the EMPLOYER, 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.
1.11.03
The comments/ approval to drawings submitted by the
Contractor shall be conveyed by the EMPLOYER as far as practicable
within 15 days and shall be modified by the Contractor if any
modifications and/or corrections are required by the EMPLOYER.
The Contractor shall incorporate such modifications and/or
corrections and submit the final drawings for approval with 15 days
from date of EMPLOYERs comments. Any delays arising out of
Page 5 of 142
Volume-V (Part-1)
failure by the Contractor to rectify the drawings in good time shall

not alter the Contractual Time Schedule.
1.11.04
The drawings submitted for approval to the EMPLOYER
shall be in quadruplicate. One print of such drawings shall be
returned to the Contractor by the EMPLOYER marked
approved/approved with corrections. The contractor shall there
upon furnish the EMPLOYER additional prints as may be required
along with one reproducible in original of the drawings after
incorporating all corrections.
1.11.05
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 EMPLOYER, if so
required.
1.11.06
All manufacturing, fabrication and Installation work
under the scope of Contractor, prior to the approval of the drawings
shall be at the Contractors risk. The contractor may incorporate
any changes in the design, which are necessary to confirm to the
provisions and intent of the contract and such changes will again be
subject to approval by the EMPLOYER.
1.11.07
The approval of the documents and drawings by the
EMPLOYER shall mean that the EMPLOYER is satisfied that:
a. The Contractor has completed the part of the Works
covered by the subject documents (i.e. confirmation of
progress of work).
b. The Works appear
Specifications.
to
comply
with
requirements
of
In no case the approval by the EMPLOYER 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.
1.11.08
All drawings shall be prepared using AutoCAD software.
After final approval all the drawings and documents (structural
drawings, BOMs, shop sketches, tower accessories drawings and
drawings of other materials) shall be submitted to the EMPLOYER in
CDs.
A copy of each drawing reviewed will be returned to the Contractor
as stipulated herein.
Page 6 of 142
Volume-V (Part-1)
1.11.09
Copies of drawings returned to the Contractor will be in
the form of a print with the EMPLOYERs marking.
1.11.10
All rights of the design/drawing for all Material and
Installation work drawings shall be strictly reserved with the
EMPLOYER only and any designs/drawings/data sheets submitted by
the contractor from time to time shall become the property of the
EMPLOYER.
Under no circumstances, the contractor shall be
allowed to user/offer above designs/drawings/data sheets to any
other authority without prior written permission of the EMPLOYER.
Any deviation to above is not acceptable and may be a cause for
rejection of the bid.
1.11.11
The manufacturing of the material shall be strictly in
accordance with the approved drawings and no deviation shall be
permitted without the written approval of the EMPLOYER. All
manufacturing and fabrication work in connection with the material
prior to the approval of the drawing shall be at Contractors risk.
1.11.12
Approval of drawing/works by EMPLOYER shall not
relieve the Contractor of his responsibility and liability for ensuring
correctness and correct interpretation of the latest revision of
applicable standards, rules and codes of practices. The plant shall
conform in all respect to high standards of engineering, design,
workmanship and latest revisions of relevant standards. EMPLOYER
shall have the power to reject any work or material, which in his
judgment is not in full accordance therewith.
1.12
QUALITY ASSURANCE PROGRAM:
1.12.01
Quality Assurance Program :
To ensure that the
Material and Services under the scope of this contract whether
manufactured or performed within the Contractor's works or at
his Sub-Contractor's premises or at the EMPLOYER's site or at
any other place of
work are in accordance with the
Specifications,
the Contractor shall
adopt suitable Quality
Assurance Program (QAP) with hold points for EMPLOYERs
inspection to control such activities at all necessary points. Such
program shall be outlined by the Contractor and shall be finally
accepted by the EMPLOYER after discussions.
1.12.02
Immediately
after
award
of
contract,
the
contractor shall submit to the EMPLOYER, the quality assurance
plan for all major items of Material covering the manufacture and
Installation activities of the transmission line. The list of selected
sub vendors for supply of minor items like Bolts & Nuts, tower
accessories etc. shall also be submitted.
Page 7 of 142
Volume-V (Part-1)
1.12.03
The contractor shall ensure that manufacturer must
establish that they are following the accepted quality assurance
programme for manufacture of offered equipments.
1.12.04
The contractor shall ensure that manufacturers of
major items of Material invariably furnish following information:(i)
Statement giving list of important raw materials, names

of sub supplier 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 manufacturers 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)
Levels 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 for quality control
and details of such tests and inspection.
(vi)
Special features provided in the equipment to make it

maintenance free.
(vii) List of testing equipment available with the

manufacturer for final testing of equipment specified
and test plant limitations, if any vis--vis type, special,
acceptance and routine tests specified in the relevant
Indian Standards or equivalent international standard.
These limitations shall be very clearly brought out in
schedule of deviations from specified test equipments.
1.12.05
The Contractor shall follow the accepted Quality
Assurance Plan in true spirit. If desired by the EMPLOYER, he shall
give access to all the Specifications, equipments and records so as
to satisfy the EMPLOYER that Quality Assurance Plan (QAP) is being
followed properly.
1.12.06
All Material shall be subjected to the routine and
acceptance tests before dispatch, as specified in this Specification.
1.13
INSPECTION AND TEST CERTIFICATES:
1.13.01
All Material to be supplied will be subject to inspection
and approval by the EMPLOYER's representative before despatch.
Inspection before despatch will not however relieve the contractor
Page 8 of 142
Volume-V (Part-1)
of
his responsibility to supply the Material strictly in accordance
with the specifications.
1.13.02
For Inspection / testing, the contractor shall intimate
the EMPLOYER at least 15 days in advance about readiness of
Material as per the scheduled delivery so that action may be taken
for getting the Material inspected. While notifying the readiness of
the Material, the factory test certificate in respect of offered Material
shall invariably be sent. The EMPLOYER will depute authorized
representative for inspection of Material or alternatively may issue
waiver of inspection.
1.13.03
The contractor will submit a test certificate to the
EMPLOYER after inspection of offered Material by EMPLOYERs
authorized representative. These test certificates should be in
accordance with latest issue of the relevant Indian Standards or as
approved by the order placing authority.
1.13.04
The Material shall not be dispatched unless the test
certificates approval and despatch instructions have been issued by
the EMPLOYER.
1.13.05
All Material shall conform to provisions of any
statutory acts such as the Indian Electricity Act, Indian Factory
Act, the Indian Boiler Act, etc. and corresponding rules and
regulations as may be applicable.
1.13.06
The EMPLOYER's representatives shall be entitled at all
reasonable time during manufacture to inspect, examine and test
at the contractor's premises the material and workmanship of the
plant to be supplied under this contract.
1.13.07
A copy of the accepted Quality Assurance Plan must be
available at the manufacturers works of the Material for reviewing
by inspecting officer of the EMPLOYER.
1.13.08
The acceptance of any quantity of plant shall in no way
relieve the Contractor of any of his responsibilities for meeting all
requirements of the specification, and shall not prevent subsequent
rejection if such plant is later found to be defective. The Contractor
will
have
to
assume
the
responsibility
for
free
replacement/rectification of such defects.
1.13.09 Testing Expenses:
The entire cost of testing for the acceptance and routine tests and
tests during manufacture specified in the bid document shall be
treated as included in the quoted unit price of plant.
1.14
SPECIAL REQUIREMENTS:
Page 9 of 142
Volume-V (Part-1)
1.14.01 EMPLOYER expects that participating bidder will take all

necessary precautions to supply best quality Material, which may
provide trouble free performance and also it is expected that the
modern practices for erection and commissioning shall be adopted
to ensure timely and trouble free commissioning of installation and
also to ensure aesthetic overall view of finished transmission line
installation.
Some of the conditions which will have to be essentially accepted
and followed by the Bidders for the purpose of participating against
the Bid and also for undertaking construction activities are
enumerated below for specific confirmation by the Bidders.
1.15
STORE FOR SUPPLY OF MATERIAL:
The Contractor shall supply the Material at selected destination set

up by him along the route of the transmission line. The Contractor
will set up above site store within one month from the date of
contract and inform the EMPLOYER. The Contractor will have to
supply above materials and receive them at these places only and
the rates quoted by the Bidder should include charges for
delivery of such materials at the store set up by him, receipt and
proper stacking/ stocking at the store.
1.16
COMMENCEMENT OF ACTIVITIES:
Commencement of following activities is subject to prior and

specific approval of the items mentioned against each:S.
No.
Activity
Items for which prior approval

is necessary from Employer
1.
Manufacturing of tower
parts.
Inspection of Proto Assembly of

each type of tower.
Submission
of quality assurance plan.
2.
Manufacturing
of
Conductors,
Ground
wire,
Insulators,
Hardware
fittings
&
Accessories
for
Conductor and Earth
wire.
Submission of Quality Assurance

Plan, approval of drawings.
3.
Dispatch
of
towers,
Conductors, Earth wire,
Insulators,
Hardware
fittings & Accessories for
Acceptance test and issue of test

certificate approval
Page 10 of 142
Volume-V (Part-1)
S.
No.
Activity
Items for which prior approval

is necessary from Employer
Conductor
wire.
and
Earth
4.
Foundation work.
Classification of foundation.
5.
Erection of tower
Quality Assurance Plan for erection.
6.
Stringing of Conductor
and Earth wire.
Stringing
method.
1.17
chart
RESPONSIBILITY FOR OBTAINING

AND TAKING ACTION IN TIME:
and
stringing
INFORMATION
Whenever any information or clarifications

in respect of
construction of line has to be obtained from various authorities, the
Contractor shall be responsible for taking action well in time so that
there are no delays on this account.
The completion period
specified in the bidding document is deemed to include the time
taken for such incidental works. Request for extension of the
completion date on such ground will not be entertained.
1.18
PERMITS AND PRIORITIES:
1.18.01 Necessary permits, if any, required for the execution of

the contract shall be arranged by the Contractor himself.
The
Contractor shall obtain the necessary license/permission as per
Central/State/local statutory bodies at his cost.
1.18.02 The Purchaser may, however, furnish to the Contractor
such certificates (on receipt of such written request from the
Contractor) as may be required for the necessary permits/priorities
for the execution of works, if it considers the demand as justified.
1.18.03 The Purchaser however, shall not be responsible for the
delay in execution of contract, if permits/priorities are not granted
in time in spite of issuance of such certificate.
1.19
WAY LEAVE:
The purchaser will arrange for necessary way leave and clearance of
trees. The Purchaser only will pay the way leave compensation along
the route.
The purchaser will also arrange for the following: (i)
(ii)
Railway clearance
PTCC clearance
Page 11 of 142
Volume-V (Part-1)
(iii) Forest clearance

(iv)
Any
other
required/requested.
necessary
clearance
if
The Contractor shall inform the purchaser about the places where
there is a way leave problem, sufficiently in advance (preferably 30
days) so that required way leave can be arranged in time.
1.20
USE OF PRIVATE ROADS/APPROACH ROAD TO SITE:
1.20.01 The purchaser will help in getting necessary permission

for use of private/forest/canal, roads for transportation of materials
and construction personnels, wherever possible under the rules. Any
charges/tole tax etc. levied by the concerned authorities for use of
such roads etc. shall be borne by the Contractor.
1.20.02 During the erection work, if approach roads are required to
be constructed for reaching the construction sites for transportation
of men/materials, the cost of construction of such approach roads
and any other expenses incurred in obtaining clearance/permission
shall be borne by the Contractor.
1.21
MATERIALS TO BE ARRANGED BY THE CONTRACTOR

FOR ERECTION WORK:
1.21.01 The supply of cement for foundation work would be

arranged by the Contractor of the quality as per IS - 269 :1989
(Ordinary Portland Cement 33 Grade) or
IS 8112 : 1987
(Ordinary Portland Cement 43 Grade) or IS 12269 : 1987
(Ordinary Portland Cement 53 Grade) or IS:1489 (PortlandPozzolana Cement (PPC)). The cost of cement shall be deemed to
be included in the quoted unit rates of concreting.
1.21.02 The cement used shall be procured from reputed
manufacturer like JP Cement, L&T, Birla Cement, ACC, Ambuja etc.
The Contractor shall submit the manufacturers certificate, for each
consignment of cement procured, to the Purchaser. The cement
shall be arranged in conventional Jute/HD bags each weighing 50
Kgs net with necessary IS certification mark on it. In case of any
dispute regarding quality of cement, sample for testing may be
taken jointly by contractors representative and Engineer in- charge
of work or any authorized representative of the Company. The
sample taken shall be tested for standard test as per IS code in
Govt. Engineering/Polytechnic College and testing charge shall be
borne by the contractor. In case the material is found defective i.e.
not as per relevant ISS, the same shall be replaced by the
Page 12 of 142
Volume-V (Part-1)
contractor at his cost. The Contractor shall also have no claim

towards suspension of work due to time taken in conducting tests in
the laboratory. Changing of brand or type of cement within the
same structure shall not be permitted without the prior approval of
the Purchaser.
1.21.03 The Quantity of cement to be used per unit quantity of
consumption for different mix (nominal mix) of concrete should be
as follows:
S.
No.
1
2
3
4
Description
Unit
1:1.5:3
nominal
mix
concrete
1:2:4
nominal mix
concrete
1:3:6
nominal mix
concrete
Random Rubble Masonry
with 1:6 cement mortar
Quantity of minimum
Cement to be used
per Unit quantity of
work(in kgs)
Cu.m.
400
Cu.m.
330
Cu.m.
220
Cu.m
83
1.21.04 The Contractor shall arrange

metal, sand, stone and
water
required for foundation/revetment work. The transport,
octroi, levy or duty on these materials shall be borne by the
Contractor himself and the purchaser will not accept any liability on
this account.
1.21.05 The Contractor will also arrange steel rods and binding
wires etc. for foundation, reinforcement and the cast incurred
will be borne by him. Materials for proper earthing of towers i.e.
earthing rod, connecting clamps and connecting wires etc. would
also be arranged by the Contractor as already specified.
***
Page 13 of 142
Volume-V (Part-1)
SECTION-2
TECHNICAL SPECIFICATION FOR SUPPLY OF TOWERS
2.01
INDIAN STANDARDS:
The 220kV & 132kV Double Circuit/ Multi circuit towers, their body
extensions, river/ line crossing structures (Gantries) under this
specification shall conform to the requirements of the latest
revisions and amendments available at the time of placement of
order of all the relevant Indian standards/codes listed here under or
equivalent International Standards, except as modified in this
document.
S.
No.
1
Indian standards or
equivalent
International
Standards
IS:209-1992
Title
Zinc ingot- Specification.
IS:278-1991
Galvanized Steel Barbed Wire.
IS:800-1991
Code of Practice for General Building

Construction in Steel.
IS:802-Part-II-1990
Code of practice for use of structural

steel in overhead transmission line.
Part-II
Fabrication,
Galvanising,
Inspection & packing.
IS 808 1991
Dimensions for Hot Rolled Steel

beam, Column, Channel and Angle
Sections.
IS:1363(Part-III)-1992
Specification for Hexagon head

bolts, screws and nut for product
grade C Hexagon nuts of
property class 5.
IS:1367-1992
Technical supply conditions for

threaded fasteners (1st Revision).
Mechanical properties and test

method for bolts, screws & studs
with full loadability.
IS:1367(Part-VI)-1994
Mechanical properties and test

method for nuts with specified proof
loads.
10
IS-1367(Part-XIII)-1983 The hot dip galvanized coating of

fasteners.
11
IS:1573-1991
Specification
for
electroplated
Page 14 of 142
Volume-V (Part-1)
S.
No.
Indian standards or
equivalent
International
Standards
Title
coating of zinc on Iron & steel.

12
IS:1586-1968
Methods of Rock well hardness test

(`B & `C scales) for steel (first
revision).
13
IS:1852-1991
Rolling and Cutting Tolerances of

Hot Rolled Steel Products.
14
IS:2016-1992
Plain Washers.
15
IS:2062-2006
Steel for general Structural purposes

Specification.
16
IS:2614-1969
Method for sampling of fasteners.
17
IS:2629-1990
Recommended practice for hot dip

galvanizing of iron and steel.
18
IS:2633-1992
Method of testing uniformity

coating of zinc coated articles.
19
IS:3063-1994
Single Coil Rectangular Section

spring washers for bolts, nuts, and
screws.
20
IS:3202-1972
Methods for testing local thickness

of electro plated coatings.
21
IS:3218(Part-V)-1979
Isometric screw threads Tolerance.
22
IS:3757-1992
High Strength Structural Bolts.
23
IS:4072-1975
Specification for steel

washers (first revision).
24
IS:4218(Part-VI)-1978
Isometric screw threads limits of

sizes for commercial bolts & nuts.
25
IS:4759-1990
Specification for Hot dip Zinc

coatings on Structural Steel and
other Allied products.
26
IS:5358-1969
Hot dip galvanized

fasteners.
27
IS:5369-1991
General Requirements
Washers.
28
IS:6610-1991
Specification for Heavy Washers for

Steel Structures.
29
IS:6623-1992
High Strength Structural Nuts.
for
spring
coatings
for
of
on
Plain
Page 15 of 142
Volume-V (Part-1)
30
Indian standards or
equivalent
International
Standards
IS:6745-1972
31
IS:6821-1973
Methods for sampling

threaded fasteners.
32
IS:8500-1992
Specification for weldable structural

steel (Medium & High Strength
Qualities).
33
IS:10238-1989
Step Bolts for Steel Structures.
34
IS:12427-1992
Specification for Transmission Tower

Bolts of property class 5.6
S.
No.
2.02
Title
Method for determination of weight

of zinc coating of zinc coated iron
and steel article.
of
non
TYPE OF TOWERS :
2.02.1
The towers will be double circuit, self-supporting lattice
type, designed for the specified loading conditions. The following
type of towers are required: (A) For 220kV Lines :i) Tower type B-0:
Tangent type tower with maximum line

deviation up to 2 to be used with
Single/Double
suspension
insulator
strings.
ii) Tower type B-30:
Medium angle tower to be used for line

deviation
from
0
to
30
with
Single/Double tension insulator strings.
iii) Tower type B-60:
Heavy angle tower to be used for line

deviation from 0 to 60 and also as
dead end tower with Single/Double
tension insulator strings.
iv) Gantry (type-AGT) Wherever necessary will also be

required
for
crossing
220/400kV
transmission lines.
(B) For 132kV Lines:i) Tower type ND-0:
Tangent type tower with maximum line

deviation up to 2 to be used with
Single/Double
suspension
insulator
strings.
Page 16 of 142
Volume-V (Part-1)
ii) Tower type ND-30: Medium angle tower to be used for line
deviation
from
0
to
30
with
iii) Tower type ND-60: Heavy angle tower to be used for line
deviation from 0 to 60 and also as
dead end tower with Single/Double
tension insulator strings.
iv) Gantry(type-3GO4):Wherever necessary will also be
required
for
crossing
132/220kV
transmission lines.
2.03
EXTENSIONS:
Suitable extension of 3M, 6M and 10M height will be supplied for

use with 220 kV towers. Similarly suitable extension of 3M, 5M and
7.5M and 10M height will be supplied for use with 132 kV towers.
2.04
TOWER TYPE JCT:
River crossing tower to be used across major river crossings with

Double suspension insulator strings.
2.05
220KV MULTI CIRCUIT TOWERS:
Wherever necessary, MC-0/MC-30/MC-60 type multi circuit towers

with 3/6/10 Meter extension may be required for transmission lines.
2.06
132KV MULTI CIRCUIT TOWERS:
Wherever necessary, MD-0/MD-15/MD-30/ MD60 132kV Multi circuit

Towers with 5M & 10M extension may be required for transmission
lines.
2.07
STUB SETTING TEMPLATES:
The Contractor will fabricate required number of adjustable stubsetting templates for each type of tower for carrying out the
foundation work. The templates will remain property of the
contractor.
2.08
PROCUREMENT OF STEEL AND ZINC:
The following provisions shall apply in connection

procurement of steel and zinc by the bidder:
with
the
2.08.1
The steel used for fabrication of tower parts, extensions,
templates etc. shall be mild steel of tested quality as per Indian
Standard 2062-1992 or equivalent International Standard.
2.08.2
The bidder should take into account the fabrication
wastage while quoting the rates. The Employer shall not accept any
Page 17 of 142
Volume-V (Part-1)
liability in connection with the actual wastage of steel during

fabrication or otherwise and no additional cost will be allowed on
this account.
2.08.3
Substitutions, if any, of steel sections of the tower parts
by higher size, due to their non-availability or otherwise shall be to
the Bidders account. The Employer shall not accept any liability on
this account.
2.08.4
The steel shall generally be procured from the Main
Steel Producers. However, sections not rolled/available from the
main producers, could be procured from re-rollers as per quality
conforming to Indian Standard, provided;
2.08.4.1
Re-rolling of structural steel sections is done from

billets/ingots of tested quality only.
2.08.4.2
Re-rolled sections are duly tested as per relevant Indian

Standard. It may however be noted that no additional
cost shall be payable towards procurement of steel
section from re-rollers.
2.08.5
The zinc used for galvanising of fabricated material shall
be Electrolytic High Grade Zinc (99.95% purity).
2.09
MATERIAL:
2.09.1
IS Steel Sections of tested quality in conformity with IS:
2062: 2006 grade E250 (Designated Yield Strength. 250 MPa) and/
or grade E350 (Designated Yield Strength 350 MPa) are to be used
in towers, extensions, stubs and stub setting templates. The
Contractor can use other equivalent grade of structural steel angle
sections and plates conforming to latest International Standards.
However, use of steel grade having designated yield strength more
than that of EN 10025 grade S355 JR/JO (designated yield strength
355 MPa) is not permitted, unless otherwise indicated in this
specification.
2.09.2
Steel plates below 6mm size exclusively used for
packing plates/packing washers produced as per IS: 1079 -1994
(Grade -0) are also acceptable. However, if below 6mm size plate
are used as load bearing plates viz gusset plates , joint splices etc.
the same shall conform to IS : 2062 or equivalent standard meeting
mechanical strength/metallurgical properties corresponding to grade
E250 or E350 (designated yield strength not more than 355MPa),
depending upon the type of grade incorporated into design. Flats of
equivalent grade meeting mechanical strength/ metallurgical
properties may also be used in place of plates for packing plates/
packing washers. The chequered plates shall conform to IS: 3502.
Page 18 of 142
Volume-V (Part-1)
SAILMA 350HI grade plate can also be accepted in place of HT

plates (EN 10025 grade S355 JR/JO / IS 2062:2006 grade 350, as
applicable) provide SAILMA 350HI grade plate meet all the
mechanical properties of plate as per EN 10025 grade S355 JR/JO
(designated yield strength 355 MPa) / IS 2062:2006 grade 350.
2.09.3
For designing of towers, preferably rationalised steel
section has been used. During execution of the project, if any
particular section is not available, the same shall be substituted by
higher section. Any cost on account of the same shall be borne by
the Contractor. However, design approval for such substitution shall
be obtained from the employere before any substitution and records
of such substitutions shall be maintained by the Contractor.
2.10
WEIGHTS:
The unit weight of each type of tower and extension including bolts
and nuts, accessories, attachments and step bolts is indicated in the
Bill of Materials which shall be supplied by the Employer to the
successful bidder. The weight of structure means the weight
calculated using black sectional (i.e. ungalvanised) weights of all
steel members of the sizes indicated in the fabrication drawings
without taking into consideration the reduction in weight due to
drilling of bolts, holes, skew cuts, chamfering etc. or increase in
weight due to galvanising.
2.11
GALVANISING:
2.11.1
The tower parts, stubs and pack washers shall be hot
dip galvanized.
The galvanization shall be done as per
requirements of IS 4759 after all fabrication work is completed.
The contractor shall also take guidelines from the recommended
practices for hot dip galvanizing laid down in IS 2629 while deciding
and implementing galvanizing procedure.
The mandatory
requirements however, are specified herein.
2.11.2
Unless otherwise specified the fabricated tower parts
and stubs shall have a minimum overall zinc coating of 610 gms per
sq.m. of surface except for plates below 5mm which shall have Zinc
coating of 460 gms per sq.m of surface. The average zinc coating
for sections 5mm & above shall be maintained as 87 microns and
that for sections below 5mm shall be maintained as 65 microns.
2.11.3
The zinc coating shall be adherent, reasonably uniform,
smooth, continuous and free from imperfections such as black/bare
spots, ash rust strains, bulky white deposits/wet storage strains and
blisters.
Page 19 of 142
Volume-V (Part-1)
2.11.4
The surface preparation for fabricated tower parts and
stubs for hot dip galvanizing shall be carried out a indicated herein
below:
(i)
Degreasing & Cleaning of Surface: Degreasing and cleaning

of surface, wherever required, shall be carried out in
accordance with clause 4.1 of IS 2629-1990.
After
degreasing the article shall be thoroughly rinsed. However, if
acidic degreasers are used rinsing is not required.
(ii)
Pickling: pickling shall be done using either hydrochloric or

sulphuric acid as recommended at clause 4.3 of IS 26291990. The actual concentration of the acids and the time
duration of immersion shall be determined by the Contractor
depending on the nature of material to be pickled. Suitable
inhibitors also shall be used with the acids to avoid over
pickling.
The acid concentration, inhibitors used, and
maximum allowable iron content shall form part of plant
standard to be formulated and submitted to Employer along
with Quality Assurance Program.
(iii)
Rinsing:
After pickling, the material shall be rinsed,
preferably in running water to remove acid traces, iron
particles or any other impurities from the surface. Two rinse
tanks are preferable, with water cascading from the second
tank to the first to ensure thorough cleaning. Wherever single
tank is employed, the water shall be periodically changed to
avoid acid contamination, and removal of other residue from
the tank.
(iv)
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.
(v)
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
Page 20 of 142
Volume-V (Part-1)
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.
(vi)
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 aluminium alloy
shall be added as per IS 2629.
(vii) 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 10C. 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.
(viii) 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 while rust attack. The temperature of the chromate
solution shall not exceed 65C. 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.
(ix)
Storing, Picking and Handling: In order to prevent while rust

formation sufficient care should be exercised while storing
Page 21 of 142
Volume-V (Part-1)
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.
(x)
The Contractor shall prepare a detailed galvanizing procedure

including Flow Chart with control parameters and all plant
standards as required above and submit to Employer for
acceptance as part of Quality Assurance Plan.
(xi)
Minor defects in hot-dip galvanised members supplied at site

shall be repaired by applying zinc rich primer and two coats of
enamel paint to the satisfaction of the employer before
erection, after obtaining specific permission from Employer.
2.12
GALVANISED BOLTS, NUTS AND WASHERS:
2.12.1
The bolts and nuts to be supplied shall be mild steel hot
dip galvanized bolts (5.6 quality) and nuts (5.0 quality). The spring
washers are to be supplied for insertion under all nuts. These
washers shall be of steel, electro galvanized, and positive lock type
and of 3.5mm thickness. Bolt heads and nuts shall be of hexagonal
shape.
2.12.2
The nuts shall be forged and tapped after galvanizing
and then lubricated. The nuts shall be chamfered on one face only;
the other face shall be machined.
2.12.3
The bolts of 16mm size shall be manufactured by
cold/hot forging process and the threads shall be rolled.
2.12.4
The bolts and nuts shall be free from forging and
threading defects such as cuts, splits, burrs, bulging, taper,
eccentricity, loose fit etc.
2.12.5
The bolts shall be threaded up to standard length only
as per relevant Indian Standard and not to full length.
2.12.6
The bolts and nuts shall conform to Indian
Standard1367:
1991
Part-III
and
Part-IV,
Indian
Standard12427:1992, Indian Standard1363-1992, Indian Standard
1367 (Part-XIII)-1983 with latest amendment or equivalent
International Standards.
2.12.7
The spring washers designated as M 16-B suitable for
16mm dia galvanized bolt shall be manufactured out of rectangular
section with tolerances as per Indian Standard 3063-1994
with latest amendments or equivalent International Standard. The
Page 22 of 142
Volume-V (Part-1)
spring steel shall conform to Indian Standard:4072-1975 with latest

amendments "Specification for steel for spring washers" or
equivalent International Standard.
2.12.8
The spring washers after coiling shall be suitably heattreated to obtain finished washer having hardness 43 to 50 HRC
when tested in accordance with Indian Standard 1586- 1968 or
2.12.9
The surface of the washers shall be free of scales and
burrs. The washers shall be coiled without any kinks (except for the
shape with turned-up ends). The ends of the washer shall not abut
when the washers are compressed. The ends shall be so served as
to prevent tangling.
2.12.10
The approximate weight of 1000 pieces of spring
washers suitable for 16mm dia bolt shall be 8.91 kg. in natural
black finish as shown in Indian Standard 3063-1994 with latest
amendments or equivalent International Standard.
2.12.11
The spring washer shall be electro galvanized with
chromate passivation. The electro galvanizing of washers should
conform to severe grading service conditions incorporated in
Indian Standard 1573: 1991 or equivalent International Standard as
"Service Grade No.4", classification Fe Zn 25. The thickness of zinc
coating should be minimum 25 microns and average thickness 38
microns. It should be further suitably heat-treated to avoid any
danger of hydrogen embrittlement.
2.13
STEP BOLTS :
Each tower will be provided, on one of the legs, with step-bolts of

16mm dia and 175mm long, spaced not more than 450mm and
extending from 3 meters above ground level up to the top portion of
the tower. The step bolts shall conform to Indian Standard13631992, Indian Standard10238:1989 and Indian Standard 1367(PartXIII):1983 or equivalent International Standards.
2.14
DANGER BOARD, NUMBER PLATE AND PHASE PLATES :
Each tower will be fitted with danger board, number plate and
phase plates. The tower to be supplied shall have provision to fix
these plates at a height of about 3 meters above ground level.
Necessary provision in tower & extensions for fixing of these items
shall be made. The Danger board, number plate and phase plates
shall be supplied conforming to following technical details:2.14.1
The danger boards shall conform to IS-2551-1982 and
their revision, if any except where modified in this specification.
Page 23 of 142
Volume-V (Part-1)
2.14.2
The danger boards, number plates and phase plates
shall conform to the drawings enclosed in this specification.
2.14.3
The colour scheme of the enamel and size of figures and
dimensions of lettering shall be as shown in the drawing as also the
overall size. The holes as indicated in the drawing shall be provided
before enamellings.
2.14.4
The thickness of the plate out of which the danger
board, number plate and phase plate will be manufactured, shall not
be less than 1.6mm.
2.14.5
The enamellings shall be done by vitreous enameling
process only.
2.14.6
All letterings shall be centrally spaced. The dimensions
of the letters, figures and their respective positions shall be as given
in drawings. The size of each letter in the word in each language
and the spacing between them for the purpose of scribing shall be
so chosen that they are uniformly written in the space earmarked
for them.
2.14.7
The corners of the plate shall be rounded off. The
location of the fixing holes shall be according to drawing annexed
with this specification.
2.14.8
The plate shall be made from mild steel at least 1.6mm
thick and vitreous enameled white, with letters, figures and the
conventional skull and cross-bones in signal red colour on the front
side. The rear side of the plate shall also be enameled.
2.15
ANTICLIMBING DEVICE WITH BARBED WIRE :
The barbed wire type anti-climbing device shall be supplied for use
at a height of approximately 3 meters as an anti-climbing deterrent
measure, as per the details given in Indian Standard: 5613(Part2/Sec-I) 1985 or equivalent International Standard. The angle
pieces with notches for accommodating barbed wire shall be used
for this purpose. The towers to be supplied by the Bidder shall
have provision of suitable bolt holes on leg members for fitting the
angles to fix the barbed wire as indicated above. The details of anticlimbing device are indicated in drawing enclosed in Annexure-8.
The requirement of angle pieces with notches and barbed wire (per
set) will be as under:(A) For 220kV Towers:Angle pieces
Bolts & nuts
Barbed wire
23.57 Kgs.
3.41 Kgs.
25.00 Kgs.
Page 24 of 142
Volume-V (Part-1)
(B) For 132kV Towers:Angle pieces

Bolts & nuts
Barbed wire
2.16
24.34 Kgs.
2.00 Kgs.
20.00 Kgs.
EARTHING :
2.16.1
A provision shall be made in all stubs for fixing earthing
material. The stub will be provided with a hole at a distance of 250
mm from bottom end and at a distance of 500 mm below ground
level for connection with earthing materials. The hole will be of 17.5
mm dia.
2.16.2
The Bidder shall also supply and erect the following
materials per earthing set for earthing of towers (four sets per
tower): (i)
One no. Hot dip galvanized earthing Mild Steel Rod (2 Meter
long, 25 mm diameter):
(ii)
Hot dip galvanized connecting clamps (`F type and Ù type2 No. per set);
(iii) Hot dip galvanized stranded steel wire of size 7/4mm, Grade
5 to be used as connecting wire conforming to Indian
Standard: 2141:1992 and Indian Standard 4826: 1979 or
equivalent International Standard (5 Meter per earthing set).
2.16.3
The details of earthing rod and clamps and earthing
arrangement for towers are shown in the drawing enclosed.
2.16.4
The earthing rod shall be of mild steel solid rod of 2
meters in length and 25mm in diameter with one end pointed. The
rods shall be galvanized as per relevant Indian Standard or
equivalent International Standard. The zinc coating on the rod shall
not be less than 610 gm/m of surface area.
2.16.5
The tower end-connecting clamp shall be of flat type
and rod end connecting clamp shall be of Ù type. The clamps
shall be of forged steel cast iron / malleable iron. The clamps should
be hot dip galvanized as per Indian Standard: 2629:1990 or
equivalent International Standard. The zinc coating on the clamps
shall not be less than 610 gm/m of surface area.
2.16.6
The hot dip galvanized stranded steel wire of size
7/4.00mm shall be supplied for connection between the earthing
rod and the stub. The steel wire shall conform to Indian Standard
2141: 1992 or equivalent International Standard and Indian
Page 25 of 142
Volume-V (Part-1)
Standard:4826: 1979 and latest revision thereof or equivalent

International Standard and shall consist of seven strands,
each strand having a diameter of 4 mm and Grade-5. The
galvanizing shall be done as per Indian Standard specification2141:
1992 or equivalent International Standard and 4826: 1979 and
latest revision thereof or equivalent International Standard for
heavy zinc coating. The coating of zinc shall not be less than 260
gm/m.
2.17
ATTACHMENT FOR INSULATOR STRING & EARTH WIRE

CLAMPS:
2.17.1
The towers shall be provided with suitable attachment
for supporting insulator strings and Earth wire suspension and
tension assembly.
2.17.2
The towers shall be provided with the cleats to support
the hanger.
2.17.3
shackle.
same.
The Earth wire suspension assembly has got a D

There shall be a suitable arrangement to support the
2.17.4
On angle towers, strain plates shall be provided for the
purpose of attaching the tension insulator string. For fixing Earth
wire tension assembly a hole 17.5mm dia shall be provided in the
strain plate.
2.18
FABRICATION WORKMANSHIP :
2.18.1
Except where hereinafter modified, details
of
fabrication shall conform to Indian Standard-802 (Part-II)-1990 or
2.18.2
The fabrication of towers shall be done strictly in
accordance with the drawings supplied by the Employer.
2.18.3
The tower shall be of bolted construction.
2.18.4
Normally
lap splice shall be used for connecting
members of un-equal size and the inside angles of lap splice shall
be rounded at the heel to fit the fillet of the outside angle.
All splices shall develop full stress in the members connected
through bolts. Butt joint as well as lap joint splices shall be made as
above and as close to the main panel as possible.
2.18.5
Joints shall be designed and detailed to avoid
eccentricity as far as possible. The use of gusset plates for joining
tower members shall be avoided as far as possible. However, where
the connections are such that the eliminations of the gusset plates
Page 26 of 142
Volume-V (Part-1)
would result in eccentric joints, gusset plates and spacer plates may
be used in conformity with modern practice.
2.18.6
The tower structures shall be accurately fabricated to
bolt together easily at site without any undue strain on the bolts.
2.18.7
No angle member shall have two leg flanges brought
together by closing the angle.
2.18.8
The diameter of the hole shall be equal to the diameter
of the bolt plus 1.5 mm.
2.18.9
All
similar
parts shall
be
made
strictly
interchangeable. All steel section before any work is done on them
shall be carefully leveled, straightened and made true to detailed
drawings by methods which will not damage the materials so that
when assembled the adjacent matching surfaces are in close
contact throughout. No rough edges shall be permitted in the entire
structures. Hammering is not permitted for straightening.
2.18.10
Cutting may be done by shearing, cropping, flame
cutting or sawing. The surface so cut shall be cleaned smooth,
reasonably square and free from deformation and distortion.
2.19
BENDING :
2.19.1
Mild steel angle sections up to 75x75 mm (up to 6mm
thick) shall bent cold up to and including bend angle of 10 Angles.
Above 75x75mm (thickness up to 6mm) and up to and including
100x100 mm (thickness up to 8 mm) may also be bent cold up to
the bend angle of 5 Deg. All other angle sections and bend angles
not covered above shall be bent hot.
2.19.2
All plates up to 12mm thickness shall be bent cold up to
a maximum bend angle of 15 Deg. Plates of thickness more than
12mm with bends greater than 15 Degree shall be bent hot.
2.19.3
All hot bend material shall be air-cooled. The bends
shall be of even profile and free from any surface damages.
2.20
DRILLING AND PUNCHING :
2.20.1
The holes in the member shall either be drilled or
punched with a jig; the former process will be preferred.
2.20.2
Punching may be adopted for sections upto 12 mm
thickness. For thicker sections drilling shall be done.
2.20.3
The holes
shall
be
punched/drilled after bending
and related position of these holes shall be maintained with the use
of proper templates/jigs and fixtures.
Page 27 of 142
Volume-V (Part-1)
2.20.4
The holes shall be perfectly circular and no tolerance in
this respect is permissible. The holes shall be perpendicular to
the plate and angle flanges.
2.20.5
Holes must be square with the plates or angles and
have their walls parallel.
2.20.6
All burrs left by drills or punch shall be removed
completely. When the tower members are in positions, the holes
shall be truly opposite to each other. Drilling or ramming
to enlarge defective holes shall not be permitted.
2.20.7
The minimum spacing of bolt and edge distance shall be
as under: -
2.21
(a)
For 16 mm dia bolt edge distance of 20 mm from hole

center to rolled or swaned edge and 23mm from hole
center to sheared or flame cut edge, hole center to hole
center distance minimum 40mm (the hole size being
17.5mm).
(b)
The gap
between
the
edges
of the connected
members in butt joint shall not be more than 6mm and
less than 4mm.
(c)
The
bolt gauge distance in flanges of
angle
sections shall generally
be in
accordance with
Table XXXI of SF6
(1)-1961-ISI
Hand
Book
for
structural
Engineers-Structural
Steel
Sections
(Revised).
TOLERANCES :
2.21.1 The maximum allowable difference in the diameter of the

hole on the two sides of the plate or angle shall not exceed 0.8 mm
on diameter. The allowable taper in drilled/punched hole shall not
exceed 0.8 mm on diameter.
2.21.2
The tolerance cumulative or between consecutive holes
shall be within +/-0.5mm.
2.21.3
The tolerance on the overall length of member shall be
within +/- 1.6 mm.
2.21.4
0.5mm.
The tolerance on gauge distance shall be within +/-
2.21.5
Rolling and weight tolerance of steel sections shall be as
per Indian Standard: 1852 or equivalent International Standard and
Indian Standard: 808 or equivalent International Standard.
Page 28 of 142
Volume-V (Part-1)
2.22
MARKING :
Every member shall be distinctly given punch mark similar to those

given in structural drawings. The mark shall be given with marking
dies of minimum 18 mm size and this mark shall be legible. Letter
XMPTBA, XMPTBB and XMPTBC for 220kV and XMPTNA,
XMPTNB and XMPTNC for 132kV shall precede erection mark where
X stands for manufacturers name, MPT stands for Madhya
Pradesh Power Transmission Company and BA, BB & BC stands for
B0, B30 & B60 type towers and NA, NB & NC stands for ND0, ND30
& ND60 type towers respectively.
2.23
QUALITY ASSURANCE PROGRAM :
The contractor shall submit the Quality Assurance Programme as

specified in clause 1.12 Section-1 of the biding document. A copy of
the accepted Quality Assurance Plan must be available at the
manufacturers works of the Plant for reviewing by inspecting officer
of the employer.
2.24
INSPECTION OF PROTOTYPES :
2.24.1
Proto type of each type of structure/extensions shall be
offered by the successful bidder for inspection within three months
time from the date of contract.
2.24.2
Notwithstanding any thing covered in the drawings and
other details furnished by the Employer, the successful bidder shall
make minor modifications, if any, in length, size, notching etc.
according to the proto assembly which are necessary for easy
assembly of the structure.
2.25
INSPECTION :
2.25.1
As specified in clause 1.13 Section-1 of the biding
document, Plant to be supplied will be subject to inspection and
approval by the Employer's representative before despatch.
2.25.2
Each consignment ready for transportation shall be
offered to the Employer for inspection before dispatch giving a
minimum time of not less than fifteen days. Only complete sets of
towers/extensions shall be offered for inspection. All materials
constituting towers (Steel parts, Bolts & nuts, spring and pack
washers, earthing sets) shall be offered simultaneously. Samples of
fabricated tower materials and accessories shall be subjected to
tests as per relevant Indian Standard or equivalent International
Standard. The Employer shall be kept informed about the source of
procurement of raw-steel, particularly through re-rollers.
The
Employer reserves right to inspect and get the samples of raw-steel
tested as per Indian Standard-2062 and relevant standards or
Page 29 of 142
Volume-V (Part-1)

borne by the bidder.
The cost of testing shall be
2.25.3
The Contractor shall keep the Employer informed in
advance of the time of starting and of the progress of manufacture
and fabrication of structures at various stages.
2.25.4
In case, any member of the structure is not found to
comply with the relevant drawing, it shall be liable for rejection
even after receipt.
2.25.5
Defects, which may appear during fabrication, shall be
made good. Any member once rejected shall be cut into pieces in
front of the Employers representative so that it is not offered again
by mistake.
2.26
GENERAL GUIDE-LINE FOR INSPECTION :
2.26.1
Fabricated Structure Members :

(i)
Visual examination and quantity verification of offered

lot.
(ii)
Sample selection from the offered lot at a ratio of 40

MT (or part thereof) 1 no. each for all tests.
(iii)
Dimension, fabrication and trueness verification of

structure member from fabrication sketch.
(iv)
Galvanising test of each sample i.e. dip test, hammer

test and mass of zinc test.
(v)
Random verification of Zinc coating of galvanized

surface by Alko-meter.
(vi)
Tensile test and bend test of each sample.
(vii) Chemical composition test of at least two samples per

offered lot of 50 MT for inspection.
(viii) Verification of manufacturers test certificate for mild
steel used in structure members.
2.26.2
Bolts-Nuts, Washer, Accessories, Attachments etc.: (To
be carried out at manufacturers works of these items)
(i)
Visual examination and quantity verification of offered

lot.
(ii)
Sample selection from the offered lot as per relevant

Indian Standard for each item.
(iii) Dimension, fabrication and trueness verification from

fabrication sketch.
(iv) Galvanising test of each sample.
Page 30 of 142
Volume-V (Part-1)
(v)
Other acceptance tests for respective items as per

relevant Indian standard.
2.26.3
The supplier shall submit the factory test certificates of
bought out accessories at the time of acceptance tests of towers.
2.26.4
Since at the time of inspection only fabricated tower
members and accessories will be verified, acceptance of any lot
shall in no way relieve the bidder of his responsibility to meet all
technical requirements of this specification for fabricated towers. In
case any shortcoming is noticed at the time of actual assembly and
erection, the Employer may reject any part or item or accessory and
the contractor will have to assume the responsibility for free
2.27
PACKING AND MARKING ON PACKING :
2.27.1
The material shall be boxed or bundled for transport in
the following manner:
(i) Angle shall be packed in bundles securely wrapped four times
around at each end and over 900 mm with No.9 SWG steel
wire with ends twisted tightly. Gross weight of any bundle
shall not be less than 450 Kg and more than 2000 Kg. The
bundle shall be in complete Tower form only.
(ii) Cleat angles, brackets, filler plates and similar small loose
pieces shall be nested and bolted together through holes and
wrapped around at least four times with No.9 SWG wire with
ends twisted tightly or packed in wooden crates. Gross
weight of each bundle shall not exceed 200 Kg.
(iii) Correct number of bolts, nuts and washers required for
structures shall be packed in heavy gunny bags accurately
tagged in accordance with the contents and a number of
bags packed in a solid box of 22mm thick lumber with
paneled ends to be accurately nailed and further reinforced
with 22 mm x 75 mm Batons round the sides and at the ends
with 25 mm x No.18 SWG iron band stretched entirely
around the batons with ends overlapping at least 150mm.
Gross weight of each box shall not exceed 200 Kg.
(iv) Packing list incorporating all relevant details e.g. quantity of
structures (complete sets), number and size of steel
sections, quantity of nuts, bolts, washers etc.
shall be
forwarded along with each consignment.
(v) In the nutshell the packing arrangement should be such that
all lots of one particular type of structure are identifiable at
site for the purpose of allocation for a particular work. In
case more than one structure of a particular type is delivered
Page 31 of 142
Volume-V (Part-1)
in area store/work site, combined packing arrangement by

way of clubbing members of similar type (for more than one
structure) in a combined package should not be done.
Uniform packing procedure for each structure should be
adopted.
2.27.2
All above packing are subject to the approval of the
Employer or his appointed representatives.
2.27.3
Each bundle or packing shall have the following marks:
(i) The name of the consignee (as per dispatch instructions

given by the Employer).
(ii) Ultimate destination as required by the Employer.
(iii) The relevant marks and number of structure members or
reference or bolts, nuts and small components like gusset
plats, various attachment, etc. for easy identification.
2.27.4
The marking shall be stenciled and indelibly inked on
the top members in the bundles, on wooden boxes and also on
gunny bas containing smaller components.
Page 32 of 142
Volume-V (Part-1)
SECTION-3
TECHNICAL SPECIFICATIONS FOR CONDUCTOR
3.01
STANDARDS:
This section provides for standard design, manufacture, stage

testing, inspection and testing before despatch, packing and
delivery of Steel Cored Aluminium Conductors specified hereunder
for their satisfactory operation. The power conductors shall conform
to the following Indian Standards, which shall mean latest revisions,
amendments/changes adopted and published, unless otherwise
specified hereinbefore:
Sr.
No.
Title
Indian Standards
or any Equivalent
International
Standard
1
2
Specification for Zinc

IS:209 -1990
for
IS:398 Part I to Part Specification
Conductors
for
V
Transmission purpose
(as relevant)
IS:1778
Reels and drums for Bare wires
IS:1521
IS:2629 -1990
Method of Tensile Testing of Steel

wire
Recommended practice for Hot Dip
Galvanising Iron and Steel
IS:2633 -1990
Method of Testing Uniformity of

Zinc coating of Zinc coated
Articles.
IS:4826
IS:6745 -1990
Galvanised coating on Round Steel

wire
Method of Determination of weight
of Zinc coating of zinc coated Iron
and Steel Articles
IS:8263
Method of Radio Interference Tests
10
IS:1841
EC Grade Aluminium Rod produced

by rolling
11
IS:5484
EC grade Aluminium Rod produced

by continuous casting and rolling
12
IS: 2141 -1990
Method of Elongation test of steel

wire
Aluminium
overhead
Page 33 of 142
Volume-V (Part-1)
3.02
PARAMETERS :
Sr. No.
Details of Stranded
Conductor
ACSR
Zebra
ACSR
Panther
3.02.01 Principal Parameters of Stranded Conductor:
i. Steel Centre
Aluminium54
Steel 7
1
Aluminium30
Steel-7
1
ii. 1st Steel Layer
iii. 1st Aluminium Layer
12
12
iv. 2nd Aluminium Layer
18
18
v. 3rd Aluminium Layer
24
a)
No. of Strands
b)
Sectional Area of Aluminium

(Sq.mm)
428.9
212.10
c)
Total Sectional Area (Sq.mm)
484.50
261.60
d)
Overall diameter(mm)
28.62
21.00
e)
Approximate weight (Kg/Km )
1621
976
f)
Calculated D.C. Resistance at

20 Deg.C (Ohm/Km)
0.06915
0.139
g)
Minimum UTS (kN)
130.32
89.67
h)
Modulus
GN/SqMtr
69
80
of
Elasticity
3.02.02 The details of Aluminium Strand are as follows :

a)
Minimum breaking load of

strand Before stranding (kN)
1.29
1.17
b)
Minimum breaking
load of
strand after stranding (kN)
1.23
1.11
c)
Maximum D.C. resistance of

strand at 20 deg.C (Ohm/Km)
3.651
4.107
d)
Nominal Strand Dia
3.18
3.00
e)
Max. Strand Dia
3.21
3.03
f)
Min. Strand Dia
3.18
3.00
Page 34 of 142
Volume-V (Part-1)
g)
Mass (Kg/Km) of
Nominal dia
Strand at
21.47
19.11
3.02.03 The details of Steel Strand are as follows:

a)
Minimum breaking load of

strand Before stranding (kN)
10.43
9.29
b)
Minimum breaking
load of
strand after stranding (kN)
9.91
8.83
c)
Nominal Strand Dia
3.18
3.00
d)
Maximum Strand Dia
3.24
3.06
e)
Minimum Strand Dia
3.18
3.00
f)
Mass (Kg/Km) of
Nom. dia
61.95
55.18
g)
Zinc coating testing
h)
Wt. Of Zinc Coating
3 dips of 1
min. each
260gms/sq.
metre
3 dips of 1
min.each
260gms/sq.
Metre
3.03
Strand at
GENERAL TECHNICAL REQUIREMENTS : MATERIAL

AND WORKMANSHIP (FOR ACSR ZEBRA & ACSR
PANTHER):
3.03.01 Materials:
The conductors shall be manufactured from EC grade aluminium
rods suitably hard-drawn on wire drawing machines. The aluminium
rods used shall comply with IS: 1841 and IS: 5484 or any
equivalent International Standard. The mechanical and electrical
properties of aluminium wire shall comply with the requirements
given in relevant standard.
3.03.02 Physical constants for Hard-drawn Aluminium:
3.03.02.1 Resistivity:
The resistivity of aluminium depends upon its purity and its physical
condition. For the purpose of this specification the maximum value
permitted is 0.28264 Ohm sq.mm/mt. at 20 C and this value has
been used for calculation of the maximum permissible value of
resistance.
NOTE: It is not intended to check the resistivity from the measured
values of resistance.
Page 35 of 142
Volume-V (Part-1)
3.03.02.2 Density:
At a temperature of 20 C the density of hard drawn aluminium has
been taken as 2.703 g/cm.3
3.03.02.3 Constant-Mass Temperature Co-efficient of
Resistance:
At a temperature of 20C, the constant-mass temperature coefficient of resistance of hard drawn aluminium measured between
two potential points rigidly fixed to the wire, the metal being
allowed to expand freely, has been taken as 0.004 per degree
Celsius.
3.03.02.4 Co-efficient of Linear Expansion:
The co-efficient of linear expansion of hard-drawn aluminium at 0
C has been taken as 23.0 x 10 -6 per C. This value holds good for
all practical purposes over the range of temperature from 0 C to
highest safe operating temperature.
3.03.03
Galvanised steel wire shall be drawn from high carbon
steel rods produced by either acidic or basic open hearth process,
electric furnace process or basic oxygen process. The mechanical
and electrical properties of wire shall comply with the requirements
given in relevant standard. The chemical composition of high carbon
steel wires is given below for guidance only.
Element Percentage Composition
Carbon
0.5 to 0.85
Maganese 0.50 to 1.10
Phosphorous Not more than 0.035
Sulphur
Not more than 0.045
Silicon
0.10 to 0.35
3.03.03.1 Physical constants for Galvanised steel wires:
3.03.03.1.1
Density :
At a temperature of 20 C, the density of galvanized steel wire is to

be taken as 7.80 g/Cm3.
3.03.03.1.2
Coefficient of Linear Expansion :
In order to obtain uniformity in calculation a value of 11.5 x 10 -6

per C may be taken as the value for the co-efficient of Linear
Expansion of galvanized steel wires used for the cores of steelreinforced aluminium conductors.
3.03.03.1.3
The zinc used for galvanizing shall be electrolytic
high-grade Zinc not less than 99.95 percent purity. It shall conform
to and satisfy all the requirements of IS: 209. Galvanising may be
Page 36 of 142
Volume-V (Part-1)
done either by hot process or electrolytic process. Minimum weight

of Zinc coating shall be 260 g/sq. metre. Neutral grease may be
applied between the layers of wire.
3.03.03.1.4
Freedom From Defects:
The wires shall be smooth and free from all imperfections such as
spills, slag inclusion, die marks, scratches, fittings, blow-holes,
projections, looseness, overlapping of strands, chipping of
aluminium layers etc. and all such other defects which may hamper
the mechanical and electrical properties of the conductor. Special
care should be taken to keep away dirt, grit etc. during stranding.
3.04
Wire Sizes
3.04.01
Nominal Size:
The aluminium and galvanized steel wires for the stranded

conductor covered by this standard shall have diameters specified in
clause 3.02.02 & 3.02.03. The diameter of the steel wires shall be
measured over the zinc coating.
3.04.02 Tolerances on Nominal Size :
Tolerance of + 1% is permitted on the nominal diameter of
Aluminium Wires of Panther and Zebra Conductor and a tolerance
of + 2 % is permitted on the nominal diameter of Galvanised Steel
Core Wire.
3.05
JOINTS IN WIRES:
3.05.01 Aluminium Wires:

No joints shall be permitted in the aluminium wires in the outermost
layer of the ACSR Conductor. Joints in the inner layers are
permitted, in addition to those made in the base rod or wire before
final drawing, but no two such joints shall be less than 15 mtr.
apart in the complete stranded conductor. Such joints shall be made
only by cold pressure butt-welding. It may please be noted that
Joints are not permitted in the outermost layer of the conductor in
order to ensure a smooth conductor finish and reduce radio
interference levels and corona losses on extra high voltage lines.
3.05.02 Galvanised Steel Wires:
There shall be no joints except those made in the base rods or wires
before final drawing, in steel wires forming the core of the steelreinforced aluminium conductor. Joints are not permitted in the
steel wires after final drawing also in order to avoid reduction in the
breaking strength of the conductor that may occur as a result of
failure of the joints.
Page 37 of 142
Volume-V (Part-1)
3.06
STRANDING :
3.06.01 The wires used in the construction of galvanized steel

reinforced aluminium conductor, before stranding, shall satisfy all
the relevant requirements of this specification.
3.06.02 The lay ratio of the different layers shall be within the
limits given in the Table below:Type of
conductor
Ratio of
Lay
Alu. wire Ratios of
diameter
Steel
to steel
core 6
wire
wire
diameter
layer
Panther
1
AL -30 Wire
ST. - 7 Wire
Zebra
1
AL -54 Wire
ST. - 7 Wire
Lay Ratios for Aluminium

wires (3 Alu. Wire Layer
Conductors)
Layer
Innermo
Outermo
immediat
st Layer
st layer
ely
beneath
outer
most
layer
Min
.
Max
.
Min
.
Max
.
Min.
Max Min
.
.
Max
.
13
28
10
14
10
16
13
28
10
14
10
16
10
17
NOTE : For the purpose of calculation, the mean lay ratio

shall be taken as the arithmetic mean of the relevant
minimum and maximum values given in this table.
3.06.03 In all constructions, the successive layers shall have
opposite directions of lay, the outermost layer being right-handed.
The wires in each layer shall be evenly and closely stranded.
3.06.04 In conductors having multiple layers of aluminium wires,
the lay ratio of any aluminium layer shall not be greater than the
lay ratio of the aluminium layer immediately beneath it.
3.06.05 The finished Conductor shall have a smooth surface
without any surface cut, abrasion, scuff marks and shall be free
from dirt, grit, etc. even if the damage to conductor is acceptable
from mechanical considerations. It will not be acceptable from
electrical considerations, and full care should be taken not to supply
damaged conductor. Projections of more than 2 mils shall not be
acceptable. Any such damage shall be properly rectified or new
conductor supplied.
Page 38 of 142
Volume-V (Part-1)
3.06.06 Failure of any sample to meet the above requirements shall

be sufficient cause for rejection of the lengths of conductor
represented by the sample. Particular care shall, therefore, be taken
during manufacture, handling, packing and transportation of the
conductor, to see that the surface is not dented, cut or damaged in
any way.
3.07
STANDARD LENGTH :
3.07.01 The standard length of conductor shall be 1500 metres. A

tolerance of +/-5% on the standard length offered by the
Contractor shall be permitted. All lengths outside this limit of
tolerance shall be treated as random lengths.
3.07.02 Contractor shall also indicate the maximum single length,
above the standard length, they can manufacture. This is required
for special stretches like river crossing etc.
3.08
GALVANISING:
3.08.01 All the wires of Iron & steel strand shall be galvanized in
accordance with IS-2629-1990. Recommended practice for hot dip
galvanizing of Iron and Steel or some other authoritative equivalent
standard.
3.09
TESTS :
3.09.01 The conductor 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.
3.09.02 Acceptance tests shall mean those tests, which are to be
carried out on samples taken from each lot offered for pre-despatch
inspection, for the purpose of acceptance of that lot.
3.09.03 Routine tests shall mean those tests which are to be
carried out on each strand/spool/length of the conductor to check
requirements which are likely to vary during production.
3.09.04 Tests during manufacture shall mean those tests, which
are to be carried out during the process of manufacture and end
inspection by the Contractor to ensure the desired quality of the end
product to be supplied by him.
3.09.05 The norms and procedure of sampling for these tests will
be as per the Quality Assurance Programme to be mutually agreed
to by the Contractor and the Employer.
3.09.06 The standards to which these tests will be carried out are
listed in para 3.01. Where a particular test is a specific requirement
of this specification, the norms and procedures of the test shall be
as mutually agreed to between the Contractor and the Employer in
the Quality Assurance Programme.
Page 39 of 142
Volume-V (Part-1)
3.09.07 For all type and acceptance tests, the acceptance values
shall be the values guaranteed by the Contractor in the Technical
Questionnaire or the acceptance value specified in this
specification, whichever is more stringent for that particular test.
3.09.08 Type Tests :
The Conductor offered shall be fully type tested for the following
tests as per the relevant International/Indian Standard and the
bidder shall furnish the report along with the offer.
a)
UTS test on stranded conductor
b) DC resistance test on stranded conductor

c)
Stress-strain test on composite conductor
3.09.09 Acceptance Tests :

a) Visual and dimensional check
b) Visual check for joints, scratches etc. and lengths of
conductor
c) Dimensional check on steel and aluminium strands
d) Check for lay ratios of various layers
e) Galvanising test on steel strands
f)
Torsion and Elongation test on steel wire
g) Breaking load test on steel and aluminium strands

h) Wrap test on steel and aluminium strands
i)
DC resistance test on aluminium strands
j)
UTS test on welded joint of aluminium strand
NOTE: All the above tests except test mentioned at (j) shall be
carried out on aluminium and steel strands after stranding
only.
3.09.10 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 specifications.
d)
All acceptance tests as mentioned in Clause 3.09.09

above shall be carried out on each coil.
3.09.11 Tests During Manufacture :

a) Chemical analysis of zinc used for galvanizing
Page 40 of 142
Volume-V (Part-1)
b) Chemical analysis of aluminium for making aluminium

strands
c) Chemical analysis of steel used for making steel strands
3.09.12 Additional Tests:
The Employer reserves the right of having at his own expenses any
other test(s) of reasonable nature carried out at Contractors
premises, at site, or in any other place in addition to the aforesaid
type, acceptance and routine tests to satisfy himself that the
material comply with the specification.
3.09.13 Test Reports
(a) Record of routine test reports shall be maintained by the
Contractor at his works for periodic inspection by the
Employers representative.
(b) Test Certificates of test during manufacture shall be
maintained by the Contractor. These shall be produced
for verification as and when desired by the Employer.
3.09.14 Test Facilities
The following additional test facilities shall be available
at Contractors Works.
(a) Calibration of various testing and measuring equipment
including
tensile
testing
machine,
resistance
measurement
facilities,
burette,
thermometer,
barometer etc.
(b) Standard resistance for calibration of resistance bridges.
(c) Finished conductor shall be checked for length
verification and surface finish on separate rewinding
machine at reduced speed (variable from 8 to 16
metres per minute). The rewinding facilities shall have
appropriate clutch system and free of vibrations, jerks
etc. with transverse layering facilities.
3.10
QUALITY ASSURANCE PROGRAM

of the employer.
Page 41 of 142
Volume-V (Part-1)
3.11
INSPECTION :
3.11.01 As specified in clause 1.13 Section-1 of the biding

3.11.02 At least 5% of the total number of drums subject to
minimum of two in any lot put up for inspection, shall be selected at
random to ascertain the length of conductor by following method:
At the works of the manufacturer the conductor shall be
transferred from one drum to another at the same time measuring
its length with the help of graduated pulley and Cyclometer. The
difference in the average length thus obtained and as declared by
the Contractor in the packing list shall be applied to all the drums if
the conductor is found short during checking
3.11.03 The supplier shall submit the factory test certificates of raw
materials & bought out accessories at the time of acceptance tests
of the Conductor.
3.12
PACKING AND FORWARDING :
3.12.01 The conductor shall be supplied in non-returnable strong

wooden drums provided with lagging of adequate strength, to
protect the conductor against all damage and displacement during
transit, storage and subsequent handling and stringing operations in
the field. The drums shall generally conform to IS: 1778 except
otherwise specified hereinafter.
3.12.02 The drums shall be suitable for wheel mounting and for
jetting off the
conductor under a minimum controlled tension of
the order of 5kN.
3.12.03 The standard drum drawings are enclosed. However,
Contractor should submit the proposed drum drawings along with
the bid. The same shall be in line with the requirements of standard
drawings and as stated herein. The Contractor shall submit four
copies of fully dimensioned drawing of the drum he wishes to
supply, for Employers approval, before taking up manufacturing of
conductor.
3.12.04 All wooden components shall be manufactured out of
seasoned soft wood free from
such defects that may materially
weaken the component part of the drums. Preservative treatment
for anti-termite /anti-fungus (Aldrine/Aldruse) shall be applied to
the entire drum with preservatives of a quality which is not
chemically harmful to the conductor.
3.12.05
The flanges shall be of two/three ply construction with
each ply at right angles to the other and nailed together. Further
the outer face of the flange shall be reinforced with the
Page 42 of 142
Volume-V (Part-1)
circumferential battens, fixing in octagonal shape. The nails shall

be driven from the inside face of flange, punched and then clenched
on the outer face. The tolerance in thickness of each ply shall be
+/- 3 mm only. There shall be at least 3 nails per plank of ply with
maximum nail spacing of 75 mm. 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. Spindle hole shall be provided
at the centers of the planks of the plies and spindle plates with 102
mm dia. Holes shall be fitted on either side of both the flanges.
3.12.06
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.
3.12.07 Barrel studs shall be used for construction of drums. The
flanges shall be holed and
the barrel supports slotted to receive
them. The barrel studs shall be threaded over a length on either
end, sufficient to accommodate washers, spindle plates and nuts for
fixing flanges at the required spacing. Barrel studs should be tack
welded with the nuts after tightening.
3.12.08 Normally, the nuts on the studs shall stand protrude of the
flanges. All the nails used on the inner surface of the flanges and
the drum barrel shall be counter sunk. The ends of barrel shall
generally be flushed with the top of the nuts.
3.12.09 The inner cheek of the flanges and drum barrel surface
shall be painted with bitumen based paint.
3.12.10
Before reeling, cardboard or double corrugated or thick
bituminised waterproof bamboo paper shall be secured to the drum
barrel and inside of flanges or the drum by means of a suitable
commercial adhesive material. The paper should be dried before
use. Medium grade craft paper shall be used in between the layer of
the conductor/earth wire. After reeling the conductor the exposed
surface of the outer layer of conductor shall be wrapped with thin
polythene sheet across the flanges to preserve the conductor from
dirt, grit and damage during transportation and handling and also to
prevent ingress of rain water during storage/transport.
3.12.11
Minimum space of 125 mm shall be provided between
the inner surface of the external protective layer and outer layer of
the conductor.
3.12.12
Each batten shall be securely nailed across grains as far
as possible to the flange edges with at least 2 nails per end. The
length of the nails shall not be less than twice the thickness of the
battens. The nail shall not protrude above the general surface and
Page 43 of 142
Volume-V (Part-1)
shall not have exposed sharp edges or allow the battens to be

released due to corrosion.
3.12.13 Outside the protective layer, there shall be minimum of
two binder consisting of hoop iron/galvanized steel wire. Each
protective layer shall have two recess to accommodate the binders.
3.12.14 The conductor ends shall be properly sealed and secured
with the help of U-nails on one side of the flanges. The end securing
shall be done by taking out at least 500 mm of steel core on either
ends by U-nails. The composite conductor shall be binded by use of
galvanized steel wire/aluminum wire at three locations at least 75
mm apart or more covered with PVC adhesive tape so as to avoid
loosening of conductor layers in transit and handling.
3.12.15 Only one length of conductor shall be wound on each
drum.
3.13
MARKING :
Each drum shall have the following information stenciled on it in

indelible ink along with other essential data:
i.
Contract
ii.
Name and address of consignee
iii.
Manufacturers name and address
iv.
Drum number
v.
Size of conductor
vi.
Length of conductor in metres
vii.
Gross weight of drum with conductor
viii.
Weight of empty drum with protective lagging
ix.
3.14
Arrow marking for unwinding
END SEALING:
Both the ends of each length of conductor should be provided with

non-destructive type metal crimped or epoxy capped seals with
punching embossing/ engraving of manufacturers monogram and
drum number.
***
Page 44 of 142
Volume-V (Part-1)
SECTION- 4
TECHNICAL SPECIFICATIONS FOR
HIGH TENSILE GALVANISED STEEL EARTH WIRE
4.01
STANDARDS:
The High Tensile Galvanised Steel Earth Wire shall conform to the
following Indian
Standards, which shall mean latest revisions,
amendments/changes adopted and published, unless otherwise
specified hereinbefore.
Indian Standards
or any Equivalent
International
Standard
IS:209 -1992
IS:2141 -1992
Specification for Earth wire for

overhead Transmission purpose
IS:1778
IS:1521
Method of Tensile Testing of Steel

wire
IS:2629 -1992

IS:2633 -1992
Method of Testing Uniformity of

Zinc coating of Zinc coated Articles.
IS:4826
Galvanised coating on Round Steel

wire
IS:6745 -1992
Method of Determination of weight

of Zinc coating of zinc coated Iron
and Steel Articles
IS: 12776
Method of Testing of Earth wire
S.
No.
4.02
Title
PARAMETERS:
4.02.01
PRINCIPAL PARAMETERS OF EARTH WIRE:
The standard technical particulars of 7/3.66mm galvanized

steel earth wire shall be as follows:a. The details of Steel strand:
i.
Material
Steel
ii.
Stranding
iii.
Weight per Km
583 Kgs
Page 45 of 142
Volume-V (Part-1)
iv.
Dia. of wire
3.66 mm
Tolerance
2%
vi
Minimum elongation in 100 mm 5 mm

length
vii
Minimum breaking strength per 1000 Kg

strand
viii
Minimum tensile strength
95 Kg./mm2
ix
D.C. resistance at 20 Deg. C
17.15 Ohms/Km
b. The details of Stranded Earth Wire :
4.03
i.
Maximum Length of Lay
198
ii.
Minimum Length of Lay
165
iii.
Minimum breaking load
iv.
Overall diameter
10.98mm
Modulus of elasticity
1.933
x
2
Kg./cm
vi
Co-efficient of linear expansion
11.50 x 10per Deg.C
vii
Weight of zinc coating on wire
260 gms./ m
(Min.)
viii
No. of one minute dip and half 3 one minute

minute dip respectively
and
1
half
minute
ix
Calculated d.c. Resistance at 20 2.5

Deg.C
Km
6972 Kgs
Ohms
106
per
GENERAL TECHNICAL REQUIREMENT : MATERIAL AND

WORKMANSHIP FOR EARTH WIRE:
4.03.01
The steel wire (strands) used in manufacture of
galvanized steel earth wire shall be drawn from steel wire rod
produced by either acid or basic open hearth process or by the
electric furnace process or basic oxygen process. The steel wire
shall not have sulphur and phosphorous contents exceeding 0.045%
each. The carbon content shall not exceed 0.55%. The steel
produced by bassemer process shall not be used for drawing of
steel wire strands. The finished earth wire shall have minimum
brittleness as it will be subjected to continuous vibration while in
use on line.
4.03.02
The steel wire shall be hot dip galvanized and shall have
zinc coating of minimum 260 gram per sq. meter of the uncoated
Page 46 of 142
Volume-V (Part-1)
wire surface. The zinc coating shall be smooth and continuous of

uniform thickness, free from imperfections not consistent with good
commercial practice and shall meet the test requirement. The zinc
used in galvanizing of earth wire shall be as per IS: 209-1992.
4.03.03
All the steel wires shall be circular, smooth, uniform and
free from imperfections, such as spills and splits, die marks
scratches, abrasions, cuts and kinks etc. drawing and after
stranding.
4.03.04
The steel wires, after galvanizing shall be bright in
appearance, smooth and free from all defects like flux, ash, cross
inclusions, bare and black spots, pimples, lumpiness in runs, rust,
stains, bulky white deposits and blisters.
4.03.05
To avoid susceptibility towards wet storage stains (white
rust) the stranded earth wire shall be provided with a protective
coating of boiled linseed oil.
4.03.06
The finished earth wire shall have a smooth surface
without any surface cuts, abrasions, scuff marks and shall be free
from dirt, grit etc.
4.03.07
Failure of any sample to meet the above requirements
shall be sufficient cause for rejection of the lot of earth wire
represented by the sample, particular care shall therefore be taken
during manufacture, handling, packing and transportation of the
earth wire so that it is not dented, cut or damaged in any way.
4.04
SIZE AND PROPERTIES:
4.04.01
The earth wire size, physical properties, tolerance in
diameter of individual strands and length of lay of the strand shall
be as given above.
4.04.02
The wires shall be so stranded together that when an
evenly distributed pulls is applied at the end of completed strands,
each wire will take an equal share of the pull.
4.04.03
The earth wire shall be supplied in the standard lengths
which shall not be less than 3 Km. Not less than 95% of the total
quantity of the earth wire shall be supplied in standard
lengths.
The quantity of earth wire in length shorter than standard one shall
not exceeds 5% of the total quantity to be supplied. Further, no
single earth wire length in respect of such 5% (maximum) supply in
random lengths shall be shorter than 50% of the standard length.
4.04.04
The length of the stranded wire shall be supplied
without joints in the individual wires comprising it, excluding welds
made in base rod before it is drawn.
Page 47 of 142
Volume-V (Part-1)
4.04.05
Each coil be warranted to contain no welds, joints or
splice other than in the base rod before it is drawn.
4.05
GALVANISING AND OILING:
4.05.01
All the wires of the strand shall be galvanized in
accordance with IS-2629-1990. Recommended practice for Hot dip
galvanizing of Iron and Steel of some other authoritative equivalent
standard.
4.05.02
The galvanized earth wire after stranding operation shall
have dipped in boiled linseed oil before winding it on drums.
4.06
TEST FOR EARTH WIRE :
4.06.01
Earth wire shall be subjected, before despatch from the
works to tests as specified in the IS-2141, IS 1521, IS 1755 & IS
4826 or any other authoritative equivalent standard.
4.06.02
All the drums of galvanized steel stranded earth wire of
the same grade, diameter and construction, manufactured under
similar condition shall be grouped to constitute one lot.
4.06.03
Samples from each lot shall be tested for ascertaining
the conformity to the requirements of the earth wire specified
herein. The drums selected shall be tested for length of the lay and
diameter of individual strands etc. The lot shall be declared
conforming to the requirement of these characteristics if all the
samples are found satisfactory. One test specimen from each wire
of the strand shall now be drawn from every selected drum and
subjected to chemical analysis, tensile tests, ductility test,
elongation test and coating test. One test specimen, of the
completed strand from each drum shall be subjected to tensile
strength. The lot shall be declared conforming to the requirements
of these characteristics, if the entire test specimen satisfies the
relevant requirement.
4.07
QUALITY ASSURANCE PROGRAM

of the employer.
4.08
INSPECTION :
4.08.01
Page 48 of 142
Volume-V (Part-1)
4.08.02
At least 5% of the total number of drums subject to
random to ascertain the length of earth wire by following method:
At the works of the manufacturer of the earth wire, the
earth wire shall be transferred from one drum to another at
the same time measuring its length with the help of
graduated pulley and Cyclometer. The difference in the
average length thus obtained and as declared by the
Contractor in the packing list shall be applied to all the
drums if the conductor/earth wire is found short during
checking.
4.08.03
raw materials & bought out accessories at the time of acceptance
tests of the earth wire.
4.09
PACKING AND FORWARDING:
4.09.01
The earth wire shall be supplied in strong wooden
drums provided with lagging of adequate strength, to protect the
conductor/earth wire against all damage and displacement during
transit, storage and subsequent handling and stringing operations in
the field. The drums shall generally conform to IS: 1778 except
otherwise specified hereinafter.
4.09.02
The drums shall be suitable for wheel mounting and for
jetting off the conductor/earth
wire under a minimum controlled
tension of the order of 5kN.
4.09.03
The standard drum drawings are enclosed. However,
Contractor should submit the proposed drum drawings along with
the bid. The same shall be in line with the requirements of standard
drawings and as stated herein. The Contractor shall submit four
copies of fully dimensioned drawing of the drum he wishes to
supply, for Employers approval, before taking up manufacturing of
earth wire.
4.09.04
All wooden components shall be manufactured out of
seasoned soft wood free from
such defects that may materially
weaken the component part of the drums. Preservative treatment
for anti-termite /anti-fungus (Aldrine/Aldruse) shall be applied to
the entire drum with preservatives of a quality which is not harmful
to the earth wire.
4.09.05
The flanges shall be of two/three ply construction with
each ply at right angles to the other and nailed together. Further
the outer face of the flange shall be reinforced with the
circumferential battens, fixing in octagonal shape. The nails shall
be driven from the inside face of flange, punched and then clenched
on the outer face. The tolerance in thickness of each ply shall be
Page 49 of 142
Volume-V (Part-1)
+/- 3 mm only. There shall be at least 3 nails per plank of ply with
maximum nail spacing of 75 mm. Where a slot is cut in the flange
to receive the inner end of the conductor/earth wire, the entrance
shall be in line with the periphery of the barrel. Spindle hole shall be
provided at the centers of the planks of the plies and spindle plates
with 102 mm dia. Holes shall be fitted on either side of both the
flanges.
4.09.06
The wooden battens used for making the barrel of the
earth wire shall be of segmental type. These shall be nailed to the
barrel supports with at least two nails. The battens shall be closely
butted and shall provide a round barrel with smooth external
surface. The edges of the battens shall be rounded or chamfered to
avoid damage to the earth wire.
4.09.07
Barrel studs shall be used for construction of drums.
The flanges shall be holed and
the barrel supports slotted to
receive them. The barrel studs shall be threaded over a length on
either end, sufficient to accommodate washers, spindle plates and
nuts for fixing flanges at the required spacing. Barrel studs should
be tack welded with the nuts after tightening.
4.09.08
Normally, the nuts on the studs shall stand protrude of
the flanges. All the nails used on the inner surface of the flanges
and the drum barrel shall be counter sunk. The ends of barrel shall
generally be flushed with the top of the nuts.
4.09.09
The inner cheek of the flanges and drum barrel surface
shall be painted with bitumen-based paint.
4.09.10
Before reeling, cardboard or double corrugated or thick
bituminised waterproof bamboo paper shall be secured to the drum
barrel and inside of flanges or the drum by means of a suitable
commercial adhesive material. The paper should be dried before
use. Medium grade craft paper shall be used in between the layer of
the conductor/earth wire. After reeling the earth wire the exposed
surface of the outer layer of earth wire shall be wrapped with thin
polythene sheet across the flanges to preserve the conductor/earth
wire from dirt, grit and damage during transportation and handling
and also to prevent ingress of rain water during storage/transport.
4.09.11
Minimum space of 125 mm shall be provided between
the inner surface of the external protective layer and outer layer of
the earth wire.
4.09.12
Each batten shall be securely nailed across grains as far
as possible to the flange edges with at least 2 nails per end. The
length of the nails shall not be less than twice the thickness of the
battens. The nail shall not protrude above the general surface and
shall not have exposed sharp edges or allow the battens to be
released due to corrosion.
Page 50 of 142
Volume-V (Part-1)
4.09.13
Outside the protective layer, there shall be minimum of
two binders consisting of hoop iron/galvanized steel wire. Each
protective layer shall have two recesses to accommodate the
binders.
4.09.14
The earth wire ends shall be properly sealed and
secured with the help of U-nails on one side of the flanges. The end
securing shall be done by taking out at least 500 mm of steel wire
on either end by U-nails. The earth wire shall be binded by use of
galvanized steel wire/aluminum wire at three locations at least 75
mm apart or more covered with PVC adhesive tape so as to avoid
loosening of earth wire layers in transit and handling.
4.09.15
drum.
4.10
Only one length of earth wire shall be wound on each
MARKING :
Each drum shall have the following information stenciled

on it in indelible ink along with other essential data:
(i)
Order Number and date.
(ii)
(iii) Manufacturers name and address

(iv) Drum number
(v)
Size of earth wire (7/3.66mm)
(vi) Length of earth wire in meters

(vii) Gross weight of drum with earth wire
(viii) Weight of empty drum with protective lagging
(ix) Arrow marking for unwinding
4.11
END SEALING :
Both the ends of each length of earth wire should be provided with
non-destructive type metal crimped or epoxy capped seals with
punching embossing/ engraving of manufacturers monogram and
drum number.
***
Page 51 of 142
Volume-V (Part-1)
SECTION- 5
TECHNICAL SPECIFICATION FOR DISC INSULATORS
5.01
STANDARDS
This section provides for the design, manufacture, stage testing and
inspection and testing before dispatch packing and delivery of disc
insulators as per technical requirements furnished in this section.
Unless otherwise specified elsewhere in this specification, the rating
as well as performance & testing of the disc insulators shall conform
but not limited to the latest revision & amendments available at the
time of placement of order of all the relevant standards as listed
hereunder, except as modified in this document.
S.
No
1
Indian
Standard
IS:209-1992
Title
IS:206-1991
Method for Chemical Analysis of Slab

Zinc
IS:731-1991
IS:2071
Part(I)-1993
Porcelain insulators for overhead power

lines with a nominal voltage
greater
th
1000V
Method of High Voltage Testing
Part(II)-1991
IS:2121
Part(I)
IS:2486
General Requirements & Tests
Part I-1993
Part II-1989
Part III
1991
Specification of Conductors and Earth

wire Accessories for Overhead Power
Lines.
Armour Rods, Binding Wires & Tapes for
Conductors
Specification for insulator fittings for
overhead power lines with a nominal
voltage greater than 1000V
IS:2629-1990
IS:2633-1992
Dimensional Requirements
Locking Devices
Galvanization for iron & steel
Testing for Uniformity of Coating of Zinc
coated articles
Page 52 of 142
Volume-V (Part-1)
9
10
IS:3188-1988
IS:6745-1990
11
12
IS : 8263-1990
IS:8269-1990
Dimensions for Disc Insulators

Determination of Weight of Zinc coating
on Zinc coated iron and steel articles
Methods of RIV Test of HV Insulators
Methods for Switching impulse test on
HV insulators
5.02 PRINCIPAL PARAMETERS

5.02.01
DETAILS OF DISC INSULATORS
i) The insulator strings shall consist of standard discs for a

three phase 50 Hz, effectively earthed 220KV/132KV
transmission system in a moderately polluted atmosphere.
The discs shall be cap and pin, ball and socket type.
ii)
The specified values and disc dimensions, impulse and
power frequency voltages, electromechanical strength
[EMS] of individual insulator units are as under. The values
given are minimum which apply to all cases. Specified
withstand and flashover voltages are referred to standard
atmospheric condition.
5.02.02
CHARACTERISTICS OF DISC INSULATORS
The disc insulators should have the following particulars and

characteristics:
S.No
Particulars
i
ii
iii
Diameter of the disc (mm)

Spacing of the disc (mm)
Size and designation of pinball shank
Creepage distance (mm)
(minimum)
Power
frequency
one
minute
dry
withstand
voltage kV (rms)
Power
frequency
one
minute
wet
withstand
voltage kV (rms)
Power frequency puncture
withstand voltage kV (rms)
Minimum
dry
impulse
iv
v
vi
vii
viii
Disc Insulators
70KN
90kN
160kN
EMS
EMS
EMS
255
255
280
145
145
170
16 mm
16 mm
20 mm
320
320
330
70
75
75
40
45
45
120
125
125
110
110
120
Page 53 of 142
Volume-V (Part-1)
ix
withstand voltage 1.2x50

micro second wave, positive
and negative Kv Peak)
Maximum
Radio
interference
voltage with 10 kV RMS to
ground. (microvolts)
Minimum corona extinction
voltage kV(rms)
50
50
50
18
5.03 SPECIFICATION DRAWINGS

The specification drawing in respect of the disc insulators indicated
above is attached with this specification. The specification drawing
is attached herewith for information and guidance of the Contractor
only. The drawings to be furnished by the Contractor shall be as per
his own design and manufacture and shall be distinct and separate
from these specification drawings.
The drawing shall include but not limited to the following
information:a)
Shell diameter and ball to ball spacing with
manufacturing tolerances.
b)
Minimum creepage distance with positive tolerance.
c)
Protected creepage distance
d)
Eccentricity of the disc
i)
Axial run out
ii)
Radial run out
e)
Unit mechanical and electrical characteristics
f)
Size and weight of ball & socket parts
g)
Weight of unit insulator disc
h)
Materials
i)
Identification mark
j)
Manufacturers catalogue number.
After placement of order, the Contractor shall submit full
dimensioned manufacturing drawing of insulator cap, pin &
insulator shell in six copies to the Employer for reference &
record.
5.04 GENERAL TECHNICAL REQUIREMENTS
5.04.01
Porcelain
The porcelain used in the manufacture of the shells shall be ivory

white, nonporous of high dielectric, mechanical and thermal
Page 54 of 142
Volume-V (Part-1)
strength, free from internal stresses, blisters, laminations, voids,

foreign matter, imperfections or other defects which might render it
in any way unsuitable for insulator shells. Porcelain shall remain
unaffected by climatic conditions, ozone, acid, alkalizes, zinc or
dust.
The manufacturing shall be by the wet process and
impervious character obtained by thorough verification.
5.04.02
Porcelain Glaze
Surfaces to come in contact with cement shall be made rough by

sand glazing. All other exposed surfaces shall be glazed with
ceramic materials having the same temperature coefficient of
expansion as that of the insulator shell. The thickness of the glaze
shall be uniform throughout and the colour of the glaze shall be
brown. The glaze shall have a visible luster, smooth on surface and
be subject to satisfactory performance under extreme tropical
climatic weather conditions and prevent ageing of the porcelain.
The glaze shall remain under compression on the porcelain body
throughout the working temperature range.
5.04.03 METAL PARTS
5.04.03.1 Cap and Ball Pins
Ball pins shall be made with drop forged steel and caps with
malleable cast iron. They shall be in one single piece and duly hot
dip galvanized.
They shall not contain parts or pieces joined
together, welded, shrink fitted or by any other process from more
than one piece of material. The pins shall be of high tensile steel,
drop forged and heat-treated. The caps shall be cast with good
quality black hearth malleable cast iron and annealed. Galvanising
shall be by the hot dip process with a heavy coating of zinc of very
high purity. The Contractor shall specify the grade, composition
and mechanical properties of steel used for caps and pins.
5.04.03.2 Security Clips
The security clips shall be made of phosphor bronze or of stainless
steel.2.5% extra security clip shall be provided.
5.05 FILLER MATERIAL
Cement to be used as a filler material shall be quick setting, fast
curing Portland cement. It shall not cause fracture by expansion or
loosening by contraction. Cement shall not react chemically with
metal parts in contact with it and its thickness shall be as small and
as uniform as possible.
The insulator design shall be such that the insulating medium shall
not directly engage with hard metal. The surfaces of porcelain and
Page 55 of 142
Volume-V (Part-1)
hard metal should be coated with resilient paint to offset the effect
of difference in thermal expansions of these materials.
5.06 MATERIAL DESIGN AND WORKMANSHIP
5.06.01
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 extra high
voltage transmission.
Bidders shall therefore offer
insulators as are guaranteed by them for satisfactory
performance on 220KV/132KV 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.
5.06.02
INSULATOR SHELL
The design of the insulator shells shall be such that stresses due to
expansion and contraction in any part of the insulator shall not lead
to deterioration.
Shells with cracks shall be eliminated by
temperature cycle test followed by mallet test. Shells shall be dried
under controlled conditions of humidity and temperature.
5.06.03
(i)
METAL PARTS
The pin and cap shall be designed such that it will not
transmit the mechanical stresses to the shell by
compression and develop uniform mechanical strength
in the insulator. The cap shall be circular with the inner
and outer surfaces concentric and of such design that it
will not yield or distort under loaded conditions. The
head portion of the pin ball shall be suitably designed so
that when the insulator is under tension the stresses are
uniformly distributed over the pinhole portion of the
shell. The pin ball shall move freely in the cap socket
either during assembly of a string or during erection of
a string or when a string is placed in position.
Page 56 of 142
Volume-V (Part-1)
(ii)
5.06.04
Metal caps shall be free from cracks, seams, shrinks, air

holes, blow holes and rough edges. All metal surfaces
shall be perfectly smooth with no projecting parts or
irregularities, which may cause corona. All load bearing
surfaces shall be smooth and uniform so as to distribute
the loading stresses uniformly. Pins shall not show any
microscopically visible cracks, inclusions and voids.
GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the
latest edition of IS: 2629. The zinc to be used for galvanizing shall
conform to grade Zn 99.95 as per IS: 209. The Zinc coating shall
be uniform, smoothly adherent, reasonably bright, continuous and
free from impurities such as flux, ash, rust stains, bulky white
deposits and blisters. Before ball fittings are galvanized, all die
flashing on the shank and on the bearing surface of the ball shall be
carefully removed without reducing the designed dimensional
requirements.
5.06.05
SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as a locking device for ball and socket
coupling shall be R shaped hump type to provide for positive
locking of the coupling as per IS:2486 (Part IV). The legs of the
security clips shall allow for spreading after installation to prevent
complete withdrawal from the socket. The locking device shall be
resilient, corrosion resistant and of sufficient mechanical strength.
There shall be no possibility of the locking device to be displaced or
be capable of rotation when placed in position and under no
circumstances shall it allow separation of insulator units and fittings.
W type security clips are also acceptable. The hole for the security
clip could be countersunk and the clip shall be of such design that
the eye of the clip may be engaged by a hot line clip puller to
provide for disengagement under energized conditions. The force
required for pulling the clip into its unlocked position shall not be
less than 50 N (5 kgs) or more than, 500 N (50 kgs).
5.06.06
BALL AND SOCKET DESIGNATION
The dimensions of the balls and sockets for 70 KN & 90 KN discs

shall be of 16 mm and for 160KN discs shall be of 20 mm
designation in accordance with the standard dimensions stated in
IS:2486 (Part II).
5.07
DIMENSIONAL TOLERANCE OF DISC INSULATOR
It shall be ensured that the dimensions of the disc insulators are

within the limits specified below:
Page 57 of 142
Volume-V (Part-1)
a.
Diameter of Disc (mm)

Rating
b.
Standard Maximum
Minimum
160 KN Disc
280
293
267
90 KN Disc
255
266
244
70 KN Disc
255
266
244
Ball to Ball Spacing between Discs (mm)

Rating
Standard
Maximum
Maximum
160 KN Disc
170
175
165
90 KN Disc
145
149
141
70 KN Disc
145
149
141
5.08 INTERCHANGEABILITY
The insulators inclusive of the ball and socket fittings shall be of
standard design suitable for use with hardware fittings of any make
conforming to relevant Indian Standards.
5.09 SUITABILITY FOR LIVE LINE MAINTENANCE
The insulators shall be compatible for use with hot line or live line
maintenance techniques so that usual hot line operations can be
carried out with ease, speed and safety.
Contractors shall indicate the methods generally adopted in routine
hot and cold line maintenance of EHV lines for similar insulators
supplied by them. Contractors shall also indicate the recommended
periodicity of such maintenance.
5.10
FREEDOM FROM DEFECTS
Insulators shall have none of the following defects:

i)
ii)
iii)
iv)
Ball pin shake

Cementing defects near the pin like small blow holes,
small hair cracks, lumps, etc.
Sand fall ferro particle defects on the surface of the
insulator.
Shell eccentricity
Page 58 of 142
Volume-V (Part-1)
5.11
INSULATOR STRINGS:
5.11.01
TYPE AND RATING
The insulator strings shall be formed with standard discs described

in this specification for use on 3 phase, 220kV/132kV, 50Hz
effectively earthed systems in a moderately polluted atmosphere.
Suspension insulator strings for use with suspension towers are to
be fitted with discs of 70 kN EMS rating while tension insulator
strings for use with Anchor/Tension towers are to be fitted with
discs of 90 kN & 160 kN EMS rating.
The Bidder may also use Long Rod Porcelain Insulators
String or Long Rod Polymer Insulators in place of Disc
Insulator Strings. The Long Rod Porcelain Insulators or Long
Rod Polymer Insulators shall have technical specification
equivalent to or better than the technical specification of
Disc Insulator Strings. It may please be noted that in a
particular work, the bidder will have to use any one type of
Insulators and combination of two different types of
Insulators in one particular work will not be allowed.
5.11.02
STRING SIZE
The size of the disc insulator, the number to be used in different

types of strings and their electro-mechanical strength shall be as
follows:
Size of
disc
insulator
(mm)
No. of
standar
d discs
Single Suspension for

220/132KV
Double Suspension for
220KV/132KV
255x145
13/9
255x145
2x13/2x
9
2x70
c)
Single Tension for 220KV
280x170
14
160
d)
Double Tension for 220KV
280x170
2x14
2x160
e)
255x145
10
90
f)
255x145
2x10
2x90
S.
No
.
a)
b)
Type of String
5.11.03
Electro
mechanic
al
strength
of
insulator
string
(kN)
70
STRING CHARACTERISTICS :
Page 59 of 142
Volume-V (Part-1)
5.11.03.1 The characteristics of the complete string shall be as

follows :
S.
NO.
Characteristics
Single/Double
Suspension
220kV
Single/Double
Suspension
132kV
220kV
132k
V
No. of Standard Discs 1x13

2x13
1x9
2x9
1x14
2x14
1x10
2x10
Nominal diameter of
discs
255
255
280
255
Power
frequency 460
Withstand
voltage
(wet) kV (rms)
280
490
300
Lighting impulse
withstand voltage
(dry)(kVp)
1200
800
1200
800
Switching surge
Withstand
voltage (Dry & wet)
(kVp)
900
350
900
350
Mechanical failing
Load (kgf)
7000/
14000
7000/
14000
16500/
33000
9000/
18000
Pollution
No deformation load
(kgf)
4690/
9380
4690/
9380
11055/
22110
6030/
12060
Corona Extinction
voltage (KV rms)
176
176
Moderately
polluted
Moderately
polluted
5.11.03.2 Insulator units after assembly shall be concentric and

coaxial within limits as permitted by Indian standards.
5.11.03.3 The string design shall be such that when units are
coupled together there shall be contact between the shell
of one unit and metal of the next adjacent unit.
5.12
TESTS :
Page 60 of 142
Volume-V (Part-1)
5.12.01
The Disc insulators offered should be fully type tested as
per the relevant standards. The following tests shall be carried out
on the insulator string and also on unit disc insulators.
5.12.02
Acceptance Tests shall mean those tests which are to be
carried out on samples taken from each lot offered for pre-despatch
inspection for the purpose of acceptance of the lot.
5.12.03
Routine Tests shall mean those tests, which are to be
carried out on each insulator to check the requirements which are
likely to vary during production.
5.12.04
Stage tests during manufacture shall mean those tests
which are to be carried out during the process of manufacture to
ensure quality control such that the end product is of the designed
quality conforming to the intent of this specification.
5.12.05
The norms and procedure of sampling for the above
tests shall be as per the relevant Indian Standard or other
internationally accepted standards.
5.12.06
The standards according to which these tests are to be
carried out are listed against each test. Where a particular test is a
specific requirement of this specification, the norms and procedure
for the same shall be as specified in Appendix-I attached hereto or
as mutually agreed to between the Contractor and the Employer in
the Quality Assurance Programme.
5.12.07
For all type and acceptance tests, the acceptance values
shall be the value guaranteed by the Contractor in the Technical
Questionnaire or the acceptance value specified in this specification
or the relevant standard whichever is more stringent for that
particular test.
5.13
DETAILS OF TYPE TESTS :
5.13.01
The Disc insulators offered shall be fully type tested for
the following tests as per relevant International/Indian Standard
and the bidder shall furnish type test reports along with the offer.
a)
Visible discharge test
IS:731
b)
Impulse voltage withstand test
IS:731
c)
Wet power frequency voltage

withstand test
IS:731
d)
Verification of dimension test
IS:731
e)
Temperature cycle test
IS:731
f)
Electro-Mechanical failing load test
IS:731
g)
Puncture test
IS:731
h)
Porosity test
IS:731
Page 61 of 142
Volume-V (Part-1)
5.14
i)
Galvanising test
IS:731
j)
24 hours mechanical failing load test
IS:731
k)
Metallurgical test
IS:2108 &
IS:2004
DETAILS OF ACCEPTANCE AND ROUTINE TESTS :
5.14.01
All Acceptance and Routine tests as stipulated herein
shall be carried out by the Contractor in the presence of Employers
representative. Immediately after finalisation of the programme of
acceptance/routine testing, the Contractor shall give sufficient
advance intimation to the Employer, to enable him to depute his
representative for witnessing the test.
5.14.02
For String Insulator
Routine tests shall be conducted:
(A)
a)
b)
c)
d)
e)
f)
g)
h)
i)
Units
following
Acceptance
&
Acceptance tests:
Verification of dimensions
Galvanising test
Mechanical performance test
Test on locking device for
ball and socket coupling
Eccentricity test
Electro-mechanical strength
test
Puncture test
Porosity test
(B)
Routine tests:
a)
Visual Inspection
b)
Mechanical routine test
c)
Electrical routine test
IS:731
IS:731
IS:731
IEC:575
IEC:372/IS-2486(partIV)
As per Specification
IS-731
IS-731
IEC:383
5.15 Tests during Manufacture (STAGE TESTS)

On all components as applicable
a)
Chemical analysis of
used for galvanizing
Zinc
Page 62 of 142
Volume-V (Part-1)
b)
Chemical
analysis,
mechanical
and
metallographic
test
and
magnetic particle inspection
As per this Specification
for malleable castings
c)
Chemical analysis, hardness

test and magnetic particle
inspection for forgings
d)
Crack detection
metal parts
test
for
5.16 ADDITIONAL TESTS :

The Employer reserves the right for carrying out any other tests of a
reasonable nature at the works of the Contractor/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 Employer to satisfy that the material complies with the intent
of this specification.
5.17 COORDINATION FOR TESTING:
For 220KV/132KV insulator strings, the Contractor is required to
produce type test reports to the satisfaction of the Employer.
However, in case the Employer desires, the Contractor 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 Contractor.
5.18 QUALITY ASSURANCE PROGRAM :
of the employer.
5.19 INSPECTION :
5.19.01
5.19.02
The acceptance of any quantity of insulators shall in no
way relieve the successful Contractor of his responsibility for
meeting all the requirement of this specification and shall not
Page 63 of 142
Volume-V (Part-1)
prevent subsequent rejection, if such disc insulators are later found

to be defective.
5.19.03
The Contractor shall submit the routine test certificates
of bought out items and raw material at the time of routine testing
of the insulator.
5.20 IDENTIFICATION MARKING :
i)
Each disc insulator shall be legibly and indelibly marked

with the trade mark of the manufacturer, the month and
year of manufacture, the guaranteed combined
mechanical and electrical strength in kilo-newtons
abbreviated by KN to facilitate easy identification and
proper use.
ii)
The marking shall be on porcelain shell of insulators.

The
marking
shall
be
printed
and
not
impressed/embossed and same shall be applied before
firing.
iii)
One 10mm thick ring of good quality paint shall be

marked on the cap of each insulator of particular
strength for easy identification of the type of insulator.
The paint shall not have any deteriorating effect on the
insulator performance. Following codes shall be used as
identification mark:For 70kN disc insulator Green
For 90kN disc insulator Blue
For 160kN disc insulator Red
5.21 DOCUMENTATION
The Contractor shall furnish full description and illustrated
catalogues of insulators offered, alongwith the bid. The
supplier shall also furnish alongwith the bid the outline
drawing of each insulator unit including cross-sectional view of
the shell. The drawing shall include the following information :
i)
Shell diameter and unit spacing with manufacturing

tolerance.
ii)
Creepage distance.
iii)
Unit mechanical and electrical characteristics as also for

the complete string-suspension and tension.
Page 64 of 142
Volume-V (Part-1)
iv)
Size and weight of ball and socket part.
v)
Weight of unit insulator disc.
vi)
Materials for the disc, cap and pin.
vii) Identification mark.

viii) Manufacturers catalogue number.
ix)
Brief installation instructions.
x)
Relevant technical details of significance.
5.22 PACKING & FORWARDING :

i)
ii)
iii)
iv)
All disc insulators shall be packed in strong seasoned

wooden crates.
The gross weight of the crates
alongwith disc insulators shall not normally exceed 100
kg. to avoid handling problem.
The packing shall be of sufficient strength to withstand
rough handling during transit, storage at site and
subsequent handling in the field.
Suitable cushioning, protective padding, or dunnage or
spacers shall be provided to prevent damage or
deformation during transit and handling.
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 wooden case/crate shall have
all the markings stenciled on it in indelible ink.
Page 65 of 142
Volume-V (Part-1)
Appendix-I
TEST DETAILS
1.
Voltage Distribution Test:
The voltage across each insulator unit shall be measured by sphere

gap method. The result obtained shall be converted into percentage
and proportionate correction be applied so as to give a total of
100% distribution. The voltage across any disc shall not exceed 9%
for suspension insulator strings and for double tension insulator
strings. The total of the voltage distribution of all discs so computed
shall be within 95% and 105%. If not, the test shall be repeated.
The proportions correction shall be made on the values so as to give
a total of 100% distribution.
2.
Mechanical Strength Test:
The complete insulator string alongwith its hardware fittings

excluding arcing horn, corona control ring/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 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.
3.
Vibration Test:
The suspension string shall be tested in suspension mode, and

tension string in tension mode itself in laboratory span of minimum
30 metres. 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 alongwith hardware fittings and
two sub-conductors (each tensioned at 4500 kg) shall be secured
with clamps. The system shall be suitable to maintain constant
tension on each sub-conductors throughout the duration of test.
Vibration Dampers shall not be used on the test span. Both the
sub-conductors shall be vertically vibrated simultaneously at one of
the resonance frequencies of the insulator string (more than 10 Hz)
by means of vibration inducing equipment.
The amplitude of
Page 66 of 142
Volume-V (Part-1)
vibration at the antinode point nearest to the string shall be

measured and the same shall not be less than + 120/f , f being the
frequency of vibration. The insulator string shall be vibrated for five
million cycles then rotated by 90 deg. and again vibrated for 5
million cycles without any failure. After the test, the disc insulators
shall be examined for looseness of pins and cap or any crack in the
cement. The hardware fittings shall be examined for fatigue failure
and mechanical strength test. There shall be no deterioration of
properties of hardware components and disc insulators after the
vibration test.
The disc insulators shall be subjected to the
following tests as per relevant standards:
S.
No.
Test
Percentage of
discs to be
tested
a)

followed by mechanical
performance test
60
b)
Puncture
porcelain
40
test
(for
insulator only)
If the results of the second test show a porcelain shell

rupture, the production does not comply with this
specification.
4.
Chemical Analysis of Zinc used for Galvanising:
Samples taken from the zinc ingot shall be chemically analysed as

per IS:209. The purity of zinc shall not less than 99.95%.
5.
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
Employer in Quality Assurance Programme.
6.
Test on Castings:
The chemical analysis, mechanical and metallographic tests and

magnetic particle inspection for castings will be as per the
Page 67 of 142
Volume-V (Part-1)
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 Employer in Quality Assurance
Programme.
7.
Eccentricity Test:
The insulator shall be vertically mounted on a fixture using dummy

pin and socket. A vertical scale with horizontal slider shall be used
for the axial run out. The pointer shall be positioned in contact with
the bottom of the outermost petticot of the disc. The disc insulators
shall be rotated with reference to the fixture and the slider shall be
allowed to move up and down on the scale but always maintaining
contact with the bottom of the outer most petticot. After one full
rotation of the disc, the maximum and minimum position the slider
has reached on the scale can be found out. Difference between the
above two readings shall satisfy the guaranteed value for axial run
out. Similarly using a horizontal scale with vertical slider the radial
run out shall be measured. The slider shall be positioned on the
scale to establish contact with the circumference of the disc
insulator and disc insulator rotated on its fixture always maintaining
the contact. After one full rotation the maximum and minimum
position of the slider reached on the scale are found out. The
difference between the above readings shall satisfy the guaranteed
value for radial run out.
8.
Crack Detection Test:
Crack detection test shall be carried out on each ball and pin before
assembly of disc unit. The manufacturer shall maintain complete
record of having conducted such tests on each and every piece of
ball pin. The Contractor shall furnish full details of the equipment
available with him for crack test and also indicate the test procedure
in detail.
SYSTEM PARTICUALRS
S.N
o.
1
2
3
4
5
PARTICULARS
System
Line voltage (kV rms)
Max.voltage (kV rms)
Frequency
Neutral grounding
Electrical System Data

A.C.
3phase
A.C.
3phase
220
245
50Hz.
effectivel
132
145
50Hz.
effectivel
A.C.
3phas
e
400
420
50 Hz
effective
Page 68 of 142
Volume-V (Part-1)
system
6
7
8
9
10.
11.
Lightning impulse withstand voltage(dry &

wet)(kVp)
Power frequency
withstand
voltage (wet) (kVp)
Switching surge
withstand
voltage (wet) (kVp)
Short circuit level (kA)
Minimum corona
extinction voltage at
50 Hz AC system dry
condition (Kv rms)
Radio interference
voltage at one MHz for
phase to earth voltage
of 266KV dry
conditions(Microvolt)
y
earthed
1050
y
earthed
550
ly
earthed
1425
395
230
630
650
325
1050
40
-
40
-
40
320
500
Page 69 of 142
Volume-V (Part-1)
SECTION- 6
TECHNICAL SPECIFICATION FOR HARDWARE
FITTINGS FOR 220/132 KV LINES
6.01
STANDARDS:
This section provides for the Design, manufacturing, stage testing,

inspection and testing before despatch, packing and delivery of
Hardware fittings for Insulator string suitable for Conductor and
Earth wire for use on 132 KV/220KV 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 here under or equivalent International
Standards, except as modified in this document:
S.
No
Indian
Standard
IS:209-1992
Specification for Zinc Ingot
Tee and Strap Hinges
IS:206
1992
IS:78141985
IS:2071
IS:731
Porcelain Insulator for Overhead Power Lines

with a Nominal Voltage Greater than 1000 V.
IS:961
Structural Steel
IS:1385
Phosphor Bronze Rods & Bar Sheet and Strips

and Wire
IS:2004
Carbon Steel Forgings for General Engineering

Purpose
IS:2107
White Hearth Malleable Iron Castings
10
IS:2108
Black Hearth Malleable Iron Castings
11
IS:2121(Part
-I & II)
Specification for Conductors and Earth wire

Accessories for Overhead Power Line, Armour
Rods Binding Wires and Tapes for Conductor
12
IS:2486
Specification for Insulator Fittings for

Overhead Power Lines with a Nominal Voltage
Greater than 1000 V.
13
IS:2629
Recommended Practice for Hot Dip

Galvanization of Iron and Steel.
Title
Phosphor Bronze Sheet and Strip

Method of high voltage testing
Page 70 of 142
Volume-V (Part-1)
S.
No
Indian
Standard
Title
14
IS:2633
Testing of Uniformity of Coating of Zinc coated

Articles
15
IS:3138
Hexagon Bolts and Nuts
16
IS:6639
Hexagon Bolts for Steel Structures
17
IS:6745
Determination of Weight of Zinc Coating on

Zinc Coated Iron and Steel Articles
18
IS:3188
Characteristic of String Insulators Units
19
IS:4218
ISO Metric screw Threads
20
IS:4172
Dimensions for Radii under the Heads of Bolts

& Screws
21
IS:4206
Dimensions for nominal lengths and Thread

length for Screws and Studs (with
amendment)
22
IS:4759
Hot Dip Zinc Coatings on Structural Steel and

other Allied Products
23
IS:1573
Electroplated Coatings of Zinc on Iron and Steel
24
IS: 398
Specification for Aluminium Conductor Steel

Reinforced for overhead transmission purpose.
25
IS: 13271966
Methods for determination of weight of tin

Coating on Tin Plates
26
IS: 48261979
Hot Dip Galvanised Coating on Round Steel

Wires
27
IS: 1363
Hexagon Head Bolts, Screws & Nuts.
28
IS: 1367
Technical supply conditions for threaded Steel

Fasteners
29
IS: 9708
Stockbridge Vibration Dampers for Overhead

Power lines.
30
IS: 8263
Method of Radio Interference Tests on High

Voltage Insulators.
31
IS:10162
Spacers and Spacer Dampers

horizontal bundle Conductors.
32
IS: 2004
Carbon Steel Forgings for general engineering

purposes.
33
BS:970
(Part-I)
General Instructions and Testing Procedures

Specific Requirements for Carbon and Carbon
Manganese Alloy and Stainless Steels.
for
twin
Page 71 of 142
Volume-V (Part-1)
6.02 PRINCIPAL PARAMETERS:

6.02.01
Details of Hardware Fittings:
The Hardware fittings shall meet the technical requirement as per

clause 6.3 and also general arrangement drawings of Hardware
fittings attached herewith. Hardware fittings shall be suitable for
single/double suspension Insulator strings 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 for lines shall be suitable for ACSR Conductor
and Earth wire as per technical parameters indicated in Annexure3
6.03 INSULATOR STRING CHARACTERISTICS:
6.03.01
The complete insulator string including Hardware fittings
shall have the following characteristics:
S.
NO.
Characteristics
Single/Double
Suspension
132kV
132kV
220kV
No. of Standard Discs 1x13
1x9
1x14
1x10
2x13
2x9
2x14
2x10
220kV
1
Single/Double
Suspension
Nominal diameter of
discs
255
255
280
255
Power
frequency 460
Withstand
voltage
(wet) kV (rms)
280
490
300
Lighting impulse
withstand voltage
(dry)(kVp)
1200
800
1200
800
Switching surge
Withstand
900
350
900
350
7000/
7000/
9000/
14000
14000
16500/
33000
voltage (Dry & wet)

(kVp)
6
7
Mechanical failing
Load (kgf)
Pollution
Moderately
polluted
18000
Moderately
polluted
Page 72 of 142
Volume-V (Part-1)
8
9
No deformation load
(kgf)
4690/
4690/
11055/
6030/
9380
9380
22110
12060
Corona Extinction
voltage (KV rms)
176
176
6.03.02
The Insulator string Hardware fittings and Earth wire
assemblies shall comply and conform to the above requirement.
6.04 BALL AND SOCKET DIMENSIONS:
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 7000 kg and
9100 kg Electro Mechanical strength Disc Insulators shall conform to
designation 16mm/16mm-B in accordance with IS:2486(Part-II) or
equivalent International Standard. The Ball and Socket dimension of
Hardware to be used with 11500 Kg & 16,500 kg Electro Mechanical
strength disc insulator shall conform to designation 20mm in
accordance with IS-2486:(Part-II) or equivalent International
Standard. 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.
6.05 REQUIRED GUARANTEED STRENGTH OF HARDWARE OF
INSULATOR STRINGS:
6.05.01
The Hardwares and Clamps of 132kV/220kV single
suspension and double suspension strings suitable for Panther ACSR
and Zebra ACSR for transmission line and shall have the ultimate
breaking strength of not less than 7,000 kgs.
6.05.02
The slipping strength of the suspension clamp shall not
be less than 15% and more than 20% of the Conductor strength
with which it is to be used.
6.05.03
The Hardware and Compression Clamp of single and
double tension strings suitable for Panther ACSR shall have ultimate
breaking strength of not less than 9,100 kgs. The slipping strength
of Compression Clamp shall not be less than 95% of the ultimate
breaking strength of Panther ACSR.
6.05.04
The Hardware and Compression Clamp of single &
double tension strings suitable for Zebra ACSR for 220kV
transmission line shall have ultimate breaking strength of not less
Page 73 of 142
Volume-V (Part-1)
than 16500 kgs. The Compression Clamp shall have slipping

strength not less than 95% of breaking strength of Zebra ACSR.
6.05.05
Each individual Hardware component of double
suspension and double tension strings such as ball-clevis, socket
clevis etc. shall have minimum breaking strength as specified for
respective single suspension and tension string respectively.
6.06 PARTICULARS OF HARDWARE FITTINGS:
Each Hardware fitting for the transmission line shall
all respect and Bidder should furnish complete
technical particulars of the items of hardware
Hardware fittings should normally comprise items
enclosed drawing as under: -
be complete in
drawings and
fittings.
The
conforming to
6.06.01 Single Suspension Hardware Fitting With AGS Type

Clamp:
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.
6.06.02 Double Suspension String Hardware Fittings With
AGS Type Clamp:
The double suspension string Hardware fittings shall comprise of
one Ball Hook, one Socket Clevis, one Top Yoke Plate, two Ball
Clevis, two Socket Clevis, one bottom Yoke Plate, two line side
Arcing Horns, one Clevis Eye and one AGS type Suspension Clamp
suitable for respective sizes of Conductors.
6.06.03 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,
one line side Arcing Horn and one Tension Clamp of compression
type having before and after compression dimensions strictly as
shown in enclosed Appendix-2.
6.06.04 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, one line side arcing horn, one
clevis and a compression type dead-end Clamp having `before and
after compression dimensions strictly as shown in enclosed
Appendix-2.
Page 74 of 142
Volume-V (Part-1)
6.07 EARTH WIRE ASSEMBLIES:

6.07.01 Earth Wire Suspension Assembly With Preformed
Armour Rods:
This shall comprise of envelope type Suspension Clamp of heattreated malleable iron, one Chain Link and one D Shackle. The
entire assembly shall be hot dip galvanized complete with minor
accessories. The breaking strength of all the Hardware items of the
assembly shall not be less than 7000 kgs. The complete assembly
of suspension clamp shall be guaranteed for slip strength of not
less han 15 KN & not more than 19 KN. The strength of the Earth
wire has been specified in Annexure-3. The suspension assembly
shall be supplied with armour rod for Earth wire.
6.07.02 Earth Wire Tension Assembly:
The Earth wire tension assembly shall have minimum breaking
strength equal to that of the Earth Wire. The slipping strength of
the Compression Clamp shall not be less than 95% of the breaking
strength of Earth Wire. The strain assembly of the Earth wire for
transmission line shall comprise of compression type dead end
Clamp and two `D Shackles complete with minor accessories such
as pins, bolts & nuts etc. Strain assembly shall be hot dip
galvanized and made inherently resistant to the atmosphere
corrosion. The dead end Clamp of the assembly shall be of
compression type. The tension clamp shall be attached to the
horizontal strain plate of the tower body by means of a D shackle.
D shackle shall be suitable for attaching the tension clamp to
strain plate of towers having 8mm thickness with a hole of 21.5
mm diameter. The tension clamp body shall be made out of steel of
304 L grade or equivalent with Brinnel Hardness not exceeding 200.
The complete assembly shall also include one 12.5mm dia, 45 mm
long HRH MS Bolt hot dip galvanized with nuts and lock washers for
attaching G.I. earth bond. A detailed drawing giving dimensional
details of the complete assembly shall accompany the tender. After
compression, dimensions of the joint shall be as indicated in
enclosed Appendix-2.
6.08 DETAILS OF COMPONENTS OF HARDWARE FITTINGS:
6.08.01 Armour Grip Suspension Clamp (AGS):
AGS fitting shall consist of 2 Neoprene Halves, a set of Helical rods
made of Aluminium alloy, two Aluminium halves casting having
inner profile matching with the profile of the Armour rod cage and
jointed by supporting strap made of Aluminium alloy.
Page 75 of 142
Volume-V (Part-1)
The Contractor should give complete data on the reduction of the

dynamic stresses of the Conductor at the point of AGS support
compared to that of bare clamp used with preformed types of
Armour rods.
The Contractor will be required to prove the comparative
performance in regard to the dynamic flexural stress pattern on the
vibrating Conductor on the tensioned span with actual tests on the
AGS unit compared to the normal bare clamp with Armour rods.
Suitable curves should be furnished for the same and also actual
reports on the stress/ strain determinations. The Contractor should
give the guaranteed value of the power loss of the AGS units to be
supplied by them supported by a test certificate of any reputed
laboratory of the country. Suitable curves should be furnished for
the power loss due to AGS unit as well as with the conventional
envelope type of Suspension Clamps.
The housing supports and housing straps should provide positive
stop closure. AGS unit should have low rotational inertia, strut
action of the Armour Cage, resilient cushioning of the neoprene
insert, immunity from high compressive and flexural stress and
wide area support. Manufacturer is required to guarantee minimum
fatigue life of the AGS units and this would be established under
actual tests on tensioned Conductor span. The manufacturer is
required to guarantee minimum 40 years life of the complete AGS
units including Neoprene cushioning and this should be established
under actual test on a tensioned Conductor span.
The rubber used with AGS unit must be capable of withstanding
desired long out-door performance including the variation of
temperature from 00C to 750C. The Contractor will have to provide
certificate from reputed manufacturers that the rubber being
supplied by them is suitable for AGS fitting and must have tensile
strength of 2000 PSI and minimum ultimate elongation 300%.
The helical retaining rods required for AGS assembly shall be made
of Aluminium alloy of HE 20 grade as per IS-6051/1970 or
equivalent International Standard duly heat treated and shall be
suitable to wrap a desired size of Conductor. The tensile strength
of the retaining rod material should not be less than 50,000 PSI
and the electrical conductivity should not be less than 40% (IACS).
The minimum slipping strength of the complete fitting shall not be
less than 15% and more than 20% of the UTS of the cable on
which it is to be used. The Clamp shall be in 2 parts made of
Aluminium and will have inner profile matching with the profile of
Armour rod. This Clamp should be made by drop forging process.
Page 76 of 142
Volume-V (Part-1)
AGS assembly should be provided with the forged steel socket eye
to match with the suspension string and should have UTS not less
than 7,000 kgs.
IT IS ESSENTIAL FOR THE CONTRACTOR TO HAVE SUITABLE
HEAT TREATMENT FACILITIES FOR ALUMINIUM ALLOY
WIRES IN THE ARMOUR GRIP SUSPENSION UNITS. FORMED
ROD BASED ITEMS WILL NOT BE ACCEPTABLE FROM
MANUFACTURERS
WHO
DO
NOT
HAVE
NECESSARY
TECHNOLOGY
FOR
DEVELOPMENT
OF
ADEQUATE
RESILIENCE,
ELONGATION
UTS
AND
TWIST
TEST
FACILITIES BACKED WITH PROPER HEAT TREATMENT
SYSTEMS.
6.08.02 AGS Preformed Armour Rods:
The AGS Preformed Armour rods set suitable for ACSR Zebra/
Panther conductor (as the case may be) shall be used to minimize
the stress developed in a conductor due to different static and
dynamic loads because of vibration due to wind, slipping of
conductor from suspension clamp as a result of unbalance
conductor tension in adjacent span and broken wire condition. It
shall be made of Aluminium alloy of HE 20 grade as per IS6051/1970 duly heat-treated. The aluminium alloy wires (pre heat
treated) for manufacturing of Armour rods can also be used,
however Contractor shall submit the test certificates in support of
their claim for using pre heat-treated wires. It shall also withstand
power arcs, chafing and abrasion from suspension clamp and
localized heating effects due to resistance losses of the conductor.
The pitch length of the rods shall be determined by the Contractor
but shall be less than that of the outer layer of ACSR conductor and
the same shall be accurately controlled to maintain uniformity and
consistently reproducible characteristics wholly independent of the
skill of lineman.
The preformed armour rod sets shall have right hand lay and the
inside diameter of the helices shall be less than the outside
diameter of the conductor to grip the same tightly. The surface of
the armour rod when fitted on the conductor shall be smooth and
free from projections, cuts and abrasions etc.
The length of each rod shall be as per drawing enclosed. The
tolerance in length of each rod shall be +/-25mm. The tolerance in
length of the rods in completed sets should be within 13 mm
Page 77 of 142
Volume-V (Part-1)
between the longest and shortest rod. The ends of the armour rod
shall be parrot billed.
The number of armour rods in each set shall be 11/12. The each
rod shall be marked in the middle with paint for easy applications
on the line.
The armour rod shall not loose their resilience even after five
applications. The conductivity of each rod of the set shall not be
less than 40% of the conductivity of International Annealed Copper
Standard (IACS). The minimum tensile strength of armour rod
should be 35 kg per sq.mm.
6.08.03 Strain Clamp:
The Strain Clamp shall be of the compression type for the specified
size of Conductor for 220/132KV lines. The outer sleeve of the
Compression Clamp and Jumper Terminal shall be of EC grade
Aluminium 99.5% pure tube formed by extrusion process and the
inner sleeves shall be of galvanized steel. The angle of jumper
terminal to be mounted should be 30 deg. with respect to the
vertical line. The Compression Clamp shall have slipping strength
not less than 95% of the ultimate breaking strength of Conductor
with which it is to be used. The compression dead end clamp for
transmission line shall be manufactured out of extruded Aluminium.
The resistance of the clamp when compressed on the conductor
shall not be more than 75% of the resistance of equivalent length
of conductor. Die compression line shall be clearly marked on each
dead-end assembly designed for continuous die compression and
shall bear the words COMPRESS FIRST suitably inscribed near the
point on each assembly where the compression begins. 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 ends of
the Zones. Tapered aluminium filler plugs shall also be provided at
the line of demarcation between Compression and Non-compression
zone. The letters, numbers and other marking on the finished
clamp shall be distinct and legible.
6.08.04 Arcing Horn:
132/220kV Insulator strings for transmission line shall be provided
with Arcing Horns of different type as indicated in the enclosed
drawings. In case of 132 kV line, the Arcing Horn shall be made
out of 25mm x 6mm size flat. At the ends of flat, spherical ball of
38 mm dia. shall be provided as shown in enclosed drawing. In
case of 220kV Hardware strings, the Arcing Horn shall be made out
Page 78 of 142
Volume-V (Part-1)
of 25mm dia steel pipe. The dimension of the Arcing Horn shall be
as indicated in the drawing. However, the height of the Arcing Horn
may be changed depending upon the length of Socket Eye, Yoke
Plate etc. Please note that Arcing Horn shall be strictly according to
above. Any other type of Arcing Horn including graded type, may
not be acceptable.
The designed fixture of the Arcing Horn with that of the string
Hardware of Yoke Plate shall be such that the possibility of relative
movement between the two, due to vibration of assembly in service
is altogether avoided. Making two bolt connections and providing a
collar to the Hardware item can achieve this. An additional nut
should be provided along with bolts and nuts to fix the Arcing Horn
with Hardware items. The provision of an additional nut will avoid
the possibility of relative movement between the Arcing Horn and
the Hardware item, due to vibration of string. The arrangement for
fixing of Arcing Horn shall be such that they do not get loose while
in service. To achieve this, they should have proper seat for the
Arcing Horn and heat-treated Belleville washers should be provided
with the bolts.
6.08.05 Socket Eye & Ball Clevis:
The Socket Eye and Ball Clevis be made of forged steel as per the
drawing enclosed.
6.08.06 U Clevis:
These shall be made of forged steel complete with galvanised steel
rivets washer and Phosphorus Bronze/Stainless Steel pins.
6.08.07 Ball Fittings:
These shall be made of forged steel in one piece. They shall be
normalized to achieve the minimum breaking strength specified in
the respective drawings. Before galvanising of ball fittings, all die
fleshing on the shank and on the bearing surface of the ball shall be
carefully removed without reducing the dimension below the
requirements. The dimension of the ball & socket shall be
16mm/20mm designation in accordance with standard dimensions
stated in IS:2486 (Part-II).
6.08.08 Dimensions & Tolerances:
6.08.08.1 The dimensions and tolerances of pin balls and socket
ends shall conform to IS 2486 Part-II/IEC-120 and shall be
checked by the gauge therein after galvanizing.
6.08.08.2 The pin balls shall be checked with the applicable GO
gauges in at least two directions, one of which shall be
Page 79 of 142
Volume-V (Part-1)
across the line of die flashing and the other 90 deg. to this
line. NO GO gauges shall not pass in any direction.
6.08.08.3 The bearing surfaces of balls and machined sockets,
before galvanizing shall not have surface roughness more
than 250 micro inches.
6.08.08.4 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.
6.08.09 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.
6.08.10 Security clip for Socket fittings:
6.08.10.1 Socket fittings shall be provided with R-shaped security
clip in accordance with IS:2486 (Part-III) 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 complete
withdrawal from the socket. The clip end shall not project
outside the recess of socket when the clip is in locked
position.
6.08.10.2 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.
6.08.10.3 The force required to pull the clip to its unlocked
position shall not be less than 50 N or more than 500N.
6.08.10.4 The security clip shall be made of stainless steel of type
AISI 302 or 304 or phosphor bronze as per IS:7814.
6.08.11 Clevis-Eye:
These shall be forged steel of malleable cast iron and shall be
complete with galvanised pin with flat washer and split pin of
Phosphorus Bronze/Stainless Steel.
Page 80 of 142
Volume-V (Part-1)
6.08.12 Yoke Plate:

6.08.12.1 The yoke plates/link plate shall be made of mild steel
plate as per IS: 2062 or equivalent standards.
Shearing/cutting of the plates shall be clean without drawn
or ragged edges. If the plates are flame cut, mechanical
guides shall be used. It shall be ensured that the grain
flow of the yoke plate shall be in the direction of the tensile
load.
6.08.12.2 Holes shall be cylindrical clean cut and perpendicular to
the plane of the material. The periphery of the holes shall
be free from burrs.
6.08.12.3 All the corners and edges should be rounded off with a
radius of at least 3mm.
6.08.12.4 Design calculation is for bearing and tensile strength for
deciding the dimensions of yoke plate shall be furnished by
the Contractor. The holes provided for bolts in the yoke
plate should satisfy shear edge condition as per IS:800.
6.09 IMPORTANT CONDITIONS:
6.09.01
All Hardware items shall be complete with minor items
such as security clip, bolts, nuts, washer, split pins and inners etc.
6.09.02
Enclosed drawings show the attachment proposed to be
fitted on the towers.
The Contractor shall be responsible for
satisfying him that the Insulator fittings offered are entirely suitable
for the proposed attachments and for the sizes of the Conductor
specified.
6.09.03
All ferrous fittings (except those specified otherwise)
shall be hot dip galvanized, after all machining and fitting has been
completed, in accordance with relevant Indian Standard. All
Hardware items (other than clamps) and those specified otherwise
should be made of Drop Forged Steel. Socket items in forged steel
must be forged. All forgings supplied should be stress relieved and
this treatment should be done at the Contractor works. Forgings,
which are not stress relieved, will not be acceptable. The items like
Yoke Plate, Arcing Horn, Bolts and Nuts shall be of mild steel and
rest of the items shall be of forged steel.
6.09.04
All Bolts, Nuts and Screw heads shall have only wide
worth standard thread and of sizes indicated in the enclosed
drawing. Bolts head and Nuts shall be hexagonal. Where required,
nuts shall be locked in approved manner. The thread in Nuts shall
be over tapped after galvanizing and shall be cut before galvanizing.
The threads shall not be under cut. The Nuts should be tapped such
Page 81 of 142
Volume-V (Part-1)
that they are fit on the bolt threads i.e. these should not have loose
fitting.
6.10 LENGTH OF STRINGS:
6.10.01
The clearance to the tower steel parts under service
conditions of Insulator have been decided on the basis that the
overall length of 9 Disc for 132kV line and 13 Disc for 220kV line
(both of 7000 kgs EMS for single suspension string) will not exceed
the length as indicated in the attached drawings. The dimension of
the Disc for Ball and Socket type will be
255mm (dia) x145mm
(height) for 7000 kgs EMS to be used with suspension strings on
132kV and 220kV lines.
6.10.02
In case of 132kV tension strings, 10 Disc insulators of
9100 kg EMS of size 255mm (dia) x 145mm (height) will be used.
In case of 220kV tension strings, 14 Disc insulators of 16,500 kgs
EMS of size 280mm (dia) x 170mm (height) will be used.
6.11 GALVANISING:
6.11.01
Hot dip galvanizing shall conform to Indian Standard
specification IS-2633 or equivalent International Standard.
Galvanising shall be uniform, free from blisters, and shall not peel
off due to abrasion, Zinc coating shall be thick enough to withstand
6 one minute dips in Copper Sulphate solution (precee test) for all
ferrous parts except for threaded portions which shall withstand at
least 4 one minute dips.
6.11.02
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.
6.12 TESTS :
6.12.01
The hardware fittings offered shall be type tested as per
the relevant standards. Further the acceptance, routine tests and
tests during manufacture shall be carried out on the conductor.
6.12.02
Acceptance tests shall mean those tests, which are to
be carried out on samples taken from each lot offered for predespatch inspection, for the purpose of acceptance of that lot.
6.12.03
Routine tests shall mean those tests which are to be
carried out on each and every product so as to check with
6.12.04
Tests during manufacture shall mean those tests, which
Page 82 of 142
Volume-V (Part-1)

6.12.05
The norms and procedure of sampling for these tests
will be as per the Quality Assurance Programme to be mutually
agreed to by the Contractor and the Employer.
6.12.06
The standards to which these tests will be carried out
are listed in para 6.01. Where a particular test is a specific
requirement of this specification, the norms and procedures of the
test shall be as mutually agreed to between the Contractor and the
Employer in the Quality Assurance Programme.
6.12.07
For all type and acceptance tests, the acceptance
values shall be the values guaranteed by the Contractor in the
Technical Questionnaire or the acceptance value specified in this
6.13 ACCEPTANCE TEST/SAMPLE TESTS:
6.13.01 On both suspension and tension hardware fittings:
a.
Visual Examination
IS:2486 (Part-I)
b.
IS:2486 (Part-I)
c.
Galvanising test/Electroplating
As per this
specification.
d.
Mechanical strength test of

welded joint
As per this
specification.
e.
Mechanical strength test for

corona control rings.
BS:3288(Part-I)
f.
Test on locking devices for ball &

socket coupling.
IEC:372(2)
g.
Mechanical strength test of each

components excluding corona
control ring and arcing horn.
As per this
specification.
6.13.02 On suspension Hardware fittings only:

a.
Clamp slip strength vs torque

test for suspension clamp.
b.
Shore hardness test of elastomer

cushion for AG suspension clamp.
c.
Bend test for armour rod set.
d.
Re silence test for armour rods

set.
e.
Conductivity test for armour rods

set
As per this
specification.
IS:2121 (Part-I)
Page 83 of 142
Volume-V (Part-1)
6.13.03 On tension hardware fittings only

a.
Slip strength test for dead end

assembly
IS:2486 (Part-I)
6.13.04 Suspension hardware for Earth wire.

a.
Visual examination
b.
Dimensional verification.
c.
Slip strength test.
d.
Mechanical strength test on each

component
Galvanising test
e.
f.
Mechanical strength test of

welded joint
6.13.05 Tension hardware for Earth

wire
a.
Visual examination
b.
c.
Slip strength test.
d.
Electrical resistance test .
6.13.06 Test during manufacture.

a.
On all components as applicable.
b.
Chemical analysis of zinc used for

galvanizing
Chemical analysis, hardness test
grain size inclusion rating and
magnetic particle inspection for
forgoing/castings.
Chemical analysis and proof load
test fabricated hardware.
Tests on malleable castings
forgings and fabricated
hardwares.
c.
d.
e.
6.14 MATERIALS AND WORKMANSHIP:

6.14.01
All the materials shall be of the latest design and
conform to the best modern practice adopted in the extra high
voltage field. The manufacturer shall supply only such material as
guaranteed by him to be satisfactory and suitable for 220/132kV
Transmission lines.
Page 84 of 142
Volume-V (Part-1)
6.14.02
The design, manufacturing process and quality control
of all the materials shall be such as to give maximum factor of
safety, maximum possible working load, highest mobility,
elimination of sharp edges and corners, best resistance to corrosion
and a good finish.
6.14.03
All ferrous parts shall be hot dip galvanised, after all
machining has been completed. Nuts may, however, be tapped
(threaded) after galvanising and the threads oiled. Spring washers
shall be electro galvanised. The bolts threads shall be under cut to
take care of increase in diameter due to galvanising. Galvanising
shall be done in accordance with IS:2629-1990 or equivalent
International Standard and satisfy the tests mentioned in IS:26331992 or equivalent International Standard.
Fasteners shall
withstand four dips while spring washers shall be guaranteed to
withstand at least six dips each lasting one minute under the
standard precee test for galvanising.
6.14.04
The Zinc coating shall be perfectly adhere, of uniform
thickness, smooth, reasonably bright, continuous and free from
imperfections such as flux, ash, rust stains, bulky while deposits
and blisters. The Zinc used for galvanising shall be grade Zn. 99.95
as per IS: 209-1992 or equivalent International Standard.
6.14.05
In case of castings, the same shall be free from all
internal defects like shrinkage, inclusion, blowholes, cracks etc.
6.14.06
All current carrying parts shall be so designed and
manufactured that contact resistance is reduced to minimum.
6.14.07
No item which would produce high electrical and
mechanical stresses in normal working shall have sharp ends or
edges, abrasions or projections and shall not cause any damage to
the Conductor in any way during erection or during continuous
operation. The design of adjacent metal parts and mating surfaces
shall be such as to prevent corrosion of the contact surface and no
maintain good electrical contact under service conditions.
6.14.08
Particular care shall be taken during manufacturing and
subsequent handling to ensure smooth surface free from abrasion
or dents.
6.14.09
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.
6.15 IDENTIFICATION MARKING:
The main component of the material covered in the specification
shall be legibly and indelibly marked with the trademark of the
Page 85 of 142
Volume-V (Part-1)
manufacturer, the month and year of manufacture, the guaranteed

combined mechanical and electrical strength in kilo-Newton
abbreviated by kN to facilitate easy identification and proper use.
Marks shall be forged or stamped with a steel die before
Galvanizing. The marks shall be distinct, durable and conspicuous.
Embossing/Engraving should be done at the time of manufacturing
process itself, but before Galvanizing. Smaller component like bolts
& nuts, split pin and washers etc. may be excluded from this
requirement.
6.16 QUALITY ASSURANCE PROGRAM :
of the employer.
6.17 INSPECTION :
6.17.01
6.17.02
The acceptance of any quantity of material shall in no
way relieve the Contractor of his responsibility for meeting all the
requirement of this specification and shall not prevent subsequent
rejection, if such materials are later found to be defective.
6.17.03
tests of the material covered in the specification.
6.18 DOCUMENTATION & LIST OF DRAWINGS:
6.18.01
The detailed drawings of each component assembly
drawings and descriptive literature of the Hardware assembly shall
be submitted for approval of EMPLOYER. The detailed dimension
drawings for each and all-individual Hardware items such as clamps,
U Clevis, Socket Eye, Yoke Plate and Socket Clevis etc. shall also be
submitted separately. Test certificates for different tests conducted
as per relevant ISS, for all the offered items must also be submitted
essentially.
6.18.02
The bidder shall furnish full description, illustrated
catalogues and dimensional drawings, along with the bid. The
drawing shall include the following information:
Page 86 of 142
Volume-V (Part-1)
(i)
General outline & assembly drawings of all the items

/material covered in the specification.
(ii)
Dimensions, unit spacings
(iii)
Unit mechanical and electrical characteristics as also for

the complete
assembly/set .
(iv)
Weight of each component.
(v)
Identification mark.
(vi)
Material designation used for different components with

reference to Standards.
(vii) Fabrication details such as welds, finishes and coatings

(viii) Manufacturers catalogue number.
(ix)
(x)
Reference of type testing.
(xi)
6.19 PACKING:
6.19.01
The material shall be packed in strong wooden boxes
with steel straps. The gross weight of packing shall be in range of
50 kgs to 200 kgs to avoid handling problem. The packing shall be
strong enough to withstand rough handling during transit or storage
in the field. All the packing cases shall be legibly marked to avoid
possibility of loss in transit. The Contractor shall be responsible for
any damage during transit due to improper and inadequate packing
and handling.
6.19.02
Each consignment shall be accompanied by a detailed
packing list showing following details:(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
package.
indicating
content
of
each
Page 87 of 142
Volume-V (Part-1)
APPENDIX-2
BEFORE AND AFTER COMPRESSION DIMENSIONS OF
COMPRESSION TYPE DEAD-END CLAMPS AND REPAIR
SLEEVE FOR CONDUCTOR AND EARTH WIRE
Dimension before
compression (Rod
cross section)
Dimension after
Length of sleeve Length of sleeve
compression (Flat
before
after compression
to flat distance of
compression
Sl.
Particular
hexagon)
No.
Panth Zebr G/ W Panth Zebra G/ W Panth Zebr G/ W Panth Zebr G/ W
er
a
er
er
a
er
a
A Aluminium sleeve
a
B
a
Inner
dimension
(mm)
Outer
dimension
(mm)
Steel sleeve
Inner
dimension
(mm)
Outer
dimension
(mm)
Repair sleeve
Outer
dimension
(mm)
23
31
38
48
32
40
9.35
9.95
11.5
18
19.2
21
15
16.1
38
48
20.8
32
46
610
711
660
763
17.5
203
241
230
233
270
262
17.5
241
279
150
270
310
175
Page 88 of 142
Volume-V (Part-1)
SECTION- 7
TECHNICAL SPECIFICATION FOR ACCESSORIES FOR
220/132kV LINES
7.01 INDIAN STANDARDS/EQUIVALENT
STANDARD:
INTERNATIONAL
This section provides for the Design, manufacturing, stage testing,

inspection and testing before despatch, packing and delivery of
Accessories suitable for Conductor and Earth wire for use on
132/220kV 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 here
under or equivalent International Standards, except as modified in
this document:
S.No
1
2
3
4
Indian
Standard/equivalent
International Standards
IS:209-1992
IS:206 1992
IS:7814-1985
IS:2071 Part-I, II & III
IS:731
6
7
IS:961
IS:1385
IS:2004
9
10
11
IS:2107
IS:2108
IS:2121(Part-I & II)
12
IS:2486
Title

Porcelain Insulator for Overhead
Power Lines with a Nominal Voltage
Structural Steel
Phosphor Bronze Rods & Bar Sheet
and Strips and Wire
Carbon Steel Forgings for General
Engineering Purpose
Specification for Conductors and Earth
wire Accessories for Overhead Power
Line, Armour Rods Binding Wires and
Tapes for Conductor
Overhead
Power Lines with a Nominal Voltage
Page 89 of 142
Volume-V (Part-1)
13
Indian
Standard/equivalent
Part-I
Part-II
Part-III
Part-IV
IS:2629
14
IS:2633
15
16
17
IS:3138
IS:6639
IS:6745
18
IS:3188
19
20
IS:4218 Part-I to VI
IS:4172
21
IS:4206
22
IS:4759
23
IS:1573-1986
24
IS: 398 (Part-II & III)
25
IS: 1327-1966
26
IS: 4826-1979
27
28
IS: 1363 Part-I to III

IS: 1367
S.No
IS: 1367 (Part-I)

IS: 1367 (Part-II)
IS: 1367 (Part-III)
Title
General Requirements and Tests

Locking Devices
Tests for Locking Devices
Testing of Uniformity of Coating of
Zinc coated Articles
Determination of Weight of Zinc
Coating on Zinc Coated Iron and
Steel Articles
Characteristic of String Insulators
Units
Isometric screw Threads
Dimensions for Radii under the Heads
of Bolts & Screws
Dimensions for nominal lengths and
Thread length for Screws and Studs
(with amendment)
Hot Dip Zinc Coatings on Structural
Steel and other Allied Products
Electroplated Coatings of Zinc on Iron
and Steel
Specification for Aluminium Conductor
Steel Reinforced for overhead
transmission purpose.
Methods for determination of weight of
tin Coating on Tin Plates
Hot Dip Galvanised Coating on
Round Steel Wires
Technical
supply
conditions
for
threaded Steel Fasteners.
Introduction
and
General
Information.
Product Grades and Tolerances.
Mechanical Properties and Test
Methods for Bolts, Screws and Studs
Page 90 of 142
Volume-V (Part-1)
S.No
Indian
Standard/equivalent
Title
with full Load ability.

Stockbridge Vibration Dampers for
Overhead Power lines.
29
IS: 9708
30
IS: 8263

on High Voltage Insulators.
31
IS:10162
Spacers and Spacer Dampers for

twin horizontal bundle Conductors.
32
IS: 2004
Carbon Steel Forgings for general

engineering purposes.
33
BS:970 (Part-I)
General Instructions and Testing

Procedures Specific Requirements for
Carbon and Carbon Manganese Alloy
and Stainless Steels.
7.02 PRINCIPAL PARAMETERS:

7.02.01
Bidders will have to furnish confirmation in regard to
compliance of our entire technical requirement. The bid should
clearly describe various technical particulars of the material as per
details given in this section. Based on above information all details
required should be furnished so that we may be able to examine
whether the bid submitted is technically acceptable or not.
7.02.02
Details of Accessories:
i.
The Conductor Accessories shall be suitable for ACSR

Conductor as per technical parameters furnished in
Annexure-6.
ii.
The Earth wire accessories shall be suitable for Earth

wire
as per technical parameters furnished in
Annexure-6.
7.03 GENERAL TECHNICAL REQUIREMENTS FOR

ACCESSORIES:
The technical requirements of the individual Accessories are
as under:
7.03.01
i.
Mid Span Joints and Repair Sleeves:

The Mid Span Joints for Conductor & Earth wire shall be
compression type.
Page 91 of 142
Volume-V (Part-1)
ii.
The Conductor Mid Span Joints shall comprise of

Aluminium and Steel Sleeves. The Earth wire Mid Span
Joints and Steel Sleeves of Conductor Mid Span Joints shall
be Hot dip Galvanized. Sleeves shall be of circular shape
suitable for compression into hexagonal shape. The
detailed drawing showing the length of Sleeves, inner and
outer cross sectional dimension, before compression for
Aluminium corresponding dimensions of hexagon after
compression for Aluminium and Steel Sleeve shall be
indicated. The Aluminium Sleeve shall be of extruded
Aluminium. The material of the Steel Sleeve shall be
specified.
iii.
The Repair Sleeve of Conductor shall be in two halves

preferably of same shape, and this should be of extruded
Aluminium. The Repair Sleeve for Earth wire shall be single
piece and Hot dip Galvanized.
Its material shall be
specified. The Repair Sleeves shall be of circular shape
suitable for compression into hexagonal shape.
iv.
The steel and Aluminium Sleeves for Mid Span Joints as

well as Aluminium Repair Sleeves and Steel Repair Sleeves
shall have their outer dia tapered towards the two ends.
Also the inside of the Sleeves shall be well rounded off, so
that there is no sharp edge, which can cut the strands.
v.
The compression type of Joints and Repair Sleeves shall be

circular shape suitable for compression into hexagonal
shape. The length of Sleeves before compression & crosssectional dimensions after compression and the cross
sectional dimensions between the flats of the opposite
sides of the hexagon & other dimensions are indicated in
Appendix-2, Section-6 in Volume-II of bid document.
vi.
Other dimensions are indicated in the enclosed drawing.
vii.
The Joints and Repair Sleeves shall conform

IS:2121/1981 or equivalent International Standard.
viii.
The conductor compressed with mid span joint or with

repair sleeve shall not permit slipping of, damage to or
failure of complete conductor or any part thereof at a load
of not less than 95% of the ultimate tensile strength of the
conductor.
ix.
The electrical resistance of the joint/repaired portion of the

conductor shall not exceed 75% of the measured
resistance of equivalent length of conductor.
to
Page 92 of 142
Volume-V (Part-1)
7.03.02
4R-VIBRATION DAMPERS FOR PANTHER & ZEBRA

ACSR:
7.03.02.1 Only Vibration Dampers having 4-resonance frequency

characteristic commonly called 4R Dampers shall be
offered.
The Damper shall eliminate fatigue on the
Conductor due to vibration and damp-out the vibrations
effectively, so that no damage due to vibration is caused to
Conductor and string.
7.03.02.2 The Dampers are to be used at all tension locations and
suspension locations. One or more Dampers are proposed
to be used on tension/suspension locations depending upon
the span. The Damper shall be such as to effectively damp
out the vibration on the conductor, so that the dynamic
strain at the suspension point with conventional type of
Suspension Clamp U bolt and keeper pieces, shall not
exceed 150 micro strains. Contractor shall recommend the
number of Dampers required to effectively damp out the
vibration of the Conductor, so that the dynamic strain at
the suspension point with conventional Suspension type
Clamp shall not exceed 150 micro strains.
7.03.02.3 The requirement indicated in Schedule-I Ais based on
use of two Vibration Dampers per Conductor per span.
However, final requirement will depend upon Bidders
recommendations duly supported by literature. Contractor
shall also recommend the number of Dampers required to
effectively damp out Conductor vibration for different
values of span lengths and the distance for fixation. While
working out Damper Characteristics, it may be kept in view
that on suspension locations, preformed Armour rods are
also to be fitted on the conductor. Contractor shall given
full details of the damper characteristics and energy
dissipation curves of the Damper and shall also guarantee
their effectiveness for damping design.
7.03.02.4 The messenger cable shall be made of high strength
steel strands of spring steel with a minimum strength of
136 Kg/sq. mm and preformed in order to prevent
subsequent dropping of weights in service. The Contractor
shall indicate full technical particulars of the messenger
cable. The keeper pieces shall have proper curvature and
edges be rounded off so that it shall have proper grip over
the conductor without any damage to conductor strands.
Clamping bolts shall be provided with self-locking nuts
designed to prevent corroding of the threads or loosening
during service ensuring that no slippage occurs up to
specified longitudinal force on clamp along the conductor.
Page 93 of 142
Volume-V (Part-1)
All ferrous parts including the messenger cable shall be

effectively sealed to prevent corrosion.
7.03.02.5 The collar for fixing the bolt shall be designed in such a
way that sufficient space is available for tightening the bolt
through spanner. Further bolt length be maintained in such
a way that it should not come out completely while affixing
the clamp on Conductor.
7.03.02.6 The Contractor shall specify the material used for the
Damper weight and shall confirm and explain, how
constant design characteristics will be maintained during
production. Fixing of the masses to the messenger cable
shall be done by pressing Aluminium Sleeves at each end
of the messenger cable under pressure. Each end should
be sealed properly so as to achieve prefect joint. The
molten metal filling method for attachment of messenger
cable to counter weight is not acceptable.
7.03.02.7 The Dampers shall meet the test requirements
specified hereunder:
The effectiveness of the Vibration Dampers shall be to
reduce the amplitude of vibration, when tested for span of
320 meters for Panther and 335 meters for Zebra ACSR,
tension taken as 25% of ultimate tensile strength in such a
order that it limits the dynamic strain in the Conductor
below 150 micro strains for 0 to 15 miles per hour wind
condition in general and 2 to 10 miles per hour wind
condition in particular condition, conforming to as close as
possible to the optimum damping force
requirement
which the Contractor can predict and furnish for the ranges
of wind velocity and the conductor tension.
7.03.02.8 The Contractor shall furnish the recommended spacing
and the basis including wind velocity range for selecting
the spacing. The results of the analysis shall account for
the following:
i.
Prediction of (a) Amplitude (b) Frequency and (c)

Vibration energy levels of Aeolian vibration on Panther
and Zebra ACSR for spans of 50, 100, 150, 200, 250,
300, 350, 400, 450 and 500 meters.
ii.
Test
results
for
various
frequency
response
characteristics of Vibration Dampers such as vibration
amplitude and phase angle including power dissipation
measured from its hysteretic loops.
7.03.02.9 Maximum residual vibration must be of such an order

that the strain level does not exceed 150 micro strains.
Page 94 of 142
Volume-V (Part-1)
7.03.02.10 The Vibration Dampers and their attachments shall have

smooth surface so that corona and radio interference
voltage levels are within specified limits.
7.03.02.11 All Ferrous parts shall be fully galvanized..
7.03.02.12 The Vibration Damper shall be capable of being installed
and removed from energized line by means of hot line
tools without completely separating components.
The
Damper Assembly shall be electrically conductive. The
transmission line details are as under:Description
S.
No.
Technical Particulars
220kV
132 kV
Single ACSR Single ACSR
Zebra
Panther
Configuration
Span length in meters:

i.
Ruling design span
350
350
ii. Maximum span
500 M
500 M
iii. Minimum span
100
100
Tensile load in Kg:

i. At minimum temp. of
and still air
0o C
4064
2794
ii. At every day temp. of 32o

C
3329
2282
iii. At 0o C and 2/3rd full wind
4360
3050
Nature of terrain
Partly hilly, partly flat with

cultivated fields
Armour rods/AGS clamp
Maximum wind load
Max
permissible
strains
AGS clamps
45 Kg/m2 Acting on full
projected area.
dynamic
150 micro strains
The Contractor shall recommend the number of vibration dampers

of the type offered and their points of fixation for spans of 100M to
1000M in steps of 50M.
7.03.02.13 The other important features of vibration dampers

as regards to materials test, etc., are as under: -
Page 95 of 142
Volume-V (Part-1)
Material:
i.
Dampers
ii.
Clamp
iii.
Messenger cable
- High strength steel wire with a

strength (kg/sq. mm) not less than
the strength of steel core of power
Conductor/Earth Wire.
iv.
As per IS-9708/1993
International Standard.
Weight
or
equivalent
Aluminium alloy
Cast Iron (Hot dip Galvanized)
Galvanising:
i.
Spring washers
Electro Galvanized.
ii.
Other Ferrous parts - Hot Dip Galvanized.
iii.
Casting
- As per IS:729-1961 or equivalent

iv.
Wires

v.
Bolts & Nuts

Slip strength of Clamp:

i.
Not less than 250 kg. When an untested Vibration

Damper is installed on Panther and Zebra ACSR
Conductor.
ii.
Not less than 200 kg. After conducting the fatigue test.
Maximum permissible dynamic strain

strains.
on the Conductor with the Damper
150 micro
Minimum number of cycles for fatigue

Performances.
Amplitude for fatigue test
highest
1 mm at the
Resonant
frequency.
Radio interference voltage at
microvolts.
266 kV (rms) phase to ground.
10 millions
Less than 500
Page 96 of 142
Volume-V (Part-1)
7.04 4R VIBRATION DAMPERS FOR 7/3.66MM 95 Kg PER

MM2 QUALITY EARTH WIRE:
7.04.01
The design and general particulars of Vibration Damper
for Earth wire shall be the same as described for Dampers for
Conductor, Preformed Armour Rods will be used at Earth wire
suspension locations. The dynamic strain at suspension point shall
not exceed 150 micro strains.
7.04.02
The entire test as described for Vibration Dampers for
Conductor shall be carried out except for Magnetic Power Loss Test.
7.05 FLEXIBLE G.I. EARTH BONDS:
The flexible G.I. MS earth bond shall be made of flexible MS wire of
size 37/7/0.417 with 9.81mm dia and area equivalent to 34 sq.mm.
The length of MS wire shall not be less than 500mm. Two steel
connecting lugs shall be press jointed to the either ends of the
flexible MS cable. One end of the lug shall have hole of 17.5mm size
and another of 14.5mm. The complete assembly shall also include
one 16mm dia 40mm long HRH M.S.Bolt hot dip galvanized with nut
and lock washer.
7.06 TECHNICAL PARTICULARS FOR CLAMPS
7.06.01
All the current carrying parts shall be designed and
manufactured to have minimum contact resistance. There shall not
be any sharp edges which may lead to accumulation of charge &
electrical breakdown. All corners/ edges shall be rounded.
7.06.02
The clamps shall be liberally designed and certain
minimum contact surface shall be provided.
7.06.03
The clamps and fittings shall be designed so that
insulators shall not be subject to any abnormal stresses due to
thermal changes in conductor.
7.06.04
All the clamps & fittings shall enable the connection to
be as short as possible. Wherever possible the clamps shall be two
separate halves. No U bolts shall be used. All components of like
design shall be inter-changeable
7.06.05
All nuts, bolts & washers shall be made of Hot dip
galvanized Mild Steel conforming to relevant ISS only.
7.06.06
The clamp in all respect shall incorporate highest
quality of modern engineering design and workmanship. The
specification is merely for the guidance of the Contractor as has
been clearly stated earlier and it is not the intention to specify the
details of design and workmanship. The clamps shall be designed
and manufactured in accordance with the Contractors standard
practices, when such practices do not conflict with this specification.
Page 97 of 142
Volume-V (Part-1)
7.06.07
The materials offered shall be complete with all
components and accessories which are necessary or useful for their
satisfactory performance and efficient maintenance. Such parts
shall be deemed to be within the scope of this specification whether
specifically included or not.
7.06.08
The design should be such that adequate clamping
pressure is obtained with the tightening of the nuts and the
pressure should be maintained throughout the service of the
connector. In order to provide for creep of Aluminium under
pressure, it is essential that only Belleville washers are used. This
should be specifically confirmed and should also indicate tightening
torque required.
7.06.09
All clamps shall be suitable to carry safely the maximum
allowable current in the associated conductor and to withstand the
maximum loads occurring under adverse circumstances and
operating conditions. The maximum fault current is 40 KA rms for a
period of 3 seconds. The temperature of the clamps and fittings
shall never exceed that of the associated conductor.
7.06.10
Fittings intended to connect two dissimilar metals shall
be designed to avoid harmful bimetallic corrosion under service
condition, by way of provision of best quality bimetallic strips.
7.06.11
The short circuit current shall be of the order of 40 KA
for 3 seconds. The clamps should be suitable to withstand the short
circuit forces corresponding to this current.
7.06.12
The design of clamps should be such that proper space
for movement of normal quality single head spanner during
tightening is available. This is an important requirement and should
be confirmed by the Contractor.
7.07 Materials:
7.07.01
The Clamps & Connectors/Spacers shall be made of
materials listed below: i.
For connecting ACSR conductor Aluminium alloy casting

conforming to designation A6 of IS:617.(Redesignation
4600)
ii.
Bolts, Nuts, plain washers and spring washers for above

items shall be made of hot dip galvanized Mild Steel
conforming to relevant IS only.
The Contractor shall ensure that the Alloy used assures
good stability and sound casting by proper fluidity. Proper
mechanical and physical strength characteristics should be
Page 98 of 142
Volume-V (Part-1)
obtained corresponding to the standard requirements of

the Alloy specified.
7.07.02
The Contractor shall ensure that the Alloy used assures
good stability and sound casting by proper fluidity. Proper
mechanical and physical strength characteristics should be obtained
corresponding to the standard requirements of the Alloy specified.
7.07.03
The clamps bodies shall be made by gravity die-casting
only and thereafter given the appropriate heat treatment and
precipitation treatment. Clamps bodies made by sand casting shall
not be accepted in any case.
7.08 CASTINGS:
All casting shall be free from blow holes, surface, Blisters and shall
be rounded off.
7.09 CONSTRUCTIONAL DETAILS:
7.09.01
All sharp edges and corners shall be blurred and
rounded off.
7.09.02
Thickness of the clamps shall not be less than 12mm
7.09.03
Bolts and nuts shall have hexagonal heads and threads
as per Indian Standard.
7.09.04
Flexible connectors, braids or laminated straps shall be
made from tinned copper strips or aluminium laminates depending
upon the clamp.
7.09.05
Size of terminal / conductor for which the clamps is
suitable shall be embossed on each component of the clamp.
7.09.06
Casting should be such that adequate free space for
placement and movement of spanners for tightening of nuts is
available.
7.10 BOLTS, NUTS & WASHERS:
These shall be as per Indian Standard and shall have tensile
strength and elongation as per grade 5.6. The Contractor should
ensure proper tightening either by use of Belleville or by the use of
torque wrenches.
7.11 GALVANISING:
Hot dip galvanizing shall conform to Indian Standard specification
IS-2633 or equivalent International Standard. Galvanising shall be
uniform, free from blisters, and shall not peel off due to abrasion,
Zinc coating shall be thick enough to withstand 6 one minute dips in
Copper Sulphate solution (precee test) for all ferrous parts except
Page 99 of 142
Volume-V (Part-1)
for threaded portions which shall withstand at least 4 one minute

dips.
7.12 TESTS:
7.12.01
The hardware fittings offered shall be type tested
as per the relevant standards. Further the acceptance, routine
tests and tests during manufacture shall be carried out on the
conductor.
7.12.02
Acceptance tests shall mean those tests, which are to
be carried out on samples taken from each lot offered for predespatch inspection, for the purpose of acceptance of that lot.
7.12.03
Routine tests shall mean those tests which are to be
carried out on each and every product so as to check with
7.12.04
Tests during manufacture shall mean those tests, which
7.12.05
The norms and procedure of sampling for these tests
will be as per the Quality Assurance Programme to be mutually
agreed to by the Contractor and the Employer.
7.12.06
The standards to which these tests will be carried out
are listed in para 6.01. Where a particular test is a specific
requirement of this specification, the norms and procedures of the
test shall be as mutually agreed to between the Contractor and the
Employer in the Quality Assurance Programme.
7.12.07
For all type and acceptance tests, the acceptance
values shall be the values guaranteed by the Contractor in the
Technical Questionnaire or the acceptance value specified in this
7.13
TYPE TESTS:
7.13.01
Flexible G.I. Bond for Earth wire:
Slip strength test

7.13.02
Mid span compression joint for conductor & Earth
wire.
i.
ii.
Iii
iv.
Slip strength test

Electrical Resistance test
Healing cycle test
Corona Extinction voltage
test dry.
As per IS 2121,2633
6745
Page 100 of 142
Volume-V (Part-1)
v.
Radio interference voltage

test Dry.
Galvanising test
vi.
7.13.03
Repair Sleeve for conductor:

i. Electrical Resistance test.
ii. Corona Extinction Voltage test. As per IS 2121
iii. Radio Interference voltage test dry.
7.13.04
Vibration Damper for conductor & Earth wire

a.
b.
c.
d.
e.
f.
g.
h.
i.
Chemical analysis of material

Dynamic Characteristic Test.
Vibration Analysis.
Clamp Slip test.
Fatigue Test.
Magnetic power loss test.
Corona extinction voltage test (Dry).
Radio interference voltage test (Dry).
Damper efficiency test.
NOTE:
Tests mentioned at (f)(g)&(h) are not applicable to
dampers for Earth wire.
7.13.05
Clamps
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Tensile Test
Resistance Test
Temperature rise Test
Short time current Test
Dimensional Check
Galvanising Test
As per IS:5561
7.14 ACCEPTANCE TEST:

7.14.01
a.
b.
c.
FLEXIBLE G.I. BOND:
Visual examination
Dimensional verification
Slip strength test.
7.14.02
Midspan
Compression
Conductor & Earth wire
i.
ii.
iii.
iv.
IS:2121
Joint
for
Power
Visual examination
Galvanising Test
Hardness test.
Page 101 of 142
Volume-V (Part-1)
v.
Failing load test (test to be

conducted after 24 hours of
compression).
7.14.03
i.
ii.
Repair Sleeves for Conductor.
Visual examination
7.14.04
Vibration Damper for power conductor/ Earth
wire.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
Visual examination
Galvanising Test
Verification of resonance
frequencies
Clamp slip test
Clamp bolt torque test
Strength of messenger cable.
Mass pull off test.
7.14.05
i.
ii.
iii.
iv.
Tensile Test
Resistance Test
Dimensional Check
Galvanising Test
7.14.06
i.
ii.
iii.
iv.
v.
Clamps
Test during manufacture.

galvanizing
Chemical analysis, hardness test
grain size inclusion rating and
forgoing/castings.
Chemical analysis and proof load
test.
Tests on malleable castings
forgings and fabricated
hardwares.
7.15 MATERIAL AND WORKMANSHIP:

7.15.01
All the materials shall be of the latest design and
conform to the best modern practice adopted in the extra high
voltage field. The Contractor shall offer only such equipment as
guaranteed by him to be satisfactory and suitable for 220/132kV
Transmission lines.
Page 102 of 142
Volume-V (Part-1)
7.15.02
The design, manufacturing process and quality control
of all the materials shall be such as to give maximum factor of
safety, maximum possible working load, highest mobility,
elimination of sharp edges and corners, best resistance to corrosion
and a good finish.
7.15.03
All ferrous parts shall be hot dip galvanised, after all
machining has been completed. Nuts may, however, be tapped
(threaded) after galvanising and the threads oiled. Spring washers
shall be electro galvanised. The bolts threads shall be under cut to
take care of increase in diameter due to galvanising. Galvanising
shall be done in accordance with IS:2629-1966 or equivalent
International Standard and satisfy the tests mentioned in IS:26331972 or equivalent International Standard.
Fasteners shall
withstand four dips while spring washers shall be guaranteed to
withstand at least six dips each lasting one minute under the
standard precee test for galvanising.
7.15.04
The Zinc coating shall be perfectly adhere, of uniform
thickness, smooth, reasonably bright, continuous and free from
imperfections such as flux, ash, rust stains, bulky while deposits
and blisters. The Zinc used for galvanising shall be grade Zn. 99.95
as per IS: 209-1966 or equivalent International Standard.
7.15.05
In case of castings, the same shall be free from all
internal defects like shrinkage, inclusion, blowholes, cracks etc.
7.15.06
All current carrying parts shall be so designed and
manufactured that contact resistance is reduced to minimum.
7.15.07
No item which would produce high electrical and
mechanical stresses in normal working shall have sharp ends or
edges, abrasions or projections and shall not cause any damage to
the Conductor in any way during erection or during continuous
operation. The design of adjacent metal parts and mating surfaces
shall be such as to prevent corrosion of the contact surface and no
maintain good electrical contact under service conditions.
7.15.08
Particular care shall be taken during manufacturing and
subsequent handling to ensure smooth surface free from abrasion
or dents.
7.15.09
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.
7.16 IDENTIFICATION MARKING:
The main component of the material covered in the specification
shall be legibly and indelibly marked with the trademark of the
manufacturer, the month and year of manufacture, the guaranteed
Page 103 of 142
Volume-V (Part-1)
combined mechanical and electrical strength in kilo-Newton

abbreviated by kN to facilitate easy identification and proper use.
Marks shall be forged or stamped with a steel die before
Galvanizing. The marks shall be distinct, durable and conspicuous.
Embossing/Engraving should be done at the time of manufacturing
process itself, but before Galvanizing. Smaller component like bolts
& nuts, split pin and washers etc. may be excluded from this
requirement.
7.17 QUALITY ASSURANCE PROGRAM
of the employer.
7.18 INSPECTION :
7.18.01
7.18.02
At least 5% of the total number of drums subject to
random to ascertain the length of conductor by following method:
At the works of the manufacturer the conductor shall be
transferred from one drum to another at the same time measuring
its length with the help of graduated pulley and Cyclometer. The
difference in the average length thus obtained and as declared by
the Contractor in the packing list shall be applied to all the drums if
the conductor is found short during checking
7.18.03
tests of the Conductor.
7.19
DOCUMENTATION & LIST OF DRAWINGS
7.19.01
The Contractor shall submit the detailed drawings of the
Accessories offered and descriptive literature. The dimensional
drawings for compression type Mid Span Joint (Aluminium & Steel
Sleeve), compression type Repair Sleeve Preformed Armour rods for
Conductor & Earth wire and 4R Vibration Dampers etc. must be
submitted. Test certificates for different tests conducted as per
relevant ISS, for all the offered items must also be submitted
essentially.
Page 104 of 142
Volume-V (Part-1)
7.19.02
The bidder shall furnish full description, illustrated
catalogues and dimensional drawings of offered items ,along with
the bid.. The drawing shall include the following information:
(i)
General outline & assembly drawings of all the items

/material covered in the specification.
(ii) Dimensions, unit spacing
(iii) Unit mechanical and electrical characteristics as also for
the complete
assembly/set .
(iv) Weight of each component.
(v) Identification mark.
(vi) Material designation used for different components with
reference to Standards.
(vii) Fabrication details such as welds, finishes and coatings
(viii) Manufacturers catalogue number.
(ix) Brief installation instructions.
(x) Reference of type testing
(xi) Relevant technical details of significance.
7.20
PACKING:
7.20.01
The material shall be packed in strong wooden boxes
with steel straps. The gross weight of packing shall be in range of
50 kgs to 200 kgs to avoid handling problem. The packing shall be
strong enough to withstand rough handling during transit or storage
in the field. All the packing cases shall be legibly marked to avoid
possibility of loss in transit. The bidder shall be responsible for any
damage during transit due to improper and inadequate packing and
handling.
7.20.02
Each consignment shall be accompanied by a detailed
packing list showing following details:(ii)
(iii)
(iv)
(v)
(vi)
(vii)
The name of the consignees

Details of consignment.
Destination.
Total weight of consignment.
Handling and unpacking instrumentation.
Bill of material indicating content of each package.
Page 105 of 142
Volume-V (Part-1)
SECTION- 8
TECHNICAL SPECIFICATION FOR ERECTION OF
220KV AND 132KV TRANSMISSION LINES
8.01
INDIAN STANDARDS/CODE :
The material and services under this section shall conform to the
requirements of the latest revisions and amendments available at
the time of placement of order of all the relevant Indian
standards/codes listed here under or equivalent International
Standards, except as modified in this document.
S.N
o.
1.
Indian standards
Title
IS:5613-1995
(part-II)
Code
of
practice
for
design,
installation and maintenance of
overhead power lines.
Sec.-1
- Designs.
Sec.-2
Installation
&
Maintenance
2.
IS:269-1967
Ordinary rapid hardening and low

heat Portland cement.
3.
IS:456-2000
Code of practice for

reinforced concrete
plain and
4.
IS:1786-1966
Cold
twisted
steel
concrete reinforcements
bars
5.
IS:4091-1967
Code of practice for design &

construction
of
foundation
for
transmission line towers & poles
8.02
for
LINE MATERIALS:
8.02.01 Conductor:
The conductor used in the132kV line will be single ACSR Panther

Conductor and the conductor size is 30/3.00mm A1. + 7/3.00 mm
steel and the conductor used in the 220kV line will be single ACSR
Zebra Conductor and the conductor size is 54/3.18mm A1. + 7/3.18
mm steel.
8.02.02
Earth wire :
Page 106 of 142
Volume-V (Part-1)
The Earth wire to be used on the line shall be 7/3.66 mm; 95

kg/mm2 quality galvanized steel stranded wire.
8.02.03 Insulator Strings with Hardware Fittings:
(A)
For 220kV lines

(i)
Single suspension and single tension strings will be used

on the line as under:
a.
At suspension locations:
13 disc single suspension strings having 70KN E&MS
of 255x145 mm size disc insulators with AGS type
clamps will be used.
b.
At tension locations :
14-disc single tension strings with 160 KN E&MS disc
insulators of 280x170 mm size disc insulators will be
used with compression type dead end clamp.
(ii)
In the cases of Railway/Road/River/Other transmission

line crossing, double suspension/double tension insulator
strings will be used.
(B) For 132kV lines

(i)
Single suspension and single tension strings will be used

on the line as under:
a.
At suspension locations:
9 disc single suspension strings having 70KN E&MS of
255x145 mm size disc insulators with AGS type
clamps will be used.
b.
At tension locations :
(ii)
10-disc single tension strings with 90 KN E&MS disc

insulators of 255x145 mm size disc insulators will be used
with compression type dead end clamp.
(iii)
In the cases of Railway/Road/River/Other transmission

line crossing, double suspension/double tension insulator
strings will be used.
8.02.04 Conductor Accessories:
(i)
(ii)
AGS type suspension clamps shall be used with

suspension strings.
Vibration Dampers
Conductors.
(4-R
type)
shall
be
used
for
8.02.05 Miscellaneous Items:
Page 107 of 142
Volume-V (Part-1)
Enameled Number Plates, Phase Plates and Danger Board,

Bolts and Nuts, Spring washers, Pack washers and other
tower accessories like D Shackle, Hanger, U-Bolts and
fasteners etc., shall be provided with the tower.
8.03
DETAILED SURVEY/CHECK SURVEY:
The contractor will have to carry out detailed survey of the line for
which route map indicating the proposed alignment of the
transmission line will be handed over by the Employer. If the
detailed survey is already conducted by the Employer for some
portion of the line, the profiles for such portion will be handed over
to the Contractor for check survey. It may please be noted that no
check survey is required to be conducted for the portion of line for
which detail survey is conducted by the contractor himself.
8.03.01 Detailed Survey:-
(d)
At the starting point of the commencement of route survey,

an angle iron spike 65 x 65 x 1000mm shall be driven firmly
into the ground to show only 150mm above the ground level.
A punch mark on the top section of the angle iron shall be
made to indicate location of the surveying instrument. Teak
wood pegs 50 x 50 x 650 mm shall be driven at prominent
positions at intervals of not more than 750 meter along the
transmission line to be surveyed up to the next angle point.
125 mm wire nails should be fixed on the top of these pegs to
show the location of instrument. The pegs shall be driven
firmly into the ground to show only 100 mm above ground
level. At angle positions, stones shall be put up for easy
identification. Paint mark in white lead paint shall be put in,
about 300 mm squares with a direction indication, on nearby
boulders, rocks, or trees, along the complete line alignment.
At peg position, identification marks giving the peg position,
with reference to painting marks, shall be given. The white
lead paint mark shall indicate to the individual the direction
of alignment from either direction.
(e)
Routing/Re-routing
of
transmission
line
through
protected/reserved forest area should be avoided. In case it
is not possible to avoid the forests or areas having large trees
completely, then keeping in view of the overall economy, the
route should be aligned in such a way that cutting of trees is
minimum.
(f)
The route should have minimum crossings of Major river,

Railway lines, National/State highways, overhead EHV power
line and communication lines.
Page 108 of 142
Volume-V (Part-1)
(g)
The number of angle points shall be kept to minimum.
(h)
The distances between the terminal points specified shall be

kept shortest possible, consistent with the terrain that is
encountered.
(i)
Marshy and low lying areas, river beds and earth slip zones
shall be avoided to minimize risk to the foundations.
(j)
It would be preferable to utilize level ground for the

alignment.
(k)
Crossing of power lines shall be minimum. Alignment will be

kept at a minimum distance of 300 m from power lines to
avoid induction problems on the lower voltage lines.
(l)
Crossing of communication line shall be minimized and it shall

be preferably at right angle. Proximity and parallelism with
telecom lines shall be eliminated to avoid danger of induction
to them
(m)
Areas subjected to flooding such as nalah shall be avoided.
(n)
Restricted areas such as civil and military airfield shall be

avoided.
Care shall also be taken to avoid aircraft landing
approaches.
(o)
All alignment should be easily accessible both in dry and rainy

seasons to enable maintenance throughout the year.
(p)
Certain areas such as quarry sites, tea, tobacco and saffron

fields and rich plantations, gardens and nurseries which will
present the Employer problems in acquisition of right of way
and way leave clearance during construction and maintenance
should be avoided.
(q)
Angle points should be selected such that shifting of the point

within 100 m radius is possible at the time of construction of
the line.
(r)
The line routing should avoid large habitations, densely

populated areas, Forests, Animal/Bird sanctuary, reserve coal
belt areas, oil pipe line/underground inflammable pipe lines
etc to the extent possible.
(s)
The areas requiring special foundations and those prone to

flooding should be avoided.
(t)
From the field book entries, the route plan and level profile
shall be plotted and prepared to the scales of
1=2000
horizontal and 1=200 vertical on 1 mm/5 mm/1 cm square
paper.
Page 109 of 142
Volume-V (Part-1)
(u)
If the difference in levels be too high, the chart may be

broken up according to requirement. A 400 meter overlap
shall be shown on each following sheet. The chart shall
progress from left to right. For convenience in handling, the
sheet size may be limited to 594x841 mm (Al) size.
(v)
After completing the detail survey, profiles shall be submitted

to the Employer duly spotted with tower for approval. While
submitting the profiles after conducting the detail survey, the
contractor will also submit a copy of route alignment on the
route map indicating the surveyed route.
8.03.02 Check Survey:-
The Contractor shall conduct the check survey only for such
portion of line for which detailed survey has been done by the
Employer after the profiles are handed over to the Contractor. The
check survey shall include checking of deviation angles, checking of
levels at critical points. After completing the check survey, profiles
shall be re-submitted to the Employer duly spotted with tower for
approval.
8.03.03 The requirement of tower site leveling and revetment
work, if required, shall also be marked by the Contractor

on the profiles while carrying out the detail or check
survey work.
8.03.04 If due to site conditions any change in
the tower
location/provision of extension is considered necessary
compared to approve profiles, the contractor shall bring
the same to the knowledge of the Employer well in time
and get revised approval of the profile before setting the
stubs. The revised approval shall be conveyed to the
Contractor by the Employer.
8.04
APPROVED PROFILE:
(Applicable for check survey only)

8.04.01 The detailed survey may be conducted by the Employer
for some portion of the transmission line and in such

case, the profiles will be handed over to contractor for
carrying out check survey and marking of towers on the
profiles. The profile will be prepared on cm. graph paper
on scale 1:2000 horizontal and 1:200 vertical.
The
profile will be submitted along with the route map showing
the route followed by the contractor during check survey.
8.04.02 The route alignment surveyed by the Employer shall be
marked at angle points. At angle points concrete blocks
Page 110 of 142
Volume-V (Part-1)
shall be provided and in the straight alignment marking

will be done by pegs.
8.04.03 The Contractor will be responsible for the correct setting of
towers as shown in approved profiles. If towers after

erection are found to be out of the approved
alignment/position in the profile, the Contractor will
dismantle and re-erect them correctly fully at his own cost
and without extension of time.
8.04.04 Soil Resistivity:-
While carrying out detailed/ check survey work, the Soil

Resistivity values will have to be measured at convenient points
along the route, not exceeding 2.50 Km between adjacent points.
The Soil Resistivity wiil be measured using 4 electrod method with
an inter electrod spacing of 50 M . The following formula shall be
used :
P=2aR
Where a =
Interelectrod spacing = 50M
R =
Earth resistance measured in Ohms
P =
Soil Resistivity in Ohm- m
The soil resistivity values shall be submitted duly marked on

the route map and also in the form of statement. The quoted rates
for detailed survey/ check survey work shall be inclusive of cost of
measuring soil resistivity values along the proposed route and the
contractor will not be paid separately for this work.
8.05
EXCAVATION:
Except as specifically otherwise provided, all excavation

for footing shall be made to the lines and grades of the foundation.
The excavation walls shall be vertical and the pit dimensions shall
be such as to allow a clearance of 150mm on all sides from the
foundation pit, where form boxes are used. In undercut/stepped
(slab type) foundations where form box is not required to be used
at the base, the pit dimensions should be as per the standard
drawings. All excavation shall be protected so as to maintain a
clean sub-grade, until the footing is placed, by using timbering,
shoring or casing, if necessary. Any sand, mud, silt or other
undesirable materials which may have accumulated in the
excavation shall be removed by the Contractor before placing
concrete.
8.05.01
The Soil to be excavated for tower foundations shall

be classified as under for the purpose of payment of excavation
for tower site leveling and building stone revetment:
8.05.02
Page 111 of 142
Volume-V (Part-1)
(a) Normal Dry Soil : Soil removable by means of ordinary pick

axes and shovels (Normal Soil, intermediate Soil
fall under this category).
(b) Wet Soil :
Soil as per (a) above, where the sub Soil

water table is encountered within the range of
foundation depth, the Soil below the water table
and that at locations where pumping or bailing out
of water is required due to presence of surface
water, will be treated as wet Soil.
(c) Black cotton (Dry/Wet) :To be used at locations where soil is

clayey type, not necessarily black in colour, which
shrinks
when
dry
and swells when
wet,
resulting in differential movement extending to a
maximum depth of about 3.5 meter below ground
level.
(d)
Soft Rock:
This will mean fissured rock i.e. decomposed
rock, hard gravel, kankar, limestone, laterite or any
other Soil of similar nature which can be excavated
with pick axe, crow bar etc. However, if required,
light blasting may be resorted to for loosening the
material but this will not in any way entitle the
excavation to be classified as hard rock.
(e) Hard Rock: Hard rock will be that which requires chiseling or
drilling and blasting.
No extra charges shall be admissible
removal the fallen earth in the pits when once excavated.
8.05.03
for
the
If water is encountered in the foundation pit, dewatering will have to be done. The cost of dewatering shall be
deemed to be included in the unit rates of excavation for
foundation work.
8.05.04
For excavation of foundation in rock, where blasting

is unavoidable, care should be taken to minimize the volume of
concrete necessary for filling up the blasted area. The blasted
area shall be reduced to the minimum possible so that the specified
form for the foundation could be obtained. No extra payment for
excavation in hard rock shall be allowed if the excavated area
exceeds the designed excavation volumes.
Similarly, no extra
payment shall be made if concrete volume exceeds the designed
volume due to excessive blasting.
8.05.05
The payment for excavation shall be made as per actual type of soil
encountered at the time of excavation, but the total payment for
Page 112 of 142
Volume-V (Part-1)
excavation portion shall not exceed the amount as payable for

excavation considering the foundation as classified for that location.
The Contractor shall arrange requisite
blasting
material, excavation and drilling equipment, necessary license
etc., at his own cost and the quoted rates shall be deemed to be
inclusive of all such costs.
8.05.06
The decision of the owner shall be final and binding with

respect to classification of soil and foundation.
8.05.07
8.06
CLASSIFICATION OF FOUNDATIONS :
The foundation designs shall depend upon the type of

Soil, sub-Soil water level and the presence of surface water
which have been classified as follows:
8.06.01
(A) For 220kV lines:(i) Normal dry : To be used for locations where normal
cohesive or non-cohesive soils are met.
(ii) Wet
dry
: To be used for locations :

(a) Where sub-soil water is met
more below the ground level.
at 1.5meter or
(b) Which are in surface water for long

periods
with water penetration not exceeding one meter
below the ground level e.g. the paddy fields.
(iii) Partially Submerged: To be used at locations where sub-soil
water level is met between 0.75 meter to 1.5
meter below the ground level.
(iv) Fully Submerged : To be used at locations where sub-soil
water level is met less than 0.75 meter
below
ground level.
(v) Black cotton(Dry/Wet): To be used at locations where soil is
clayey type, not necessarily black in
colour,
which shrinks when dry and swells when wet,
maximum depth of about 3.5meter below ground
level.
(vi) Dry Fissured rock: To be used at locations where decomposed
or fissured rock, hard gravel, kanker, limestone,
laterite or any other soil of similar nature is
met. Under cut type foundation is to be used for
fissured rock locations.
Page 113 of 142
Volume-V (Part-1)
(vii)
Submerged Fissured rock: In case of fissured rock

locations where water level is met at 1.5meter or
more below ground level, submerged fissured
rock foundations shall be adopted. If after soil
investigation, water level is encountered at less
than 1.5meter below ground level, a separate
foundation shall be developed.
(viii)
Hard rock : The locations where chiseling, drilling and

blasting is required for excavation, hard rock
type foundations are to be used.
(B) For 132kV lines:(i)
Normal dry : To be used for locations where normal dry

cohesive or non-cohesive soils are met.
(ii)
Wet
: To be used for locations :
(a)
Where sub-soil water is met at 1.5 meter or more

below the ground level.
(b)
Which are in surface water for long

periods with
water penetration not exceeding
one meter
below the ground level e.g. the paddy fields.
(iii) Black cotton (Dry/Wet): To be used at locations where soil

is clayey type, not necessarily black in colour,
which shrinks when dry and swells when wet,
maximum depth of about 3.5 meter below ground
level.
(iv) Soft rock: To be used at locations where decomposed or
fissured rock, hard gravel, kanker, limestone,
laterite or any other soil of similar nature is met.
Under cut type foundation is to be used for fissured
rock locations.
(v) Hard rock : The locations where chiseling, drilling and
blasting
is required for excavation, hard rock
type foundations are to be used.
8.07
SHORING OF PITS:
Shoring of pits with shuttering on the internal walls surrounding the

vertical facing of approved dimensions of the pit shall be done when
the Soil condition is so bad that there is likelihood of accident due
to falling of surrounding earth in foundation pit. The cost of carrying
Page 114 of 142
Volume-V (Part-1)
out shoring & shuttering shall be deemed to be included in the unit

rate of excavation for foundation work and no extra payment shall
be made on this account.
8.08
TOWER SITE LEVELLING:
In case of foundations located on sloping ground, it may be

necessary to level the ground for locating the tower. In leveling the
tower site, only excavation will be allowed. The Contractor shall
quote separate rates for excavation for purpose of site leveling for
dry Soil, wet Soil, soft and hard rock in respective Schedule. The
requirement of tower site leveling will be decided by the Employers
site Engineer and will be marked by the Contractor in the profiles
while carrying out the check survey work.
8.09
SETTING OF STUBS:
The Contractor shall be responsible for correct setting

of stubs. Discrepancies, if any, shall be brought to the notice of
Employer and final approval shall be taken before execution of
work. The stub shall be set correctly in accordance with approved
method at the exact locations and alignment and imprecisely
correct levels. The stub setting Templates shall be used for proper
setting of stubs. Stubs shall be set in the presence of Employers
representative available at site whenever required and for which
the contractor shall give adequate advance intimation to the site
Engineer.
8.09.01
The foundations are to be made as per designs and

drawings approved by the Employer. Extent of the work as defined
by such drawings shall not be exceeded except in very exceptional
cases where the prior approval of Employer has been obtained.
8.09.02
The setting of stubs in hard rock foundation may

require cutting of stubs depending on depth at which hard rock is
encountered. The cutting of stubs and drilling of new holes for
fixing cleats etc. shall be considered inclusive in the rate of
foundation of towers in hard rock. However, the cut pieces of stubs
shall be returned to EMPLOYER.
8.09.03
Setting of stub at each location shall be approved by

the Employers site Engineer. This approval shall not however,
absolve the Contractor of his responsibility of correct setting of
stubs and casting of foundations, who will be required to rectify the
faulty work at his own expense.
8.09.04
8.10
PLACEMENT OF REINFORCEMENT:
Some of the tower foundations may be designed with

steel reinforcement so as to achieve better foundation strength with
8.10.01
Page 115 of 142
Volume-V (Part-1)
lesser space. The cost of placing of reinforcement steel, binding etc.

in the foundation pit shall be paid as per rate to be quoted in the
price schedule.
The Contractor shall arrange foundation reinforcement
steel etc. at their cost which shall be deemed to be included in the
quoted rate of placement of reinforcement steel.
The
reinforcement bars will have to be properly cut, bent in required
shape and placed in the foundation in approved manner after due
cleaning of oil, grease or organic matter. The reinforcement shall
be properly tied by binding wire.
8.10.02
8.11
CONCRETE:
The cement concrete used for the foundation shall be of

1:2:4 mix ratio (M150) with 20mm nominal size stone metal for
chimney portion and 40mm nominal size stone metal for pyramid or
slab portions. 1:3:6 mix ratios (M 100) shall be used for base
padding (lean pad). For RCC, the aggregates shall preferably be of
20mm nominal size.
8.11.01
The cement required for the purpose of foundations,

building revetment walls etc. shall be arranged by the Contractor
at his own cost, which shall be deemed to be included in the cost of
foundations.
8.11.02
The sand used for the concrete shall be arranged by the

Contractor at his own cost including necessary license etc., which
shall be deemed to be included in the cost of foundations. The
sand shall be composed of
hard silicate materials. It shall be
clean and of a sharp angular grit type and free from earthy or
organic matter and deleterious salts.
8.11.03
The aggregate shall be arranged by the contractor at

his own cost including necessary license etc, which shall be deemed
to be included in the cost of foundations. The aggregate shall be of
clean broken hard granite or other stone specified or approved by
the Employer. It shall be of hard and coarse-grained quality. It
shall also be as far as possible cube like, preferably angular, but
not flaky, perfectly clean and free from earth, organic or other
deleterious matter. 40mm aggregate shall be of size as will pass
through a mesh of 40 mm measured in the clear and 20 mm
aggregate through 20mm square mesh measured in clear.
8.11.04
The water used for mixing concrete shall be arranged

by the contractor at his own cost including necessary license etc,
which shall be deemed to be included in the cost of foundations.
The water used shall be fresh, clean and free from oil, acid and
alkali, organic materials
or other deleterious substances.
8.11.05
Page 116 of 142
Volume-V (Part-1)
Salty/Saline or brackish water should not be used.

is generally satisfactory.
Potable water
The concrete shall be mixed in a mechanical mixer.

However in case of locations not accessible for concrete mixers,
hand mixing may be permitted at the discretion of our site
Engineer.
8.11.06
Mixing shall be continued until there is uniform

distribution of materials and the mixing is uniform in colour
and
consistency but in no case the mixing is done for less than two
minutes. Normally mixing shall be done close to the foundation,
but in case it is not possible, the concrete may be mixed at the
nearest convenient place. The concrete shall be transported from
the place of mixing to the place of final deposit as rapidly as
practicable by methods, which shall prevent the segregation or loss
of any ingredient. The concrete shall be placed and compacted
before setting commences. The transportation cost of these
materials shall be deemed to be included in the cost of foundations.
8.11.07
The concrete should be mixed as stiff as per the

requirements of placing the concrete in the form boxes, with ease
and the degree to which the concrete resists segregation. Hence
the quantity of water used should not be too much.
8.11.08
Proper form boxes adequately braced to retain proper

shape while concreting should be used for chimney or pyramid and
slab portions. The form boxes should be made water tight so that
cement cream may not come out leaving only sand and jelly
consequently forming of honeycombing in the concrete. The form
boxes shall be cleaned and oiled
before these are used for
concreting.
8.11.09
The concrete shall be laid in 150mm layers and

consolidated well so that the cement cream works up to the top
and no honeycombing is left in the concrete. Concreting is to be
done continuously so that the subsequent layers are laid before the
initial setting of the bottom layer begins. The consolidation of
concrete shall normally be done by using vibrators.
8.11.10
After
concreting the chimney portion up to
the
required height, the top surface should be finished smooth, with
slight slope towards the outer edge, to drain off the
rainwater
falling on the coping.
8.11.11
In wet locations, the site must be kept completely dewatered both during the placing of the concrete and up to 24 hours
after completion. There should be no spilling to concrete by water
during this period.
8.11.12
Page 117 of 142
Volume-V (Part-1)
The form boxes shall be removed only after at least 24

hours after the completion of concreting. After removal of the
forms and boxes the concreted surface wherever required shall be
repaired with a mixture of rich cement and sand mortar in the
shortest possible time.
8.11.13
The cost of carrying out concreting of shall be payable as per unit

rates quoted by the Bidder.
8.12
BACKFILLING AND REMOVAL OF STUB

TEMPLATE:
Following opening of form work and removal of

shoring and shuttering, if required, backfilling shall be started
after 24 hours of casting repairs, if any, to the foundation
concrete. Backfilling shall normally be done with the excavated
Soil, unless it consists of large boulders, which shall be broken to a
maximum size of 80mm.
8.12.01
The backfill materials should be clean and free from

organic or other foreign materials The earth shall be deposited
in maximum 200mm layers, leveled, and wetted and rammed
properly before another layer of earth is deposited. Care shall be
taken that the back filling is started from the foundation end only
in the pits towards the outer end.
8.12.02
The backfilling and grading shall be carried to an

elevation of about 150mm above the finished ground level to drain
out water.
After backfilling, 50mm high earthen embankment
(bandh) will be made along the sides of excavated pits and
sufficient water will be poured in the backfilled earth for at least
next 24 hours.
8.12.03
The stub setting Templates shall be opened only after

the completion of back-filling.
8.12.04
After completing stringing work, if level of backfilling

of some of the locations gets settled and it is required to backfill
the locations again, the same would be done by the contractor at
no extra cost.
8.12.05
No extra charge is admissible for carrying out

backfilling
of
foundation
pit
(including
backfilling
from borrowed earth if required) and the cost of backfilling
shall be deemed to be included in the cost of excavation quoted
by the bidder in the price schedule.
8.12.06
8.13
CURING:
The concrete, after it is 24 hours old, shall be cured by keeping

the concrete wet continuously for a period of 14 days after laying.
Page 118 of 142
Volume-V (Part-1)
The pit may be backfilled with selected earth sprinkled with

necessary amount of water and well consolidated in layers not
exceeding 200mm of consolidated thickness after a minimum
period of 24 hours and thereafter both the backfilled earth and
exposed chimney top shall be kept wet for the remainder of the
prescribed time of 14 days.
The uncovered concrete chimney
above the backfilled earth shall be kept wet by providing empty
cement bags dipped in water fully wrapped around the concrete
chimney for curing duly ensuring that the bags are kept wet by
frequent pouring of
water on them. The Contractor may use anti
curing paint. However no extra payment shall be made on this
account.
8.14
BUILDING STONE REVETMENT:
Stone revetment in 1:5 cement mortars shall be constructed by the

Contractor at specified locations. The detailed proposal in
consultation with the site Engineer, for carrying out revetment work
shall be submitted to the O/o. Chief Engineer (Trans), Jabalpur
through concerned Superintending Engineer, EHT Construction
and approval shall be obtained before carrying out revetment work.
The top seal cover of revetment work shall be done with 1:2:4
normal mixes. All materials including cement shall be provided by
the contractor and cost of building revetment shall be deemed to
include cost of such materials also i.e. Cement, sand, metal and
stone. Curing of revetment shall be done as specified for tower
foundation. The back filling of the inside of the revetment wall with
Soil/borrowed earth will be paid for extra on per m basis and
shall include its compacting and watering. The excavation for
revetment foundation shall be paid at the rates as indicated by the
bidder in Price Schedule.
The revetment work, wherever
necessary, shall have to be completed before taking up final
tensioning work in the Section.
8.15
TOWER EARTHING:
For the purpose of earthing, necessary earthing rods

(25mm dia, 2 meter long) connecting clamps, and connecting
wire will be provided by the contractor. The earthing rods are to
be hammered preferably in the side wall of foundation pits and
connected to stub by 7/4.00mm Earth wire and with necessary
connecting clamps before concreting the foundation. If it is not
possible to tie the rods in the foundation pit i.e. in rocky location,
they shall be buried near the foundation pit and connected to the
stubs. The earthing rods are to be provided in every leg of the
tower. Each tower shall be earthed before the foundation is casted.
8.15.01
The tower footing resistance of all towers shall be

measured in dry whether after the erection and before the stringing
8.15.02
Page 119 of 142
Volume-V (Part-1)
of Earth wire. The counterpoise earthing shall be resorted to, in

accordance with the instructions of the site Engineer, in case the
tower footing resistance (TFR) exceeds the specified value. It shall
be ensured that the tower footing resistance is less than 10 ohms.
Each tower footing resistance shall be intimated (along with the
tower location number) while submitting the progress report of
tower erection.
8.15.03 Counterpoise Earthing :
In case of high resistivity, counterpoise earthing

shall
be
provided which consists of four lengths
of galvanized steel
stranded wires, 7/4.00mm fitted with each leg of the tower with
proper clamps for connection to the tower leg at one end. The
counterpoise will be laid radially away from the tower and will
normally be 15 meters in length, buried to the depth of 600mm
below the ground level.
The length of counterpoise wire may
be increased if the resistance requirements are not met. Connecting
clamps shall be buried in the chimney portion of the foundation.
Contractor shall quote for the laying of counterpoise earthing on
per running meter basis, excluding cost of all materials. The scope
of work of connecting the counterpoise to the tower legs shall be
deemed to be included in the cost of laying of counterpoise. The
counterpoise shall preferably be laid through soft soil areas if
available. The planning of laying counterpoise shall be done as per
approval of site Engineer. The cost of laying of counterpoise shall
be inclusive of excavation and backfilling work also.
The Contractor shall have to provide rod earthing at the end of
each counterpoise wire and this may lead to T.F.R. values within
specified limits. This work of additional rod earthing shall be paid
extra on per location basis as per the rates indicated in Price
Schedule.
8.16
TOWER ERECTION/ ASSEMBLY:
Towers shall be erected after the foundation concrete is at least

14 days old, but a gap of 24 days shall be preferred. The method
followed for the erection of towers, shall ensure the points
mentioned below:
(i)
Straining of the members shall not be permitted for bringing

them into position. It may, however, be necessary to match
hole positions at joints and to facilitate this, Tommy bars not
more than 450mm long may be used.
(ii)
Before starting erection of an upper section, the lower section

of tower shall be completely braced and all bolts provided
in accordance with approved drawings.
Page 120 of 142
Volume-V (Part-1)
(iii)
All plan diagonals relevant to a section of tower shall be

placed in position before assembly of upper section is taken
up.
(iv)
The bolt positions in assembled towers shall be as per IS:

5613 (Part-II/Sec.2), 1995 with latest amendments.
(v)
Tower shall be fitted with Number, Phase and Danger Plates

which shall be arranged by the Contractor.
(vi)
Anti-climbing Devices:
Barbed wire will be used at a height of approx. 3 meters and
above as an anti-climbing measure, which shall be arranged
by the Contractor. At every location three layers of Barbed
wires will be provided each inside and outside the tower in
horizontal plane. Spacing between the layers with fixing
arrangements shall be provided as per the provisions of
IS:5613 (Part-II/Sec.1)-1976 with latest amendments. The
galvanized angle pieces with notches for accommodating
Barbed wire with Bolts Nuts etc. shall be supplied by the
Contractor. After the Barbed wire is placed in position in the
notches, the notch opening shall be welded to avoid the
theft of Barbed wire and anti-corrosive treatment with
cold galvanizing paint shall be given, as also in the case of
bolts to be welded below bottom cross arm level. Suitable
locking arrangement (pad-lock) shall also be provided.
(vii) All blank holes, if any left, after complete erection of the
tower, are to be filled up by bolts and nuts of proper size.
8.17
TIGHTENING PUNCHING AND WELDING

OF BOLTS AND NUTS:
All nuts shall be tightened properly using correct size of

spanners. Before tightening, it will be seen that packing washers
and plates are placed in relevant gaps between members, bolts of
proper size and length are provided and one spring washer is used
under each nut and in case of step bolts, spring washers shall be
placed under the outer nut.
8.17.02
The tightening shall progressively be carried out from
the top to 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 three positions on the
periphery 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 have to
be replaced.
8.17.01
Page 121 of 142
Volume-V (Part-1)
The threads of all the bolts projected outside the nuts

shall be welded around the periphery of nut & bolts. The welding
of bolt projections as above shall be provided from ground level
to bottom cross arm level in all towers and also on extensions up to
10M except in case of special river crossing tower in which case
welding shall be done up to 20 meter height from ground level.
8.17.04
After welding, cold galvanized paint having at least
90% zinc content shall be applied on the welded portion. At least
two coats of the paint shall be applied. The cost of such paint and
welding etc., including application of paint etc., shall be deemed to
be included in the quoted erection rates.
8.17.03
8.18
INSULATOR HOISTING:
Suspension insulator strings shall be used on suspension towers

and tension insulator strings on angle and
dead end towers.
They shall be fixed on all the towers just prior to the stringing.
Damaged Insulators and fittings, if any, shall not be used in the
assemblies. Before 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 the purpose.
Security clips shall be fitted in position for the Insulators before
hoisting. Arcing Horns shall be fitted in an
approved manner.
Torque wrench shall be used for fixing different line materials and
their components, like suspension clamps etc. for Conductor and
Earth wire etc.
8.19
HANDLING OF CONDUCTOR AND EARTH WIRE:
The Contractor shall be entirely responsible for any

damage caused to the towers or Conductors during stringing.
While running out the Conductors, proper care shall be taken
ensuring that the Conductors do not touch and rub against the
ground or objects which could cause scratches or damage to the
Conductor strands. The Conductors shall be run out of the drums
from the top in order to avoid damage due to chafing. The drum
stand shall be provided with a suitable braking device to avoid
damage, loose running out and kinking of Conductor.
The
Conductor will be pulled by pull cable and consequently pass over
the running out blocks. The groove of the running out blocks will
be of such a design that the seat is semi-circular and larger than
the diameter of the Conductor and it does not slip over or rub
against the sides. The grooves shall be lined with hard rubber or
neoprene to avoid damage to Conductor and shall be mounted on
properly lubricated bearings.
8.19.01
The running blocks shall be suspended in a manner to

suit the design of the cross arm.
All running out
blocks especially those at the tensioning end, will be fitted on
8.19.02
Page 122 of 142
Volume-V (Part-1)
the cross arm 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. The Conductor
shall be continuously observed for loose or broken strands or any
other kind of damage. When approaching towards end of a drum
length, at least three coils shall be left when the stringing
operations are to be stopped. These coils are to be removed
carefully if another length is required to be run out, new length
may be joined to the length already run out by the compression
joint in approved manner.
The Conductor joints and clamps shall be erected in
such a manner that no bird caging, over tensioning of individual
wires or layers or other deformities or damage to the conductor
shall occur.
Clamps or bracing devices shall under erection
conditions allow no relative movement of strands or layers of the
conductors.
8.19.03
Repairs of Conductors, in the event of damage being

caused to isolated strands of a conductor during the course of
erection, if necessary, shall be carried out during the running out
operations, with repair sleeves. Repairing of Conductor surface
with repair sleeve shall be done only in case of minor damage,
scuff marks etc., keeping in view both electrical and mechanical
safety requirements. The final Conductor surface shall be clean,
smooth and shall be without any projections, sharp points, cuts,
abrasions etc. Repair sleeves may be used when the damage is
limited to the outermost layer of the Conductor and is equivalent
to the severance of not more than one third of the strands of the
outermost layer. No repair sleeve shall be fitted within 30 m of
tension or suspension clamp or fittings. Further, more than one
repair sleeve per Conductor shall not be normally used in any single
span.
8.19.04
Conductor splices shall be so made that they do not

crack or get damaged in the stringing operation. The
Contractor shall use only such equipment/methods
during
Conductor stringing which ensures complete compliance in this
regard.
8.19.05
Derricks shall be used where roads, rivers, canals,

telecommunication or overhead power lines, railway lines, fences
or walls have to be crossed during stringing operations. It
shall be seen that normal services are not interrupted and no
damage is caused to property. Shut down shall be obtained when
working at crossing of overhead power lines.
8.19.06
The sequence of running out shall be from top

downwards, i.e. the Earth wire shall be run out first followed
8.19.07
to
Page 123 of 142
Volume-V (Part-1)
by the Conductors in succession. Imbalances of loads on towers

shall be avoided as far as possible i.e. both Earth wires, then both
bundles of top Conductor and then both bundles of middle
Conductor followed by both bundle Conductors of bottom Cross-arm
should be strung.
The proposed transmission line may run parallel for
certain distance with the existing 400/220/132KV lines which will
remain energized during the stringing period. As a result there is
a possibility of dangerous voltage build up due to electromagnetic
and electrostatic coupling in the pulling cables, Conductors and
Earth wires, which although comparatively small in magnitude
during normal operations, can be severe during switching and
ground fault conditions on the energised lines. It shall be the
Contractor's responsibility to take adequate safety precautions to
protect his employees and others from this potential danger.
8.19.08
8.20
STRINGING OF CONDUCTOR AND EARTH

WIRE:
The contractor shall give complete details of the stringing methods,
which he proposes to follow. At least one month in advance of
the commencement of stringing, the contractor will submit the
stringing charts for the conductors 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 Employer.
The stringing shall be carried out as per
the stringing charts approved by the Employer and in
accordance with relevant IS. All the tolerances for the line shall
conform to IS 5613 (Part-2/Sec-2) 1995
8.21
JOINTING:
8.21.01
The number of joints in Conductor/Earth wire shall be
kept to minimum possible by properly selecting the drums from
available lot of respective drums. All the joints on the Conductor
and Earth wire shall be of compression type. Each part of the
joint shall be cleaned by wire brush to make it free of rust or dirt
etc. and properly greased with anti-corrosive compound, as
approved by our Engineer before the final compression is done
with the compressors. The cost of such
grease etc. used for
joints shall not be paid extra and shall be deemed to be included in
the stringing rates.
All joints shall be made at least 30 meter away from the
structures. No joints shall be made in the spans crossing over the
main roads, railways, rivers etc. Not more than one joint per
Conductor shall be allowed in one span. Care shall be taken to
mark the conductor for properly centering the compression clamp
before compressing. During compression operation, the conductor
8.21.02
Page 124 of 142
Volume-V (Part-1)
shall be handled in such a manner as to prevent lateral or vertical

bearing against the dies. After pressing the joint the aluminum
sleeve
shall have all corners rounded, burrs and sharp edges
removed and smoothened.
Suitable protector shall be used during stringing of
Conductor to avoid any damage to the joint while it passes over
the traveler.
8.21.03
8.22
SAGGING IN OPERATION:
The Conductors shall be pulled up to the desired sag

and left in running block for at least one hour after which the sag
shall be rechecked and adjusted, if necessary, before transferring
the conductor from the running out blocks to the suspension
clamps. The Conductors shall be clamped within 36 hours of
sagging in.
8.22.01
The sag will be checked in the first and the last span of
the section in case of sections up to eight spans and in one
intermediate span also for sections with more than eight spans.
The sag shall also be rechecked when the Conductor have been
drawn up and transferred from running blocks to the insulator
clamps.
8.22.02
The
running out blocks, when suspended from
the transmission structure for sagging shall be so adjusted that
the Conductors on running out blocks will be at the same height as
that of the suspension clamps to which it is to be secured.
8.22.03
At sharp vertical angles, the sags and tensions shall

be checked on both sides of the angle. The Conductor and Earth
wire shall be checked on the running out blocks for equality of
tension on both sides. The suspension insulator assemblies will
normally assume vertical positions when the Conductor is clamped.
8.22.04
Tensioning and sagging operations shall be carried out

in calm weather, when rapid changes in temperature are not likely
to occur.
8.22.05
8.23
TENSIONING & SAGGING OF CONDUCTOR AND

EARTH WIRE:
The tensioning and sagging shall be done in accordance with

the approved stringing charts before the Conductor and Earth
wire is finally attached to the towers through the insulator strings
for the Conductor and Earth wire clamps for the Earth wire
Dynamometers shall be used for measuring tension in the Conductor
and Earth wire.
Page 125 of 142
Volume-V (Part-1)
8.24
CLIPPING IN:
8.24.01
Clipping of the Conductors in position shall be done in
accordance with the method approved by our Engineer.
At
suspension location free center type suspension clamp with Armour
rod set or AGS type suspension clamp shall be used.
The jumpers at the section and angle towers shall be
formed to parabolic shape to ensure maximum
clearance
requirements.
Pilot suspension insulator string shall be used, if
necessary, to restrict the jumper swings to the design values.
Jumper connections of transposition towers shall be so made that
adequate clearances are available from tower body as well as phase
conductors.
8.24.02
Fasteners in all fittings and accessories shall be secured

in position. The security clip shall be properly opened and sprung
into position.
8.24.03
8.25
FIXING OF CONDUCTORS AND EARTH WIRE

ACCESSORIES :
Vibration dampers (4-R type) and other Conductor and Earth wire
Accessories supplied by the Employer shall be installed by the
Contractor as per the design/drawing requirement and as per
instructions of the Engineer. While installing the Conductor and
Earth wire Accessories, proper care shall be taken to ensure that
the surfaces are clean and smooth and no damage shall occur to
any part of the Accessories.
8.26
MAINTENANCE:
8.26.01
For a period of 12 (twelve) calendar
months
commencing immediately upon the satisfactory completion of the
final tests at site and taking over of the line, the Contractor's
liability shall be limited to the replacement (supply and reerection) of any defective parts that may develop on line of his
own manufacture or those of his Sub-Contractors approved by the
Employer under the conditions provided for by the contract under
proper use and arising solely from faulty materials, or
workmanship.
If it becomes necessary for the Contractor to replace
or renew any defective portions of the line under this clause,
the provisions of this clause shall apply to the portions of the line
so replaced or renewed until the expiration of six months from the
date of such replacement or renewal or until the end of the above
mentioned period of twelve months whichever may be the later.
8.26.02
If any defects be not remedied within a reasonable

time, the Employer may proceed to do the work at the Contractor's
risk and expense, but without prejudice to any other rights which
8.26.03
Page 126 of 142
Volume-V (Part-1)
the Employer may have against the Contractor in respect of such

defects. The Contractor shall bear reasonable cost of minor repairs
carried out on his behalf at site. At the end of the maintenance
period the Contractors liability ceases.
In respect of plant not covered by the first paragraph of this clause,
the Employer shall be entitled to the benefit of any guarantee given
to the Contractor by the original Contractor or manufactures of
such plant.
8.27
REPLACEMENT:
If any replacements are to be effected after stringing and

tensioning or during maintenance, members and bracing shall not
be removed without reducing the tension on the tower with
proper guying or releasing the Conductor. If the replacement of
cross arms becomes necessary after stringing, the Conductor shall
be suitably tied to the tower at tension points or transferred to
suitable roller pulleys at suspension points.
8.28
PRE-COMMISSIONING:
After completion of the works, final checking of the line shall be

done by the Contractor to ensure that all the foundation works,
tower erection, and stringing have been done strictly in accordance
with the specification and as approved by the Employer. All
the works shall be thoroughly inspected keeping in view the
following main points:
8.28.01
Sufficient back-filled earth is lying over each foundation
pit and it is adequately compacted.
Concrete chimneys and their copings are in good finely
shaped conditions.
8.28.02
All the tower members are correctly used, strictly

according to approved drawing and are free from defects or
damages, whatsoever.
8.28.03
All bolts are properly tightened and punched/tack

welded as per this specification.
8.28.04
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.
8.28.05
All
Conductor
properly installed.
8.28.06
and
Earth
wire
Accessories
are
All other requirements to complete the work like fixing

of Danger Plate, Phase Plate, Number Plate, Anti-climbing devices,
Aviation Signal (wherever required) etc. are properly installed and
8.28.07
Page 127 of 142
Volume-V (Part-1)
the painting has been done wherever required as per Aviation

Rules.
It should be ensured
wherever required.
8.28.08
8.29
that revetment is provided,
COMMISSIONING:-
The line insulation is tested by the Contractor by

providing his own equipment labour etc. to the satisfaction of the
Employer to ascertain the insulation condition of the line.
8.29.01
Conductor continuity test is carried out to verify that

each Conductor of the overhead line is properly connected
electrically also.
8.29.02
The line may be charged at a low value of Power

Voltage for the purpose of testing and commissioning.
8.30
Frequency
TAKING OVER:
When all performance tests called for by the Specification

have been successfully carried out, the transmission line shall be
accepted and taken over when it has been satisfactorily put into
operation on site, or within one month of its being ready to be
put into operation, whichever shall be the earlier and the
Engineer shall forthwith issue a taking over certificate. The
Engineer shall not delay the issue of any taking over certificate
contemplated by this clause on account of minor defects in the
plant which do not materially effect the commercial use thereof,
provided that the Contractor shall undertake to make good the
same in due course.
Page 128 of 142
Volume-V (Part-1)
ANNEXURE- 1
GUARANTEED TECHNICAL PARTICULARS OF CONDUCTOR &
EARTH WIRE
[A]
ACSR CONDUCTOR
S.
Description
ZEBRA
PANTHER
No.
1.
Particulars of ACSR Conductor
i. Standard nominal Copper area (sq.

260
mm)
ii. Stranding, lay and wire dia (mm)
54/7/3.1
8
iii. Diameter of complete conductor (mm)
28.62
iv. Overall diameter when wrapped with
preformed Armour Rod (mm)
130
30/7/3.00
21.00
44.36
33.78
436
586
b. Aluminium Section (kg)
1185
390
c. Conductor (kg)
1621
976
130.32
89.67
0.06915
0.139
7.942
7.069
7.942
7.069
484.5
261.60
69
80
a. Aluminium strand Kg/sq.cm
23X10-6
23X10-6
b. Steel strand Kg/sq.cm
11.5X10-
11.5X10-6
c. ACSR Conductor Kg/sq.cm
19.3X10-
17.8X10-6
v. Weight (kg/km)
a. Steel Section (kg)
2.
Guaranteed ultimate tensile strength of

conductor in KN
3.
Calculated
D.C.
resistance/km
of
conductor when corrected to standard
weight at 20oC
4.
Standard Cross Sectional Area of
i.
Aluminium strand in sq. mm
ii. Standard Cross Sectional Area of Steel
strand in sq. mm
iii. Standard Cross Sectional Area of
conductor in sq. mm.
5.
of Conductor
(GN/M2 )
6.
Co-efficient of liner expansion per oC of
Page 129 of 142
Volume-V (Part-1)
Description
S.
ZEBRA
PANTHER
No.
6
7.
Mean Lay-ratio
i. First layer
13-28
13-28
ii. Second layer
10-17
10-16
iii. Third layer
10-16
10-14
iv. Fourth layer
10-14
8.
i.
Continuous maximum current rating of

conductor in still air at 40 oC ambient
temperature (amp)
ii. Temperature rise for the above current
(oC)
9.
i.
ii.
10.
i.
Standard length of conductor (km.)

Tolerance in length (in percent)
750
427
35 oC
30 oC
1.5
1.5
+/- 5%
+/- 5%
Particulars of strands
Aluminiu
Minimum ultimate tensile strength in
m/ St eel
kg/sq.mm.
Aluminiu
m/ St eel
a.
b.
ii.
a.
b.
iii
Aluminimum strand
16.56
16.02
Steel strand
134
127.41
Nominal strand Dia
3.18/3.18
3.0/3.0
Maximum (mm)
3.21/3.24 3.03/3.06
Minimum (mm0
3.18/3.18
3.0/3.0
Mass (kg/Km) of strand at Nominal Dia
21.47
19.11
of Aluminium
iv.
Mass (kg/Km) of strand at Nominal Dia

of Steel
v.
Minimum breaking load in KN for
a. Aluminium strand
i) Before stranding
ii) After stranding
b. Steel strand
i) Before stranding
ii) After stranding
c. Approximate breaking load of conductor
in kgs
61.95
55.18
1.29
1.23
1.17
1.11
10.43
9.91
13316
9.29
8.83
9127
Page 130 of 142
Volume-V (Part-1)
S.
Description
ZEBRA
PANTHER
3 dips 1
min.
3 dips 1
min.
260
260
99.95%
IS:209
99.95%
IS:209
No.
vi. Zinc coating
a. Uniformity of coating, number and
duration of dips(according to Preece
test)
b. Minimum
weight
of
coating
(gms/sq.meter)
c. Purity of zinc and the standard to which
it will conform
Page 131 of 142
Volume-V (Part-1)
[B]
HTGS EARTH WIRE
S.N.
Particulars
HTGS EARTH WIRE
1 Particulars of single steel wire before
stranding
a) No. of wires
7
b) Diameter (mm)
3.66 mm
c) Tolerance
2%
Plus
3.74
Minus
3.58
d) Minimum elongation in 100 mm
5 mm
length
e) Breaking load (Kg.)
Standard/Minimum
1179/1000
f) Minimum ultimate tensile stress
95
(Kg/mm2)
g) D.C. resistance at 20 deg. C
17.57(Max.)
(Ohm/Km)
2 Stranded Wire
a) Length of lay (mm)
Maximum
Minimum
b) Overall diameter of Earth wire(mm)
c) Area of cross section of Earth wire
(sq. mm.)
d) Breaking load (Kg.)
Standard/Minimum
e) Resistance in Ohms per Km. at 20
deg. C.
f) Modulus of elasticity of Earth Wire
(Kg/cm2)
g) Weight of Earth wire (Kg/Km)
h) Co-efficient of linear expansion (per
deg. C)
3 Quality of zinc used (Specify the
grading and percentage)
4 Coating of zinc on wires In Gms. per
sq. mtrs.
5 Nos. of Dip
6 Oiling/greasing on Earth wire
7 Tolerance in standard length
198
165
10.98
73.64
7431/6972
2.5
19 x10 5Kg/cm2
583
11.5x10-6 /deg. C
Zn - 99.95 %
260
3,one minute&1, half
minute
Boiled Linseed Oil
Plus/Minus 5%
Page 132 of 142
Volume-V (Part-1)
ANNEXURE-2
GUARANTEED TECHNICAL PARTICULARS OF DISC
INSULATORS
S.
No.
1.
2.
3.
4.
5.
6.
7.
7.1
7.2
Description
70 kN EMS
Single
Double
Suspensio Suspensi
n
on
16 mm
Size and designation of
Ball
&
Socket
and
standard to which it will
conform (mm)
No. of insulator discs 9/132KV 2x9/132KV
13/220K 2x13/220K
per string
V
V
Outside dia. of the disc
255
mm
Spacing - mm
145
Creepage distance of
320
the single disc-mm
Electro-mechanical
7000
strength of single disc
kg.
Withstand voltage of
single disc-kVp
Power frequency
70
a) Dry kV (rms)
40
b) Wet kV (rms)
Impulse voltage
1.2/50 microsecond
110
a) Positive kV
110
b) Negative - kV
8.
Withstand voltage for

the complete string
8.1
Power frequency (with

and
without
Corona
ring)
a) Dry kV (rms)
b) Wet kV (rms)
8.2
9.
9.1
Lightning
Impulse
voltage
1.2/50
microsecond (With and
without Corona ring)
a) Positive kVp
b) Negative kVp
Flashover voltage for
the disc
Power frequency
a) Dry kV (rms)
b) Wet kV (rms)
90kN EMS
Single
Double
Tension Tensio
n
16 mm
10
2X10
20 mm
14
2X14
255
280
145
320
170
340
9178
16500
75
45
75
45
110
115
120
120
280
280
400/405
300/305
.
550
550
800/805
805/810
75
45
80
50
160kN EMS
Double
Single
Tension Tension
490/690
490/690
1050/1425
1050/1425
85
55
Page 133 of 142
Volume-V (Part-1)
S.
No.
Description
9.2
Lightning impulse
voltage 1.2/50
microsecond
a) Positive kVp
b) Negative kVp
the complete string
Power frequency (with
Corona ring)
a) Dry kV (rms)
10.
10.
1
10.
2
11.
12.
13.
14.
15.
b) Wet kV (rms)
Lightning Impulse
voltage 1.2/50
microseconds (with and
a) Positive kVp
b)
Negative kVp
Max. voltage (%) across
any disc in the string
(with
and
without
Corona ring)
P.F. Puncture Voltage of
each
disc
insulator
KV(rms)
Maximum RIV with 10
KV(RMS) of each disc
insulator (microvolts)
Weight of each disc
(kgs)
Electromechanical
strength of complete
string (kgs.)
70 kN EMS
Single
Double
Suspensio Suspensi
n
on
90kN EMS
Single
Double
Tension Tensio
n
115
115
115
120
290
290
470
470
560
560
1060
1060
160kN EMS
Double
Single
Tension Tension
130
130
415/420
310/315
500
500
825/830
830/835
1050
1050
9%
13%
14%
110
125
125
50
50
50
5.2
5.2
9.5
7000
14000
9178
18356
16500
Page 134 of 142
33000
Volume-V (Part-1)
ANNEXURE-3
GUARANTEED TECHNICAL PARTICULARS OF HARDWARE
FITTINGS FOR ACSR ZEBRA/PANTHER AND EARTH WIRE FOR
LINE
S.
No.
A)
1
6
7
Particulars
Conventional
Hardware Sets:
Panther
ACSR
Zebra ACSR
Earth Wire
(7/3.66)
mm
Type
Length of single suspension

strings with 9 Disc Insulators
and 13 Disc Insulators of
1551
2171
size 255 mm (Dia.) x 145 mm
(Height)
respectively
for
Panther & Zebra ACSR. In mm
Length of double suspension
strings 9x2 Disc Insulators &
13x2
Disc
Insulators
of
1873
2429
255mm (Dia)
x 145 mm
(height) size respectively for
Panther and Zebra ACSR.
Length
of
single
tension
strings with 10 Disc Insulator
of 255 mm(Dia)x145 mm
(Height) size for Panther and
1728
2679
14 Disc Insulator of 280 mm
(Dia) x170 mm (Height) size
for Zebra Conductor.
Length of double tension
strings
with
10x2
Disc
insulator of 255 mm x 145
2069
3202
mm size for Panther and 14x2
disc insulators of size 280 mm
x 170 mm for Zebra ACSR.
Minimum breaking strength of
suspension strings Hardware.
(i) Single
7000kgf
7000kgf
2x7000kgf
(ii) Double
2x7000kgf
Minimum slipping strength of
15to20% of UTS of
suspension clamp.
Conductor
Minimum breaking strength of
tension strings Hardware.
(i) Single
9000kgf
16500kgf
(ii) Double
2x9000kgf
2x16500kgf
Minimum slipping strength of 95% of UTS
95% of UTS
tension clamp.
of Conductor of Conductor
185
NA
375
NA
7000kgf
25% of UTS
of Wire
7000kgf
95% of UTS
of wire
Page 135 of 142
Volume-V (Part-1)
S.
No.
Particulars
Ball & Socket designation of

Hardware items for Tension
Type of strings.
Ball & Socket designation of
Hardware
items
for
suspension strings.
Unit
weight
of
Single
Suspensions String Hardware
sets(without Disc Insulators)
Unit
weight
of
double
suspension string Hardware
sets(without Disc Insulators)
Unit weight of single tension
string Hardware sets (without
Disc Insulators).
Unit weight of double tension
Hardware sets (without Disc
Insulators).
Type of suspension clamp.
10
11
12
13
14
15
16
17
Material used for suspension

Clamp giving reference of ISS
Type of tension clamp.
18
Material used for tension

Clamp giving reference of ISS
19 Unit weight and material used
for each of the following
Hardware items in Kg.
a. Ball hook
b. Socket type horn holder
c. `D Shackle
d. Ball link
e. Socket clevis
f. Ball clevis
g. Clevis Eye
h. Chain Link
Panther
ACSR
Zebra ACSR
Earth Wire
(7/3.66)
mm
16mm
16mm
NA
16mm
16mm
NA
6.4kg
appox.
11kg appox.
2.9kg
appox.
24.5kg
appox.
29.32kg
appox.
NA
6.6kg
appox.
9.8kg appox.
2.3kg
appox.
21kg appox.
31.7kg appox.
NA
AGS Type
AGS Type
Envelope
Type
Al. Alloy
Al. Alloy
MCI
Compressio
n Type
Extruded Al.
Alloy
Extruded Al.
Alloy
Mild Steel
0.775kg
appox.
0.920kg
appox.
0.450/
0.950kg
appox.
0.375kg
appox.
0.650kg
appox.
0.300kg
appox.
0.650kg
appox.
0.600kg
appox.
0.775kg
appox.
0.920kg
appox.
0.950/
2.000kg
appox.
0.750kg
appox.
0.650/1.275k
g appox.
0.300/0.600k
g appox.
0.650kg
appox.
1.500kg
appox.
NA
NA
0.450kg
appox.
NA
NA
NA
NA
0.350kg
appox.
Page 136 of 142
Volume-V (Part-1)
Particulars
S.
No.
i. Suspension Clamp
j. Tension Clamp with Jumper
Sleeves.
20 Power loss in Aluminium alloy
Suspension Clamp at 400
amps.
21 Power loss in extruded
Aluminum Tension Clamp at
400 amps.
22 Type of arcing horn
B)
Panther
ACSR
3.0kg
appox.
2.4kg
appox.
Zebra ACSR
6.0kg appox.
4.5kg appox.
100 Milli
Watt
143 Milli Watt
Earth Wire
(7/3.66)
mm
2.0kg
appox.
1.0kg
appox.
NA
NA
Insignificant
(i)
132 kV
Flat type
NA
NA
(ii)
220 kV
Pipe type
Pipe type
NA
AGS Type
Assembly:
Suspension
Type of material used for

retaining
rod
for
AGS
assembly giving reference of
ISS
2
Minimum tensile strength of
retaining rod material.
3
Chemical
composition
of
retaining rod material.
4
Electrical
conductivity
of
Armour Rod material (in
percentage of the conductivity
of IACS i.e. International
Annealed Copper Standard)
5
Slipping strength of cushioned
suspension assembly
6
Breaking strength of
cushioned suspension
assembly
7
Physical properties of
synthetic rubber:
a. Minimum tensile strength
Al.Alloy of HE 20 Grade as
per IS:6051
NA
35kg/sq. mm
NA
As per IS:733
NA
Not less than 40% of the

IACS
NA
15to20% of UTS of
Conductor
NA
7000 kgf
NA
2000PSI
NA
300%
NA
b. Minimum ultimate elongation

8
Details of the retaining

rods of AGS assembly:
a. Length of Armour Rod (mm)
1550
2080
NA
b. Diameter of Armour Rod(mm)
6.35
7.87
NA
11
12
NA
c. Number of Armour Rod/set
Page 137 of 142
Volume-V (Part-1)
Particulars
S.
No.
d. Wt. of each Armour Rod(gm)

e. Tolerance in diameter of each
Armour Rod
i.
Maximum (mm)
ii.
Minimum (mm)
f. Tolerance in flattening Max.

(mm)
g. Pitch length of the helix (mm)
Panther
ACSR
Zebra ACSR
Earth Wire
(7/3.66)
mm
NA
150
292
+/- 1%
+/- 1%
+/- 1%
+/- 0.08
+/- 1%
+/- 0.08
NA
190.5
260.4
NA
+/- 6
+/- 6
+/- 6
+/- 6
+/- 0.2
+/- 0.2
+/- 0.2
+/- 0.2
NA
NA
h. Tolerance in pitch length

i. Maximum (mm)
ii. Minimum (mm)
i. Tolerance in internal diameter
of helix.
i.
Maximum (mm)
ii.
Minimum (mm)
j. Tolerance in outer diameter

of helix
i.
Maximum (mm)
ii.
9
Power loss at 400 Amp.

Current AGS suspension
assembly
200 Milli
Watt
NA
NA
NA
NA
+/- 0.2
Minimum (mm)
NA
NA
501.50 Milli
Watt
NA
Page 138 of 142
Volume-V (Part-1)
ANNEXURE-4
GUARANTEED TECHNICAL PARTICULARS FOR
ACCESSORIES FOR ZEBRA/PANTHER ACSR & EARTH
WIRE FOR LINES
S.
No.
A
1
2
3
4
Particulars
Panther ACSR
MIDSPAN JOINTS (Compression Type)

95% of UTS of
Breaking strength.
Conductor
95%
of UTS of
Slipping strength.
Conductor
100% of eqvt.
Conductivity.
Length of
conductor
Before and after
compression dimensions in
Al.
Steel
mm
38.0
18.0
OD
23.0
9.35
ID
37.0
17.40
Across Corner
32.0
15.10
Across Flat
Zebra ACSR
Earth Wire
(7/3.66) mm
95% of UTS of
Conductor
95% of UTS of
Conductor
100% of eqvt.
Length of
conductor
95% of UTS of
Earth wire
95% of UTS of
Earth wire
100% of eqvt.
Length of Earth
wire
Al.
48.0
31.0
46.0
40.0
Steel
19.20
9.95
18.80
16.10
Al.
NA
NA
NA
NA
Steel
21.0
11.5
20.20
17.50
5 Material from which

following is made. Also
give reference to ISS for
the same.
Extruded
Aluminium.
Mild Steel
Galvanised
Extruded
Aluminium.
Mild Steel
Galvanised
Mild Steel
Galvanised
1.15
1.91 Appox.
NA
0.28 Appox.
0.41 Appox.
0.470 Appox.
Al.
Steel
610
203
+/-5
+/-5
660
233
+/-5
+/-5
REPAIR SLEEVE (Compression Type)
Al.
Steel
711
241
+/-5
+/-5
763
273
+/-5
+/-5
a.
Aluminium sleeve.
b.
Steel sleeve.
NA
6 Unit weight of:

a.
Aluminium sleeve.
b.
Steel sleeve.
7 Length of steel and

Aluminium sleeve in mm
Before compression
Tolerance
After compression
Tolerance
B
Al.
NA
NA
NA
NA
Steel
230
+/-5
252
+/-5
1 Breaking strength of cable

with sleeve compressed.
95% of UTS of
Conductor
95% of UTS of
Conductor
95% of UTS of
Earth wire
2 Conductivity of cable with
100% of eqvt.
100% of eqvt.
100% of eqvt.
Page 139 of 142
Volume-V (Part-1)
Particulars
S.
No.
sleeve compressed.
Panther ACSR
Zebra ACSR
Length of
conductor
Length of
conductor
Earth Wire
(7/3.66) mm
Length of Earth
wire conductor
3 Before and after

compression dimensions in
mm
OD
ID
38.0
23.0
4 Material from which sleeve

is made with IS for the
same.
Extruded
Aluminium.
Extruded
Aluminium.
0.40 appx.
0.740 appx.
0.400 kg appx.
241 +/- 0.5

270 +/- 5.0
279 +/- 5
310 +/- 5
254 +/- 5
280 +/- 5
21
4R Type
28.62
10.98
5 Unit weight of repair

sleeve.
6 Length of repair sleeve in
mm Before compression
After compression.
C 4R VIBRATION DAMPER
1 Type
2 Suitable for conductor
size.
3 Material used for :
a.
Clamp
b.
Messenger cable.
4 Number of strands and

dia. of each wire used in
messenger cable.
5 Over all dia. of messenger
cable.
6 Weight per Km of
messenger cable.
7 Slipping strength of
messenger cable.
8 Total weight of each
damper with tolerance.
9 Weight of each counter
weight with tolerance.
a. Heavier mass.
b.
Lighter mass.
1 Natural frequencies of
0 damper.
1 Clamping torque (Kg
1 meter).
20.8
41.3
48.0
31.0
Mild Steel
Galvanised
Al. Alloy GDC

H T G S IS:4826
19/2.11
19/2.59
19/2.11
10.55 mm
appox.
-
12.95mm appox.
-
10.55mm
appox.
-
2.5 KN
2.5 KN
2.5 KN
3.4 kg
+/- 5%
6.5 kg
+/- 5%
2.4 kg
+/- 5%
3.3 kg
+/- 5%
2.3 kg
+/- 5%
1.150 kg +/5%
2.4 kg +/- 5%
0.950 kg +/1.750 kg +/5%
5%
12+/-1 18.5+/-1 8+/-1 12+/-1 12+/-1 18.5+/-1
30+/-2 46+/-2 17.5+/-2
30+/-2 46+/-2
30+/-2
6.5
7.5
6
Page 140 of 142
Volume-V (Part-1)
Particulars
Panther ACSR
Zebra ACSR
Minimum fatigue test

at the highest resonant
frequency.
b. Amplitude of fatigue
test of the resonant
frequency.
10 Million cycles
10 Million cycles
+/- 1
+/- 1
+/- 1
2.5 KN
2.5 KN
2.5 KN
Less than 1Watt
Less than 1Watt
Less than
1Watt
Max. Wind load

45 kg/sq. m
Max. Wind load

45 kg/sq. m
Max. Wind load

45 kg/sq. m
1 Maximum dynamic strain

6 on the conductor with the
damper at clamping
points.
150 Micro strain
150 Micro strain
150 Micro
strain
1 Standard to which
7 material will be
manufactured and tested.
IS:9708
IS:9708
IS:9708
S.
No.
1
2
a.
1 Slip strength of clamp.

3
1 Maximum magnetic power
4 loss of damper at 500
Amps, 50 Hz, AC current.
1 Wind velocity range for
5 which damper will be
effective.
Earth Wire
(7/3.66) mm
10 Million
cycles
Page 141 of 142
Volume-V (Part-1)
ANNEXURE-5
LIST OF DRAWINGS
S.No
Particulars
1.
Details of earthing arrangement.
2.
Number plate for 220 kV Transmission line.
3.
Phase
4.
Danger Board for 220 kV Transmission line.
5.
Anticlimbing device for 220kV towers
6.
Number plate for 132 kV Transmission line.
7.
Phase
8.
Anticlimbing device for 132kV towers.
9.
Flexible GI Bond for earth wire.
10.
Drum for Panther conductor
11.
Drum for Zebra conductor
12.
Drum for earth wire
13.
220kV Single & Double suspension insulator string hardware for

Zebra ACSR conductor
14.
220kV Single & Double tension insulator string hardware for Zebra
ACSR conductor
15.
132kV Single & Double suspension insulator string hardware for

Panther ACSR conductor
16.
132kV Single & Double tension insulator string hardware for

Panther ACSR conductor
17.
Hardware fittings for Earth wire
18.
Mid span compression joint for Zebra ACSR Conductor
19.
Vibration damper for Zebra ACSR Conductor
20.
Repair sleeve for Zebra ACSR
21.
Mid span compression joint for panther ACSR
22.
Vibration damper for Panther ACSR Conductor
23.
Repair sleeve for panther ACSR
24.
Mid span compression joint for earth wire
25.
Vibration damper for earth wire
26.
Repair sleeve for earth wire
27.
Disc Insulators of Ball & Socket type
plate for 220 kV Transmission line.
plate for 132 kV Transmission line.
Page 142 of 142
MADHYA PRADESH POWER TRANSMISSION CO. LTD.

SHAKTI BHAWAN RAMPUR: JABALPUR
VOLUME V(Part-2)
Technical Book Serial No.
TECHNICAL SPECIFICATION FOR SUPPLY

OF MATERIALS AND CONSTRUCTION OF
400KV TRANSMISSION LINES.
O/o CHIEF ENGINEER (PROCUREMENT)

MPPTCL, JABALPUR.
TABLE OF CONTENTS
PART I
Specifications
&
requirements
Transmission Line Materials
Section- 1
Common Technical Requirement . 1
Section- 2
Technical Specifications for Towers ..
12
Section- 3
Technical Specifications for Conductor .
27
Section- 4
Technical Specifications for Earth wire .... 41
Section- 5
Technical Specifications for Disc Insulators 48
Section- 6
Technical Specifications for Hardware fittings and

accessories for Conductor & Earthwire....................64
Technical Specifications for erection of transmission
lines........................................... 91
Section- 7
Annexure 1
for
supply
Annexure 2
Technical Particulars of ACSR Conductors & Earth 108

wire
Technical Particulars of Disc Insulators
111
Annexure 3
List of Sample Drawings
115
of
Volume-V (Part-2)
SECTION-1
COMMON TECHNICAL REQUIREMENT
1.1
SCOPE:
1.1.1 The provisions under this section are to supplement common

requirements for supply of Transmission Line Materials and
Installation work.
Section-2 to Section-8 contains technical
specification for all the Materials to be used for Construction of
Transmission Lines. The bidders shall furnish catalogues, engineering
data / technical information, drawing etc. in conformity with the
technical specification.
1.1.2 The scope of work involves fabrication, galvanizing and delivery of 400kV
Double Circuit towers, their body extensions, river crossing Towers, Hangers,
U bolts, D Shackles, Bolts and Nuts, Spring washers, pack washers, step
bolts, tower accessories (earthing rod with clamps, Danger Boards, Number
plates, Phase plates and Anti-climbing Devices (including fixing arrangements
and barbed wire), ACSR Conductor, Earth wire, Disc insulators, hardware and
accessories for conductor and Earth wire and complete erection of
transmission lines including, detailed survey/check survey, casting of
foundations, tower erection, stringing etc. and testing & commissioning of the
transmission lines. Cement and reinforcement steel for foundation of towers,
extensions, river/ line crossing structures and any such materials required for
erection work shall also be provided by the successful Bidder. The Bidder is
also required to provide required number of stub setting templates for
each installation work at his own cost.
1.1.3 This section also provides for the Design, manufacturing, stage testing,
inspection and testing before despatch, packing and delivery of materials for
use on 400kV transmission lines in the State of Madhya Pradesh.
1.1.4 It is not the intent to specify completely herein all details of the design and
construction of Material. However, the Material shall conform in all respects to
high standards of engineering, design and workmanship and shall be capable
of performing the duties specified herein. The Material offered shall be
complete with all components necessary for its effective and trouble free
operation. Such components shall be deemed to be within the scope of
Bidders supply, irrespective of whether these are specifically brought out in
this specification or not.
1.1.5 If due to site condition any other type of tower (which is not envisaged at
present) is required to be provided, the same will also be supplied by the
bidder at the same rates terms and conditions.
1.2
CLIMATIC CONDITION
The equipments and materials shall be suitable for satisfactory
continuous operation under the following climatic conditions:
1
MADHYA PRADESH
Maximum ambient air temperature (0C)
50
95(sometimes
approaches
saturation)
Average daily ambient air temperature (0C )
32 Centigrade
Page 1 of 116
Volume-V (Part-2)

(Average number of thunder storm days)
50
1250
Wind Zone as per IS 802(Part-I)- 1995
Max. Altitudes above mean sea level (meters)
1000
1
Seismic level (Horizontal acceleration) (g)
0.3
0
NOTE: Moderately hot and humid tropical climate conducive to rust and
fungus growth. The climatic conditions are also prone to wide
variations in ambient conditions. Smoke is also present in the
atmosphere. Heavy lightening also occurs during June to October.
1.3
STANDARDS:
1.3.1 Bidders may please note that all offered materials shall be manufactured,
tested and supplied with all guaranteed technical particulars generally
conforming to meet the requirement of technical specification as brought out
in various Sections and latest revisions of relevant standards of international
electro technical commission or equivalent national standards of India with
latest amendments of relevant standards rules and codes. The lists of
standards are specified in relevant Sections of bid document.
1.3.2 The works covered by the specification shall be designed, engineered,
manufactured, built, tested and commissioned in accordance with the Acts,
Rules Laws and Regulations of India.
1.3.3 The Contractor shall also note that list of standards presented in this
specification is not complete. Wherever necessary the list of standards shall
be considered in conjunction with specific IS/IEC.
1.3.4 When the specific requirements stipulated in the specifications exceed or
differ than those required by the applicable standards, the stipulation of the
specification shall take precedence.
1.4
ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS :
1.4.1 The lists of Indian standards are specified in individual sections for various
materials and Installation work of bid document. However, the Material and
Installation work meeting any other authoritative International Standard,
which ensures equal or better quality than the Standards mentioned in bid
document, shall also be acceptable. Material for which Indian Standards
are not available, any equivalent International Standards will be
applicable. Please attach photocopy of all such Standards according to
which the material and Installation work have been offered.
1.4.2 If the material offered by the Bidder conform to any other standards, salient
points of comparison between the standards adopted and the specific
standards shall be clearly brought out in relevant schedule of deviation. It will
be sole responsibility of Bidder to prove that the salient features of offered
materials are equivalent or better than Indian standards as indicated in
Section-2 to Section- 8 of Volume-V(Part-1) of bid document.
1.4.3 The Material and Installation work conforming to standards other than
specified in individual sections for various Material and Installation work shall
be subject to Employers approval.
Page 2 of 116
Volume-V (Part-2)
1.5
TYPE TESTS:
1.5.1 Type tests shall mean those tests, which are to be carried out to prove the
process of manufacture and general conformity of the Material.
1.5.2 The offered Material (except Towers & Tower Accessories) should be fully type
tested as per the relevant standards. Bidder shall invariably furnish type test
reports
from
the
reputed
and
approved
national/international
laboratory/Government approved test houses to prove that specifications of
Material to be supplied conform to the relevant standard. Test certificates
shall clearly indicate the type and other details etc., so that relevant details of
offered Material could be verified. While submitting the bid the details and
type etc., shall be clearly indicated. Type test reports so furnished should not
pertain to the period earlier than five years from the date of opening of Bid.
In case the type tests were carried out earlier than five years, the
manufacturer will have to conduct these tests without any extra cost to the
Employer. In both the above cases type test certificate must be submitted
with the offer. The Bidders have to submit one complete set of Test reports
for the offered Material. Further, for any change in the design/type already
type tested and the design/type offered against this specification, the
Employer reserves the right to demand repetition of tests without any extra
cost.
1.6
DISCREPANCY IN TECHNICAL PARTICULARS:

The bidders will have to furnish confirmation in regard to compliance of our
entire technical requirement. The bid should clearly describe various technical
particulars of the material as per this specification.
1.7
MANUFACTURER'S AUTHORISATION:
The bidders shall have to submit the documentation from the manufacturer of
the Material on the format specified in this volume that they are authorised to
supply the material indicated in their bids in the employer's country
1.8
SCHEDULE OF QUANTITIES:
1.8.1 The requirements of various Materials and Installation work are indicated in
Price Schedules. In these schedules short description of material has been
given. The details of all such description are given in relevant sections of
Volume-V(Part-1) of bid document. The bidder shall refer these detailed
descriptions for clarity.
1.8.2 Although all the quantity of Material and Installation work have been included
in the bid as mentioned in Price Schedules.
However there may be
requirement of some minor nature items required for successful erection /
commissioning of transmission line work covered under this Bid.
Bidder
should include all such items in the bid proposal sheets which are not
specifically mentioned but are essential for the execution of the contract. The
cost of supply of such item which explicitly may not appear in various
schedules and are required for successful commissioning of transmission line
shall deemed to be inclusive in the bid price and shall be provided at no extra
cost to Employer.
1.9
PERFORMANCE GUARANTEE PERIOD:

All the Material & its accessories and Installation work covered under the Bid
shall guaranteed for performance and quality for a period of 24 months from
the date of completion of facilities (or any part thereof). In case after
commissioning of transmission line, any operational problem is observed in
Page 3 of 116
Volume-V (Part-2)
any Material/ installation work because of which any major rectification or

replacement work is done, then the guarantee for such Material / installation
work shall be extended by a period equal to the period during which the
facilities or such part can not be used by the EMPLOYER.
1.10
WORKMANSHIP:
All Material shall be of the best class and quality most suitable for the
conditions of operation under the climate conditions as per clause no. 1.02
above for supply of Material. The workmanship shall be of the best grade and
the entire construction in accordance with the best modern practice.
1.11
DRAWINGS AND DOCUMENTS:
1.11.1 In addition to those stipulated in Vol. I of bidding document, the following also
shall apply in respect of Contractor drawings.
1.11.2 With in one month from the award of contract, the contractor shall submit the
drawing of all Material for approval. Each drawing submitted by the Contractor
shall be clearly marked with the name of the EMPLOYER, 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.
1.11.3 The comments/ approval to drawings submitted by the Contractor shall be
conveyed by the EMPLOYER as far as practicable within 15 days and shall be
modified by the Contractor if any modifications and/or corrections are
required by the EMPLOYER.
The Contractor shall incorporate such
modifications and/or corrections and submit the final drawings for approval
with 15 days from date of EMPLOYERs comments. Any delays arising out of
failure by the Contractor to rectify the drawings in good time shall not alter
the Contractual Time Schedule.
1.11.4 The drawings submitted for approval to the EMPLOYER shall be in
quadruplicate. One print of such drawings shall be returned to the Contractor
by the EMPLOYER marked approved/approved with corrections.
The
contractor shall there upon furnish the EMPLOYER additional prints as may be
required along with one reproducible in original of the drawings after
incorporating all corrections.
1.11.5 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 EMPLOYER, if so required.
1.11.6 All manufacturing, fabrication and Installation work under the scope of
Contractor, prior to the approval of the drawings shall be at the Contractors
risk. The contractor may incorporate any changes in the design, which are
necessary to confirm to the provisions and intent of the contract and such
changes will again be subject to approval by the EMPLOYER.
1.11.7 The approval of the documents and drawings by the EMPLOYER shall mean
that the EMPLOYER is satisfied that:
a. The Contractor has completed the part of the Works covered by the
subject documents (i.e. confirmation of progress of work).
b. The Works appear to comply with requirements of Specifications.
Page 4 of 116
Volume-V (Part-2)
In no case the approval by the EMPLOYER 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.
1.11.8 All drawings shall be prepared using AutoCAD software. After final approval
all the drawings and documents (structural drawings, BOMs, shop sketches,
tower accessories drawings and drawings of other materials) shall be
submitted to the EMPLOYER in CDs.
A copy of each drawing reviewed will be returned to the Contractor as
stipulated herein.
1.11.9 Copies of drawings returned to the Contractor will be in the form of a print
with the EMPLOYERs marking.
1.11.10 All rights of the design/drawing for all Material and Installation work
drawings shall be strictly reserved with the EMPLOYER only and any
designs/drawings/data sheets submitted by the contractor from time to time
shall become the property of the EMPLOYER. Under no circumstances, the
contractor shall be allowed to user/offer above designs/drawings/data sheets
to any other authority without prior written permission of the EMPLOYER.
Any deviation to above is not acceptable and may be a cause for rejection of
the bid.
1.11.11 The manufacturing of the material shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written
approval of the EMPLOYER. All manufacturing and fabrication work in
connection with the material prior to the approval of the drawing shall be at
Contractors risk.
1.11.12 Approval of drawing/works by EMPLOYER shall not relieve the Contractor of
his responsibility and liability for ensuring correctness and correct
interpretation of the latest revision of applicable standards, rules and codes
of practices. The plant shall conform in all respect to high standards of
engineering, design, workmanship and latest revisions of relevant standards.
EMPLOYER shall have the power to reject any work or material, which in his
judgment is not in full accordance therewith.
1.12
QUALITY ASSURANCE PROGRAM:
1.12.1 Quality Assurance Program : To ensure that the Material and Services
under the scope of this contract whether manufactured or performed
within the Contractor's works or at his Sub-Contractor's premises or at
the EMPLOYER's site or at any other place of work are in accordance
with the Specifications, the Contractor shall adopt suitable Quality
Assurance Program (QAP) with hold points for EMPLOYERs inspection to
control such activities at all necessary points.
Such program shall be
outlined by the Contractor and shall be finally accepted by the EMPLOYER
after discussions.
1.12.2 Immediately after award of contract, the contractor shall submit to the
EMPLOYER, the quality assurance plan for all major items of Material
covering the manufacture and Installation activities of the transmission line.
The list of selected sub vendors for supply of minor items like Bolts & Nuts,
tower accessories etc. shall also be submitted.
Page 5 of 116
Volume-V (Part-2)
1.12.3 The contractor shall ensure that manufacturer must establish that they are
following the accepted quality assurance programme for manufacture of
offered equipments.
1.12.4 The contractor shall ensure that manufacturers of major items of Material
invariably furnish following information:(i)
Statement giving list of important raw materials, names of sub

supplier 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 manufacturers 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)
Levels 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 for quality control and details of such tests and
inspection.
(vi)
Special features provided in the equipment to make it maintenance

free.
(vii)
List of testing equipment available with the manufacturer for final

testing of equipment specified and test plant limitations, if any vis-vis type, special, acceptance and routine tests specified in the relevant
Indian Standards or equivalent international standard. These
limitations shall be very clearly brought out in schedule of deviations
from specified test equipments.
1.12.5 The Contractor shall follow the accepted Quality Assurance Plan in true spirit.
If desired by the EMPLOYER, he shall give access to all the Specifications,
equipments and records so as to satisfy the EMPLOYER that Quality
Assurance Plan (QAP) is being followed properly.
1.12.6 All Material shall be subjected to the routine and acceptance tests before
dispatch, as specified in this Specification.
1.13
INSPECTION AND TEST CERTIFICATES:
1.13.1 All Material to be supplied will be subject to inspection and approval by the
EMPLOYER's representative before despatch. Inspection before despatch will
not however relieve the contractor of
his responsibility to supply the
Material strictly in accordance with the specifications.
1.13.2 For Inspection / testing, the contractor shall intimate the EMPLOYER at least
15 days in advance about readiness of Material as per the scheduled delivery
so that action may be taken for getting the Material inspected. While
notifying the readiness of the Material, the factory test certificate in respect
of offered Material shall invariably be sent. The EMPLOYER will depute
authorized representative for inspection of Material or alternatively may
issue waiver of inspection.
1.13.3 The contractor will submit a test certificate to the EMPLOYER after inspection
of offered Material by EMPLOYERs authorized representative. These test
certificates should be in accordance with latest issue of the relevant Indian
Standards or as approved by the order placing authority.
Page 6 of 116
Volume-V (Part-2)
1.13.4 The Material shall not be dispatched unless the test certificates approval and
despatch instructions have been issued by the EMPLOYER.
1.13.5 All Material shall conform to provisions of any statutory acts such as the
Indian Electricity Act, Indian Factory Act, the Indian Boiler Act, etc. and
corresponding rules and regulations as may be applicable.
1.13.6 The EMPLOYER's representatives shall be entitled at all reasonable time
during manufacture
to inspect, examine and test at the contractor's
premises the material and workmanship of the plant to be supplied under
this contract.
1.13.7 A copy of the accepted Quality Assurance Plan must be available at the
manufacturers works of the Material for reviewing by inspecting officer of
the EMPLOYER.
1.13.8 The acceptance of any quantity of plant shall in no way relieve the Contractor
of any of his responsibilities for meeting all requirements of the specification,
and shall not prevent subsequent rejection if such plant is later found to be
defective. The Contractor will have to assume the responsibility for free
The entire cost of testing for the acceptance and routine tests and tests
during manufacture specified in the bid document shall be treated as included
in the quoted unit price of plant.
1.14
SPECIAL REQUIREMENTS:
1.14.1 EMPLOYER expects that participating bidder will take all necessary precautions
to supply best quality Material, which may provide trouble free performance
and also it is expected that the modern practices for erection and
commissioning shall be adopted to ensure timely and trouble free
commissioning of installation and also to ensure aesthetic overall view of
finished transmission line installation.
1.14.2 Some of the conditions which will have to be essentially accepted and
followed by the Bidders for the purpose of participating against the Bid and
also for undertaking construction activities are enumerated below for specific
confirmation by the Bidders.
1.15
STORE FOR SUPPLY OF MATERIAL:
The Contractor shall supply the Material at selected destination set up by him along
the route of the transmission line. The Contractor will set up above site store within
one month from the date of contract and inform the EMPLOYER. The Contractor will
have to supply above materials and receive them at these places only and the
rates quoted by the Bidder should include charges for delivery of such materials at
the store set up by him, receipt and proper stacking/ stocking at the store.
1.16
COMMENCEMENT OF ACTIVITIES:
Commencement of following activities is subject to prior and specific approval of the

items mentioned against each:-
Page 7 of 116
Volume-V (Part-2)
S.
No.
Activity
Items for which prior

necessary from Employer
1.
Manufacturing of tower parts.
Inspection of Proto Assembly of each type

of tower.
Submission
of
quality
assurance plan.
2.
Manufacturing of Conductors,
Ground
wire,
Insulators,
Hardware
fittings
&
Accessories for Conductor and
Earth wire.
Submission of Quality
approval of drawings.
3.
Dispatch
of
towers, Acceptance test and issue of test certificate
Conductors,
Earth
wire, approval
Insulators, Hardware fittings
& Accessories for Conductor
and Earth wire.
4.
Foundation work.
Classification of foundation.
5.
Erection of tower
Quality Assurance Plan for erection.
6.
Stringing of Conductor and Stringing chart and stringing method.

Earth wire.
1.17
RESPONSIBILITY
ACTION IN TIME:
FOR
OBTAINING
INFORMATION
approval
Assurance
AND
is
Plan,
TAKING
Whenever any information or clarifications in respect of construction of line

has to be obtained from various authorities, the Contractor shall be
responsible for taking action well in time so that there are no delays on this
account. The completion period specified in the bidding document is deemed
to include the time taken for such incidental works. Request for extension of
the completion date on such ground will not be entertained.
1.18
PERMITS AND PRIORITIES:
1.18.1 Necessary permits, if any, required for the execution of the contract shall
be arranged by the Contractor himself.
The Contractor shall obtain the
necessary license/permission as per Central/State/local statutory bodies
at his cost.
1.18.2 The Purchaser may, however, furnish to the Contractor such certificates (on
receipt of such written request from the Contractor) as may be required for
the necessary permits/priorities for the execution of works, if it considers the
demand as justified.
1.18.3 The Purchaser however, shall not be responsible for the delay in execution of
contract, if permits/priorities are not granted in time in spite of issuance of
such certificate.
1.19
WAY LEAVE:
The purchaser will arrange for necessary way leave and clearance of trees. The
Purchaser only will pay the way leave compensation along the route.
The purchaser will also arrange for the following: (i) Railway clearance
(ii) PTCC clearance
(iii) Forest clearance
Page 8 of 116
Volume-V (Part-2)
(iv) Any other necessary clearance if required/requested.

The Contractor shall inform the purchaser about the places where there is a way
leave problem, sufficiently in advance (preferably 30 days) so that required way
leave can be arranged in time.
1.20
USE OF PRIVATE ROADS/APPROACH ROAD TO SITE:
1.20.1 The purchaser will help in getting

necessary permission for use of
private/forest/canal, roads for transportation of materials and construction
personnels, wherever possible under the rules. Any charges/tole tax etc.
levied by the concerned authorities for use of such roads etc. shall be borne
by the Contractor.
1.20.2 During the erection work, if approach roads are required to be constructed for
reaching the construction sites for transportation of men/materials, the cost
of construction of such approach roads and any other expenses incurred in
obtaining clearance/permission shall be borne by the Contractor.
1.21
MATERIALS
TO
ERECTION WORK:
BE
ARRANGED
BY
THE
CONTRACTOR
FOR
1.21.1 The supply of cement for foundation work would be arranged by the
Contractor of the quality as per IS - 269 :1989 (Ordinary Portland Cement
33 Grade) or IS 8112 : 1987 (Ordinary Portland Cement 43 Grade) or IS
12269 : 1987 (Ordinary Portland Cement 53 Grade) or IS:1489 (PortlandPozzolana Cement (PPC)). The cost of cement shall be deemed to be
included in the quoted unit rates of concreting.
1.21.2 The cement used shall be procured from reputed manufacturer like JP
Cement, L&T, Birla Cement, ACC, Ambuja etc. The Contractor shall submit
the manufacturers certificate, for each consignment of cement procured, to
the Purchaser. The cement shall be arranged in conventional Jute/HD bags
each weighing 50 Kgs net with necessary IS certification mark on it. In case
of any dispute regarding quality of cement, sample for testing may be taken
jointly by contractors representative and Engineer in- charge of work or any
authorized representative of the Company. The sample taken shall be tested
for standard test as per IS code in Govt. Engineering/Polytechnic College
and testing charge shall be borne by the contractor. In case the material is
found defective i.e. not as per relevant ISS, the same shall be replaced by
the contractor at his cost. The Contractor shall also have no claim towards
suspension of work due to time taken in conducting tests in the laboratory.
Changing of brand or type of cement within the same structure shall not be
permitted without the prior approval of the Purchaser.
1.21.3 The Quantity of cement to be used per unit quantity of consumption for
different mix (nominal mix) of concrete should be as follows:
S.
No.
1
2
3
4
Description
1:1.5:3 nominal mix concrete

1:2:4 nominal mix concrete
1:3:6 nominal mix concrete
Random
Rubble
Masonry
with 1:6 cement mortar
Unit
Cu.m.
Cu.m.
Cu.m.
Cu.m
Quantity
of
minimum
Cement to be used per
Unit quantity of work(in
kgs)
400
330
220
83
Page 9 of 116
Volume-V (Part-2)
1.21.4 The Contractor shall arrange

metal, sand, stone and water
required for
foundation/revetment work. The transport, octroi, levy or duty on these
materials shall be borne by the Contractor himself and the purchaser will not
accept any liability on this account.
1.21.5 The Contractor will also arrange steel rods and binding wires etc. for
foundation, reinforcement and the cast incurred will be borne by him.
Materials for proper earthing of towers i.e. earthing rod, connecting clamps
and connecting wires etc. would also be arranged by the Contractor as
already specified.
***
Page 10 of 116
Volume-V (Part-2)
SECTION-2
TECHNICAL SPECIFICATIONS FOR TOWERS
Clause No.
2.01
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
Name of Clause
INDIAN STANDARDS/CODE
TYPE OF TOWERS
EXTENSIONS
STUB SETTING TEMPLATES
DESIGN
GALVANIZING PASSIVATION AND PAINTING
MATERIAL
WEIGHTS
BOLTS AND NUTS AND WASHERS:
STEP BOLTS
DANGER BOARD, NUMBER PLATE AND PHASE PLATES
ANTICLIMBING DEVICE WITH BARBED WIRE:
EARTHING
ATTACHMENT FOR INSULATOR STRING & GROUNDWIRE CLAMPS
FABRICATION WORKMANSHIP
BENDING
DRILLING AND PUNCHING
TOLERANCES
MARKING
Page 11 of 116
Volume-V (Part-2)
SECTION-2
TECHNICAL SPECIFICATIONS FOR TOWERS
2.01
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
here under or equivalent International Standards , except as modified in this
document.
S.No.
Indian standards
Title
1.
IS:209-1992
Zinc ingot- Specification.
2.
IS:278-1991
Galvanized Steel Barbed Wire.
3.
IS:800-1991
Code of Practice for General Building

Construction in Steel.
4.
IS:802 -1990 ( Part-II)

steel in over-head Transmission Line :
Fabrication, Galvanising, Inspection &
packing.
5.
IS:802 -1990 ( Part-III)

steel in over-head Transmission Line
Towers: Testing
6.
IS:808-1991
Dimensions
for
Hot
Steel
Beam,
Column,
and Angle Sections.
7.
Specification for Hexagon head bolts,

screws and nut for product grade C
Hexagon nuts of property class 5.
8.
IS:1367-1979
Technical supply conditions for threaded

fasteners (1st Revision).
9.
Mechanical properties and test method

for bolts, screws & studs with full
loadability.
10.
IS:1367(Part-VI)-1994
Mechanical properties and test method

for nuts with specified proof loads.
11.
IS-1367(Part-XIII)-1983
The hot dip

fasteners.
12.
IS:1573-1991
Specification for electroplated coating of

zinc on Iron & steel.
13.
IS:1586-1968
Methods of Rock well hardness test (`B

& `C scales) for steel (first revision).
14.
IS:1852-1991
Rolling and Cutting Tolerances of Hot

Rolled Steel Products.
15.
IS:2016-1992
Plain Washers.
16.
IS:2062-1992
Steel for general Structural purposes

Specification.
17.
IS:2614-1969
Method for sampling of fasteners.
18.
IS:2629-1990
Recommended practice for

galvanizing of iron and steel.
19.
IS:2633-1992
Method of testing uniformity of coating of

zinc coated articles.
galvanized
Rolled
Channel
coating
hot
of
dip
Page 12 of 116
Volume-V (Part-2)
S.No.
Indian standards
Title
20.
IS:3063-1994
Single Coil Rectangular Section spring

washers for bolts, nuts, and screws.
21.
IS:3202-1972
Methods for testing local thickness of

electro plated coatings.
22.
IS:3218(Part-V)-1979
Isometric screw threads Tolerance.
23.
IS:3757-1992
High Strength Structural Bolts.
24.
IS:4072-1975
Specification for steel for spring washers

(first revision).
25.
IS:4218(Part-VI)-1978
Isometric screw threads limits of sizes for

commercial bolts & nuts.
26.
IS:4759-1990
Specification, for Hot dip Zinc coatings on

Structural
Steel
and
other
Allied
products.
27.
IS:5358-1969
Hot dip galvanized coatings on fasteners.
28.
IS:5369-1991
General Requirements for Plain Washers.
29.
IS:5613-1995 (part-II)
Code of practice for design, installation

and maintenance of overhead power
lines.
Sec.-1
- Designs.
Sec.-2
Maintenance
Installation
&
30.
IS:6610-1991
Specification for Heavy Washers for Steel

Structures.
31.
IS:6623-1992
High Strength Structural Nuts.
32.
IS:6745-1972
Methods for determination of weight of

zinc coating of zinc coated iron and steel
articles.
33.
IS:6821-1973
Methods for sampling of non threaded

fasteners.
34.
IS:8500-1992
Specification for weldable structural steel

(Medium & High Strength Qualities).
35.
IS:10238-1989
Step Bolts for Steel Structures.
36.
IS:12427-1992
Specification for Transmission

Bolts of property class 5.6
37.
IS:269-1967
Ordinary rapid hardening and low heat

Portland cement.
38.
IS:456-2000
Code
of
practice
reinforced concrete
39.
IS:1786-1966
Cold twisted
steel bars
reinforcements
40.
IS:4091-1967
Code of practice for design & construction

of foundation for transmission line towers
& poles
2.02
for
Tower
plain
and
for concrete
TYPE OF TOWERS:
The towers are self supporting lattice type, designed for the specified
loading conditions. There will generally be following type of towers:-
Page 13 of 116
Volume-V (Part-2)
a.
Tower type FD-0:
Tangent type tower with maximum line deviation

up to 2 to be used with
Single/Double
suspension insulator strings.
b.
Tower type FD-30/FDT:
Medium angle tower to be used for line deviation

from 0 to 30 with Single/Double tension
insulator strings. FD-30 type tower is also used
as Transposition tower with modified cross arms.
c.
Tower type FD-60:
Heavy angle tower to be used for line deviation

from 0 to 60 and also as dead end tower with
d.
River Crossing Towers:-
The Bidder will have to supply River Crossing

Towers for crossing major river. Similarly for
crossing 400kV line if FD60+ 30/35M extension
tower is required, the same will have to be
supplied by the contractor after approval of the
Purchaser.
2.03
EXTENSIONS:
Suitable extension of 3M, 6M, 10M height shall be supplied for use with the
FD-0, FD-30 and FD-60 type towers. 18/25M extension shall be supplied for
FD-0 type tower depending upon the requirement intimated by the Purchaser.
2.04
STUB SETTING TEMPLATES:

The stub setting template shall be required for each type of tower and its
respective extensions and shall be supplied by the Bidder for each type of
tower and its respective extensions. The template shall be of adjustable
type i.e. for use with normal towers as well as extensions.
2.05
DESIGN:
2.05.1 400kV Towers/extensions to be supplied are designed as per

I)-1977.
IS 802(Part-
2.05.2 The towers have square base with twin MOOSE ACSR conductor per phase in
vertical formation and two ground-wires of 7/3.66 mm galvanized stranded
steel wire of 95kg/sq.mm grade placed on the top of the towers. .
2.06
GALVANIZING PASSIVATION AND PAINTING:

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.
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 & sections below 5mm which shall have Zinc coating of 460 gms per
sq. m of surface. The average zinc coating for all sections and plates 5mm &
above shall be maintained as 87 microns and that for plates and sections
below 5mm shall be maintained as 65 microns.
Page 14 of 116
Volume-V (Part-2)
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.
The surface preparation for fabricated tower parts and stubs for hot
dip galvanizing shall be carried out a indicated herein below:
(i)
Degreasing & Cleaning of Surface: Degreasing and cleaning of surface,

wherever required, shall be carried out in accordance with clause 4.1 of IS
2629-1985. After degreasing the article shall be thoroughly rinsed. However,
if acidic degreasers are used rinsing is not required.
(ii)
Pickling: pickling shall be done using either hydrochloric or sulphuric acid as

recommended at clause 4.3 of IS 2629-1985. 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 MPPTCL along
with Quality Assurance Program.
(iii)
Rinsing: After pickling, the material shall be rinsed, preferably in running

water to remove acid traces, iron particles or any other impurities from the
surface. Two rinse tanks are preferable, with water cascading from the
second tank to the first to ensure thorough cleaning. Wherever single tank is
employed, the water shall be periodically changed to avoid acid
contamination, and removal of other residue from the tank.
(iv)
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 MPPTCL 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 dragout 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.
(v)
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 MPPTCL
along with Quality Assurance Program.
(vi)
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
Page 15 of 116
Volume-V (Part-2)
minimum 98.5 % zinc by mass. It shall be periodically measured and

recorded. Zinc aluminium alloy shall be added as per IS 2629.
(vii)
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 10C. 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.
(viii)
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 while rust attack. The temperature of the
chromate solution shall not exceed 65C. 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.
(ix)
Storing, Picking and Handling: In order to prevent while 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.
(x)
The Contractor shall prepare a detailed galvanizing procedure including Flow

Chart with control parameters and all plant standards as required above and
submit to Purchaser for approvals as part of Quality Assurance Plan.
(xi)
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.
2.07
MATERIAL :
2.07.1 IS Steel Sections of tested quality in conformity with IS:2062 : 2006 grade
E250 (Designated Yield Strength. 250 MPa) and/ or grade E350 (Designated
Yield Strength 350 MPa) are to be used in towers, extensions, stubs and stub
setting templates. The Contractor can use other equivalent grade of structural
steel angle sections and plates conforming to latest International Standards.
However, use of steel grade having designated yield strength more than that
of EN 10025 grade S355 JR/JO (designated yield strength 355 MPa) is not
permitted, unless otherwise indicated in this specification.
2.07.2 Steel plates below 6mm size exclusively used for packing plates/packing
washers produced as per IS : 1079 -1994 (Grade -0) are also acceptable.
However, if below 6mm size plate are used as load bearing plates viz gusset
plates , joint splices etc. the same shall conform to IS : 2062 or equivalent
standard meeting mechanical strength/metallurgical properties corresponding
to grade E250 or E350 (designated yield strength not more than 355MPa),
Page 16 of 116
Volume-V (Part-2)
depending upon the type of grade incorporated into design.

Flats of
equivalent grade meeting mechanical strength/ metallurgical properties may
also be used in place of plates for packing plates/ packing washers. The
chequered plates shall conform to IS : 3502. SAILMA 350HI grade plate can
also be accepted in place of HT plates (EN 10025 grade S355 JR/JO / IS
2062:2006 grade 350, as applicable) provide SAILMA 350HI grade plate
meet all the mechanical properties of plate as per EN 10025 grade S355
JR/JO (designated yield strength 355 MPa) / IS 2062:2006 grade 350.
2.07.3 For designing of towers, preferably rationalised steel sections has been used.
During execution of the project, if any particular section is not available, the
same shall be substituted by higher section. Any cost on account of the same
shall be borne by the Contractor. However, design approval for such
substitution shall be obtained from the Owner before any substitution and
records of such substitutions shall be maintained by the Contractor.
2.08
WEIGHTS :
The unit weight of each type of tower and extension including bolts and
nuts, accessories, attachments and step bolts is indicated in the Bill of
Materials which shall be supplied by the Employer to the successful Bidder.
The weight of structure means the weight calculated using black sectional
(i.e. ungalvanised) weights of all steel members of the sizes indicated in the
fabrication drawings without taking into consideration the reduction in
weight due to drilling of bolts, holes, skew cuts, chamfering etc. or increase
in weight due to galvanising. 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.
2.09
GALVANISED BOLTS AND NUTS AND WASHERS :
2.09.1 The design of the towers and extensions are based on use of HRH mild steel
hot dip galvanized bolts (5.6 quality) and nuts (5.0 quality). The connections
are designed on the basis of use of 16mm dia bolts. The spring washers shall
be provided for insertion under all nuts.
2.09.2 The nuts shall be forged and tapped after galvanizing and then lubricated.
The nuts shall be chamfered on one face only, the other face shall be
machined.
2.09.3 The 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.
2.09.4 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 M16.
2.09.5 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
2.09.6 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
Page 17 of 116
Volume-V (Part-2)
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.
2.09.7 Flat and tapered washers shall be provided wherever necessary. Spring
washers shall be provided for insertion under all nuts. These washers shall be
steel electrogalvanised, positive lock type and 3.5mm in thickness for 16mm
dia bolt and 4.5mm for 24mm bolt.
2.09.8 To avoid bending stress in bolts or to reduce it to minimum, no bolt shall
connect aggregate thickness of members more than three (3) times its
diameter.
2.09.9 The bolt positions in assembled towers shall be as per structural drawing.
2.09.10
Bolts at the joints shall be so staggered that nuts shall be tightened with
spanners without fouling.
2.09.11
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
2.09.12
The bolts and nuts shall be free from forging and threading defects such
as cuts, splits, burrs, bulging, taper, eccentricity, loose fit etc.
2.09.13
The bolts shall be threaded up to standard length only as per relevant

Indian Standard and not to full length.
2.09.14
The bolts and nuts shall confirm to IS 1967-1971 Part-III and Part-IV, IS
12427, IS 1363-92, IS 1367 Part-XIII with latest amendment.
2.09.15
The spring washers designated as M 16-B suitable for

16mm dia
galvanized bolt shall be manufactured out of rectangular section with
tolerances as per IS 3063-1994 with latest amendments.
The spring
steel shall conform
to
IS- 4072-1975 with latest amendments
"Specification for steel for spring washers".
2.09.16
The spring washers after coiling shall be suitably heat treated so as to

result in the finished washer having hardness 43 to 50 HRC when tested in
accordance with IS 1586- 1968.
2.09.17
The surface of the washers shall be free of scales and burrs.

The
washers shall be coiled without any kinks (except for the shape with
turned-up ends). The ends of the washer shall not abut when the
washers are compressed.
The ends shall be so served as to prevent
tangling.
2.09.18
The approximate weight of 1000 pieces of spring washers suitable for

16mm dia bolt shall be 8.91 kg. in natural black finish as shown in IS
3063-1972 with latest amendments.
2.09.19
The spring washer shall be electro galvanized with chromate passivation.

The electro galvanizing of washers should conform to 'severe grading
service conditions incorporated in IS 1573-1986 as "Service Grade
No.4", classification Fe Zn 25. The local thickness of zinc coating should
Page 18 of 116
Volume-V (Part-2)
be minimum 25 microns and average thickness 38 microns. It should

be further suitably heat treated to avoid
any danger of hydrogen
embrittlement.
2.10
STEP BOLTS :
Each tower will be provided, on one of the legs, with step-bolts of 16mm dia
and 175mm long, spaced not more than 450mm and extending from 3
meters. approx. above ground level up to the top portion of the tower. The
step bolts shall
be confirm to IS 1363-1992, IS 10238:1989 and IS
1367(Part-XIII): 1983.
2.11
DANGER BOARD, NUMBER PLATE AND PHASE PLATES :

Each tower will be fitted with danger board, number plate and phase plates.
The tower to be supplied shall have provision to fix these plates at a height of
about 3 meters above ground level. Necessary provision in tower & extensions
for fixing of these items shall be made. The Danger board, number plate and
phase plates shall be supplied conforming to following technical details:-
2.11.1 The danger boards shall conform to IS-2551-1982 and their revision, if any
except where modified in this specification.
2.11.2 The danger boards, number plates and phase plates shall conform to the
drawings enclosed in this specification.
2.11.3 The colour scheme of the enamel and size of figures and dimensions of
lettering shall be as shown in the drawing as also the overall size. The holes
as indicated in the drawing shall be provided before enamellings.
2.11.4 The thickness of the plate out of which the danger board, number plate and
phase plate will be manufactured, shall not be less than 1.6mm.
2.11.5 The enamellings shall be done by vitreous enameling process only.
2.11.6 All letterings shall be centrally spaced. The dimensions of the letters, figures
and their respective positions shall be as given in drawings. The size of each
letter in the word in each language and the spacing between them for the
purpose of scribing shall be so chosen that they are uniformly written in the
space earmarked for them.
2.11.7 The corners of the plate shall be rounded off. The location of the fixing holes
shall be according to drawing annexed with this specification.
2.11.8 The plate shall be made from mild steel at least 1.6mm thick and vitreous
enameled white, with letters, figures and the conventional skull and crossbones in signal red colour on the front side. The rear side of the plate shall
also be enameled.
2.11.9 The corners of the danger, number and circuit plates shall be rounded off to
remove sharp edges.
2.11.10
The letters of number and phase plates shall be red enameled with white
enameled background.
Page 19 of 116
Volume-V (Part-2)
2.12
ANTICLIMBING DEVICE WITH BARBED WIRE :

The barbed wire type anticlimbing device shall be used at a height of
approximately 3 meters as an anticlimbing deterrent measure, as per the
details given in IS:5613(Part- 2/Sec-I)1985. The towers to be supplied by the
Bidder shall have provision to fix the barbed wire as indicated above.
Thus the angle pieces with notches for accommodating barbed wire shall be
supplied with the towers alongwith with provision for suitable bolt holes on
leg members for fitting the angles. It should have the facility of the locking
arrangement. The Barbed wire shall confirm to IS:278/1978 with latest
amendment and shall be type 'A-3'.
The Barbed wire shall be made of Hot dip Galvanised MS solid wire of size
2.5mm dia (for line wire) and 2.0 mm dia (for point wire). The barbs shall
have four points and shall be formed by twisting 2 point wires, each two
turns, tightly around both line wires making altogether four complete turns.
The wire shall be galvanised by Hot dip process as per IS:2629/1966 (with
latest amendment). The galvanised wire shall confirm to the requirement as
per IS:4826/1971 with latest amendment in all respect. IS:2633/1972 and IS
6745/1972 for testing of uniformity & mass of zinc coating. The zinc coating
shall be medium type on line wire and light type on point wire i.e. having zinc
coating minimum 110 gm/m on line wire and 70 gm/m on point wire.
2.13
EARTHING :
2.13.1 A provision shall be made in the stub for fixing earthing material. The stub
will be provided with a hole at a distance of 250 mm from bottom end and at
a distance of 500 mm below ground level for connection with earthing
materials. The hole will be of 17.5 mm dia.
2.13.2 The Bidder shall also supply the following materials per earthing set for
earthing of towers (four sets per tower): (i)
One no. Hot dip galvanized earthing Mild Steel Rod (2 Meter long, 25 mm
diameter):
(ii)
Hot dip galvanized connecting clamps (`F type and Ù type- 2 Nos. per
set);
(iii)
Hot dip galvanized stranded steel wire of size 7/4.00mm, Grade 5 to be

used as connecting wire conforming to Indian Standard:2141:1992 and
Indian Standard 4826: (5 Meter per earthing set).
2.13.3 The details of earthing rod and clamps and earthing arrangement for towers
are shown in the drawing enclosed.
2.13.4 The earthing rod shall be of mild steel solid rod of 2 meters in length and
25mm in diameter with one end pointed. The rods shall be galvanized as per
relevant Indian Standard . The zinc coating on the rod shall not be less than
610 gm/m of surface area.
2.13.5 The tower end-connecting clamp shall be of flat type and rod end connecting
clamp shall be of Ù type. The clamps shall be of forged steel cast iron /
malleable iron. The clamps should be hot dip galvanized as per Indian
Page 20 of 116
Volume-V (Part-2)
Standard:2629:1990 . The zinc coating on the clamps shall not be less than
610 gm/m of surface area.
2.13.6 The hot dip galvanized stranded steel wire of size 7/4.00mm shall be supplied
for connection between the earthing rod and the stub. The steel wire shall
conform to Indian Standard 2141: 1992 and Indian Standard:4826: 1979
and latest revision thereof and shall consist of seven strands, each strand
having a diameter of 4 mm and Grade-5. The galvanizing shall be done as
per Indian Standard specification2141: 1992 and 4826: 1979 and latest
revision thereof for heavy zinc coating. The coating of zinc shall not be less
than 260 gm/m.
2.14
ATTACHMENT FOR INSULATOR STRING & GROUNDWIRE CLAMPS:
2.14.1 The towers shall be provided with suitable attachment for supporting
insulator strings and ground-wire suspension and tension assembly.
2.14.2 The towers shall be provided with the cleats to support the hanger. The
details of hanger are shown in the drawing enclosed.
2.14.3 The ground-wire suspension assembly has got a 'D shackle. There shall be
a suitable arrangement to support the same.
2.14.4 On angle towers, strain plates shall be provided for purpose of attaching
the tension insulator string.
For fixing ground-wire tension assembly
a hole 17.5mm dia shall be provided in the strain plate.
2.15
FABRICATION WORKMANSHIP :
2.15.1 Except where hereinafter modified, details

IS-802(Part-II)-1990.
of fabrication shall conform to
2.15.2 The fabrication of towers shall be done strictly in

drawing supplied by the Employer.
accordance with the
2.15.3 The towers shall be of bolted construction.

2.15.4 Normally lap splice shall be used for connecting members of un-equal size
and the inside angles of lap splice shall be rounded at the heel to fit the
fillet of the outside angle. All splices shall develop full stress in the
members connected through bolts. Butt-joint as well as lap joint splices
shall be made as above and as close to the main panel as possible.
2.15.5 Joints are designed and detailed to avoid eccentricity as far as possible.
The use of gusset plates for joining tower members shall be avoided as far
as possible. However, where the connections are such that the eliminations
of the gusset plates would result in eccentric joints, gusset plates and spacer
plates may be used in conformity with modern practice.
2.15.6 The tower structures shall be accurately fabricated to bolt together easily at
site without any undue strain on the bolts.
2.15.7 No angle member shall have two leg flanges brought together by closing the
angle.
2.15.8 The diameter of the hole shall be equal to the diameter of the bolt plus 1.5
mm.
Page 21 of 116
Volume-V (Part-2)
2.15.9 All similar parts shall be made strictly interchangeable. All steel
section before any work is done on them shall be carefully leveled,
straightened and made true to detailed drawings by methods which will not
injure
the materials so
that when assembled the adjacent matching
surfaces are in close contact throughout .No rough edges shall be
permitted in the entire structures.
Hammering is not permitted for
straightening.
2.15.10
Cutting may done by shearing, cropping, flame cutting or sawing .
The surface so cut shall be cleaned smooth , reasonably square and free
from deformation and distortion.
2.16
BENDING :
2.16.1 Mild steel angle sections up to 75x75 mm (up to 6mm thick) shall bent cold
up to and including bend angle of 10 Angles. Above 75x75mm (thickness up
to 6mm) and up to and including 100x100 mm (thickness up to 8 mm) may
also be bent cold up to the bend angle of 5 Deg. All other angle sections and
bend angles not covered above shall be bent hot.
2.16.2 All plates up to 12mm thickness shall be bent cold up to a maximum bend
angle of 15 Deg. Plates of thickness more than 12mm with bends greater
than 15 Degree shall be bent hot.
2.16.3 All hot bend material shall be air-cooled. The bends shall be of even profile
and free from any surface damages.
2.17
DRILLING AND PUNCHING :
2.17.1 The holes in the member shall either be drilled or punched with a jig , the
former process will be preferred.
2.17.2 Punching may be adopted for sections upto 12 mm thickness. For thicker
sections drilling shall be done.
2.17.3 The holes shall be punched/drilled after bending and related position of
these
holes
shall
be
maintained
with the use of
proper
templates/jigs and fixtures .
2.17.4 The holes shall be perfectly circular and no tolerance in this respect is
permissible. The holes shall be perpendicular to the plate and angle
flanges.
2.17.5 Holes must be square with the plates or angles and have their walls parallel.
2.17.6 All burrs left by drills or punch shall be removed completely. When the tower
members are in positions, the holes shall be truly opposite to each other.
Drilling or ramming to enlarge defective holes shall not be permitted.
2.17.7 The minimum spacings of bolt and edge distance shall be as under :a.
For 16 mm dia bolt edge distance of 20 mm from hole center to rolled or

swaged edge and 23mm from hole center to sheared or flame cut edge,
hole center to hole center distance minimum 40mm (the hole size being
17.5mm).
b.
The gap between the edges of the connected members in butt joint
shall not be more than 6mm and less than 4mm.
Page 22 of 116
Volume-V (Part-2)
2.18
c.
The bolt gauge distance in flanges of angle sections shall generally be in

accordance with Table XXXI of SF6(1)-1961-ISI Hand
Book
for
structural Engineers-Structural Steel Sections (Revised).
d.
The bolt gauge distance in flanges of

angle sections shall
generally be in accordance with Table XXXI of SF6(1)-1961-ISI
Hand Book for structural
Engineers-Structural Steel
Sections
(Revised).
TOLERANCES :
2.18.1 The maximum allowable difference in the diameter of the hole on the two
sides of the plate or angle shall not exceed 0.8 mm on diameter. The
allowable taper in drilled/punched hole shall not exceed 0.8 mm on diameter.
2.18.2 The tolerance cumulative or between consecutive
+/- 0.5mm.
holes
shall
be
within
2.18.3 The tolerance on the overall length of member shall be within +/- 1.6 mm.
2.18.4 The tolerance on gauge distance shall be within +/- 0.5mm.
2.18.5 Rolling and weight tolerance of steel sections shall be as per Indian Standard:
1852 and Indian Standard: 808.
2.19
MARKING :
All members shall be distinctly given punch mark similar to those given in
structural drawings. The mark shall be given with marking dies of minimum
18 mm size and this mark shall be legible. Letter XMPTFD0, XMPTFD30 and
XMPTFD60 shall precede erection mark where X stands for manufacturers
name, MPT stands for Madhya Pradesh Power Transmission Company and
FD0, FD30 & FD60 stands for type towers.
2.20
QUALITY ASSURANCE PROGRAM :

The contractor shall submit the Quality Assurance Programme as specified in
clause 1.12 Section-1 of the biding document. A copy of the accepted Quality
Assurance Plan must be available at the manufacturers works of the Plant for
reviewing by inspecting officer of the employer.
2.21
INSPECTION OF PROTOTYPES :
2.21.1 Proto type of each type of structure/extensions shall be offered by the

successful bidder for inspection within three months time from the date of
contract.
2.21.2 Notwithstanding any thing covered in the drawings and other details furnished
by the Employer, the successful bidder shall make minor modifications, if any,
in length, size, notching etc. according to the proto assembly which are
necessary for easy assembly of the structure.
2.22
INSPECTION :
2.22.1 As specified in clause 1.13 Section-1 of the biding document, Plant to be

supplied will be subject to inspection and approval by the Employer's
representative before despatch.
Page 23 of 116
Volume-V (Part-2)
2.22.2 Each consignment ready for transportation shall be offered to the Employer
for inspection before dispatch giving a minimum time of not less than fifteen
days. Only complete sets of towers/extensions shall be offered for inspection.
All materials constituting towers (Steel parts, Bolts & nuts, spring and pack
washers, earthing sets) shall be offered simultaneously. Samples of fabricated
tower materials and accessories shall be subjected to tests as per relevant
Indian Standard or equivalent International Standard. The Employer shall be
kept informed about the source of procurement of raw-steel, particularly
through re-rollers. The Employer reserves right to inspect and get the
samples of raw-steel tested as per Indian Standard-2062 and relevant
standards or equivalent International Standard. The cost of testing shall be
borne by the bidder.
2.22.3 The Contractor shall keep the Employer informed in advance of the time of
starting and of the progress of manufacture and fabrication of structures at
various stages.
2.22.4 In case, any member of the structure is not found to comply with the relevant
drawing, it shall be liable for rejection even after receipt.
2.22.5 Defects, which may appear during fabrication, shall be made good. Any
member once rejected shall be cut into pieces in front of the Employers
representative so that it is not offered again by mistake.
2.23
GENERAL GUIDE-LINE FOR INSPECTION :
2.23.1 Fabricated Structure Members :

(i)
Visual examination and quantity verification of offered lot.
(ii)
Sample selection from the offered lot at a ratio of 40 MT (or part thereof) 1
no. each for all tests.
(iii)
Dimension, fabrication and trueness verification of structure member from

fabrication sketch.
(iv)
Galvanising test of each sample i.e. dip test, hammer test and mass of zinc
test.
(v)
Random verification of Zinc coating of galvanized surface by Alko-meter.
(vi)
Tensile test and bend test of each sample.
(vii)
Chemical composition test of at least two samples per offered lot of 50 MT

for inspection.
(viii)
Verification of manufacturers test certificate for mild steel used in structure

members.
2.23.2 Bolts-Nuts, Washer, Accessories, Attachments etc.: (To be carried out at

manufacturers works of these items)
(i)
Visual examination and quantity verification of offered lot.
(ii)
Sample selection from the offered lot as per relevant Indian Standard for each
item.
(iii)
Dimension, fabrication and trueness verification from fabrication sketch.
Page 24 of 116
Volume-V (Part-2)
(iv)
Galvanising test of each sample.
(v)
Other acceptance tests for respective items as per relevant Indian standard.
2.23.3 The supplier shall submit the factory test certificates of bought out
accessories at the time of acceptance tests of towers.
2.23.4 Since at the time of inspection only fabricated tower members and
accessories will be verified, acceptance of any lot shall in no way relieve the
bidder of his responsibility to meet all technical requirements of this
specification for fabricated towers. In case any shortcoming is noticed at the
time of actual assembly and erection, the Employer may reject any part or
item or accessory and the contractor will have to assume the responsibility for
free replacement/rectification of such defects.
2.24
PACKING AND MARKING ON PACKING :
2.24.1 The material shall be boxed or bundled for transport in the following manner:
(i)
Angle shall be packed in bundles securely wrapped four times around at each
end and over 900 mm with No.9 SWG steel wire with ends twisted tightly.
Gross weight of any bundle shall not be less than 450 Kg and more than 2000
Kg. The bundle shall be in complete Tower form only.
(ii)
Cleat angles, brackets, filler plates and similar small loose pieces shall be
nested and bolted together through holes and wrapped around at least four
times with No.9 SWG wire with ends twisted tightly or packed in wooden
crates. Gross weight of each bundle shall not exceed 200 Kg.
(iii)
Correct number of bolts, nuts and washers required for structures shall be
packed in heavy gunny bags accurately tagged in accordance with the
contents and a number of bags packed in a solid box of 22mm thick lumber
with paneled ends to be accurately nailed and further reinforced with 22 mm x
75 mm Batons round the sides and at the ends with 25 mm x No.18 SWG iron
band stretched entirely around the batons with ends overlapping at least
150mm. Gross weight of each box shall not exceed 200 Kg.
(iv)
Packing list incorporating all relevant details e.g. quantity of structures

(complete sets), number and size of steel sections, quantity of nuts, bolts,
washers etc. shall be forwarded along with each consignment.
(v)
In the nutshell the packing arrangement should be such that all lots of one
particular type of structure are identifiable at site for the purpose of allocation
for a particular work. In case more than one structure of a particular type is
delivered in area store/work site, combined packing arrangement by way of
clubbing members of similar type (for more than one structure) in a combined
package should not be done. Uniform packing procedure for each structure
should be adopted.
2.24.2 All above packing are subject to the approval of the Employer or his
appointed representatives.
2.24.3 Each bundle or packing shall have the following marks:
(i)
The name of the consignee (as per dispatch instructions given by the
Employer).
(ii)
Ultimate destination as required by the Employer.
Page 25 of 116
Volume-V (Part-2)
(iii)
The relevant marks and number of structure members or reference or bolts,

nuts and small components like gusset plats, various attachment, etc. for
easy identification.
2.24.4 The marking shall be stenciled and indelibly inked on the top members in the
bundles, on wooden boxes and also on gunny bas containing smaller
components.
***
Page 26 of 116
Volume-V (Part-2)
SECTION-3
TECHNICAL SPECIFICATIONS FOR CONDUCTOR
3.1
SCOPE :
3.1.1
This specification provides for standard design, manufacture, stage

testing, inspection and testing before despatch, packing and delivery
of Steel Cored Aluminium Conductor specified hereunder for their
satisfactory operation in various lines and sub-stations of the State.
The Conductor is to be used as power conductor on double circuit
transmission lines.
3.1.2
Bidders are required to quote for supply of all materials as detailed in the
specification. The bidder shall furnish full particulars as called for in various
clauses, in addition to filling and completing the schedules annexed to this
specification.
3.1.3
The unit rate quoted shall be inclusive of deployment of all plant, equipment,
men, material, skilled & unskilled labors etc. essential for satisfactory supply
of ACSR Moose.
3.1.4
All the raw materials for supply of ACSR Moose shall be included in the
Bidders scope of supply. Bidder shall inform the sources from where he
proposes to procure the raw materials.
3.2
STANDARDS:
3.2.1
The power conductor shall conform to the following Indian Standards, which
shall mean latest revisions, amendments/changes adopted and published,
unless otherwise specified hereinbefore.
Sl. No.
Indian Standards
or any Equivalent
International
Standard
IS:209
IS:398 Part I to
Part V (as relevant)
Specification for Aluminium Conductors

for overhead Transmission purpose.
IS:1778
IS:1521
Method of Tensile Testing of Steel wire
IS:2629

IS:2633
Method of Testing Uniformity of Zinc

coating of Zinc coated Articles.
IS:4826
Galvanised coating on Round Steel wire
IS:6745
Method of Determination of weight of Zinc

coating of zinc coated Iron and Steel
Articles
IS:8263
10
IS:1841
EC Grade Aluminium Rod produced by
Title
Hot
Dip
Page 27 of 116
Volume-V (Part-2)
rolling
11
IS:5484
EC grade Aluminium Rod produced by

continuous casting and rolling
12
IS: 2141
Method of Elongation test of steel wire
3.2.2
Acceptance of Other Authoritative Standards :

In the paragraph above, relevant Indian standards have been mentioned.
However, the ACSR Moose meeting any other authoritative international
standard, which ensures equal or better quality than the standards,
mentioned above shall also be acceptable. Please attach photocopy of all such
standards according to which the, ACSR Moose have been offered.
In this bid, the Bidders will have to furnish confirmation in regard to
compliance of our entire technical requirement.
The bid should clearly
describe various technical particulars of the, ACSR Moose as per details given
in this specification.
3.3
CLIMATIC CONDITIONS :
3.3.1
The ACSR conductor shall be suitable for being installed directly in air
supported with suspension insulator strings or anchored through tension
insulator strings supported with hanger/suspension clamp or tension clamp at
the cross arms of single circuit and double circuit transmission line towers.
The conductor shall be therefore suitable for satisfactory continuous operation
under the following climatic conditions:
MADHYA PRADESH
50.
1.
95(sometimes approaches
saturation)
Average daily ambient air temperature (0C

)
40 Centigrade

50
1250
Maximum wind pressure (kg/ square metre) 150

(metres)
10
1000
0.3
NOTE: Moderately hot and humid tropical climate conducive to rust and
fungus growth. The climatic conditions are also prone to wide variations in
ambient conditions. Stroke is also present in the atmosphere. Heavy
lightening also occurs during June to October.
3.4
PARAMETERS :
Page 28 of 116
Volume-V (Part-2)
3.4.1
Principal Parameters of Stranded Conductor:

Sr. No.
Details of Stranded Conductor
ACSR
Moose
a)
No. of Strands
Aluminium-54
Steel 7
i.
Steel Centre
ii.
1st Steel Layer
iii.
1st Aluminium Layer
12
iv.
2nd Aluminium Layer
18
v.
3rd Aluminium Layer
24
b)
Sectional Area of Aluminium (Sq.mm)
528.5
c)
Total Sectional Area (Sq.mm)
597.0
d)
Overall diameter(mm)
31.77 mm
e)
Approximate weight (Kg/Km )
2004
f)
Calculated D.C. Resistance at 20 Deg.C

(Ohm/Km)
0.05552
g)
Minimum UTS (kN)
161.2
h)
Modulus of Elasticity kg/cm2
0.703x106
3.4.1.1 The details of aluminium strand are as follows :

Sr.
No.
Details of Aluminium Strands
a)
Minimum breaking load of strand

(kN)
b)
Minimum breaking load of strand after stranding

(kN)
c)
Maximum D.C. resistance of

(Ohm/Km)
d)
Nominal Strand Dia
3.53
e)
Max. Strand Dia
3.55
f)
Min. Strand Dia
3.53
g)
Mass (Kg/Km) of
ACSR
Moose
Before stranding
1.49
strand at 20 deg.C
Strand at Nominal dia
1.57
2.921
21.47
3.4.1.2 The details of steel strand are as follows:

Sr.
No
Details of Steel Strands
p)
Minimum breaking load of strand Before

stranding (kN)
ACSR Moose
12.86
Page 29 of 116
Volume-V (Part-2)
3.5
3.5.1
q)
Minimum breaking load of strand after stranding

(kN)
r)
Nominal Strand Dia
3.53
s)
Maximum Strand Dia
3.60
t)
Minimum Strand Dia
3.53
u)
Mass (Kg/Km) of
v)
Zinc coating testing
w)
Wt. of Zinc Coating
Strand at Nom. dia
12.22
76.34
3 dips of 1
min. each
(gms/sq. metre)
GENERAL
TECHNICAL
REQUIREMENTS
WORKMANSHIP (FOR ACSR MOOSE):
260
MATERIAL
AND
Materials:
3.5.1.1 The conductors shall be manufactured from EC grade aluminium rods suitably
hard-drawn on wire drawing machines. The aluminium rods used shall comply
with IS: 1841 and IS: 5484 or any equivalent International Standard. The
mechanical and electrical properties of aluminium wire shall comply with the
requirements given in relevant standard.
3.5.1.2 Physical constants for Hard-drawn Aluminium:
i. Resistivity:
The resistivity of aluminium depends upon its purity and its physical condition.
For the purpose of this specification the maximum value permitted is 0.28264 Ohm
sq.mm/mt. at 20 C and this value has been used for calculation of the maximum
permissible value of resistance.
NOTE : It is not intended to check the resistivity from the measured values of
resistance.
ii.
iii.
Density:
At a temperature
taken as 2.703 g/cm.3
of 20 C the density of hard drawn aluminium has been
Constant-Mass Temperature Co-efficient of Resistance:

At a temperature of 20C, the constant-mass temperature co-efficient of
resistance of hard drawn aluminium measured between two potential points rigidly
fixed to the wire, the metal being allowed to expand freely, has been taken as 0.004
per degree Celsius.
iv. Co-efficient of Linear Expansion:

The co-efficient of linear expansion of hard-drawn aluminium at 0 C has been
taken as 23.0 x 10 -6 per C. This value holds good for all practical purposes over the
range of temperature from 0 C to highest safe operating temperature.
Galvanised steel wire shall be drawn from high carbon steel rods produced by
either acidic or basic open hearth process, electric furnace process or basic oxygen
process. The mechanical and electrical properties of wire shall comply with the
Page 30 of 116
Volume-V (Part-2)
requirements given in relevant standard. The chemical composition of high carbon

steel wires is given below for guidance only.
Element
Percentage Composition
Carbon
0.5 to 0.85
Maganese
0.50 to 1.10
Phosphorous
Not more than 0.035
Sulphur
Not more than 0.045
Silicon
0.10 to 0.35
3.5.1.3 Physical constants for Galvanised steel wires:

i. Density :
At a temperature of 20 C, the density of galvanized steel wire is to be taken
as 7.80 g/Cm3.
ii. Coefficient of Linear Expansion :
In order to obtain uniformity in calculation a value of 11.5 x 10 6 C may be
taken as the value for the co-efficient of Linear Expansion of galvanized steel wires
used for the cores of steel-reinforced aluminium conductors.
iii. The zinc used for galvanizing shall be electrolytic high-grade Zinc not less than 99.95
percent purity. It shall conform to and satisfy all the requirements of IS: 209.
Galvanising may be done either by hot process or electrolytic process. Minimum
weight of Zinc coating shall be 260 g/sq. metre. Neutral grease may be applied
between the layers of wire.
iv. Freedom From Defects:
The wires shall be smooth and free from all imperfections such as spills, slag
inclusion, die marks, scratches, fittings, blow-holes, projections, looseness,
overlapping of strands, chipping of aluminium layers etc. and all such other defects
which may hamper the mechanical and electrical properties of the conductor. Special
care should be taken to keep away dirt, grit etc. during stranding.
3.5.2
Wire Sizes
3.5.2.1 Nominal Size:

The aluminium and galvanized steel wires for the stranded conductor covered by
this standard shall have diameters specified in clause 3.4.1.1 & 3.4.1.2. The diameter
of the steel wires shall be measured over the zinc coating.
3.5.2.2 Tolerances on Nominal Size :
Tolerance of + 1% is permitted on the nominal diameter of Aluminium Wires of
Moose Conductor and a tolerance of + 2 % is permitted on the nominal diameter of
Galvanised Steel Core Wire.
3.5.3
Joints in Wires:
3.5.3.1 Aluminium Wires:

No joints shall be permitted in the aluminium wires in the outermost layer of the
ACSR Conductor. Joints in the inner layers are permitted, in addition to those made in
the base rod or wire before final drawing, but no two such joints shall be less than 15
Page 31 of 116
Volume-V (Part-2)
mtr. apart in the complete stranded conductor such joints shall be made only by cold
pressure butt-welding. It may please be noted that Joints are not permitted in the
outermost layer of the conductor in order to ensure a smooth conductor finish and
reduce radio interference levels and corona losses on extra high voltage lines.
3.5.3.2 Galvanised Steel Wires:
There shall be no joints except those the base rods or wires before final drawing, in
steel wires forming the core of the steel-reinforced aluminium conductor. Joints are
not permitted in the steel wires after final drawing also in order to avoid reduction in
the breaking strength of the conductor that may occur as a result of failure of the
joints.
Stranding:
3.5.4
3.5.4.1 The wires used in the construction of galvanized steel reinforced aluminium
conductor, before stranding, shall satisfy all the relevant requirements of this
specification.
3.5.4.2 The lay ratio of the different layers shall be within the limits given in
Table below:-
the
LAY RATIO OF ALUMINIUM CONDUCTORS GALVANISED STEEL-REINFORCED

(Moose Aluminium-54 Wire Steel - 7 Wire)
Ratio
of Alu.
wire
diamet
er to
steel
wire
diamet
er
Lay Ratios
of Steel
core 6 wire
layer
Lay Ratios for Aluminium wires (3 Alu.

Wire Layer Conductors)
Outermost
layer
Layer
immediatel
y beneath
outer most
layer
Innermost
Layer
Min.
Max.
Min.
Max.
Min.
Max.
Min
.
Max.
16
18
10
12
11
13
12
14
NOTE : For the purpose of calculation, the mean lay ratio shall be taken as the
arithmetic mean of the relevant minimum and maximum values given in this table.
3.5.4.3 In all constructions, the successive layers shall have opposite directions of lay,
the outermost layer being right-handed. The wires in each layer shall be
evenly and closely stranded.
3.5.4.4 In conductors having multiple layers of aluminium wires, the lay ratio of any
aluminium layer shall not be greater than the lay ratio of the aluminium layer
immediately beneath it.
Page 32 of 116
Volume-V (Part-2)
3.5.4.5 The finished Conductor shall have a smooth surface without any surface cut,
abrasion, scuff marks and shall be free from dirt, grit, etc. even if the damage
to conductor is acceptable from mechanical considerations. It will not be
acceptable from electrical considerations, and full care should be taken not to
supply damaged conductor. Projections of more than 2 mils shall not be
acceptable. Any such damage shall be properly rectified or new conductor
supplied.
3.5.4.6 Failure of any sample to meet the above requirements shall be sufficient
cause for rejection of the lengths of conductor represented by the sample.
Particular care shall, therefore, be taken during manufacture, handling,
packing and transportation of the conductor, to see that the surface is not
dented, cut or damaged in any way.
3.5.5
Standard Length :
3.5.5.1 The standard length of conductor shall be 1500 metres. A tolerance of +/-5%
on the standard length offered by the supplier shall be permitted. All lengths
outside this limit of tolerance shall be treated as random lengths.
3.5.5.2 Random lengths will be accepted provided no length is less than 70% of the
standard length specified and the total quantity of such random lengths shall
not be more than 5% of the total quantity ordered.
3.5.5.3 Supplier shall also indicate the maximum single length, above the standard
length, they can manufacture in the guaranteed technical particulars. This is
required for special stretches like river crossing etc. The purchaser reserves
the right to place orders for the above length to the 5% of the total ordered
quantity on the same terms and conditions applicable for the standard lengths
during the pendency of the contract.
3.5.6
Galvanising:
3.5.6.1 All the wires of Iron & steel strand shall be galvanized in accordance with IS2629-1966. Recommended practice for hot dip galvanizing of Iron and Steel
or some other authoritative equivalent standard.
3.5.6.2 Specific technical requirements for galvanizing and relevant tests quoted in
clause-6 of this specification for guidance shall be complied.
3.6
TESTS :
3.6.1
The conductor 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.
3.6.2
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.
3.6.3
All the materials offered shall be fully type tested as per the relevant
standards 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
Page 33 of 116
Volume-V (Part-2)
years, prior to the date of opening of bid. For any change in the design/type
already type tested and the design/type offered against this specification, the
purchaser reserves the right to demand repetition of tests without any extra
cost.
3.6.4
Acceptance tests shall mean those tests, which are to be carried out on
samples taken from each lot offered for pre-despatch inspection, for the
purpose of acceptance of that lot.
3.6.5
Routine tests shall mean those tests which are to be carried out on each
strand/spool/length of the conductor to check requirements which are likely
to vary during production.
3.6.6
Tests during manufacture shall mean those tests, which are to be carried out
during the process of manufacture and end inspection by the supplier to
ensure the desired quality of the end product to be supplied by him.
3.6.7
The norms and procedure of sampling for these tests will be as per the
Quality Assurance Programme to be mutually agreed to by the Supplier and
the Purchaser as per relevant clause of General Conditions of Contract.
3.6.8
The standards and norms to which these tests will be carried out are listed in
para 2.0. Where a particular test is a specific requirement of this specification,
the norms and procedures of the test shall be as mutually agreed to between
the Supplier and the Purchaser in the Quality Assurance Programme.
3.6.9
For all type and acceptance tests, the acceptance values shall be the values
guaranteed by the Supplier in the Guaranteed Technical Particulars of his
proposal or the acceptance value specified in this specification, whichever is
more stringent for that particular test.
3.6.10 Type Tests :

The Conductor offered shall be fully type tested as per the relevant
International/Indian Standard and the bidder shall furnish the report along with the
offer. These tests must not have been conducted earlier than 5 years prior to the date
of opening of bid. 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.
The above said test reports submitted with the offer shall not be older than five
years, prior to the date of opening of bid.
a)
b)
c)
3.6.11
UTS test on stranded conductor

DC resistance test on stranded conductor
Stress-strain test on composite conductor
Acceptance Tests :
a)
Visual and dimensional check
b)
Visual check for joints, scratches etc. and lengths of conductor
Page 34 of 116
Volume-V (Part-2)
NOTE:
d)
Dimensional check on steel and aluminium strands
d)
Check for lay ratios of various layers
e)
Galvanising test on steel strands
f)
Torsion and Elongation test on steel wire
g)
Breaking load test on steel and aluminium strands
h)
Wrap test on steel and aluminium strands
i)
DC resistance test on aluminium strands
j)
UTS test on welded joint of aluminium strand
All the above tests except test mentioned at (j) shall be carried out on
and steel strands after stranding only.
aluminium
3.6.12 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 specifications.
d)
All acceptance tests as mentioned in Clause 6.1.10 above shall be

carried out on each coil.
3.6.13 Tests During Manufacture :

a)
Chemical analysis of zinc used for galvanizing
b)
Chemical analysis of aluminium for making aluminium strands
c)
Chemical analysis of steel used for making steel strands

The entire cost of testing for the acceptance and routine tests and tests
during manufacture specified herein shall be treated as included in the quoted unit
price of conductor, except for the expenses of the inspection/Purchasers
representative.
3.6.15 Additional Tests:
The Purchaser reserves the right of having at his own expenses any other test(s) of
reasonable nature carried out at Suppliers premises, at site, or in any other place in
addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
material comply with the specification.
Page 35 of 116
Volume-V (Part-2)
3.6.16 Sample Batch for Type Testing

(a) The bidder shall offer at least three (3) drums for selection of samples required for
conducting all the type tests, in case of change in design/type already tested and
the design type offered against this specification, for which the purchaser reserves
the right to demand carrying out type test without any extra cost.
(b) The bidder is required to carry out all the acceptance tests successfully in the
presence of Purchasers representative before despatch of conductor.
3.6.17 Test Reports
(a) Record of routine test reports shall be maintained by the Supplier at his works for
periodic inspection by the Purchasers representative.
(b) Test Certificates of test during manufacture shall be maintained by the Supplier.
These shall be produced for verification as and when desired by the Purchaser.
3.6.18 Test Facilities
The following additional test facilities shall be available at Bidders Works.
(a) Calibration of various testing and measuring equipment including tensile testing
machine, resistance measurement facilities, burette, thermometer, barometer etc.
(b) Standard resistance for calibration of resistance bridges.
(c) Finished conductor shall be checked for length verification and surface finish on
separate rewinding machine at reduced speed (variable from 8 to 16 metres per
minute). The rewinding facilities shall have appropriate clutch system and free of
vibrations, jerks etc. with transverse layering facilities.
3.7
INSPECTION :
3.7.1
The purchasers representative shall at all times be entitled to have access to

the works and all places of manufacture where conductor shall be
manufactured and the representative shall have full facilities for unrestricted
inspection of the Suppliers works, raw materials and process of manufacture
for conducting necessary tests as detailed herein.
3.7.2
The Supplier shall keep the Purchaser 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.
3.7.3
No material shall be despatched from its point of manufacture before it has

been satisfactorily inspected and tested, unless the inspection is waived off by
the purchaser in writing. In the later case also, the conductor shall be
despatched only after satisfactory testing for all tests specified herein has
been completed.
Page 36 of 116
Volume-V (Part-2)
3.7.4
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 if such material is
later found to be defective.
3.7.5
At least 5% of the total number of drums subject to minimum of two in any

lot put up for inspection, shall be selected at random to ascertain the length
of conductor by following method:
At the works of the manufacturer the conductor shall be transferred from one
drum to another at the same time measuring its length with the help of graduated
pulley and Cyclometer. The difference in the average length thus obtained and as
declared by the supplier in the packing list shall be applied to all the drums if the
conductor is found short during checking
3.8
QUALITY ASSURANCE PLAN :
3.8.1
The Supplier shall invariably furnish following information along with his offer,
failing which his offer may be liable for rejection. Information shall be
separately given for individual type of equipment offered.
(i) Statement giving list of important raw materials names of sub supplies for the
raw materials, list of standards according to which the raw materials are
tested, list of tests normally carried out on raw materials in presence of
Suppliers representative, copies of test certificates.
(ii) Information and copies of test certificates as in (i) above in respect of bought
out accessories.
(iii) List of manufacturing facilities available.
(iv) Level of automation achieved and list of areas where manual process exists.
(v) List of areas in manufacturing process, where stage inspections are normally
carried out for quality control and details of such tests and inspections.
(vi) Special features provided in the equipment to make it maintenance free.
(vii) List of testing equipments available with the Supplier for final testing of
material specified and test plant limitation. If any, vis-a-vis the type, special,
acceptance and routine tests specified in the relevant standards. These
limitations shall be very clearly brought out in schedule of deviation from
specified test requirements.
3.8.2
3.8.3
The successful Supplier shall within 30 days of placement of order, submit

following information to the purchaser.
(i)
List of raw materials as well as bought out accessories and the names
of sub-suppliers selected from those furnished along with offer.
(ii)
Type test certificates of the raw material and bought out
(iii)
Quality assurance plan (QAP) with hold points for Purchasers

inspection. The quality assurance of plan and Purchasers hold points
shall be discussed between the Purchaser and Supplier, before QAP is
finalized.
accessories.
The successful Supplier shall submit the routine test certificates of bought out
accessories and central excise passes for raw material viz. oil, copper,
Page 37 of 116
Volume-V (Part-2)
aluminium, conductors insulating materials, core material at the time of

routine testing of the Conductor.
3.9
DOCUMENTATION :
3.9.1
Six sets of type test reports, duly approved by the

Purchaser shall be
submitted by the supplier for distribution, before commencement of supply.
Adequate copies of acceptance and routine test certificates, duly approved by
the Purchaser shall accompany with despatched consignments.
3.9.2
The manufacturing of the material shall be strictly in accordance with the

approval of the Purchaser. All manufacturing and fabrication work in
Suppliers risk.
3.9.3
Approval of drawing/work by Purchaser shall not relieve the Supplier of his

responsibility and liability for ensuring correctness and correct interpretation
of the latest revision of applicable standards, rules and codes of practices.
The material shall conform in all respect to high standards of engineering,
design, workmanship and latest revisions of relevant standards at the time of
ordering. Purchaser shall have the power to reject any work or material,
which in his judgment is not in full accordance therewith.
3.10
PACKING AND FORWARDING :
3.10.1 The conductor shall be supplied in non-returnable strong wooden drums

provided with lagging of adequate strength, to protect the conductor against
all damage and displacement during transit, storage and subsequent handling
and stringing operations in the field. The drums shall generally conform to IS:
1778 except otherwise specified hereinafter.
3.10.2 The drums shall be suitable for wheel mounting and for jetting off the
conductor under a minimum controlled tension of the order of 5kN.
3.10.3 The standard drum drawings are enclosed however, supplier should submit
the proposed drum drawings along with the bid. The same shall be in line with
the requirements of standard drawings and as stated herein. After placement
of the letter of Award, the supplier shall submit four copies of fully
dimensioned drawing of the drum he wishes to supply, for Purchasers
approval, before taking up manufacturing of conductor. After getting approval
from the Purchaser, Supplier shall submit 30 more copies of the approved
drawing to Purchaser for further distribution and field use at Purchasers end.
3.10.4 All wooden components shall be manufactured out of seasoned soft wood free
from such defects that may materially weaken the component part of the
drums. Preservative treatment for anti-termite /anti-fungus (Aldrine/Aldruse)
shall be applied to the entire drum with preservatives of a quality which is not
chemically harmful to the conductor.
3.10.5 The flanges shall be of two/three ply construction with each ply at right
angles to the other and nailed together. Further the outer face of the flange
shall be reinforced with the circumferential battens, fixing in octagonal shape.
Page 38 of 116
Volume-V (Part-2)
The nails shall be driven from the inside face of flange, punched and then
clenched on the outer face. The tolerance in thickness of each ply shall be +/3 mm only. There shall be at least 3 nails per plank of ply with maximum
nail spacing of 75 mm. 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. Spindle hole shall be provided at the centers of the planks of the plies
and spindle plates with 102 mm dia. Holes shall be fitted on either side of
both the flanges.
3.10.6 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.
3.10.7 Barrel studs shall be used for construction of drums. The flanges shall be
holed and the barrel supports slotted to receive them. The barrel studs shall
be threaded over a length on either end, sufficient to accommodate washers,
spindle plates and nuts for fixing flanges at the required spacing. Barrel studs
should be tack welded with the nuts after tightening.
3.10.8 Normally, the nuts on the studs shall stand protrude of the flanges. All the
nails used on the inner surface of the flanges and the drum barrel shall be
counter sunk. The ends of barrel shall generally be flushed with the top of the
nuts.
3.10.9 The inner cheek of the flanges and drum barrel surface shall be painted with a
bitumen based paint.
3.10.10 Before reeling, cardboard or double corrugated or thick bituminised
waterproof bamboo paper shall be secured to the drum barrel and inside of
flanges or the drum by means of a suitable commercial adhesive material.
The paper should be dried before use. Medium grade craft paper shall be used
in between the layer of the conductor/earth wire. After reeling the conductor
the exposed surface of the outer layer of conductor shall be wrapped with thin
polythene sheet across the flanges to preserve the conductor from dirt, grit
and damage during transportation and handling and also to prevent ingress of
rain water during storage/transport.
3.10.11 Minimum space of 125 mm shall be provided between the inner surface of the
external protective layer and outer layer of the conductor.
3.10.12 Each batten shall be securely nailed across grains as far as possible to the
flange edges with at least 2 nails per end. The length of the nails shall not be
less than twice the thickness of the battens. The nail shall not protrude above
the general surface and shall not have exposed sharp edges or allow the
battens to be released due to corrosion.
3.10.13 Outside the protective layer, there shall be minimum of two binder consisting
of hoop iron/galvanized steel wire. Each protective layer shall have two recess
to accommodate the binders.
3.10.14 The conductor ends shall be properly sealed and secured with the help of Unails on one side of the flanges. The end securing shall be done by taking out
at least 500 mm of steel core on either ends by U-nails. The composite
conductor shall be binded by use of galvanized steel wire/aluminum wire at
three locations at least 75 mm apart or more covered with PVC adhesive tape
so as to avoid loosening of conductor layers in transit and handling.
Page 39 of 116
Volume-V (Part-2)
3.10.15 Only one length of conductor shall be wound on each drum.
3.11
ink
MARKING :
Each drum shall have the following information stenciled on it in indelible

along with other essential data:
i.
Contract/Award letter number
ii.
iii.
iv.
Drum number
v.
Size of conductor
vi.
Length of conductor in metres
vii.
Gross weight of drum with conductor
viii.
ix.
3.12
END SEALING :
Both the ends of each length of conductor should be provided with non-destructive
type metal crimped or epoxy capped seals with punching embossing/ engraving of
manufacturers monogram and drum number.
3.13
CHECK MEASUREMENT
3.13.1 At least 5% of the total number of drums in any lot put up for inspection shall
be selected at random to ascertain the length of conductor by rewinding
method. The % shortage if any in the length thus obtained and as declared
by the supplier in the packing list, shall be applied to all the drums if the
conductor is found short during checking.
3.13.2 The length of conductor shall also be verified at the consignees end. Where
length measurement machines are not available the length will be verified by
the weighment basis. The determining factor will be length weight ratio of
the sample drums verified at the firms premises of the Lot of which the drum
under measurement at the consignees end forms a part.
Page 40 of 116
Volume-V (Part-2)
SECTION-4
TECHNICAL SPECIFICATIONS FOR EARTH WIRE
4.01 STANDARDS:
The high Tensile Steel Galvanised Earth Wire shall conform to the following
Indian
Standards, which shall mean latest revisions, amendments/changes
adopted and published, unless otherwise specified hereinbefore.
Title
Sl.
No.
Indian Standards or any

Equivalent International
Standard
IS:209
IS:2141
Specification for Earth

Transmission purpose
3
4
5
IS:1778
IS:1521
IS:2629

Method of Tensile Testing of Steel wire
Recommended practice for Hot Dip Galvanising
Iron and Steel
IS:2633
7
8
IS:4826
IS:6745
IS: 12776
Method of Testing Uniformity of Zinc coating of

Zinc coated Articles.
Galvanised coating on Round Steel wire
Method of Determination of weight of Zinc
coating of zinc coated Iron and Steel Articles
Method of Testing of Ground wire
wire
for
overhead
4.02 CLIMATIC CONDITIONS :

The Earth wire shall be suitable for being installed directly in air supported with
suspension clamp or tension clamp at the cross arms of single circuit and double
circuit transmission line towers. The earth wire shall be therefore suitable for
satisfactory continuous operation under the following climatic conditions:
1
2
Location in the State of
MADHYA PRADESH
0
Maximum ambient air temperature ( C)

0
50.
Minimum temperature in shade ( C )
1.
95(sometimes
approaches saturation)
Average daily ambient air temperature (0C )
40 Centigrade

50
Average rainfall (mm)
1250
Maximum wind pressure (kg/ square

meters)
150

(meters)
1000
1
0
0.3
Page 41 of 116
Volume-V (Part-2)
NOTE: Moderately hot and humid tropical climate conducive to rust and fungus
growth. The climatic conditions are also prone to wide variations in ambient
conditions. Stroke is also present in the atmosphere. Heavy lightening also occurs
during June to October.
4.03 PARAMETERS :
4.03.1 PRINCIPAL PARAMETERS OF EARTH WIRE:
The standard technical particulars of 7/3.66mm galvanized steel earth wire
shall be as follows :(A) The details of Steel strand:
Sr. No.
Details of steel strands
Earth Wire
a)
Material
Steel
b)
Stranding
c)
Weight per Km
583 Kgs
d)
Dia. of wire
3.66 mm
e)
Tolerance
2%
f)
Minimum elongation in 100 mm length
5 mm
g)
Minimum breaking strength per strand
1000 Kg
h)
Minimum tensile strength
95 Kg./mm2
i)
D.C. resistance at 20 Deg. C
17.15 Ohms/Km
(B) The details of Stranded Earth Wire :

Sr. No.
Details of Stranded Earth Wire
Earth Wire
i.
Maximum Length of Lay
198
ii.
Minimum Length of Lay
165
iii.
Minimum breaking load
iv.
Overall diameter
10.98mm
1.933 x 106 Kg./cm2
vi
Co-efficient of linear expansion
11.50 x 10Deg.C
vii
Weight of zinc coating on wire
viii
No. of one minute dip and half minute

dip respectively
260 gms./ m 2 (Min.)

3 one minute and
ix
Calculated d.c. Resistance at 20 Deg.C
6972 Kgs
1 half
per
minute
2.5 Ohms per Km
4.04 GENERAL TECHNICAL PARTICULARS : MATERIAL AND WORKMANSHIP

FOR EARTH WIRE:
4.04.1 The steel wire (strands) used in manufacture of galvanized steel earth wire
shall be drawn from steel wire rod produced by either acid or basic open
hearth process or by the electric furnace process or basic oxygen process.
The steel wire shall not have sulphur and phosphorous contents exceeding
0.045% each. The carbon content shall not exceed 0.55%. The steel
produced by bassemer process shall not be used for drawing of steel wire
Page 42 of 116
Volume-V (Part-2)
strands. The finished earth wire shall have minimum brittleness as it will be
subjected to continuous vibration while in use on line.
4.04.2 The steel wire shall be hot dip galvanized and shall have clause A (heavy)
zinc coating of minimum 260 gram per sq. meter of the uncoated wire
surface. The zinc coating shall be smooth and continuous of uniform
thickness, free from imperfections not consistent with good commercial
practice and shall meet the test requirement. The zinc used in galvanizing of
earth wire shall be as per IS: 209-1966.
4.04.3 All the steel wires shall be circular, smooth, uniform and free from
imperfections, such as spills and splits, die marks scratches, abrasions, cuts
and kinks etc. drawing and after stranding.
4.04.4 The steel wires, after galvanizing shall be bright in appearance, smooth and
free from all defects like flux, ash, cross inclusions, bare and black spots,
pimples, lumpiness in runs, rust, stains, bulky white deposits and blisters.
4.04.5 To avoid susceptibility towards wet storage stains (white rust) the stranded
earth wire shall be provided with a protective coating of boiled linseed oil.
4.04.6 The finished earth wire shall have a smooth surface without any surface
cuts, abrasions, scuff marks and shall be free from dirt, grit etc.
4.04.7 Failure of any sample to meet the above requirements shall be sufficient
cause for rejection of the lot of earth wire represented by the sample,
particular care shall therefore be taken during manufacture, handling,
packing and transportation of the earth wire so that it is not dented, cut or
damaged in any way.
4.05 Size and Properties:
4.05.1 The earth wire size, physical properties, tolerance in diameter of individual
strands and length of lay of the strand shall be as given above.
4.05.2 The wires shall be so stranded together that when an evenly distributed
pulls is applied at
the end of completed strands, each wire will take an
equal share of the pull.
4.05.3 The earth wire shall be supplied in the standard lengths which shall not be
less than 3 Km. and such lengths will be specifically indicated in the tender.
Not less than 95% of the total quantity of the earth wire shall be supplied in
standard
lengths. The quantity of earth wire in length shorter than
standard one shall not exceeds 5% of the total quantity to be supplied.
Further, no single earth wire length in respect of such 5% (maximum)
supply in random lengths shall be shorter than 50% of the standard length.
4.05.4 The length of the stranded wire shall be supplied without joints in the
individual wires comprising it, excluding welds made in base rod before it is
drawn.
4.05.5 Each coil be warranted to contain no welds, joints or splice other than in the
base rod before it is drawn.
4.06 GALVANISING AND OILING:
4.06.1 All the wires of the strand shall be galvanized in accordance with IS-26291966. Recommended practice for Hot dip galvanizing of Iron and Steel of
some other authoritative equivalent standard.
Page 43 of 116
Volume-V (Part-2)
4.06.2 The galvanized earthwire after stranding operation shall have dipped in
boiled linseed oil before winding it on drums.
4.07 TEST FOR EARTH WIRE :
4.07.1 Earth wire shall be subjected, before despatch from the works to tests as
specified in the IS-2141,
IS 1521, IS 1755 & IS 4826 or any other
authoritative equivalent standard.
4.07.2 All the drums of galvanized steel stranded earth wire of the same grade,
diameter and construction, manufactured under similar condition shall be
grouped to constitute one lot.
4.07.3 Samples from each lot shall be tested for ascertaining the conformity to the
requirements of the earth wire specified herein. The drums selected shall be
tested for length of the lay and diameter of individual strands etc. The lot
shall be declared conforming to the requirement of these characteristics if all
the samples are found satisfactory. One test specimen from each wire of the
strand shall now be drawn from every selected drum and subjected to
chemical analysis, tensile tests, ductility test, elongation test and coating
test. One test specimen, of the completed strand from each drum shall be
subjected to tensile strength. The lot shall be declared conforming to the
requirements of these characteristics, if the entire test specimen satisfies
the relevant requirement.
4.08 INSPECTION :
4.08.1 The purchasers representative shall at all times be entitled to have access
to the works and all places of manufacture where earth wire shall be
manufactured and the representative shall have full facilities for unrestricted
inspection of the Suppliers works, raw materials and process of
manufacture for conducting necessary tests as detailed herein.
4.08.2 The Supplier shall keep the Purchaser informed in advance of the time of
starting and of the progress of manufacture of earth wire in its various
stages so that arrangements can be made for inspection.
4.08.3 No material shall be despatched from its point of manufacture before it has
been satisfactorily inspected and tested, unless the purchaser in writing
waives off the inspection. In the later case also, the earth wire shall be
despatched only after satisfactory testing for all tests specified herein has
been completed.
4.08.4 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 if such material is
later found to be defective.
4.08.5 At least 5% of the total number of drums subject to minimum of two in any
lot put up for inspection, shall be selected at random to ascertain the length
of earth wire by following method:
At the works of the manufacturer of the earth wire, the earth wire shall be
transferred from one drum to another at the same time measuring its length
with the help of graduated pulley and Cyclometer. The difference in the
average length thus obtained and as declared by the supplier in the packing
list shall be applied to all the drums if the conductor/earth wire is found
short during checking
4.09 DOCUMENTATION:
4.09.1 Six sets of type test reports, duly approved by the
Purchaser shall be
submitted by the supplier for distribution, before commencement of supply.
Page 44 of 116
Volume-V (Part-2)
Adequate copies of acceptance and routine test certificates, duly approved

by the Purchaser shall accompany with despatched consignments.
4.09.2 The manufacturing of the material shall be strictly in accordance with the
approval of the Purchaser. All manufacturing and fabrication work in
Suppliers risk.
4.09.3 Approval of drawing/work by Purchaser shall not relieve the Supplier of his
responsibility and liability for ensuring correctness and correct interpretation
of the latest revision of applicable standards, rules and codes of practices.
The equipment shall conform in all respect to high standards of engineering,
design, workmanship and latest revisions of relevant standards at the time
of ordering. Purchaser shall have the power to reject any work or material,
which in his judgment is not in full accordance therewith.
4.10 PACKING AND FORWARDING:
4.10.1 The earth wire shall be supplied in strong wooden drums provided with
lagging of adequate strength, to protect the conductor/earth wire against all
damage and displacement during transit, storage and subsequent handling
and stringing operations in the field. The drums shall generally conform to
IS: 1778 except otherwise specified hereinafter.
4.10.2 The drums shall be suitable for wheel mounting and for jetting off the
conductor/earth
wire under a minimum controlled tension of the order of
5kN.
4.10.3 After placement of the letter of Award, the supplier shall submit four copies
of fully dimensioned drawing of the drum he wishes to supply, for
Purchasers approval, before taking up manufacturing of earth wire. After
getting approval from the Purchaser, Supplier shall submit 30 more copies
of the approved drawing to Purchaser for further distribution and field use at
Purchasers end.
4.10.4 All wooden components shall be manufactured out of seasoned soft wood
free from such defects that may materially weaken the component part of
the drums. Preservative treatment for anti-termite /anti-fungus
(Aldrine/Aldruse) shall be applied to the entire drum with preservatives of a
quality which is not harmful to the earth wire.
4.10.5 The flanges shall be of two/three ply construction with each ply at right
angles to the other and nailed together. Further the outer face of the flange
shall be reinforced with the circumferential battens, fixing in octagonal
shape. The nails shall be driven from the inside face of flange, punched and
then clenched on the outer face. The tolerance in thickness of each ply shall
be +/- 3 mm only. There shall be at least 3 nails per plank
of ply with
maximum nail spacing of 75 mm. Where a slot is cut in the flange to receive
the inner end of the conductor/earth wire, the entrance shall be in line with
the periphery of the barrel. Spindle hole shall be provided at the centers of
the planks of the plies and spindle plates with 102 mm dia. Holes shall be
fitted on either side of both the flanges.
4.10.6 The wooden battens used for making the barrel of the earth wire shall be of
segmental type. These shall be nailed to the barrel supports with at least
two nails. The battens shall be closely butted and shall provide a round
barrel with smooth external surface. The edges of the battens shall be
rounded or chamfered to avoid damage to the earth wire.
4.10.7 Barrel studs shall be used for construction of drums. The flanges shall be
holed and
the barrel supports slotted to receive them. The barrel studs
shall be threaded over a length on either end, sufficient to accommodate
Page 45 of 116
Volume-V (Part-2)
washers, spindle plates and nuts for fixing flanges at the required spacing.
Barrel studs should be tack welded with the nuts after tightening.
4.10.8 Normally, the nuts on the studs shall stand protrude of the flanges. All the
nails used on the inner surface of the flanges and the drum barrel shall be
counter sunk. The ends of barrel shall generally be flushed with the top of
the nuts.
4.10.9 The inner cheek of the flanges and drum barrel surface shall be painted with
bitumen-based paint.
4.10.10 Before reeling, cardboard or double corrugated or thick bituminised
waterproof bamboo paper shall be secured to the drum barrel and inside of
flanges or the drum by means of a suitable commercial adhesive material.
The paper should be dried before use. Medium grade craft paper shall be
used in between the layer of the conductor/earth wire. After reeling the
conductor/earth wire the exposed surface of the outer layer of
conductor/earth wire shall be wrapped with thin polythene sheet across the
flanges to preserve the conductor/earth wire from dirt, grit and damage
during transportation and handling and also to prevent ingress of rain
water during storage/transport.
4.10.11 Minimum space of 125 mm shall be provided between the inner surface of
the external protective layer and outer layer of the conductor/earth wire.
4.10.12 Each batten shall be securely nailed across grains as far as possible to the
flange edges with at least 2 nails per end. The length of the nails shall not
be less than twice the thickness of the battens. The nail shall not protrude
above the general surface and shall not have exposed sharp edges or allow
the battens to be released due to corrosion.
4.10.13 Outside the protective layer, there shall be minimum of two binders
consisting of hoop iron/galvanized steel wire. Each protective layer shall
have two recesses to accommodate the binders.
4.10.14 The earth wire ends shall be properly sealed and secured with the help of
U-nails on one side of the flanges. The end securing shall be done by taking
out at least 500 mm of steel wire on either end by U-nails. The earth wire
shall be binded by use of galvanized steel wire/aluminum wire at three
locations at least 75 mm apart or more covered with PVC adhesive tape so
as to avoid loosening of earth wire layers in transit and handling.
4.10.15 Only one length of earth wire shall be wound on each drum.
4.11 MARKING :
ink
Each drum shall have the following information stenciled on it in indelible

along with other essential data:
x.
Order Number and date.
xi.
xii.
xiii.
Drum number
xiv.
Size of earth wire (7/3.66mm)
xv.
Length of earth wire in meters
Page 46 of 116
Volume-V (Part-2)
xvi.
Gross weight of drum with earth wire
xvii.
xviii.
4.12
END SEALING :
Both the ends of each length of earth wire should be provided with non-destructive
type metal crimped or epoxy capped seals with punching embossing/ engraving of
manufacturers monogram and drum number.
***
Page 47 of 116
Volume-V (Part-2)
SECTION-5
TECHNICAL SPECIFICATIONS FOR DISC INSULATORS
5.01
SCOPE
5.01.1 This specification provides for the design, manufacture, stage testing and
inspection and testing before despatch, packing and delivery F.O.R. destination of
disc insulators as per technical requirements furnished in this specification for
various 400 KV Transmission lines to be constructed anywhere in the state of
Madhya Pradesh.
5.01.2These insulators are to be used for suspension
and Tension strings for the
suspension and Tension of the power conductors on 400 KV Double Circuit
transmission lines.
5.02
STANDARDS
5.02.1 Unless otherwise specified elsewhere in this specification, the rating as well as
performance & testing of the disc insulators shall conform but not limited to the
latest revision & amendments available at the time of placement of order of all the
relevant standards as listed hereunder, except as modified in this document.
S. No Indian
1
IS:209-1992
2
IS:206-1991
Standard
Title
Method for Chemical Analysis of Slab Zinc
IS:731-1991
Porcelain insulators for overhead power

lines with a nominal voltage greater
than 1000V
IS:2071
Method of High Voltage Testing
Part(I)-1993
Part(II)-1991
Part(III)-1991
5
IS:2121
Specification of Conductors and Earth wire

Accessories for Overhead Power Lines.
Part(I)
Armour Rods, Binding Wires & Tapes for

Conductors
IS:2486
Specification
for insulator fittings
for
overhead power lines with a nominal
voltage greater than 1000V
Part I-1993
General Requirements & Tests
Part II-1989
Part III
-1991
Locking Devices
IS:2629-1990

Galvanization for iron & steel
IS:2633-1992
Testing for Uniformity of Coating of Zinc

coated articles
IS:3188-1988
Dimensions for Disc Insulators
Hot
Dip
Page 48 of 116
Volume-V (Part-2)
10
IS:6745-1990
Determination of Weight of Zinc coating

on Zinc coated iron and steel articles
11
IS : 8263-1990
Methods of RIV Test of HV Insulators
12
IS:8269-1990
Methods for Switching impulse test on HV

insulators
5.02.2 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.
5.03
CLIMATIC CONDITIONS
5.03.1 The insulators shall be suitable for being installed directly in air with power
conductors of Double Circuit Double Strung transmission lines. They shall be
therefore suitable for satisfactory continuous operation under the following
climatic conditions: 1
MADHYA PRADESH
50
Average daily ambient air temperature

(0C )
40 Centigrade

.
50
1250
Maximum wind pressure ( kg/ square

meter)
150
Maximum Altitudes above mean sea level

(meters)
1000
10
Seismic level(Horizontal acceleration) (g)
0.3
1
95(sometimes
approaches saturation)
NOTE:- Moderately hot and humid tropical climate conducive to rust and fungus
5.04
PRINCIPAL PARAMETERS
5.04.1DETAILS OF DISC INSULATORS

5.04.1.1 The insulator strings shall consist of standard discs for a three phase 50 Hz,
effectively earthed 400KV transmission system in a moderately polluted
atmosphere. The discs shall be cap and pin, ball and socket type.
Page 49 of 116
Volume-V (Part-2)
5.04.1.2 The specified values and disc dimensions, impulse and power frequency
voltages, electromechanical strength [EMS] of individual insulator units are as
under. The values given are minimum which apply to all cases. Specified
withstand and flashover voltages are referred to standard atmospheric condition.
CHARACTERISTICS OF DISC INSULATORS
The disc insulators should have the following particulars and characteristics:
S.No
Particulars
i
ii
iii
Diameter of the disc (mm)

Spacing of the disc (mm)
Size and designation of pin-ball
shank
Creepage distance (mm) (minimum)
Power frequency one minute dry
Power frequency one minute wet
Power frequency puncture withstand
voltage kV (rms)
iv
v
vi
vii
viii
ix
x
Minimum dry impulse withstand

voltage 1.2x50 micro second wave,
positive and negative Kv Peak)
Maximum
Radio
interference
voltage with 10 kV RMS to ground.
(microvolts)
Minimum corona extinction voltage
kV(rms)
Disc Insulators
120kN EMS
160kN EMS
255
280
145
170
20 mm
20 mm
320
75
330
75
45
45
125
125
110
120
50
50
18
18
5.04.2SPECIFICATION DRAWINGS
5.04.2.1 The specification drawing in respect of the disc insulators indicated above is
attached with this specification. The specification drawing is attached herewith
for information and guidance of the Supplier only. The drawings to be furnished
by the Supplier shall be as per his own design and manufacture and shall be
distinct and separate from these specification drawings.
The drawing shall include but not limited to the following information :a)
b)
c)
d)
Shell diameter and ball to ball spacing with manufacturing tolerances.

Minimum creepage distance with positive tolerance.
Protected creepage distance
Eccentricity of the disc
i) Axial run out
ii) Radial run out
e)
f)
g)
h)
i)
j)
Unit mechanical and electrical characteristics

Size and weight of ball & socket parts
Weight of unit insulator disc
Materials
Identification mark
Page 50 of 116
Volume-V (Part-2)
After placement of award, the supplier shall submit full dimensioned

manufacturing drawing of insulator cap, pin & insulator shell in six copies to the
purchaser for reference & record.
5.05
GENERAL TECHNICAL REQUIREMENTS
5.05.1Porcelain
The porcelain used in the manufacture of the shells shall be ivory white, nonporous
of high dielectric, mechanical and thermal strength, free from internal stresses,
blisters, laminations, voids, foreign matter, imperfections or other defects which
might render it in any way unsuitable for insulator shells. Porcelain shall remain
unaffected by climatic conditions, ozone, acid, alkalizes, zinc or dust.
The
manufacturing shall be by the wet process and impervious character obtained by
thorough verification.
5.05.1.1 Porcelain Glaze
Surfaces to come in contact with cement shall be made rough by sand glazing. All
other exposed surfaces shall be glazed with ceramic materials having the same
temperature coefficient of expansion as that of the insulator shell. The thickness of
the glaze shall be uniform throughout and the colour of the glaze shall be brown.
The glaze shall have a visible luster, smooth on surface and be subject to satisfactory
performance under extreme tropical climatic weather conditions and prevent ageing
of the porcelain. The glaze shall remain under compression on the porcelain body
throughout the working temperature range.
5.05.2METAL PARTS
5.05.2.1 Cap and Ball Pins
Ball pins shall be made with drop forged steel and caps with malleable cast iron.
They shall be in one single piece and duly hot dip galvanized. They shall not contain
parts or pieces joined together, welded, shrink fitted or by any other process from
more than one piece of material. The pins shall be of high tensile steel, drop forged
and heat-treated. The caps shall be cast with good quality black hearth malleable
cast iron and annealed. Galvanising shall be by the hot dip process with a heavy
coating of zinc of very high purity. The Supplier shall specify the grade, composition
and mechanical properties of steel used for caps and pins.
5.05.2.2 Security Clips
The security clips shall be made of phosphor bronze or of stainless steel. 2.5% extra
security clip shall be provided.
5.05.3FILLER MATERIAL
Cement to be used as a filler material shall be quick setting, fast curing Portland
cement. It shall not cause fracture by expansion or loosening by contraction.
Cement shall not react chemically with metal parts in contact with it and its thickness
shall be as small and as uniform as possible.
The insulator design shall be such that the insulating medium shall not directly
engage with hard metal. The surfaces of porcelain and hard metal should be coated
with resilient paint to offset the effect of difference in thermal expansions of these
materials.
5.05.4MATERIAL DESIGN AND WORKMANSHIP
5.05.4.1 GENERAL
Page 51 of 116
Volume-V (Part-2)
(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
extra high voltage transmission. Bidders shall therefore offer insulators as are
guaranteed by them for satisfactory performance on 400KV 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.
5.05.4.2 INSULATOR SHELL
The design of the insulator shells shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration. Shells with
cracks shall be eliminated by temperature cycle test followed by mallet test. Shells
shall be dried under controlled conditions of humidity and temperature.
5.05.4.3 METAL PARTS
(i)
The pin and cap shall be designed such that it will not transmit the
mechanical stresses to the shell by compression and develop uniform mechanical
strength in the insulator. The cap shall be circular with the inner and outer surfaces
concentric and of such design that it will not yield or distort under loaded conditions.
The head portion of the pin ball shall be suitably designed so that when the insulator
is under tension the stresses are uniformly distributed over the pinhole portion of the
shell. The pin ball shall move freely in the cap socket either during assembly of a
string or during erection of a string or when a string is placed in position.
(ii)
Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes
and rough edges. All metal surfaces shall be perfectly smooth with no projecting
parts or irregularities, which may cause corona. All load bearing surfaces shall be
smooth and uniform so as to distribute the loading stresses uniformly. Pins shall not
show any microscopically visible cracks, inclusions and voids.
5.05.4.4 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the latest edition of
IS:2629. The zinc to be used for galvanizing shall conform to grade Zn 99.5 as per
IS:209. The Zinc coating shall be uniform, smoothly adherent, reasonably bright,
continuous and free from impurities such as flux, ash, rust stains, bulky white
deposits and blisters. Before ball fittings are galvanized, all die flashing on the shank
and on the bearing surface of the ball shall be carefully removed without reducing
the designed dimensional requirements.
5.05.4.5 SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as a locking device for ball and socket coupling shall be
R shaped hump type to provide for positive locking of the coupling as per IS:2486
(Part IV). The legs of the security clips shall allow for spreading after installation to
prevent complete withdrawal from the socket. The locking device shall be resilient,
corrosion resistant and of sufficient mechanical strength.
There shall be no
possibility of the locking device to be displaced or be capable of rotation when placed
in position and under no circumstances shall it allow separation of insulator units and
fittings. W type security clips are also acceptable. The hole for the security clip
could be countersunk and the clip shall be of such design that the eye of the clip may
be engaged by a hot line clip puller to provide for disengagement under energized
conditions. The force required for pulling the clip into its unlocked position shall not
be less than 50 N (5 kgs) or more than, 500 N (50 kgs).
Page 52 of 116
Volume-V (Part-2)
5.05.5BALL AND SOCKET DESIGNATION

The dimensions of the balls and sockets for 120KN discs shall be of 20 mm
designation in accordance with the standard dimensions stated in IS:2486 (Part II).
5.05.6DIMENSIONAL TOLERANCE OF DISC INSULATOR
It shall be ensured that the dimensions of the disc insulators are within the limits
specified below:
a.
Diameter of Disc (mm)
Rating
Standard
Maximum
120 KN Disc
255
266
160 KN Disc
280
293
b.
Minimum
244
267
Ball to Ball Spacing between Discs (mm)
Rating
Standard
Maximum
Minimum
120 KN Disc
145
149
141
160 KN Disc
170
175
165
5.05.7INTERCHANGEABILITY
The insulators inclusive of the ball and socket fittings shall be of standard design
suitable for use with hardware fittings of any make conforming to relevant Indian
Standards.
5.05.8CORONA 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 and porcelain
shall not produce any noise generating corona under all operating conditions.
5.05.9SUITABILITY FOR LIVE LINE MAINTENANCE
5.05.9.1 The insulators shall be compatible for use with hot line or live line maintenance
techniques so that usual hot line operations can be carried out with ease, speed
and safety.
5.05.9.2 Suppliers shall indicate the methods generally adopted in routine hot and cold
line maintenance of EHV lines for similar insulators supplied by them. Suppliers
shall also indicate the recommended periodicity of such maintenance.
5.05.10 FREEDOM FROM DEFECTS
Insulators shall have none of the following defects:
i)
ii)
iii)
Ball pin shake

Cementing defects near the pin like small blow holes, small hair cracks,
lumps, etc.
Sand fall ferro particle defects on the surface of the insulator.
Page 53 of 116
Volume-V (Part-2)
iv)
Shell eccentricity
5.05.11 INSULATOR STRINGS

5.05.11.1 TYPE AND RATING
The insulator strings shall be formed with standard discs described in this
specification for use on 3 phase, 400kV, 50Hz effectively earthed systems in a
moderately polluted atmosphere.
Suspension insulator strings for use with
suspension towers are to be fitted with discs of 120KN EMS rating .Tension insulator
strings for use with Anchor/Tension towers are to be fitted with discs of 160 kN EMS
rating.
5.05.11.2 STRING SIZE
The size of the disc insulator, the number to be used in different types of strings and
their electro-mechanical strength shall be as follows:
S.No.
Type of String
Size of
disc
insulator
(mm)
No.of
standard
discs
Electro
mechanical
strength of
insulator
string (kN)
a)
Single Suspension for 400KV
255 X145
23
120
b)
Double Suspension for 400KV
255 x145
2x23
2x120
c)
280x170
24
160
d)
280x170
2x24
2x160
5.05.12 STRING CHARACTERISTICS

5.05.12.1
S.No
The characteristics of the complete string shall be as follows :

Particulars
Single / Double
Suspension
Single /Double
Tension
400KV
400KV
i.
Switching surge withstand

voltage(dry & wet) KV peak
1050
1050
ii
Lightening Impulse withstand

voltage (dry) KV peak
1600
1700
iii
Power frequency withstand voltage

(wet) KV r.m.s
680
690
iv
Mechanical failing Load-kgf
11500/23000
16500/ 33000
No deformation load-kgf
7705/ 15410
11055/ 22110
vi.
Corona Extinction Voltage KV rms
320
320
vii.
Max.RIV for complete string at

266KV(rms) line to ground voltage
(micro volt)
500
500
viii.
Max.voltage across any disc
9%
9%
Page 54 of 116
Volume-V (Part-2)
5.05.12.2
Insulator units after assembly shall be concentric and coaxial within limits as
permitted by Indian standards.
5.05.12.3
The string design shall be such that when units are coupled together there
shall be contact between the shell of one unit and metal of the next adjacent
unit.
5.06
TESTS
The following tests shall be carried out on the insulator string and also on unit disc
insulators.
5.06.1TYPE 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. The successful supplier
shall indicate his schedule for carrying out these tests. For any change in the
design/type already type tests and the design/type offered against this specification ,
the purchaser reserves the right to demand repetition of test without extra cost
5.06.2ACCEPTANCE TESTS
This shall mean those tests which are to be carried out on samples taken from each
lot offered for pre-despatch inspection for the purpose of acceptance of the lot.
5.06.3ROUTINE TESTS
This shall mean those tests, which are to be carried out on each insulator to check
the requirements which are likely to vary during production.
5.06.4STAGE 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.
5.06.5TEST 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.
5.06.6TEST PROCEDURES AND SAMPLING NORMS
5.06.6.1
The norms and procedure of sampling for the above tests shall be as
per the relevant Indian Standard or other Internationally accepted
standards. This will be discussed and mutually agreed to between the
successful Supplier and Purchaser before placement of order. The
standards and norms according to which these tests are to be carried
out are listed against each test. Where a particular test is a specific
requirement of this specification, the norms and procedure for the
same shall be as specified in Appendix-I attached hereto or as
Page 55 of 116
Volume-V (Part-2)
mutually agreed to between the successful Supplier and the

Purchaser in the Quality Assurance Programme. The supplier shall
offer at least three times the quantity of materials required for
conducting all the type tests for sample selection. Before sample
selection, the supplier shall be required to conduct all the acceptance
tests successfully in presence of Purchasers representative.
5.06.7
DETAILS OF TYPE TESTS
5.06.7.1
The material offered shall be fully type tested as per this specification and the
Supplier shall furnish four sets of type test reports alongwith the offer. These
tests must not have been conducted earlier than five years.
5.06.7.2
TYPE TESTS
(A) The following type tests shall be conducted on all types of the complete
insulator string with hardware fittings :
a)
Power frequency voltage withstand test with corona control

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

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

control rings and arcing horn under (dry/wet) conditions
d)
Switching surge voltage withstand test under wet condition.
e)
Impulse voltage withstand test under dry condition.
f)
Voltage Distribution test
g)
Impulse voltage flash over test under dry condition
h)
Corona and RIV Test under dry condition.
i)
Mechanical strength test
j)
Vibration test.
(B) Following type tests shall be conducted on string insulators/unit disc insulators
a)
Visible discharge test
IS:731
b)
Impulse voltage withstand test
IS:731
c)
Wet power frequency voltage withstand

test
IS:731
d)
Verification of dimension test
IS:731
e)
IS:731
f)
Electro-Mechanical failing load test
IS:731
g)
Puncture test
IS:731
h)
Porosity test
IS:731
i)
Galvanising test
IS:731
j)
24 hours mechanical failing load test
k)
Metallurgical test
IS:731
IS:2108 &
IS:2004
5.06.8 DETAILS OF ACCEPTANCE AND ROUTINE TESTS

Page 56 of 116
Volume-V (Part-2)
6.8.1 All Acceptance and Routine tests as stipulated herein shall be carried out by the
Supplier in the presence of Purchasers representative.Immediately after finalisation
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.
6.8.2
For String Insulator Units following Acceptance & Routine tests shall be
conducted:
(A)
Acceptance tests:
a)
IS:731
b)
IS:731
c)
Galvanising test
IS:731
d)
Mechanical performance test
IEC:575
e)
Test on locking device for ball and

socket coupling
IEC:372/IS-2486(part-IV)
f)
Eccentricity test
As per Specification
g)
Electro-mechanical strength test
h)
Puncture test
i)
Porosity test
(B)
IS-731
Routine tests:
a)
Visual Inspection
b)
Mechanical routine test
c)
Electrical routine test
IS-731
IEC:383
5.06.9Tests during Manufacture (STAGE TESTS)

On all components as applicable
5.06.10
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

forgings
d)
Crack detection test for metal parts
As per this
Specification
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
Page 57 of 116
Volume-V (Part-2)
and routine tests at the cost of the Purchaser to satisfy that the material complies
with the intent of this specification.
5.06.11
COORDINATION FOR TESTING:
For 400KV 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.
5.07
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 disc insulators are later found to be
defective.
5.08
IDENTIFICATION MARKING
5.08.1
Each disc insulator shall be legibly and indelibly marked with the trade mark of
the manufacturer, the month and year of manufacture, the guaranteed
combined mechanical and electrical strength in kilo-newtons abbreviated by
KN to facilitate easy identification and proper use.
5.08.2
The marking shall be on porcelain shell of insulators. The marking shall be

printed and not impressed/embossed and same shall be applied before firing.
5.08.3
One 10mm thick ring of good quality paint shall be marked on the cap of each
insulator of particular strength for easy identification of the type of insulator.
The paint shall not have any deteriorating effect on the insulator performance.
Following codes shall be used as identification mark:For 120KN disc insulator- Yellow
For 160kN disc insulator Red
5.09
QUALITY ASSURANCE PLAN
5.09.1
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.
Page 58 of 116
Volume-V (Part-2)
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 Suppliers 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 the insulators to make it maintenance free.
vii) List of testing equipment available with the Supplier for final testing of insulators
specified and test plant limitation, if any, vis-a-vis the type, special, acceptance and
routine tests specified in the relevant standards.
5.09.2
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 alongwith the offer.
ii) Type test certificates of the raw material and bought out
accessories.
iii) Quality assurance plan (QAP) with hold points for Purchasers inspection. The QAP
and Purchasers hold points shall be discussed between the Purchaser and the
Supplier before the QAP is finalized.
5.09.3
5.10
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.
DOCUMENTATION
5.10.1
The Supplier shall furnish full description and illustrated catalogues of

insulators offered, alongwith the bid. The supplier shall also furnish alongwith
the bid the outline drawing of each insulator unit including cross-sectional view
of the shell. The drawing shall include the following information :
i)
Shell diameter and unit spacing with manufacturing tolerance.
ii)
Creepage distance.
iii)
Unit mechanical and electrical characteristics as also for the complete stringsuspension and tension.
iv)
Size and weight of ball and socket part.
v)
Weight of unit insulator disc.
vi)
Materials for the disc, cap and pin.
vii)
Identification mark.
viii)
ix)
Page 59 of 116
Volume-V (Part-2)
x)
5.10.2
5.11

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

i)
All disc insulators shall be packed in strong seasoned wooden crates. The
gross weight of the crates alongwith disc insulators shall not normally exceed
100 kg. to avoid handling problem.
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 wooden case/crate shall have all the markings stenciled on it
in indelible ink.
Page 60 of 116
Volume-V (Part-2)
Appendix-I
TEST DETAILS
1.
Voltage Distribution Test:

The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage and proportionate
correction be applied so as to give a total of 100% distribution. The voltage across any
disc shall not exceed 9% for suspension insulator strings and for double tension
insulator strings. The total of the voltage distribution of all discs so computed shall be
within 95% and 105%. If not, the test shall be repeated. The proportions correction
shall be made on the values so as to give a total of 100% distribution.
2.
Mechanical Strength Test:

The complete insulator string alongwith its hardware fittings excluding arcing
horn, corona control ring/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 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.
3.
Vibration Test:
The suspension string shall be tested in suspension mode, and tension string
in tension mode itself in laboratory span of minimum 30 metres. 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 alongwith hardware
fittings and two sub-conductors (each tensioned at 4500 kg) shall be secured with
clamps. The system shall be suitable to maintain constant tension on each subconductors throughout the duration of test. Vibration Dampers shall not be used on the
test span. Both the sub-conductors shall be vertically vibrated simultaneously at one of
the resonance frequencies of the insulator string (more than 10 Hz) by means of
vibration inducing equipment. The amplitude of vibration at the antinode point nearest
to the string shall be measured and the same shall not be less than + 120/f , f being
the frequency of vibration. The insulator string shall be vibrated for five million cycles
then rotated by 90 deg. and again vibrated for 5 million cycles without any failure.
After the test, the disc insulators shall be examined for looseness of pins and cap or any
crack in the cement. The hardware fittings shall be examined for fatigue failure and
mechanical strength test. There shall be no deterioration of properties of hardware
components and disc insulators after the vibration test. The disc insulators shall be
subjected to the following tests as per relevant standards:
Test
Percentage
of discs to
be tested
Temperature cycle test followed by

mechanical performance test
60
Puncture test (for porcelain
40
Page 61 of 116
Volume-V (Part-2)
insulator only)
If the results of the second test show a porcelain shell rupture, the production does
not comply with this specification.
4.
Chemical Analysis of Zinc used for Galvanising:
Samples taken from the zinc ingot shall be chemically analysed as per IS:209. The purity
of zinc shall not less than 99.95%.
5.
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 Purchaser in Quality Assurance Programme.
6.
Test 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 Purchaser in Quality Assurance Programme.
7.
Eccentricity Test:
The insulator shall be vertically mounted on a fixture using dummy pin and socket. A
vertical scale with horizontal slider shall be used for the axial run out. The pointer
shall be positioned in contact with the bottom of the outermost petticot of the disc.
The disc insulators shall be rotated with reference to the fixture and the slider shall
be allowed to move up and down on the scale but always maintaining contact with
the bottom of the outer most petticot. After one full rotation of the disc, the
maximum and minimum position the slider has reached on the scale can be found
out. Difference between the above two readings shall satisfy the guaranteed value
for axial run out. Similarly using a horizontal scale with vertical slider the radial run
out shall be measured. The slider shall be positioned on the scale to establish
contact with the circumference of the disc insulator and disc insulator rotated on its
fixture always maintaining the contact. After one full rotation the maximum and
minimum position of the slider reached on the scale are found out. The difference
between the above readings shall satisfy the guaranteed value for radial run out.
8.
Crack Detection Test:

Crack detection test shall be carried out on each ball and pin before assembly
of disc unit. The manufacturer shall maintain complete record of having conducted such
tests on each and every piece of ball pin. The supplier shall furnish full details of the
equipment available with him for crack test and also indicate the test procedure in
detail.
Page 62 of 116
Volume-V (Part-2)
SYSTEM PARTICUALRS
S.No
.
1
PARTICULARS
System
Electrical
System Data
A.C.
3phase
2
3
4
5
6
Line voltage (kV rms)

Max.voltage (kV rms)
Frequency
Neutral grounding system
Lightning impulse with-stand voltage(dry
& wet)(kVp)
Power frequency withstand

voltage (wet) (kVp)
630
Switching surge withstand

voltage (wet) (kVp)
1050
9
10.
Short circuit level (kA)

Minimum corona extinction voltage at
50 Hz AC system dry condition (Kv rms)
Radio interference voltage at one MHz
for phase to earth voltage of 266KV dry
conditions(Microvolt)
40
320
11.
400
420
50 Hz
effectively earthed
1425
500
Page 63 of 116
Volume-V (Part-2)
SECTION -6
TECHNICAL SPECIFICATIONS FOR HARDWARE FITTINGS & ACCESSORIES
FOR 400 kV LINES
4.01
SCOPE:
4.01.1 This section provides for manufacturing, stage testing, inspection and testing before
despatch, packing and delivery of Hardware fittings for Insulator string and
accessories suitable for Conductor and Ground wire for use on 400KV transmission
line.
4.01.2 It is not the intent to specify completely herein all details of the design and
construction of material. However, the material shall conform in all respects to high
standards of engineering, design and workmanship and shall be capable of
performing the duties specified herein. The material offered shall be complete with
all components necessary for its effective and trouble free operation. Such
components shall be deemed to be within the scope of Bidders supply, irrespective
of whether these are specifically brought out in this specification or not.
4.02
STANDARDS:
4.02.1 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 here under
except as modified in this document:
S.No
Indian Standard
Title
IS:209-1992
IS:206 1992
IS:7814-1985
IS:2071 Part-I, II & III
IS:731
Porcelain Insulator for Overhead Power Lines

with a Nominal Voltage Greater than 1000 V.
IS:961
Structural Steel
IS:1385
Phosphor Bronze Rods & Bar Sheet and

Strips and Wire
IS:2004
Carbon Steel Forgings for General Engineering

Purpose
IS:2107
10
IS:2108
11
IS:2121(Part-I & II)
Specification for Conductors and Ground wire

Accessories for Overhead Power Line, Armour
Rods Binding Wires and Tapes for Conductor
IS:2486

Overhead Power Lines with a Nominal
Voltage Greater than 1000 V.
Part-I
General Requirements and Tests
12
Page 64 of 116
Volume-V (Part-2)
S.No
Indian Standard
Title
Part-II
Part-III
Locking Devices
Part-IV
Tests for Locking Devices
13
IS:2629

14
IS:2633
Testing of Uniformity of Coating of Zinc

coated Articles
15
IS:3138
16
IS:6639
17
IS:6745
Determination of Weight of Zinc Coating on

Zinc Coated Iron and Steel Articles
18
IS:3188
Characteristic of String Insulators Units
19
IS:4218 Part-I to VI
ISO Metric screw Threads
20
IS:4172
Dimensions for Radii under the Heads of

Bolts & Screws
21
IS:4206
Dimensions for nominal lengths and Thread

length for Screws and Studs (with
amendment)
22
IS:4759
Hot Dip Zinc Coatings on Structural Steel and

other Allied Products
23
IS:1573-1986
Electroplated Coatings of Zinc on Iron and

Steel
24
IS: 398 (Part-II & III)
Specification for Aluminium Conductor Steel

Reinforced for overhead transmission
purpose.
25
IS: 1327-1966
Methods for determination of weight of tin

Coating on Tin Plates
26
IS: 4826-1979
Hot Dip Galvanised Coating on Round Steel

Wires
27
IS: 1363 Part-I to III
IS: 1367
28
IS: 1367 (Part-I)

IS: 1367 (Part-II)
IS: 1367 (Part-III)
29
IS: 9708
30
IS: 8263
31
IS:10162
Technical supply conditions for threaded

Steel Fasteners.
Introduction and General Information.
Product Grades and Tolerances.
Mechanical Properties and Test Methods for
Bolts, Screws and Studs with full Load ability.
Stockbridge Vibration Dampers for Overhead
Power lines.
Method of Radio Interference Tests on High
Voltage Insulators.
Spacers
and
Spacer
Dampers
for
twin
Page 65 of 116
Volume-V (Part-2)
S.No
Indian Standard
32
IS: 2004
33
BS:970 (Part-I)
Title
horizontal bundle Conductors.
Carbon
Steel
Forgings
for
general
engineering purposes.
General Instructions and Testing Procedures
Specific Requirements for Carbon and Carbon
Manganese Alloy and Stainless Steels.
4.02.2 In the paragraph 2.1 above, relevant Indian Standards have been mentioned.
However, the Hardware fittings meeting any other authoritative international
standard, which ensures equal or better quality than the Standards, mentioned
above shall also be acceptable. Please attach photocopy of all such Standards
according to which the Hardware fittings have been offered.
4.03
TOPOGRAPHY AND CLIMATIC CONDITIONS:

The material to be supplied against this specification shall be suitable for
satisfactory operation under the tropical climatic conditions as under:
MADHYA PRADESH
Maximum ambient air temp.
50 0C
Minimum temperature in shade
1 0C.
Maximum relative humidity
95%(sometimes approaches
Saturation)
Average daily ambient air temp.
40 0C
Isoceraunic Level (Average

thunder storm days)
Average rainfall
1250 mm
1000 meter
Seismic level (Horizontal acceleration)
number
of
50 days per year
0.3 g
NOTE:- Moderately hot and humid tropical climate conducive to rust and fungus
4.04
PRINCIPAL PARAMETERS:
4.04.1 DETAILS OF HARDWARE FITTINGS:

(a)
The Hardware fittings shall meet the technical requirement as per specification
and also general arrangement drawings of Hardware fittings attached herewith.
Hardware fittings shall be suitable for single/double suspension Insulator strings,
single/double tension Insulator strings and single suspension-pilot insulator strings.
Each Hardware fitting shall be supplied complete in all respect and shall include all
components, which are required for making complete set.
(b)
The hardware fittings for lines shall be suitable for ACSR Moose Conductor and
Groundwire as per technical parameters indicated below:Ground Wire
S.N
o
Particulars
Moose ACSR
1.
2.
Material
Size
ACSR
Steel
325 mm Cu. eq. --
Page 66 of 116
Volume-V (Part-2)
3.
4.
10
11
Nominal Aluminium area

Stranding and wire diameter
(no./mm)
Number of strands in each layer.
Central core
1st layer
2nd layer
3rd layer
4th layer
Sectional area of Alu.
Total sectional area
Approximate overall diameter
Overall diameter when wrapped with
preformed Armour Rod
Approximate weight
Calculated D.C. resistance at 20 C
12
13
Approximate Breaking Load

Co-efficient of Linear Expansion
14
Final Modulus of Elasticity
5.
6.
7.
8.
9.
4.05
515.70 mm
54/3.53 Alu.+
7/3.53 steel.
1 of steel
6 of steel
12 of Alu.
18 of Alu.
24 of Alu.
515.70
597 mm
31.77 mm
2004 Kg per Km
0.0551
Ohm/km
16250 Kgs.
19.53 x 10-6
per C
0.686 X 106
kg/cm
-7/3.66mm.
1 of steel
6 of steel
--10.98 mm
18.30 mm
583Kg per Km
2.5 Ohm/km
6972 kgs
11.5 x 10-6
per C
1.931X106
kg/cm
INSULATOR STRING CHARACTERISTICS:
(a) The complete insulator string including Hardware fittings shall have the following
characteristics:
S.
No
Characteristics
No. of Standard Discs
Nominal diameter of discs
Power frequency Withstand voltage (wet)

kV (rms)
Lighting impulse withstand voltage
(dry)(kVp)
Switching surge Withstand voltage (Dry &
wet) (kVp)
Mechanical failing Load (kgf)
Pollution
Corona Extinction voltage (KV rms)
4
5
Single/
Double
Suspension
1x23
2x23
Single/
Double
Tension
1x24
2x24
280
280
680
690
1600
1700
1050
1050
11500/23000
16500/33000
Moderately
polluted
320
Moderately
polluted
320
(b) The Insulator string Hardware fittings shall comply and conform to the above
requirement.
4.06
BALL AND SOCKET DIMENSIONS:

The Ball and Socket for Hardware fittings shall necessarily conform to the
dimensions as stipulated in the Indian Standards. The Ball and Socket dimension of
Hardware to be used with 11500 Kg & 16,500 kg Electro Mechanical strength disc
insulator shall conform to designation 20mm in accordance with IS-2486:(Part-II).
Page 67 of 116
Volume-V (Part-2)
The Bidder shall submit 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 (PartIV) or equivalent International Standard.
4.07
REQUIRED GUARANTEED STRENGTH OF HARDWARE OF INSULATOR STRINGS:
4.07.1 The slipping strength of the suspension clamp shall not be less than 15% and more
than 20% of the Conductor strength with which it is to be used.
4.07.2 The Hardware and Compression Clamp of single & double tension strings suitable for
Moose ACSR for 400KV transmission line shall have ultimate breaking strength of not
less than 16500 kgs. The Compression Clamp shall have slipping strength not less
than 95% of breaking strength of Moose ACSR.
4.07.3 Each individual Hardware component of double suspension and double tension
strings such as ball-clevis, socket clevis etc. shall have minimum breaking strength
as specified for respective single suspension and tension string respectively.
4.08
PARTICULARS OF HARDWARE FITTINGS:

Each Hardware fitting shall be complete in all respect and Bidder should
furnish complete drawings and technical particulars of the items quoted. The
Hardware fittings should normally comprise items conforming to enclosed drawing
as under: -
4.08.1 Single Suspension Hardware Fitting with AGS Type Clamp:

Single suspension Hardware string shall comprise of one Anchor Shackle,
Horn holder Ball eye, line side arcing horn, yoke plate, corona control ring and two
Suspension Clamps of AGS type with armour rod as per enclosed drawing.
4.08.2 Double Suspension String Hardware Fittings with AGS Type Clamp:
The double suspension string Hardware fittings shall comprise of one Anchor
Shackle, one Top Yoke Plate, two Ball Clevis, two Socket Clevis, corona control ring,
one bottom Yoke Plate, two line side Arcing Horns, two Clevis Eye and two AGS type
Suspension Clamps with armour rod as per enclosed drawing.
4.08.3 Single suspension Pilot string for Moose ACSR:
The single suspension pilot string for Moose ACSR shall comprise of one
Anchor Shackle, one Horn holder Ball eye, one line side arcing horn, one yoke plate,
corona control ring and two envelope type suspension clamps as per enclosed
drawing.
4.08.4 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, one line side Arcing Horn
and one Tension Clamp of compression type having before and after compression
dimensions strictly as shown in Clause 7.10 below.
4.08.5 Double Tension String Hardware Fittings:
The double tension string Hardware shall comprise of two Anchor shackle, one
chain link one top yoke plate, two ball clevis, two socket clevis, one bottom yoke
plate, one arcing horn, two socket clevis, two clevis eye and two compression type
dead-end Clamps having `before and after compression dimensions strictly as
shown in Clause 7.10 below.
4.09
GROUNDWIRE ASSEMBLIES:
4.09.1 Ground Wire Suspension Assembly With Preformed Armour Rods:

This shall comprise of envelope type Suspension Clamp of heat-treated
malleable iron, one Chain Link and one D Shackle. The entire assembly shall be hot
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dip galvanized complete with minor accessories. The breaking strength of all the
Hardware items of the assembly shall not be less than 7000 kgs. The complete
assembly of suspension clamp shall be guaranteed for slip strength of not less than
15 KN & not more than 19 KN. The strength of the Ground wire has been specified
in Clause 7.04.01. The suspension assembly shall be supplied with armour rod for
groundwire.
4.09.2 Ground Wire Tension Assembly:
The Ground wire tension assembly shall have minimum breaking strength
equal to that of the Ground Wire. The slipping strength of the Compression Clamp
shall not be less than 95% of the breaking strength of Ground Wire. The Ground
wire tension assemblies shall be of two types as under: The strain assembly of the Ground wire shall comprise of compression type
dead end Clamp and two `D Shackles complete with minor accessories such as
pins, bolts & nuts etc. Strain assembly shall be hot dip galvanized and made
inherently resistant to the atmosphere corrosion. The dead end Clamp of the
assembly shall be of compression type. The tension clamp shall be attached to the
horizontal strain plate of the tower body by means of a D shackle. D shackle
shall be suitable for attaching the tension clamp to strain plate of towers with a hole
of 21.5 mm diameter. The tension clamp body shall be made out of steel of 304 L
grade or equivalent with Brinnel Hardness not exceeding 200. The complete
assembly shall also include one 12.5mm dia, 45 mm long HRH MS Bolt hot dip
galvanized with nuts and lock washers for attaching copper earth bond. A detailed
drawing giving dimensional details of the complete assembly shall accompany the
tender. After compression, dimensions of the joint shall be as indicated in Clause
4.10 below.
4.10
BEFORE AND AFTER COMPRESSION DIMENSIONS OF COMPRESSION TYPE DEADEND CLAMPS FOR CONDUCTOR AND GROUND WIRE
Sr.
Particular
No.
Dimension
before
compression
(Rod cross
section)
Length of
Dimension
Length of
sleeve after
after
sleeve
compression
compression
before
(Flat to flat compression
distance of
hexagon)
G/ W Moose G/ W Moose G/ W Moose G/ W Moose
A Aluminium clamp
a
b
Inner dimension
(mm)
Outer dimension (mm)
Steel clamp
Inner dimension
(mm)
b
4.11
34
54
11.5
11.1
21
21
17.5
46
735
785
17.5
230
250
262
285
DETAILS OF COMPONENTS OF HARDWARE FITTINGS:
4.11.1Suspension Assembly for twin Moose:

a)
The suspension assembly suitable for twin ACSR Moose Conductor for 400KV
Lines shall include two armour-grip suspension clamps except for pilot insulator
string for which two suitable Envelope type suspension clamps shall be used.
b) The suspension clamp alongwith standard preformed armour rods set shall be
designed to have maximum mobility in any direction and minimum moment of
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inertia so as to have minimum stress on the conductor in the case of oscillation of

the same.
c)
The suspension clamp alongwith standard preformed armour rods shall have slip
strength between 20 to 29KN.
d) The suspension assembly shall be smooth without any cuts, grooves, abrasions,
projections, ridges or excrescence, which might damage the conductor.
4.11.2Armour Grip Suspension Clamp (AGS):
(a) AGS fitting shall consist of 2 Neoprene Halves, a set of Helical rods made of
Aluminium alloy, two Aluminium halves casting having inner profile matching with
the profile of the Armour rod cage and jointed by supporting strap made of
Aluminium alloy.
(b) The Bidder should give complete data on the reduction of the dynamic stresses of
the Conductor at the point of AGS support compared to that of bare clamp used
with preformed types of Armour rods.
(c) The Bidder will be required to prove the comparative performance in regard to
the dynamic flexural stress pattern on the vibrating Conductor on the tensioned
span with actual tests on the AGS unit compared to the normal bare clamp with
Armour rods. Suitable curves should be furnished along with the bid for the same
and also actual reports on the stress/ strain determinations. The Bidder should
give the guaranteed value of the power loss of the AGS units offered by them
supported by a test certificate of any reputed laboratory of the country. Suitable
curves should be furnished along with the bid for the power loss due to AGS unit
as well as with the conventional envelope type of Suspension Clamps.
(d) The housing supports and housing straps should provide positive stop closure.
AGS unit should have low rotational inertia, strut action of the Armour Cage,
resilient cushioning of the neoprene insert, immunity from high compressive and
flexural stress and wide area support. Manufacturer is required to guarantee
minimum fatigue life of the AGS units and this would be established under actual
tests on tensioned Conductor span. The manufacturer is required to guarantee
minimum 40 years life of the complete AGS units including Neoprene cushioning
and this should be established under actual test on a tensioned Conductor span.
(e) The rubber used with AGS unit must be capable of withstanding desired long outdoor performance including the variation of temperature from 0C to 75C. The
Bidder will have to provide certificate from reputed manufacturers that the rubber
being supplied by them is suitable for AGS fitting and must have tensile strength
of 2000 PSI and minimum ultimate elongation 300%.
(f) The helical retaining rods required for AGS assembly shall be made of Aluminium
alloy of HE 20 grade as per IS-6051/1970 or equivalent International Standard
duly heat treated and shall be suitable to wrap a desired size of Conductor. The
tensile strength of the retaining rod material should not be less than 50,000 PSI
and the electrical conductivity should not be less than 40% (IACS). The minimum
slipping strength of the complete fitting shall not be less than 15% and more
than 20% of the UTS of the cable on which it is to be used. The Clamp shall be in
2 parts made of Aluminium and will have inner profile matching with the profile of
Armour rod. This Clamp should be made by drop forging process. AGS assembly
should be provided with the forged steel socket eye to match with the suspension
string and should have UTS not less than 7,000 kgs.
IT IS ESSENTIAL FOR THE MANUFACTURER TO HAVE SUITABLE HEAT
TREATMENT FACILITIES FOR ALUMINIUM ALLOY WIRES IN THE ARMOUR GRIP
SUSPENSION UNITS. FORMED ROD BASED ITEMS WILL NOT BE ACCEPTABLE FROM
MANUFACTURERS WHO DO NOT HAVE NECESSARY TECHNOLOGY FOR DEVELOPMENT
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OF ADEQUATE RESILIENCE, ELONGATION UTS AND TWIST TEST FACILITIES BACKED

WITH PROPER HEAT TREATMENT SYSTEMS.
4.11.3AGS Preformed Armour Rods:
(a) The AGS Preformed Armour rods set suitable for ACSR Moose conductor shall be
used to minimize the stress developed in a conductor due to different static and
dynamic loads because of vibration due to wind, slipping of conductor from
suspension clamp as a result of unbalance conductor tension in adjacent span
and broken wire condition. It shall be made of Aluminium alloy of HE 20 grade as
per IS-6051/1970 duly heat-treated. The aluminium alloy wires (pre heat
treated) for manufacturing of Armour rods can also be used, however Bidder
should submit the test certificates in support of their claim for using pre heattreated wires. It shall also withstand power arcs, chafing and abrasion from
suspension clamp and localized heating effects due to resistance losses of the
conductor.
(b) The pitch length of the rods shall be determined by the supplier but shall be less
than that of the outer layer of ACSR conductor and the same shall be accurately
controlled to maintain uniformity and consistently reproducible characteristics
wholly independent of the skill of lineman.
(c) The preformed armour rod sets shall have right hand lay and the inside diameter
of the helices shall be less than the outside diameter of the conductor to grip the
same tightly. The surface of the armour rod when fitted on the conductor shall
be smooth and free from projections, cuts and abrasions etc.
(d) The length of each rod shall be as per drawing enclosed. The tolerance in length
of each rod shall be +/-25mm. The tolerance in length of the rods in completed
sets should be within 13 mm between the longest and shortest rod. The ends of
the armour rod shall be parrot billed.
(e) The number of armour rods in each set shall be 11/12. The each rod shall be
marked in the middle with paint for easy applications on the line.
(f) The armour rod shall not loose their resilience even after five applications. The
conductivity of each rod of the set shall not be less than 40% of the conductivity
of International Annealed Copper Standard (IACS). The minimum tensile strength
of armour rod should be 35 kg per sq.mm.
4.11.4Strain Clamp:
(a) The Strain Clamp shall be of the compression type for the specified size of
Conductor for 400KV lines. The outer sleeve of the Compression Clamp and
Jumper Terminal shall be of EC grade Aluminium 99.5% pure tube formed by
extrusion process and the inner sleeves shall be of galvanized steel. The angle of
jumper terminal to be mounted should be 30 deg. with respect to the vertical
line. The Compression Clamp shall have slipping strength not less than 95% of
the ultimate breaking strength of Conductor with which it is to be used. The
compression dead end clamp for transmission line shall be manufactured out of
extruded Aluminium.
(b) The resistance of the clamp when compressed on the conductor shall not be more
than 75% of the resistance of equivalent length of conductor. Die compression
line shall be clearly marked on each dead-end assembly designed for continuous
die compression and shall bear the words COMPRESS FIRST suitably inscribed
near the point on each assembly where the compression begins. 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 ends of the Zones. Tapered aluminium filler plugs shall also
be provided at the line of demarcation between Compression and Noncompression zone. The letters, numbers and other marking on the finished clamp
shall be distinct and legible.
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4.11.5Socket Eye & Ball Clevis:

The Socket Eye and Ball Clevis be made of forged steel as per the drawing
enclosed.
4.11.6U Clevis:
These shall be made of forged steel complete with galvanised steel rivets
washer and Phosphorus Bronze/Stainless Steel pins.
4.11.7Ball Fittings:
These shall be made of forged steel in one piece. They shall be normalized to
achieve the minimum breaking strength specified in the respective drawings. Before
galvanising of ball fittings, all die fleshing on the shank and on the bearing surface
of the ball shall be carefully removed without reducing the dimension below the
requirements. The dimension of the ball & socket shall be 20mm designation in
accordance with standard dimensions stated in IS:2486 (Part-II).
4.11.8Dimensions & Tolerances:
(a) 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.
(b) 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.
(c) The bearing surfaces of balls and machined sockets, before galvanizing shall not
have surface roughness more than 250 micro inches.
(d) 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.
4.11.9Socket Fittings:
Socket fittings shall be made of clause 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.
4.11.10
Security clip for Socket fittings:
(a) Socket fittings shall be provided with R-shaped security clip in accordance with
IS:2486 (Part-III) 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 complete withdrawal from the socket. The clip end shall not
project outside the recess of socket when the clip is in locked position.
(b) 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.
(c) The force required to pull the clip to its unlocked position shall not be less than
50 N or more than 500N.
(d) The security clip shall be made of stainless steel of type AISI 302 or 304 or
phosphor bronze as per IS:7814.
4.11.11
Clevis-Eye:
These shall be forged steel of malleable cast iron and shall be complete with
galvanised pin with flat washer and split pin of Phosphorus Bronze/Stainless Steel.
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4.11.12
Yoke Plate:
(a) The yoke plates/link plate shall be made of mild steel plate as per IS:2062 or
equivalent standards. Shearing/cutting of the plates shall be clean without drawn
or ragged edges. If the plates are flame cut, mechanical guides shall be used. It
shall be ensured that the grain flow of the yoke plate shall be in the direction of
the tensile load.
(b) Holes shall be cylindrical clean cut and perpendicular to the plane of the material.
The periphery of the holes shall be free from burrs.
(c) All the corners and edges should be rounded off with a radius of at least 3mm.
(d) Design calculation is for bearing and tensile strength for deciding the dimensions
of yoke plate shall be furnished by the Bidder. The holes provided for bolts in the
yoke plate should satisfy shear edge condition as per IS:800.
4.11.13
Corona Control Ring :
(a) The corona control ring shall be provided with hardware fittings and shall be of
such design that it should cover at-least one disc insulator in disc insulator
strings so that they will reduce the voltage across the insulator units. It shall also
improve corona and radio interference performance of the complete insulator
string alongwith hardware fittings.
(b) The corona control rings shall conform to the specification drawings. The same
shall be made of aluminium alloy tube of minimum 2.5mm wall thickness of type
6063 or equivalent. The same shall be heat treated to maintain consistency in
material properties during service.
(c) Welding of corona control ring shall be done with Argon welding. The welded
locations shall be suitably grinded and shall not allow penetration of water inside
the tube during service. The mechanical strength of welded joint shall not be less
than 20kN.
(d) The corona control ring shall be buffed and have a brushed satin finish. No
blemish shall be seen or felt while rubbing a hand over the surface.
4.11.14
Sag Adjustment Device:
(a) The sag adjustment devices to be provided with double tension hardware fittings
shall be of three plate type. The sag adjustment device shall be provided with a
safety locking arrangement.
(b) Sag adjuster plates shall be made from high qualify mild steel plate as per
IS:2062. The grain flow shall not be in a direction transverse to the tensile load.
Cutting/shearing and drilling of holes shall be similar to those for yoke plate
mentioned under clause 10.13.2 & 10.13.4.
(c) The maximum length of the sag adjustment plate from the connecting part of the
rest of the hardware fittings shall be 520 mm. The details of the minimum and
maximum adjustment possible and the steps of adjustment shall be clearly
indicated in the drawing. An adjustment of 150mm maximum at the interval of
6mm shall be possible with the sag adjustment plate.
4.12
IMPORTANT CONDITIONS:
4.12.1 All Hardware items shall be complete with minor items such as security clip, bolts,
nuts, washer, split pins and inners etc.
4.12.2 Enclosed drawings show the attachment proposed to be fitted on the towers. The
Bidder 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.
4.12.3 All ferrous fittings (except those specified otherwise) shall be hot dip galvanized,
after all machining and fitting has been completed, in accordance with relevant
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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 Bidder 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.
4.12.4 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 under cut. The Nuts should be tapped such that they are fit on the bolt
threads i.e. these should not have loose fitting.
4.13
LENGTH OF STRINGS:
4.13.1 The clearance to the tower steel parts under service conditions of Insulator have
been decided on the basis of length of string that the overall length of the 23 Disc for
400KV line will not exceed the length as indicated in the attached drawings. The
dimension of the Disc for Ball and Socket type will be 280mm x145mm for 11500
kgs EMS to be used with suspension strings.
4.13.2 In case of 400kV tension strings, 24 Disc insulators of 16500 kg EMS of size 280mm
(dia) x 170mm (height) will be used.
4.14
GENERAL TECHNICAL REQUIREMENT FOR ACCESSORIES

Details of Accessories:
i.
The Conductor Accessories shall be suitable for ACSR Moose Conductor as per
technical parameters furnished in Clause 7.04.
ii.
The Ground wire accessories shall be suitable for Ground wire as per technical
parameters furnished in Clause 7.04.
The technical requirements of the individual Accessories are as under:

4.14.1MID SPAN JOINTS AND REPAIR SLEEVES:
(a) The Mid Span Joints for Conductor & Ground wire shall be compression type.
(b) The Conductor Mid Span Joints shall comprise of Aluminium and Steel Sleeves.
The Ground wire Mid Span Joints and Steel Sleeves of Conductor Mid Span Joints
shall be Hot dip Galvanized. Sleeves shall be of circular shape suitable for
compression into hexagonal shape. The detailed drawing showing the length of
Sleeves, inner and outer cross sectional dimension, before compression for
Aluminium corresponding dimensions of hexagon after compression for Aluminium
and Steel Sleeve shall be indicated. The Aluminium Sleeve shall be of extruded
Aluminium. The material of the Steel Sleeve shall be specified.
(c) The Repair Sleeve of Conductor shall be in two halves preferably of same shape,
and this should be of extruded Aluminium. . The sleeve shall be manufactured
from 99.5% pure aluminium and shall have a smooth surface The Repair Sleeve
for Ground wire shall be single piece and Hot dip Galvanized. Its material shall be
specified. The Repair Sleeves shall be of circular shape suitable for compression
into hexagonal shape.
(d) The steel and Aluminium Sleeves for Mid Span Joints as well as Aluminium Repair
Sleeves and Steel Repair Sleeves shall have their outer dia tapered towards the
two ends. Also the inside of the Sleeves shall be well rounded off, so that there is
no sharp edge, which can cut the strands. A dimensional drawing must be
enclosed with the bid.
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(e) The compression type of Joints and Repair Sleeves shall be circular shape suitable
for compression into hexagonal shape. The length of Sleeves before compression
& cross-sectional dimensions after compression and the cross sectional dimensions
between the flats of the opposite sides of the hexagon shall be as under:-
Sr.
Particular
No.
Dimension
before
compression
(Rod cross
section)
Length of
Dimension
Length of
sleeve after
after
sleeve
compression
compression
before
(Flat to flat compression
distance of
hexagon)
G/ W Moose G/ W Moose G/ W Moose G/ W Moose
A Aluminium Sleeves
a
b
Inner dimension
(mm)
Steel Sleeves
a
b
Inner dimension
(mm)
REPAIR SLEEVES
34
54
11.5
11.1
21
21
20.8
54
46
735
785
17.5
17.5
230
250
262
285
17.5
46
254
305
280
330
(f) Other dimensions are indicated in the enclosed drawing. The Bidder shall indicate
the elongation of the above sleeves after compression.
(g) The Joints and Repair Sleeves shall conform to IS:2121/1981 or equivalent
(h) The conductor compressed with mid span joint or with repair sleeve shall not
permit slipping of, damage to or failure of complete conductor or any part thereof
at a load of not less than 95% of the ultimate tensile strength of the conductor.
(i) The electrical resistance of the joint/repaired portion of the conductor shall not
exceed 75% of the measured resistance of equivalent length of conductor.
4.14.24R-VIBRATION DAMPERS FOR MOOSE ACSR:
(a) Only Vibration Dampers having 4-resonance frequency characteristic commonly
called 4R Dampers shall be offered. The Damper shall eliminate fatigue on the
Conductor due to vibration and damp-out the vibrations effectively, so that no
damage due to vibration is caused to Conductor and string.
(b) The Dampers are to be used at all tension locations and suspension locations. One
or more Dampers are proposed to be used on tension/suspension locations
depending upon the span. The Damper shall be such as to effectively damp out
the vibration on the conductor, so that the dynamic strain at the suspension point
with conventional type of Suspension Clamp U bolt and keeper pieces, shall not
exceed 150 micro strains. The manufacturer shall recommend the number of
Dampers required to effectively damp out the vibration of the Conductor, so that
the dynamic strain at the suspension point with conventional Suspension type
Clamp shall not exceed 150 micro strains.
(c) The requirement indicated in Price Schedule is based on use of two Vibration
Dampers per Conductor per span. However, final requirement will depend upon
Manufacturers recommendations duly supported by literature. Manufacturer shall
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also recommend the number of Dampers required to effectively damp out

Conductor vibration for different values of span lengths and the distance for
fixation. While working out Damper Characteristics, it may be kept in view that on
suspension locations, preformed Armour rods are also to be fitted on the
conductor. Manufacturer shall give full details of the damper characteristics and
energy dissipation curves of the Damper and shall also guarantee their
effectiveness for damping design.
(d) The messenger cable shall be made of high strength steel strands of spring steel
with a minimum strength of 136 Kg/sq. mm and preformed in order to prevent
subsequent dropping of weights in service. The Manufacturer shall indicate full
technical particulars of the messenger cable. The keeper pieces shall have proper
curvature and edges be rounded off so that it shall have proper grip over the
conductor without any damage to conductor strands. Clamping bolts shall be
provided with self-locking nuts designed to prevent corroding of the threads or
loosening during service ensuring that no slippage occurs up to specified
longitudinal force on clamp along the conductor. All ferrous parts including the
messenger cable shall be effectively sealed to prevent corrosion.
(e) The collar for fixing the bolt shall be designed in such a way that sufficient space
is available for tightening the bolt through spanner. Further bolt length be
maintained in such a way that it should not come out completely while affixing the
clamp on Conductor.
(f) The Bidder shall specify the material used for the Damper weight and shall confirm
and explain, how constant design characteristics will be maintained during
production. Fixing of the masses to the messenger cable shall be done by pressing
Aluminium Sleeves at each end of the messenger cable under pressure. Each end
should be sealed properly so as to achieve prefect joint. The molten metal filling
method for attachment of messenger cable to counter weight is not acceptable.
The Bidder should specifically bring out the procedure for attachment in the bid.
(g) The Dampers shall meet the test requirements specified hereunder:
The effectiveness of the Vibration Dampers shall be to reduce the amplitude of
vibration, when tested for span of 400 meters for Moose ACSR, tension taken as
25% of ultimate tensile strength in such a order that it limits the dynamic strain
in the Conductor below 150 micro strains for 0 to 15 miles per hour wind
condition in general and 2 to 10 miles per hour wind condition in particular
condition, conforming to as close as possible to the optimum damping force
requirement which the Bidder can predict and furnish for the ranges of wind
velocity and the conductor tension.
(h) The Bidder shall furnish the recommended spacing and the basis including wind
velocity range for selecting the spacing. The results of the analysis shall account
for the following:
i.
ii.
Prediction of (a) Amplitude (b) Frequency and (c) Vibration energy levels of
Aeolian vibration on Moose ACSR for spans of 100m to 1100m.
Test results for various frequency response characteristics of Vibration
Dampers such as vibration amplitude and phase angle including power
dissipation measured from its hysteretic loops.
(i) Maximum residual vibration must be of such an order that the strain level does
not exceed 150 micro strains.
(j) The Vibration Dampers and their attachments shall have smooth surface so that
corona and radio interference voltage levels are within specified limits.
(k) All Ferrous parts shall be fully galvanized.
(l) The Vibration Damper shall be capable of being installed and removed from
energized line by means of hot line tools without completely separating
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components.
The Damper Assembly shall be electrically conductive. The
transmission line details are as under:S.N
Description
Technical Particulars
Configuration
Twin ACSR Moose
Span length in meters:

i.
Ruling design span
400m
ii. Maximum span
1100m
iii. Minimum span
100m
Tensile load in Kg:

i. At minimum temp. of 0o C and still air
4145 Kg.
ii. At every day temp. of 32 C
3614 Kg.
iii. At 0o C and 2/3rd full wind
4477 Kg.
Nature of terrain
Armour rods/AGS clamp
Partly hilly, partly flat with cultivated

fields
AGS clamps
Maximum wind load
45 Kg/m2 .
Max permissible dynamic strains
150 micro strains
The Bidder shall recommend the number of vibration dampers of the type offered
and their points of fixation for spans ranging from 100M to 1100M in steps of
50M .
(m)
The other important features of vibration dampers as regards to materials
test, etc., are as under: Material:
i.
Dampers
- As per IS-9708/1993 or equivalent International Standard.
ii.
Clamp
- Aluminium alloy
iii.
Messenger cable
- High strength steel wire with a strength (kg/sq. mm) not less than
iv.
Weight
- Cast Iron (Hot dip Galvanized)
the strength of steel core of power
Conductor/Ground Wire.
Galvanising:
i.
Spring washers
ii.
Other Ferrous parts- Hot Dip Galvanized.
- Electro Galvanized.
iii.
Casting
iv.
Wires
v.
Bolts & Nuts
- As per IS:729-1961 or equivalent International Standard.

Slip strength of Clamp:

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
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messenger cable and have sufficient and permanent grip on the messenger cable
under all service conditions
Maximum permissible dynamic strain on
the Conductor with the Damper
150 micro
strains.
Minimum number of cycles for fatigue

Amplitude for fatigue test
10 millions Performances.
1 mm at the highest Resonant
frequency.
Radio interference voltage at

phase to ground.
266 KV (rms) -
Less than 500 microvolts.
4.14.34R VIBRATION DAMPERS FOR 7/3.66MM 95 Kg PER MM2 QUALITY GROUND

WIRE:
The design and general particulars of Vibration Damper for Ground wire shall be
the same as described for Dampers for Conductor, Preformed Armour Rods will
be used at Ground wire suspension locations. The dynamic strain at suspension
point shall not exceed 150 micro strains.
b) All the test as described for Vibration Dampers for Conductor shall be carried out
except for Magnetic Power Loss Test.
a)
4.14.4LINE SPACERS AND JUMPER SPACERS :

a)
Line spacers shall be used for maintaining the intra phase spacing of 450mm
between conductors of each bundle under all normal working conditions. The
supplier shall indicate the number of spacers required per phase per span, for
spans ranging from 100M to 1100M with the longitudinal spacing recommended
for the spacers offered by them for giving the best possible performance. The
supplier shall also furnish all the relevant technical documents in support of their
placement chart alongwith the bid.
b)
Jumpers at tension points shall also be fitted with line spacers so as to limit the
length of free conductor to 3.65M and to maintain the intra phase spacing of
450mm. The supplier may quote for rigid line spacer for the jumper. Spacers for
jumpers shall meet all the requirements of spacers used along the line except on
its performance for vibration and movement. Spacers requiring retaining rods
shall not be quoted for jumpers.
c)
The spacer offered by the supplier shall satisfy the following requirements:-
d)
e)
Spacers shall restore normal spacing of the sub-conductor after displacement due
to wind, electromagnetic and electrostatic forces under all operating conditions
including the specified short circuit level without permanent deformation/damage
either to the conductor or the assemblies themselves. They shall maintain as
uniform firm grip on the conductors. They shall also have long life without fatigue
or wear. The clamp shall grip the conductor efficiently to prevent the tortional
movement of conductor. The clamping shall be designed to compensate for any
reduction due to conductor creep.
They shall preferably be of one piece construction and shall not have separate
small components. All fasteners shall be captive and need not be removed in
order to fit the spacer to the sub-conductor.
For spacers requiring retaining rods, the retaining rods shall be designed for the
specified conductor size. The rods shall be made of high strength special
aluminium alloy of type 6061 or equivalent material having minimum tensile
strength of 35 Kg/sq.mm. The ends of retaining rods shall be properly terminated
(parrot billed/ball end). The retaining rods (Armour rods) shall be of preformed
type. The rods shall be heat-treated to give proper resilience and retain the same
during service. The dimensions shall be generally as follows:-
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i.
Length of each rod: About 1086 15mm
ii. Diameter of each rod: 7.87 0.1mm

The conductivity of the rods shall not be less than 40% IACS (International
Annealed Copper Standards). Direction of lay shall preferably be of right
hand. Number of rods in the set shall be about 8. The center line of the rod
shall be suitably marked for ease of installation.
f)
Where elastomer surfaced clamp grooves are used, the elastomer shall be firmly
fixed to the clamp.
g)
Any nut used, shall be locked in an approved manner against loosening caused
by vibrations. The ends of bolts and nuts shall be properly rounded off for
specified corona performance.
h)
Nut cracker, hinged open and or boltless type clamps are acceptable provided
adequate grip can be maintained on the conductor. Designs requiring clamping
bolt cap screw on lock pin shall utilize a single captive fastener.
i)
Clamp with cap shall be designed to prevent its cap from slipping out of position
when being tightened.
j)
The clamp grooves shall be in uniform contact with the conductor over the entire
clamping surface, except for rounded edges. The groove of the clamp body and
clamp cap shall be smooth and free from projections, dirt or other material,
which may cause damage to the conductor when the clamp is installed.
k)
Universal type bolted clamps, covering a range of conductor sizes will not be
permitted.
l)
No rubbing, other than that of the conductor clamp hinges or clamp swing bolts
shall take place between any part of the spacer. All joints shall have a flexible
medium such that there is no relative slip between them.
m)
The spacers shall be flexible enough so as to avoid distortion or damage to the

conductor or to themselves. Rigid spacers are acceptable only for jumpers.
n)
The spacer shall not damage or chafe the conductor in any way which might
affect its mechanical strength or corona performance. The spacer clamp shall not
damage the conductor under any condition.
o)
The spacer assembly shall not have any projection, cut abrasion etc., or
chattering part which might cause corona.
p)
The material used in the spacer shall be corrosion resistant. As far as possible,
the spacer shall be made of aluminium alloy of the type 6061. If iron or steel
parts are used, they shall be galvanized conforming to relevant Indian Standard
and shall have magnetic power loss of not more than one watt for, 600 amps
50Hz alternating current.
q)
Elastomer, if used, shall be resistant to the effects of ozone, ultraviolet radiation

and other atmospheric contaminants likely to be encountered in service, at
temperatures upto 75C. It shall have good fatigue resistant characteristics. The
physical properties of the elastomer shall be indicated in the offer. These shall be
discussed and finalized with the successful supplier at the time of quality plan
approval.
r)
The spacer assembly shall have electrical continuity. The electrical resistance
between the sub-conductor across the assembly. In case of spacer having
elastomer clamp grooves, shall lie between 0.1 and 0.01 mega ohm in order to
ensure satisfactory electrical performance under service conditions.
s)
The spacer assembly shall be easy in installation/removal and reinstallation

without any damage.
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t)
The spacer assembly shall be capable of being installed and removed from the
energized line by means of hot line techniques.
i.
The offer shall include placement charts recommending number of spacers

per phase per span and the sub span lengths to be maintained between the
spacers while installing on the twin bundle conductors.
ii. The placement of spacers shall be in such a way that adjacent sub spans are
sufficiently detuned and the critical wind velocity of each sub span shall be
kept more than 60Km/hr. The placement shall ensure bundle stability under
all operating conditions.
iii. The placement chart shall be provided for spans ranging from 100m to
1100m.
iv. The supplier shall also furnish all the relevant technical documents in support
of their placement charts alongwith the bid.
4.14.5FLEXIBLE COPPER EARTH BONDS:
The flexible copper earthing bond shall be made of flexible copper cable of size
37/7/0.417 with 9.81mm dia and copper area equivalent to 34 sq.mm. The length of
copper cable shall not be less than 500mm. Two steel connecting lugs shall be press
jointed to the either ends of the flexible copper cable. One end of the lug shall have
hole of 17.5mm size and another of 14.5mm. The complete assembly shall also
include one 16mm dia 40mm long HRH M.S.Bolt hot dip galvanized with nut and lock
washer.
4.14.6T-CONNECTOR
T-Connector of compression type shall be used for jumper connection at
transposition tower . It shall be manufactured out of 99.5% pure aluminium and shall
be strong enough to withstand normal working loads. The T-connector shall have a
resistivity across jumper less than 75% resistivity of equivalent length of conductor.
The T-connector shall not permit slipping off, damage to or failure of complete
conductor . The welded portions shall be designed for 30 kN axial tensile load. Leg
sleeve of T-connector should be kept at an angle of 15 deg. from vertical and
horizontal plane of the conductor in order to minimise jumper pull at the welded
portion . The dimensions and dimensional tolerances of T-connector shall be as per
Standard Technical Particulars.
4.14.7HANGER SHACKLE:
This shall comprise of one anchor shackle, one long bolt with washer and split pin.
The breaking strength of the hanger shackle assembly shall not be less than 11500
kg.
4.14.8TECHNICAL PARTICULARS FOR CLAMPS & SPACERS
a)
All the current carrying parts shall be designed and manufactured to have
minimum contact resistance. The maximum tension per conductor is expected to
be 2000 Kgs. There shall not be any sharp edges which may lead to accumulation
of charge & electrical breakdown. All corners/ edges shall be rounded.
b) The clamps shall be liberally designed and certain minimum contact surface shall
be provided.
c)
The clamps and fittings shall be designed so that insulators shall not be subject to
any abnormal stresses due to thermal changes in conductor.
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d) All the clamps & fittings shall enable the connection to be as short as possible.
Wherever possible the clamps shall be two separate halves. No U bolts shall be
used. All components of like design shall be inter-changeable
e)
Spacer shall prevent clashing of the T clamps and minimize effects of short
circuit forces between bundle conductors on structures. They shall be capable of
withstanding electro-magnetic and electrostatic forces during short circuit without
deformation or damage to the conductor or spacer.
f)
Spacers shall permit the relative axial and torsional movement of sub-conductors
and maintain their correct separation without lubrication or maintenance.
g) All nuts, bolts & washers shall be made of Hot dip galvanized Mild Steel
conforming to relevant ISS only.
h) The clamp in all respect shall incorporate highest quality of modern engineering
design and workmanship. The specification is merely for the guidance of the
Bidder as has been clearly stated earlier and it is not the intention to specify the
details of design and workmanship. The clamps shall be designed and
manufactured in accordance with the Bidders standard practices, when such
practices do not conflict with this specification.
i)
The materials offered shall be complete with all components and accessories which
are necessary or useful for their satisfactory performance and efficient
maintenance. Such parts shall be deemed to be within the scope of this
specification whether specifically included or not.
j)
The design should be such that adequate clamping pressure is obtained with the
tightening of the nuts and the pressure should be maintained throughout the
service of the connector. In order to provide for creep of Aluminium under
pressure, it is essential that only Belleville washers are used. This should be
specifically confirmed and should also indicate tightening torque required.
k) All clamps shall be suitable to carry safely the maximum allowable current in the
associated conductor and to withstand the maximum loads occurring under
adverse circumstances and operating conditions. The maximum fault current is 40
KA rms for a period of 3 seconds. The temperature of the clamps and fittings shall
never exceed that of the associated conductor.
l)
Fittings intended to connect two dissimilar metals shall be designed to avoid

harmful bimetallic corrosion under service condition, by way of provision of best
quality bimetallic strips.
m) The short circuit current shall be of the order of 40 KA for 3 seconds. The clamps
should be suitable to withstand the short circuit forces corresponding to this
current.
n) The design of clamps should be such that proper space for movement of normal
quality single head spanner during tightening is available. This is an important
requirement and should be confirmed by the Bidder.
4.14.9Materials:
The Clamps & Connectors/Spacers shall be made of materials listed below: a) For connecting ACSR conductor Aluminium alloy casting conforming to designation
A6 of IS:617.(Redesignation 4600)
b) Bolts, Nuts, plain washers and spring washers for above items shall be made of
hot dip galvanized Mild Steel conforming to relevant IS only.
c) The Bidder shall ensure that the Alloy used assures good stability and sound
casting by proper fluidity. Proper mechanical and physical strength characteristics
should be obtained corresponding to the standard requirements of the Alloy
specified.
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d) The Bidders shall ensure that the Alloy used assures good stability and sound
casting by proper fluidity. Proper mechanical and physical strength characteristics
should be obtained corresponding to the standard requirements of the Alloy
specified.
e) The clamps bodies shall be made by gravity die-casting only and thereafter given
the appropriate heat treatment and precipitation treatment. Clamps bodies made
by sand casting shall not be accepted in any case.
4.15
CASTINGS:
All casting shall be free from blow holes, surface, Blisters and shall be rounded off.
4.16
CONSTRUCTIONAL DETAILS:
a)
All sharp edges and corners shall be blurred and rounded off.
b) Thickness of the clamps shall not be less than 12mm.

c)
Bolts and nuts shall have hexagonal heads and threads as per Indian Standard.
d) Flexible connectors, braids or laminated straps shall be made from tinned copper
strips or aluminium laminates depending upon the clamp.
4.17
e)
Size of terminal / conductor for which the clamps is suitable shall be embossed on
each component of the clamp.
f)
Casting should be such that adequate free space for placement and movement of
spanners for tightening of nuts is available.
BOLTS, NUTS & WASHERS:

These shall be as per Indian Standard and shall have tensile strength and elongation
as per grade 5.6. Further details are indicated in Section-5.
4.18
GALVANISING:
a) Hot dip galvanizing shall conform to Indian Standard specification IS-2633 or
equivalent International Standard. Galvanising shall be uniform, free from blisters,
and shall not peel off due to abrasion, Zinc coating shall be thick enough to
withstand 6 one minute dips in Copper Sulphate solution (precee test) for all
ferrous parts except for threaded portions which shall withstand at least 4 one
minute dips.
b) The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash rust,
stains, bulky white deposits and blisters. The zinc used for galvanising shall be Zinc
of any grade in IS: 209:1992 ingot (fourth revision) or IS:13229:1991.
4.18.1 The Bidder must emboss/engrave their name in each forged steel item and
Aluminium castings such as Ball Hook, Yoke Plate, Socket Clevis, Clevis Eye, ClevisClevis, Anchor Shackle/D-Shackle, Chain Link, Suspension Clamps of AGS type,
Tension Clamps and Arcing Horns. This is very essential. If the Bidder will not agree
with this condition, their offer will be treated as non-responsive.
4.19
TESTS :
The following Type Tests, Stage Tests, Routine Tests and Acceptance Test shall be
carried out on power Conductor & Ground wire Hardware fittings & Accessories.
a) Type Tests
The material supplied shall be fully Type Tested as per this specification and the
Bidder shall furnish two sets of Type Test reports before taking up the supplies..
These tests must not have been conducted earlier than five years. For any change in
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the design/type already Type Tested and the design/type offered against this
specification, the purchaser reserves the Rights to demand repetition of test without
any extra cost.
b) Stage Tests:
Stage Tests during manufacturing shall mean those test required to be carried out
during the process of manufacturing to ensure quality control such that last product is
of the designed quality conforming to the intent of this specification.
c) Routine Tests:
Routine Tests are those tests, which required to be carried out on each and every
finished product so as to check with requirements that are likely to vary during
production.
d) Acceptance Tests:
Acceptance Tests shall mean those tests, which required to be carried out on samples
taken from each lot offered for pre-despatch inspection for purposes of acceptance of
that lot.
e) Test Values:
For all type and acceptance tests, the acceptance values shall be the value
guaranteed by the Bidder in the guaranteed technical particulars or the acceptance
value specified in this specification, the relevant Indian Standard or equivalent
f) 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 Bidder and Purchaser before
placement of order.
4.20
TYPE TESTS FOR HARDWARE FITTINGS

4.20.1
a.
On the complete insulator string with hardware fittings

Power frequency voltage withstand and
flashover test with corona control grading
ring under dry/wet condition.
BS:137 (Part-I)
b.
Switching surge voltage withstand test

under wet condition.
IEC:383
c.
Impulse voltage withstand test under dry

condition
IEC:383
d.
Impulse voltage flashover test under dry

condition
IEC:383
e.
Voltage distribution test
f.
Corona and RIV test under dry condition.
As per specification
g.
Mechanical strength test for complete

string
h.
Vibration test
NOTE: For electrical tests, the insulator string shall be mounted on a
stimulated tower.
4.20.2
On Suspension Hardware fittings only.
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a.
b.
Magnetic power loss test for suspension

Clamp bl
slip strength for AGS clamp
As per
specification
c.
Clamp slip strength Vs torque test for suspension

clamp
d.
Test on neoprene
e.
Ozone test.
f.
Heat resistance test.
4.20.3
On Tension Hardware Fittings only
a.
Electrical resistance test for dead end assembly.
b.
Heating cycle test for dead end assembly
c.
Slip strength test for dead end assembly.
d.
Mechanical strength test.
IS:2486(Part-I)
4.20.4 All the type tests given under clause no 7.20.1 above shall be conducted separately
on single/double suspension and tension insulator string alongwith hardware fittings.
4.20.5 The tests specified under clause no. 7.20.1 (e) & (f) (i.e. the voltage distribution test
and corona/RIV Dry test) shall also be conducted on single suspension pilot double
suspension and single tension insulator string alongwith hardware fittings.
4.20.6 The mechanical strength test given under clause no. 7.20.1 (g) above shall also be
conducted on single suspension pilot, double suspension and single tension insulator
string alongwith hardware fittings.
4.20.7 The magnetic power loss test specified under 7.20.2 (a) shall be conducted on single
suspension, single suspension pilot and double suspension assembly.
4.21
ACCEPTANCE TEST/SAMPLE TESTS:
4.21.1On both suspension and tension hardware fittings:

a.
Visual Examination
IS:2486 (Part-I)
b.
IS:2486 (Part-I)
c.
Galvanising test/Electroplating
As per this specification.
d.
Mechanical strength test of welded joint
e.
Mechanical strength test for corona

control rings.
f.
Test on locking devices for ball & socket

coupling.
g.
Mechanical strength test of each

components excluding corona control
ring and arcing horn.
BS:3288(Part-I)
IEC:372(2)
4.21.2 On suspension Hardware fittings only:

a.
Clamp slip strength vs torque test for

suspension clamp.
b.
Shore hardness test of elastomer

cushion for AG suspension clamp.
c.
Bend test for armour rod set.
IS:2121 (Part-I)
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d.
Re silence test for armour rods set.
e.
Conductivity test for armour rods set
4.21.3 On tension hardware fittings only:

a.
Slip strength test for dead end assembly
IS:2486 (Part-I)
4.21.4 On Suspension hardware for groundwire

a.
Visual examination
b.
c.
Slip strength test.
d.
Mechanical strength test on each

component
e.
Galvanising test
f.
Mechanical strength test of welded joint
4.21.5 On Tension hardware for groundwire:

a.
Visual examination
b.
c.
Slip strength test.
d.
Electrical resistance test.
4.21.6 Test during manufacture:
4.22
a.
b.

galvanizing
c.
Chemical analysis, hardness test grain

size inclusion rating and magnetic
particle inspection for forgoing/castings.
d.
Chemical analysis and proof load test

fabricated hardware.
e.
Tests on malleable castings forgings and

fabricated hardwares.
TYPE TESTS FOR ACCESSORIES
4.22.1Flexible Copper Bond for Ground wire:

Slip strength test:
4.22.2Spacer/Rigid Spacer for power conductor.
i.
Visual examination
ii.
iii.
Galvanising test
As per
IS:2121
this
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iv.
Movement test (except for spacer for

jumpers
v.
Compressive and Tensile test
vi.
Clamp slip Test
vii.
viii.
Assembly torque test
ix.
Hardness test for neoprene
specification,
IS:2633
& IS:6745
4.22.3Mid span compression joint for conductor & groundwire.

i.
Slip strength test
ii.
Electrical Resistance test
iii.
Healing cycle test
iv.
Corona Extinction voltage test dry.
v.
Radio interference voltage test Dry.
vi.
Galvanising test
As per IS 2121,2633 6745
4.22.4Repair Sleeve for conductor:

i.
Electrical Resistance test.
ii
Corona Extinction Voltage test.
iii
Radio Interference voltage test dry.
As per IS 2121
4.22.5Vibration Damper for conductor & groundwire

a.
Chemical analysis of material
b.
Dynamic Characteristic Test.
c.
Vibration Analysis.
d.
Clamp Slip test.
e.
Fatigue Test.
f.
Magnetic power loss test.
g.
Corona extinction voltage test (Dry).
h.
Radio interference voltage test (Dry).
i.
Damper efficiency test.
NOTE:
Tests mentioned at (f), (g) & (h) are not applicable to dampers for groundwire.
4.22.6Clamps
i.
Tensile Test
ii.
Resistance Test
iii.
Temperature rise Test
iv.
Short time current Test
v.
Dimensional Check
vi.
Galvanising Test
(As per IS:5561)
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4.23
ACCEPTANCE TEST
(A)
FLEXIBLE COPPER BOND:
a.
Visual examination
b.
Dimensional verification
c.
Slip strength test.
(B)
SPACERS/ RIGID SPACER FOR POWER CONDUCTOR:
a.
Visual examination.
b.
c.
Galvanising Test.
d.
Clamp slip test
e.
f.
Movement test (except for spacers for

jCompressive
)
& Tensil test.
g.
h.
Assembly torque test
i.
Hardness test for neoprene
(C)
Midspan Compression Joint for Power Conductor & Groundwire
i.
Visual examination
ii.
iii.
Galvanising Test
iv.
Hardness test.
v.
Failing load test (test to be conducted after 24

hours of compression).
(D)
Repair Sleeves for Conductor.
i.
Visual examination
ii.
(E)
Vibration Damper for power conductor/ groundwire.
i.
Visual examination
ii.
iii.
Galvanising Test
iv.
Verification of resonance frequencies
v.
Clamp slip test
vi.
vii.
Strength of messenger cable.
viii.
Mass pull off test.
(F)
IS:2121
Clamps
i.
Tensile Test
ii.
Resistance Test
iii.
Dimensional Check
iv.
Galvanising Test
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(G)
4.24
Test during manufacture.
i.
ii.
Chemical analysis of zinc used for galvanizing
iii.
Chemical analysis, hardness test grain size

inclusion rating and magnetic particle
inspection for forgoing/castings.
iv.
Chemical analysis and proof load test.
v.
Tests on malleable castings forgings and

fabricated hardwares.
DRAWING AND LITERATURE:

The detailed drawings of each component assembly of the Hardware assembly &
Accessories and descriptive literature shall be submitted before taking up supplies.
The detailed dimension drawings for each and all-individual Hardware items such as
clamps, U Clevis, Socket Eye, Yoke Plate and Socket Clevis etc. shall also be
submitted separately. The dimensional drawings for compression type Mid Span Joint
(Aluminium & Steel Sleeve), compression type Repair Sleeve Preformed Armour rods
for Conductor & Ground wire and 4R Vibration Dampers etc. must be submitted. Test
certificates for different tests conducted as per relevant ISS, for all the offered items
must also be submitted essentially.
4.25
MATERIALS AND WORKMANSHIP:
4.25.1 All the materials shall be of the latest design and conform to the best modern
practice adopted in the extra high voltage field. The Bidder shall supply only such
equipment as guaranteed by him to be satisfactory and suitable for 400 KV
Transmission line.
4.25.2 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.
4.25.3 All ferrous parts shall be hot dip galvanised, after all machining has been completed.
Nuts may, however, be tapped (threaded) after galvanising and the threads oiled.
Spring washers shall be electro galvanised. The bolts threads shall be under cut to
take care of increase in diameter due to galvanising. Galvanising shall be done in
accordance with IS:2629 or equivalent International Standard and satisfy the tests
mentioned in IS:2633
or equivalent International Standard.
Fasteners shall
withstand four dips while spring washers shall be guaranteed to withstand at least
six dips each lasting one minute under the standard precee test for galvanising.
4.25.4 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 galvanising shall be grade Zn. 99.95%
as per IS: 209:1992 ingot (fourth revision) or IS:13229:1991.
4.25.5 In case of castings, the same shall be free from all internal defects like shrinkage,
inclusion, blowholes, cracks etc.
4.25.6 All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum.
4.25.7 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
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to prevent corrosion of the contact surface and no maintain good electrical contact
under service conditions.
4.25.8 Particular care shall be taken during manufacturing and subsequent handling to
ensure smooth surface free from abrasion or dents.
4.25.9 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.
4.26
INSPECTION:
4.26.1 Purchaser and its representatives shall at all times be entitled to have access to the
works and to all places of manufacturing and the Supplier shall afford all facilities to
them for unrestricted inspection of the works, inspection of material, inspection of
manufacturing process and for conducting necessary tests as specified herein.
4.26.2 The successful Bidder shall keep the Purchaser informed in advance of the time of
starting and progress of manufacturing of material in its various stages so that
arrangements could be made for inspection.
4.26.3 No material shall be despatched from its point of manufacturing unless the material
has been satisfactorily inspected and tested.
4.26.4 The acceptance of any quantity of material shall in no way relieve the successful
Bidder of his responsibility for meeting all the requirement of this specification and
shall not prevent subsequent rejection, if such materials are later found to be
defective.
4.27
IDENTIFICATION MARKING:
4.28
The main component of the material covered in the specification shall be

legibly and indelibly marked with the trademark of the manufacturer, the month and
year of manufacture, the guaranteed combined mechanical and electrical strength in
kilo-Newton abbreviated by kN to facilitate easy identification and proper use.
Words MPPTCL shall also be embossed/engraved on the main components. Marks
shall be forged or stamped with a steel die before Galvanizing. The marks shall be
distinct, durable and conspicuous. Embossing/Engraving should be done at the time
of manufacturing process itself, but before Galvanizing. Smaller component like bolts
& nuts, split pin and washers etc. may be excluded from this requirement.
PACKING:
4.28.1 The material shall be packed in strong wooden boxes with steel straps. The gross
weight of packing shall be in range of 50 kgs to 200 kgs to avoid handling problem.
The packing shall be strong enough to withstand rough handling during transit or
storage in the field. All the packing cases shall be legibly marked to avoid possibility
of loss in transit. The Bidder shall be responsible for any damage during transit due
to improper and inadequate packing and handling.
4.28.2 Each consignment shall be accompanied by a detailed packing list showing following
details:-
4.29
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.
STANDARD AND TESTS:
4.29.1 The original or attested photocopy of test certificates for material for the test
conducted at Govt. Laboratory are required to be submitted giving results of sample
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test as per technical values given above respectively in support of compliance of

materials to the specification in the quality, performance and composition.
4.29.2 The materials offered shall conform to relevant Indian Standard. The material shall
be tested before dispatch. The MPPTCL may at its option, depute its representative
for inspection and witnessing of test. The test as specified shall be carried out and
the test report shall be submitted for an approval before dispatch.
4.29.3 Further, the MPPTCL reserves the right to carry out test as mentioned above from
bulk quantity received at the cost of supplier to ascertain the quality of the material
supplied. The supply should strictly as per our specification. The MPPTCL at its
discretion for ensuring that material supplied are conforming to specified quality and
composition may get it tested from National Laboratory by drawing samples from the
lot after the same is received by consignees. If the test result do not conform to
specified quality, the lot will be rejected and replacement shall be made free of cost
and testing charges will be to the account of supplier. If some material is already
used by time the results are received, the MPPTCL may accept such material which
has been used at the reduced cost as may be fixed at its discretion. The test as
specified shall be carried out and the test report shall be submitted for an approval
before dispatch.
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SECTION-7
TECHNICAL SPECIFICATIONS FOR ERECTION OF TRANSMISSION LINES
7.01
The material and services under this section shall conform to the requirements of the
latest revisions and amendments available at the time of placement of order of all
the relevant Indian standards/codes listed here under or equivalent International
Standards, except as modified in this document.
S.No.
Indian standards
IS:5613-1995 (partII)
Title
Code of practice for design, installation
and maintenance of overhead power lines.
Sec.-1
Sec.-2
- Designs.
- Installation & Maintenance
IS:269-1967
Ordinary rapid hardening and low heat

Portland cement.
IS:456-2000
Code
of
practice
reinforced concrete
IS:1786-1966
Cold twisted
steel
reinforcements
IS:4091-1967
Code of practice for design & construction

of foundation for transmission line towers
& poles
7.02
for
bars
plain
and
for concrete
LINE MATERIALS:
7.02.1 Conductor:
The Conductor used in the line will be single ACSR Moose Conductor. The
Conductor size is 54/3.53mm A1. + 7/3.53 mm Steel.
7.02.2 Ground-wire :
The Ground-wire to be used on the line shall be 7/3.66 mm; 95 kg/mm2
quality galvanized steel stranded wire.
7.02.3 Insulator Strings with Hardware Fittings:
(i)
Single suspension and double tension strings will be used on the line as under:
(a) At Suspension Locations:
23 Disc single suspension strings having 120KN E&MS of 255x145 mm size
Disc Insulators with AGS type clamps will be used.
(b) At Tension Locations :
24 Disc double tension strings with 160 KN E&MS Disc insulators of 280x170
mm size Disc Insulators will be used with compression type dead end clamp.
(ii)
Pilot strings will be used at deep angle tower locations for restraining the
swing of jumpers.
(iii)
In cases of Railway/Road/River/Other transmission line crossings, double

suspension insulator strings will be used.
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7.02.4 Conductor Accessories:

(i)
AGS type suspension clamps shall be used with suspension strings.
(ii)
Vibration Dampers (4-R type) and Spacers or Spacer-Dampers shall be used

for Conductors.
7.02.5 Miscellaneous Items:

Enameled Number Plates, Phase Plates and Danger Board, Bolts and Nuts,
Spring washers, Pack washers and other tower accessories like D Shackle,
Hanger, U-Bolts and fasteners etc., shall be provided with the tower by the
Contractor. The Contractor shall supply anticlimbing device (including Barbed
wire) separately. Copper earth bond will be used for connecting Ground wire
suspension and tension clamp with tower body, which shall also be provided by
the Contractor.
7.03
DETAILED SURVEY/CHECK SURVEY:

The contractor will have to carry out detailed survey of the line for which
route map indicating the proposed alignment of the transmission line will be
handed over by the Employer. If the detailed survey is already conducted by
the Employer for some portion of the line, the profiles for such portion will be
handed over to the Contractor for carrying out check survey. It may please be
noted that no check survey is required to be conducted for the portion of line
for which detail survey is conducted by the contractor himself.
7.03.1 Detailed Survey:(a)
At the starting point of the commencement of route survey, an angle iron

spike 65 x 65 x 1000mm shall be driven firmly into the ground to show only
150mm above the ground level. A punch mark on the top section of the angle
iron shall be made to indicate location of the surveying instrument. Teak wood
pegs 50 x 50 x 650 mm shall be driven at prominent positions at intervals of
not more than 750 meter along the transmission line to be surveyed up to the
next angle point. 125 mm wire nails should be fixed on the top of these pegs
to show the location of instrument. The pegs shall be driven firmly into the
ground to show only 100 mm above ground level. At angle positions, stones
shall be put up for easy identification. Paint mark in white lead paint shall be
put in, about 300 mm squares with a direction indication, on nearby
boulders, rocks, or trees, along the complete line alignment. At peg
position, identification marks giving the peg position, with reference to
painting marks, shall be given. The white lead paint mark shall indicate to the
individual the direction of alignment from either direction.
(b)
Routing/Re-routing of transmission line through protected/reserved forest area

should be avoided.
In case it is not possible to avoid the forests or areas
having large trees completely, then keeping in view of the overall economy,
the route should be aligned in such a way that cutting of trees is minimum.
(c)
The route should have minimum crossings of Major river, Railway lines,
National/State highways, overhead EHV power line and communication lines.
(d)
The number of angle points shall be kept to minimum.
(e)
The distances between the terminal points specified shall be kept shortest
possible, consistent with the terrain that is encountered.
(f)
Marshy and low lying areas, river beds and earth slip zones shall be avoided to
minimize risk to the foundations.
(g)
It would be preferable to utilize level ground for the alignment.
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(h)
Crossing of power lines shall be minimum. Alignment will be kept at a

minimum distance of 300 m from power lines to avoid induction problems on
the lower voltage lines.
(i)
Crossing of communication line shall be minimized and it shall be preferably at

right angle. Proximity and parallelism with telecom lines shall be eliminated to
avoid danger of induction to them
(j)
Areas subjected to flooding such as nalah shall be avoided.
(k)
Restricted areas such as civil and military airfield shall be avoided.

also be taken to avoid aircraft landing approaches.
(l)
All alignment should be easily accessible both in dry and rainy seasons to
enable maintenance throughout the year.
Care shall
(m) Certain areas such as quarry sites, tea, tobacco and saffron fields and rich
plantations, gardens and nurseries which will present the Employer problems
in acquisition of right of way and way leave clearance during construction and
maintenance should be avoided.
(n)
Angle points should be selected such that shifting of the point within 100 m
radius is possible at the time of construction of the line.
(o)
The line routing should avoid large habitations, densely populated areas,
Forests, Animal/Bird sanctuary, reserve coal belt areas, oil pipe
line/underground inflammable pipe lines etc to the extent possible.
(p)
The areas requiring special foundations and those prone to flooding should be
avoided.
(q)
From the field book entries, the route plan and level profile shall be plotted
and prepared to the scales of 1=2000 horizontal and 1=200 vertical on 1
mm/5 mm/1 cm square paper.
(r)
If the difference in levels be too high, the chart may be broken up according to
requirement. A 400 meter overlap shall be shown on each following sheet.
The chart shall progress from left to right. For convenience in handling, the
sheet size may be limited to 594x841 mm (Al) size.
(s)
After completing the detail survey, profiles shall be submitted to the Employer
duly spotted with tower for approval. While submitting the profiles after
conducting the detail survey, the contractor will also submit a copy of route
alignment on the route map indicating the surveyed route.
7.03.2 Check Survey:

(a) The Contractor shall conduct the check survey after the profiles are handed over
to the Contractor. The check survey shall include checking of deviation angles,
checking of levels at critical points. After completing the check survey the tower
spotting shall be carried out by the Contractor and profiles shall be submitted to
the purchaser for final approval. The Contractor shall be responsible for correct
setting of stubs. Discrepancies, if any, shall be brought to the notice of
purchaser and final approval shall be taken before execution of work.
(b) The requirement of tower site leveling and revetment work, if required, shall
also be marked by the Contractor on the profiles while carrying out the detail or
check survey work.
(c) If due to site conditions any change in the tower location/provision of
extension is considered necessary compared to approve profiles, the
contractor shall bring the same to the knowledge of the purchaser well in time
and get revised approval of the profile before setting the stubs. The revised
approval shall be conveyed to the Contractor by the Purchaser.
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7.03.3 Soil Resistivity:While carrying out detailed/ check survey work, the Soil Resistivity values
will have to be measured at convenient points along the route, not
exceeding 2.50 Km between adjacent points. The Soil Resistivity wiil be
measured using 4 electrod method with an inter electrod spacing of 50 M .
The following formula shall be used :
Where a =
R =
P =
P=2aR
Interelectrod spacing = 50M
Earth resistance measured in Ohms
Soil Resistivity in Ohm- m
The soil resistivity values shall be submitted duly marked on the route map
and also in the form of statement. The quoted rates for detailed survey/
check survey work shall be inclusive of cost of measuring soil resistivity
values along the proposed route and the contractor will not be paid
separately for this work.
7.04
APPROVED PROFILE:
(Applicable for check survey only)
7.04.1 The detailed survey has been conducted by the Purchaser or any other
agency appointed by the Purchaser and the profiles shall be handed over
to Contractor progressively for carrying out check survey and submission of
profiles for approval of the purchaser. The profiles shall be prepared on cm.
graph paper on scale 1:2000 horizontal and 1:200 vertical.
7.04.2 The route alignment surveyed by the Purchaser shall be marked at angle
points. At angle points concrete blocks shall be provided and in the straight
alignment marking will be done by pegs.
7.04.3 The Contractor will be responsible for the correct setting of towers as shown
in approved profiles. If towers after erection are found to be out of the
approved alignment/position in the profile, the Contractor will dismantle and
re-erect them correctly fully at his own cost and without extension of time.
7.05
EXCAVATION:
7.05.1 Except as specifically otherwise provided, all excavation for footing shall be
made to the lines and grades of the foundation. The excavation walls shall be
vertical and the pit dimensions shall be such as to allow a clearance of
150mm on all sides from the foundation pit, where form boxes are used. In
undercut/stepped (slab type) foundations where form box is not required to
be used at the base, the pit dimensions should be as per the standard
drawings. All excavation shall be protected so as to maintain a clean subgrade, until the footing is placed, by using timbering, shoring or casing, if
necessary. Any sand, mud, silt or other undesirable materials which may
have accumulated in the excavation shall be removed by the Contractor
before placing concrete.
7.05.2 The Soil to be excavated for tower foundations shall be classified as under
for the purpose of payment of excavation for tower site leveling and
building stone revetment:
(a)
Dry Soil :
Soil removable by means of ordinary pick axes and shovels

(Normal Soil, intermediate Soil and black cotton Soil fall under
this category).
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(b)
(c)
(d)
Wet Soil :
Soil as per (a) above, where the sub Soil water table is
encountered within the range of foundation depth, the Soil below
the water table and that at locations where pumping or bailing
out of water is required due to presence of surface water, will
be treated as wet Soil.
Soft Rock:
This will mean fissured rock i.e. decomposed rock, hard gravel,
kankar, limestone, laterite or any other Soil of similar nature
which can be excavated with pick axe, crowbar etc. However, if
required, light blasting may be resorted to for loosening the
material but this will not in any way entitle the excavation to be
classified as hard rock
Hard Rock : Hard rock will be that which requires chiseling or drilling and
blasting.
7.05.3 No extra charges shall be admissible for the removal the fallen earth in
the pits when once excavated.
7.05.4 If water is encountered in the foundation pit, de-watering will have to be
done. The cost of dewatering shall be deemed to be included in the
unit rates of excavation for foundation indicated by the Bidder in the offer.
7.05.5 For foundation in rock, where blasting is unavoidable, care should be
taken to minimize the volume of concrete necessary for filling up the
blasted area. The blasted area shall be reduced to the minimum possible so
that the specified form for the foundation could be obtained. No extra
payment for excavation in hard rock shall be allowed if the excavated area
exceeds the designed excavation volumes. Similarly, no extra payment shall
be made if concrete volume exceeds the designed volume due to excessive
blasting.
This is to specify here that during excavation, if hard rock soil is
encountered but keeping in view the soil strata actually
encountered, soft rock foundation is adopted then the rates for
excavation for hard rock shall be limited to the extent of approved
rate for excavation in soft rock.
7.05.6 The Contractor shall arrange requisite blasting material, excavation and
drilling equipment, necessary license etc., at his own cost and the quoted
rates shall be deemed to be inclusive of all such costs.
7.05.7 The decision of the owner shall be final and binding with respect to
classification of soil and foundation.
7.06
CLASSIFICATION OF FOUNDATIONS :
7.06.1 The foundation designs have been carried out depending upon the type of
Soil, sub-Soil water level and the presence of surface water as follows:
(ii)
Dry Soil : To be used for locations where normal

cohesive Soils are met.
(iii) Wet Soil : To be used for locations :
dry cohesive or non-
(a) Where sub-Soil water is met at 1.5meter or more below the

level.
ground
(b) Which are in surface water for long

periods with water penetration
not exceeding one meter below the ground level e.g. the paddy fields.
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(iv) Partially Submerged: To be used at locations where sub-soil water level is

met between 0.75 meter to 1.5 meter below the ground
level.
(v)
Fully Submerged : To be used at locations where sub-soil water level is met

less than 0.75 meter below ground level.
(vi) Black cotton(Dry/Wet): To be used at locations where Soil is clayey type, not
necessarily black in colour, which shrinks when dry and swells when wet,
resulting in differential movement extending to a maximum depth of about
3.5meter below ground level.
(vii) Dry Fissured rock: To be used at locations where decomposed or fissured
rock, hard gravel, kanker, limestone, laterite or any other soil of similar
nature is met. Under cut type foundation is to be used for fissured rock
locations.
(viii) Submerged Fissured rock: In case of fissured rock locations where water
level is met at 1.5meter or more below ground level, submerged fissured
rock foundations shall be adopted. If after soil investigation, water level is
encountered at less than 1.5meter below ground level, a separate foundation
shall be developed.
(ix) Hard rock : The locations where chiseling, drilling and blasting is required for
excavation, hard rock type foundations are to be used.
7.06.2 The foundation of towers will be classified as per above soil strata and as per
the instructions of Executive Engineer (EHT-C) and Superintending Engineer
(EHT-C) concerned and circulars issued by this office. The decision of MPPTCL
in the regard shall be final and binding on the contractor.
7.07
SHORING OF PITS:
Shoring of pits with shuttering on the internal walls surrounding the vertical
facing of approved dimensions of the pit shall be done when the Soil condition
is so bad that there is likelihood of accident due to falling of surrounding earth
in foundation pit. The cost of carrying out shoring & shuttering shall be
deemed to be included in the unit rate of excavation of tower and no extra
payment shall be made on this account.
7.08
TOWER SITE LEVELLING:

In case of foundations located on sloping ground, it may be necessary to level
the ground for locating the tower. In leveling the tower site, only excavation
will be allowed. The Contractor shall quote separate rates for excavation for
purpose of site leveling for dry Soil, wet Soil, soft and hard rock in respective
Schedule. The requirement of tower site leveling will be decided by the
Purchasers site Engineer and will be marked by the Contractor in the profiles
while carrying out the check survey work.
7.09
SETTING OF STUBS:
7.09.1 The stub shall be set correctly in accordance with approved method at the
exact locations and alignment and imprecisely correct levels. The stub setting
Templates shall be used for proper setting of stubs. Stubs shall be set in the
presence of purchasers representative available at site whenever required
and for which the contractor shall give adequate advance intimation to the
site Engineer.
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7.09.2 The foundations are to be made as per designs and drawings approved by
the purchaser. Extent of the work as defined by such drawings shall not be
exceeded except in very exceptional cases where the prior approval of
purchaser has been obtained.
7.09.3 Each
tower shall be provided with suitable foundation based on the
approved designs after classification of Soil. The Soil classification shall be
done after digging minimum section of all foundation pits of a tower up to full
depth (excluding hard rock locations). The Soil should be classified strictly as
per the details of Soil encountered in the foundation pit. For example, dry Soil
foundation should be adopted at the locations where dry Soil is encountered
in the full depth of foundation. Similarly the wet type foundation should be
adopted at the locations where water level is met at level of 1.5meter or
more, below the ground level or in paddy fields or other places, which remain
in surface water for long periods with water penetration not exceeding one
meter
below
the ground level. Deviations, if any, from the
approved/specified conditions shall be brought to the notice of C.E.
(EHT:C&M) through site Engineer before taking up the work and his
decision shall be final in this regard and communicated through site
Engineer. If at a later date, it is found that the works carried out by the
Contractor are not according to the specifications and are without specific
approval, the entire payments made to the Contractor for carrying out such
works shall be recovered and the Contractor will have to rectify the same at
the rates indicated in the order for carrying out such work and without
extension of time.
7.09.4 The setting of stubs in hard rock foundation may require cutting of stubs
depending on depth at which hard rock is encountered. The cutting of stubs
and drilling of new holes for fixing cleats etc. shall be considered inclusive in
the rate of foundation of towers in hard rock. However, the cut pieces of
stubs shall be returned to MPPTCL.
7.09.5 Setting of stub at each location shall be approved by the purchasers site
Engineer. This approval shall not however, absolve the Contractor of his
responsibility of correct setting of stubs and casting of foundations, who will
be required to rectify the faulty work at his own expense.
7.10
PLACEMENT OF REINFORCEMENT:
7.10.1 Some of the tower foundations may be designed with steel reinforcement so
as to achieve better foundation strength with lesser space. The Contractor will
indicate in relevant schedules, the details of reinforcement to be provided
alongwith the weight and size of reinforcement rods. The cost of placing of
reinforcement steel, binding etc. in the foundation pit shall be deemed to be
included in the quoted rates of foundations of towers.
7.10.2 The Contractor shall arrange foundation reinforcement steel etc. at their cost
which shall be deemed to be included in the quoted cost of foundations. The
reinforcement bars will have to be properly cut, bent in required shape and
placed in the foundation in approved manner after due cleaning of oil, grease
or organic matter. The reinforcement shall be properly tied by binding wire.
7.10.3 Reinforcement shall conform to IS:1786 for deform and cold twisted bars (Fe
500). Thermo Mechanically Treated (TMT) bars (equivalent grade ) in place
of cold twisted bars are also accepted. Hard drawn steel wire shall conform to
IS:432.
7.11
CONCRETE:
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7.11.1 The cement concrete used for the foundation shall be of 1:2:4 mix ratio
(M150) with 20mm nominal size stone metal for chimney portion and 40mm
nominal size stone metal for pyramid or slab portions. 1:3:6 mix ratios
(M 100) shall be used for base padding (lean pad). For RCC, the aggregates
shall preferably be of 20mm nominal size.
7.11.2 Concrete aggregates shall confirm to IS:383
7.11.3 The cement required for the purpose of foundations,
building revetment
walls etc. shall be arranged by the Contractor at his own cost, which shall be
deemed to be included in the cost of concreting.
7.11.4 The sand used for the concrete shall be arranged by the Contractor at his own
cost including necessary license etc., which shall be deemed to be included in
the cost of concreting. The sand shall be composed of
hard silicate
materials. It shall be clean and of a sharp angular grit type and free from
earthy or organic matter and deleterious salts.
7.11.5 The aggregate shall be arranged by the contractor at his own cost including
necessary license etc, which shall be deemed to be included in the cost of
concreting. The aggregate shall be of clean broken hard granite or other
stone specified or approved by the purchaser. It shall be of hard and coarsegrained quality. It shall also be as far as possible cube like, preferably
angular, but not flaky, perfectly clean and free from earth, organic or other
deleterious matter. 40mm aggregate shall be of size as will pass through a
mesh of 40 mm measured in the clear and 20 mm aggregate through 20mm
square mesh measured in clear.
7.11.6 The water used for mixing concrete shall be arranged by the contractor at his
own cost including necessary license etc, which shall be deemed to be
included in the cost of concreting. The water used shall be fresh, clean and
free from oil, acid and alkali, organic materials
or other deleterious
substances. Salty/Saline or brackish water should not be used.
Potable
water is generally satisfactory.
7.11.7 The concrete shall be mixed in a mechanical mixer. However in case of
locations not accessible for concrete mixers, hand mixing may be permitted at
the discretion of our site Engineer.
7.11.8 Mixing shall be continued until there is uniform distribution of materials and
the mixing is uniform in colour and consistency but in no case the mixing is
done for less than two minutes. Normally mixing shall be done close to
the foundation, but in case it is not possible, the concrete may be mixed at
the nearest convenient place. The concrete shall be transported from the
place of mixing to the place of final deposit as rapidly as practicable by
methods, which shall prevent the segregation or loss of any ingredient. The
concrete shall be placed and compacted before setting commences. The
transportation cost of these materials shall be deemed to be included in the
cost of concreting.
7.11.9 The concrete should be mixed as stiff as per the requirements of placing
the concrete in the form boxes, with ease
and
the
degree
to which the concrete resists segregation. Hence the quantity of water used
should not be too much.
7.11.10
Proper form boxes adequately braced to retain proper shape while
concreting should be used for chimney or pyramid and slab portions. The
form boxes should be made water tight so that cement cream may not come
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out leaving only sand and jelly consequently forming of honeycombing in the
concrete. The form boxes shall be cleaned and oiled before these are used
for concreting.
7.11.11
The concrete shall be laid in 150mm layers and consolidated well
so that the cement cream works up to the top and no honeycombing is left
in the concrete. Concreting is to be done continuously so that the subsequent
layers are laid before the initial setting of the bottom layer begins. The
consolidation of concrete shall normally be done by using vibrators.
7.11.12
After concreting the chimney portion up to the
required height,
the top surface should be finished smooth, with slight slope towards the
outer edge, to drain off the rainwater falling on the coping.
7.11.13
In wet locations, the site must be kept completely de-watered both
during the placing of the concrete and up to 24 hours after completion. There
should be no spilling to concrete by water during this period.
7.11.14
The form boxes shall be removed only after at least 24 hours after the
completion of concreting. After removal of the forms and boxes the concreted
surface wherever required shall be repaired with a mixture of rich cement and
sand mortar in the shortest possible time.
7.11.15
The cost of carrying out concreting of foundations in all respect,

shall be deemed to be included in the unit rates of foundations of tower
in different type of Soils quoted by the Bidder.
7.12
BACKFILLING AND REMOVAL OF STUB TEMPLATE:
7.12.1 Following opening of form work and removal of shoring and shuttering,
if required, backfilling shall be started after 24 hours of casting repairs, if
any, to the foundation concrete. Backfilling shall normally be done with
the excavated Soil, unless it consists of large boulders, which shall be
broken to a maximum size of 80mm.
7.12.2 The backfill materials should be clean and free from organic or other
foreign materials The
earth
shall be deposited
in
maximum
200mm layers, leveled, and wetted and rammed properly before
another layer of earth is deposited. Care shall be taken that the back filling is
started from the foundation end only in the pits towards the outer end.
7.12.3 The backfilling and grading shall be carried to an elevation of about 150mm
above the finished ground level to drain out water. After backfilling, 50mm
high earthen embankment (bandh) will be made along the sides of excavated
pits and sufficient water will be poured in the backfilled earth for at least next
24 hours.
7.12.4 The stub setting Templates shall be opened only after the completion of backfilling.
7.12.5 After completing stringing work, if level of
backfilling of some of the
locations gets settled and it is required to backfill the locations again, the
same would be done by the contractor at no extra cost.
7.12.6 No extra charge is admissible for carrying out
backfilling of foundation
pit (including backfilling from borrowed earth if required) and the cost of
backfilling including cost of materials shall be deemed to be included in the
cost of excavation of towers quoted by the in the bid.
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7.13
CURING:
The concrete, after it is 24 hours old, shall be cured by keeping the
concrete wet continuously for a period of 14 days after laying. The pit may
be backfilled with selected earth sprinkled with necessary amount of water
and well consolidated in layers not exceeding 200mm of consolidated
thickness after a minimum period of 24 hours and thereafter both the
backfilled earth and exposed chimney top shall be kept wet for the remainder
of the prescribed time of 14 days. The uncovered concrete chimney above the
backfilled earth shall be kept wet by providing empty cement bags dipped in
water fully wrapped around the concrete chimney for curing duly ensuring that
the bags are kept wet by frequent pouring of water on them. The Contractor
may use anti curing paint. However no extra payment shall be made on this
account.
7.14
BUILDING STONE REVETMENT:

Stone revetment in 1:6 cement mortars shall be constructed by the Contractor
at specified locations. The detailed proposal in consultation with the site
Engineer, for carrying out revetment work shall be submitted to the
O/o. CHIEF ENGINEER
(Procurement), Jabalpur
through
concerned
Superintending Engineer, EHT Construction and approval shall be obtained
before carrying out revetment work. The top seal cover of revetment work
shall be done with 1:2:4 normal mix. All materials including cement shall be
provided by the contractor and cost of building revetment shall be deemed to
include cost of such materials also i.e. Cement, sand, metal and stone. Curing
of revetment shall be done as specified for tower foundation. The back filling of
the inside of the revetment wall with Soil/borrowed earth will be paid for
extra on per m basis and shall include its compacting and watering.
The excavation for revetment foundation shall be paid at the rates as indicated
by the Bidder in Price Schedule. The revetment work, wherever necessary,
shall have to be completed before taking up final tensioning work in the
Section.
7.15
TOWER EARTHING:
7.15.1 For the purpose of earthing, necessary earthing rods (25mm dia, 2
meter long) connecting clamps, and connecting wire will be provided by
the Contractor. The earthing rods are to be hammered preferably in the
foundation pits and connected to stub by 7/4.00mm earth-wire and
with necessary connecting clamps before concreting the foundation. If it is not
possible to tie the rods in the foundation pit i.e. in rocky location, they shall
be buried near the foundation pit and connected to the stubs. The earthing
rods are to be provided on diagonally opposite legs of the tower. Each tower
shall be earthed before the foundation is casted.
7.15.2 The tower footing resistance of all towers shall be measured in dry whether
after the erection and before the stringing of Ground-wire. The counterpoise
earthing shall be resorted to, in accordance with the instructions of the site
Engineer, in case the tower footing resistance (TFR) exceeds the specified
value. It shall be ensured that the tower footing resistance is less than 10
ohms. Each tower footing resistance shall be intimated (along with the tower
location number) while submitting the progress report of tower Erection.
7.15.3 Counterpoise Earthing :
(a)
In case of high resistivity, counterpoise earthing shall be provided which

consists of four lengths of galvanized steel stranded wires, 7/4.00mm
fitted with each leg of the tower with proper clamps for connection to the
tower leg at one end. The counterpoise will be laid radially away from the
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tower and will normally be 15 meters in length, buried to the depth of

600mm below the ground level.
The length of counterpoise wire may
be increased if the resistance requirements are not met. Connecting clamps
shall be buried in the chimney portion of the foundation. Contractor shall
quote for the laying of counterpoise earthing on per running meter basis,
including cost of all materials. The scope of work of connecting
the counterpoise to the tower legs shall be deemed to be included in the
cost of laying of counterpoise (with cost of materials). The counterpoise
connecting wire and clamps will be arranged by the Contractor. The
counterpoise shall preferably be laid through soft soil areas if available.
The planning of laying counterpoise shall be done as per approval of site
Engineer. The cost of laying of counterpoise shall be inclusive of excavation
and backfilling work also.
(b) The Contractor shall have to provide rod earthing at the end of each
counterpoise wire and this may lead to T.F.R. values within specified limits.
This work of additional rod earthing shall be paid extra on per location basis
as per the rates indicated in Price Schedule. Which shall include the cost of
providing such earthing and cost of materials i.e. earthing rods (4 Nos. for
counterpoise earthing i.e. additional earthing of towers) and connecting
arrangements for one tower.
7.16
TOWER ERECTION/ ASSEMBLY:
7.16.1 Towers shall be erected after the foundation concrete is at least 14 days old,
but a gap of 24 days shall be preferred. The method followed for the erection
of towers, shall ensure the points mentioned below:
7.16.2 Straining of the members shall not be permitted for bringing them into
position. It may, however, be necessary to match hole positions at joints
and to facilitate this, Tommy bars not more than 450mm long may be used.
7.16.3 Before starting erection of an upper section, the lower section of tower shall
be completely braced and all bolts provided in accordance with approved
drawings.
7.16.4 All plan diagonals relevant to a section of tower shall be placed in position
before assembly of upper section is taken up.
7.16.5 The bolt positions in assembled towers shall be as
II/Sec.2), 1995 with latest amendments.
per IS: 5613 (Part-
7.16.6 Tower shall be fitted with Number, Phase and Danger Plates which shall be
arranged by the Contractor.
7.16.7 Anti-climbing Devices:
Barbed wire will be used at a height of approx. 3 meters and above as an
anti-climbing measure, which shall be arranged by the Contractor. At every
location three layers of Barbed wires will be provided each inside and outside
the tower in horizontal plane. Spacing between the layers with fixing
arrangements shall be provided as per the provisions of
IS:5613 (PartII/Sec.1)-1976 with latest amendments. The galvanized angle pieces with
notches for accommodating Barbed wire with Bolts Nuts etc. shall be supplied
by the Contractor. After the Barbed wire is placed in position in the notches,
Page 101 of 116
Volume-V (Part-2)
the notch opening shall be welded to avoid the theft of Barbed wire and
anti-corrosive treatment with cold galvanizing paint shall be given, as
also in the case of bolts to be welded below bottom cross arm level.
Suitable locking arrangement (pad-lock) shall also be provided.
7.16.8 All blank holes, if any left, after complete erection of the tower, are to be
filled up by bolts and nuts of proper size.
7.17
TIGHTENING PUNCHING AND WELDING OF BOLTS AND NUTS:
7.17.1 All nuts shall be tightened properly using correct size of spanners. Before
tightening, it will be seen that packing washers and plates are placed in
relevant gaps between members, bolts of proper size and length are provided
and one spring washer is used under each nut and in case of step bolts,
spring washers shall be placed under the outer nut.
7.17.2 The tightening shall progressively be carried out from the top to 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
three positions on the periphery 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 have to be
replaced.
7.17.3 The threads of all the bolts projected outside the nuts shall be welded all
around the periphery of nut-bolts. The welding of nut-bolts as above shall be
carried out from ground level to bottom cross arm level in all towers upto
+6M extensions. In case of +10M/18M/25M extension towers and special
river crossing towers, nut-bolts welding shall be done up to 25 meter height
from ground level.
7.17.4 After welding, cold galvanized paint having at least 90% zinc content shall
be applied on the welded portion. At least two coats of the paint shall be
applied. The cost of such paint and welding etc., including application of paint
etc., shall be deemed to be included in the quoted erection rates.
7.18
INSULATOR HOISTING:
Suspension insulator strings shall be used on suspension towers and tension
insulator strings on angle and
dead end towers. They shall be fixed on all
the towers just prior to the stringing. Damaged Insulators and fittings, if
any, shall not be used in the assemblies. Before 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 the purpose. Security
clips shall be fitted in position for the Insulators before hoisting. Arcing Horns
shall be fitted in an approved manner. Torque wrench shall be used for fixing
different line materials and their components, like suspension clamps etc. for
Conductor and Ground-wire etc.
7.19
HANDLING OF CONDUCTOR AND EARTHWIRE:
7.19.1 The Contractor shall be entirely responsible for any damage caused to the
towers or Conductors during stringing. While running out the Conductors,
proper care shall be taken ensuring that the Conductors do not touch and rub
against the ground or objects which could cause scratches or damage to the
Conductor strands. The Conductors shall be run out of the drums from the
top in order to avoid damage due to chafing.
The drum stand shall be
Page 102 of 116
Volume-V (Part-2)
provided with a suitable braking device to avoid damage, loose running out
and kinking of Conductor. Proper care shall be taken to avoid injury to
Conductor while making it pass over the bull wheel of tensioner. After the
tensioner, the Conductor will be pulled by pull cable and consequently pass
over the running out blocks. The groove of the running out blocks will be of
such a design that the seat is semi-circular and larger than the diameter
of the Conductor and it does not slip over or rub against the sides. The
grooves shall be lined with hard rubber or neoprene to avoid damage to
Conductor and shall be mounted on properly lubricated bearings.
7.19.2 The running blocks shall be suspended in a manner to suit the design of
the cross arm. All running out blocks especially those at the tensioning end,
will be fitted on the cross arm 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. The Conductor shall be
continuously observed for loose or broken strands or any other kind of
damage. When approaching towards end of a drum length, at least three
coils shall be left when the stringing operations are to be stopped. These coils
are to be removed carefully if another length is required to be run out,
new length may be joined to the length already run out by the compression
joint in approved manner.
The Conductor joints and clamps shall be erected in such a manner that no
bird caging, over tensioning of individual wires or layers or other deformities
or damage to the conductor shall occur. Clamps or bracing devices shall
under erection conditions allow no relative movement of strands or layers of
the conductors.
7.19.3 Repairs of Conductors, in the event of damage being caused to isolated
strands of a conductor during the course of erection, if necessary, shall be
carried out during the
running out operations, with repair sleeves.
Repairing of Conductor surface with repair sleeve shall be done only in case
of minor damage, scuff marks etc., keeping in view both electrical and
mechanical safety requirements. Number of damaged strands shall not
exceed 1/6th of the total strands in the outer layer. The final Conductor
surface shall be clean, smooth and shall be without any projections, sharp
points, cuts, abrasions etc. Repair sleeves may be used when the damage
is limited to the outermost layer of the Conductor and is equivalent to the
severance of not more than one third of the strands of the outermost layer.
No repair sleeve shall be fitted within 30 m of tension or suspension clamp or
fittings. Further, more than one repair sleeve per Conductor shall not be
normally used in any single span.
7.19.4 Conductor splices shall be so made that they do not crack or get damaged in
the stringing operation. The Contractor shall use only such equipment/
methods during Conductor stringing which ensures complete compliance in
this regard.
7.19.5 Derricks shall be used where roads, rivers, canals, telecommunication or
overhead power lines, railway lines, fences or walls have to be crossed
during stringing operations. It shall be seen that normal services are not
interrupted and no damage is caused to property. Shut down shall be
obtained when working at crossing of overhead power lines.
7.19.6 The sequence of running out shall be from top to downwards, i.e. the
Ground-wire shall be run out first followed by the Conductors in succession.
Imbalances of loads on towers shall be avoided as far as possible i.e. both
Ground-wires, then both bundles of top Conductor and then both bundles of
Page 103 of 116
Volume-V (Part-2)
middle Conductor followed by both bundle Conductors of bottom Cross-arm

should be strung.
7.19.7 The proposed transmission line may run parallel for certain distance with the
existing 400/220/132KV lines which will remain energized during the stringing
period. As a result there is a possibility of dangerous voltage build up due
to electromagnetic and electrostatic coupling in the pulling cables,
Conductors and Ground-wires, which although comparatively small in
magnitude during normal operations, can be severe during switching and
ground fault conditions on the energised lines. It shall be the Contractor's
responsibility to take adequate safety precautions to protect his employees
and others from this potential danger.
7.20
STRINGING OF CONDUCTOR AND EARTHWIRE:
7.20.1 The stringing of the Conductor shall be done by control in tension method by
means of tension stringing equipments. The equipments shall be capable of
maintaining a continuous tension. The maximum tension imposed on a
conductor during stringing operations shall not exceed than that necessary to
clear obstructions on the ground. The contractor shall indicate in their offer,
the sets of tension stringing equipment he is having in his possession and the
sets of stringing equipment he would deploy exclusively for this work.
7.20.2 After being pulled, the Conductor/Ground-wire shall not be allowed to hang in
the stringing blocks for more than 96 hours before being pulled to the
specified sag.
7.20.3 The Contractor shall give complete details of the stringing methods, which he
proposes to follow. At least one month in advance of the commencement
of stringing, the Contractor will submit the stringing charts for the
Conductors and Ground-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 purchaser. The stringing shall be carried out
as per the stringing charts approved by the purchaser and in accordance
with relevant IS. All the tolerances for the line shall conform to IS :5613
(Part-2/Sec-2) 1995.
7.20.4 In hilly terrain and thick forest, where deployment of tension stringing
machine is not possible, manual stringing may be adopted after getting
approval of Purchasers site Engineer. The contractor shall deploy appropriate
tools/equipments/machinery to ensure that the stringing operation is carried
out without causing damage to conductor/earth wire and conductor/earth wire
is installed at the prescribed sag-tension as per the approved stringing charts.
7.21
JOINTING:
7.21.1 The number of joints in Conductor/Ground-wire shall be kept to minimum

possible by properly selecting the drums from available lot of respective
drums.
All the joints on the Conductor and Ground-wire shall be of
compression type. Each part of the joint shall be cleaned by wire brush to
make it free of rust or dirt etc. and properly greased with anti-corrosive
compound, as approved by our Engineer before the final compression is
done with the compressors. The cost of such
grease etc. used for joints
shall not be paid extra and shall be deemed to be included in the stringing
rates.
7.21.2 All joints shall be made at least 30 meter away from the structures. No joints
shall be made in the spans crossing over the main roads, railways, rivers etc.
Page 104 of 116
Volume-V (Part-2)
Not more than one joint per Conductor shall be allowed in one span. Care
shall be taken to mark the conductor for properly centering the compression
clamp before compressing. During compression operation, the conductor shall
be handled in such a manner as to prevent lateral or vertical bearing
against the dies. After pressing the joint the aluminum sleeve
shall
have all corners rounded, burrs and sharp edges removed and smoothened.
7.21.3 Suitable protector shall be used during stringing of Conductor to avoid any
damage to the joint while it passes over the traveler.
7.22
SAGGING IN OPERATION:
7.22.1 The Conductors shall be pulled up to the desired sag and

block for at least one hour after which the sag shall be
adjusted, if necessary, before transferring the conductor from
blocks to the suspension clamps. The Conductors shall be
36 hours of sagging in.
left in running
rechecked and
the running out
clamped within
7.22.2 The sag will be checked in the first and the last span of the section in case of
sections up to eight spans and in one intermediate span also for sections with
more than eight spans.
The sag shall also be rechecked when the
Conductor have been drawn up and transferred from running blocks to the
insulator clamps.
7.22.3 The
running out blocks, when suspended from
the transmission
structure for sagging shall be so adjusted that the Conductors on running out
blocks will be at the same height as that of the suspension clamps to which it
is to be secured.
7.22.4 At sharp vertical angles, the sags and tensions shall be checked on both
sides of the angle. The Conductor and Ground-wire shall be checked on the
running out blocks for equality of tension on both sides. The suspension
insulator assemblies will normally assume vertical positions when the
Conductor is clamped.
7.22.5 Tensioning and sagging operations shall be carried out in calm weather,
when rapid changes in temperature are not likely to occur.
7.23
TENSIONING & SAGGING OF CONDUCTOR AND EARTHWIRE:

The tensioning and sagging shall be done in accordance with the
approved stringing charts before the Conductor and Ground-wire is finally
attached to the towers through the insulator strings for the Conductor and
Ground-wire clamps for the Ground-wire Dynamometers shall be used for
measuring tension in the Conductor and Ground-wire.
7.24
CLIPPING IN:
7.24.1 Clipping of the Conductors in position shall be done in accordance with the
method approved by our Engineer. At suspension location free center type
suspension clamp with Armour rod set or AGS type suspension clamp shall be
used.
7.24.2 The jumpers at the section and angle towers shall be formed to parabolic
shape to ensure maximum clearance requirements.
Pilot suspension
insulator string shall be used, if necessary, to restrict the jumper swings to
the design values. Jumper connections of transposition towers shall be so
Page 105 of 116
Volume-V (Part-2)
made that adequate clearances are available from tower body as well as
phase conductors.
7.24.3 Fasteners in all fittings and accessories shall be secured in position.
security clip shall be properly opened and sprung into position.
7.25
The
FIXING OF CONDUCTORS AND EARTHWIRE ACCESSORIES :

Spacers, spacer dampers, Vibration dampers (4-R type) and other Conductor
and Ground-wire Accessories supplied by the purchaser shall be installed by
the Contractor as per the design/drawing requirement and as per instructions
of the Engineer. Spacers shall be fitted within 24 hours of the Conductor
clamping. While installing the Conductor and Ground-wire Accessories, proper
care shall be taken to ensure that the surfaces are clean and smooth and no
damage shall occur to any part of the Accessories.
7.26
REPLACEMENT:
If any replacements are to be effected after stringing and tensioning or
during maintenance, members and bracing shall not be removed without
reducing the tension on the tower with proper guying or releasing the
Conductor.
If the replacement of cross arms becomes necessary after
stringing, the Conductor shall be suitably tied to the tower at tension points or
transferred to suitable roller pulleys at suspension points.
7.27
FINAL CHECKING TESTING AND COMMISSIONING:

After completion of the works, final checking of the line shall be done by the
Contractor to ensure that all the foundation works, tower erection, and
stringing have been done strictly in accordance with the specification and
as approved by the purchaser. All the works shall be thoroughly inspected
keeping in view the following main points:
(a)
Sufficient back-filled earth is lying over each foundation pit and it is

adequately compacted.
(b)
Concrete chimneys and their copings are in good finely shaped conditions.
(c)
All the tower members are correctly used, strictly according to approved
drawing and are free from defects or damages, whatsoever.
(d)
All bolts are properly tightened and punched/tack

specification.
(e)
The stringing of the Conductors and Ground-wire has been done as per the
approved sag and tension charts and desired clearances are clearly available.
(f)
All Conductor and Ground-wire
welded as per this
Accessories are properly installed.
(g)
All other requirements to complete the work like fixing of Danger Plate,
Phase Plate, Number Plate, Anti-climbing devices, Aviation Signal
(wherever required) etc. are properly installed and the painting has been
done wherever required as per Aviation Rules.
(h)
It should be ensured
(i)
The line insulation is tested by the Contractor by providing his own

equipment labour etc. to the satisfaction of the purchaser to ascertain the
insulation condition of the line.
(j)
Conductor continuity test is carried out to verify that each Conductor of the
overhead line is properly connected electrically also.
that revetment is provided, wherever required.
Page 106 of 116
Volume-V (Part-2)
The line may be charged at a low value of Power

purpose of testing.
***
Frequency Voltage for the
Page 107 of 116
Volume-V (Part-2)
ANNEXURE- 1
GUARANTEED TECHNICAL PARTICULARS OF CONDUCTOR & EARTH WIRE
(A) ACSR MOOSE CONDUCTOR.
S.NO.
1
2
PARTICULARS
ACSR MOOSE Stranding and Size in mm
ACSR MOOSE
54/7/3.53
Stranding and wire dia in mm
a)
Aluminium
b)
7/3.53
Steel
Standard nominal copper area in sq.mm
Actual aluminium area in sq.mm.
528.5
5
a)
Standard area of cross section in sq.mm.

Aluminium strand
9.787
b)
Steel strand
9.787
c)
6
Conductor
Diameter of complete conductor in mm.
Minimum ultimate tensile stress in Kg./sq.mm.
a)
Aluminium strand
b)
8
Steel strand
Guaranteed ultimate tensile strength of
Conductor in Kg.
Min. breaking load in KN for
a)
i)
ii)
b)
i)
Aluminium strand
Before stranding
After Stranding
Steel strand
Before standing
12.86
After stranding
12.22
ii)
10
a)
b)
Zinc coating of steel strand

Number and duration of dips
Minimum weight of coating in gms./sq.mtr.
54/3.53
325
597
31.77
16.38
134
Min. 161.20
1.57
1.49
3 dips 1 min.
260
11
12
No. of standard length in one reel

Weight in Kg./Km. (Approx.)
One
a)
Aluminium
1465
b)
Steel
c)
Conductor
539
2004
Page 108 of 116
Volume-V (Part-2)
S.NO.
13
14 a)
b)
PARTICULARS
Resistance in ohms per km at 20 deg. C
Continuous max. current rating of conductor in
still air at 40 deg. C ambient temperature
Amps.
Temperature rise for the above current deg. C.
15
Lay Ratio
17
0.0552
900
35 Deg. C
Steel core : 6 wire layer
16-18
Aluminium: 12 wire layer
12-14
18 wire layer
11-13
24 wire layer
16
ACSR MOOSE
Modulus of elasticity of
Conductor Kg/Sq.mm
Co-efficient of linear expansion per degree
centigrade of:
0.703x106
23x10-6
a)
Aluminium strand
b)
Steel strand Kg./Sq.cm
11.5x10-6
c)
Conductor Kg./sq.cm.
19.3x10-6
18
Kg./sq.cm
10-12
Percentage of carbon in steel wire
0.50-0.85
19
Standard length of each piece in Km.
1.5
20
Tolerance, if any, on standard length
+/- 5%
The conductor should conform strictly to the Guaranteed Technical

Particulars as detailed above. The conductor shall conform to IS:398 Part-II
1996 & as amended up-to-date.
(B)
HTGS EARTH WIRE
S.N.
1
Particulars
HTGS EARTH WIRE
Particulars of single steel wire before

stranding
a) No. of wires
b) Diameter (mm)
c) Tolerance
Plus
Minus
d) Minimum elongation in 100 mm length
7
3.66 mm
2%
3.74
3.58
5 mm
e) Breaking load (Kg.)

Standard/Minimum
f) Minimum ultimate tensile stress (Kg/mm2)
g) D.C. resistance at 20 deg. C (Ohm/Km)
2
1179/1000
95
17.57(Max.)
Stranded Wire
a) Length of lay (mm)
Page 109 of 116
Volume-V (Part-2)
S.N.
Particulars
Maximum
Minimum
b) Overall diameter of Earth wire(mm)

c) Area of cross section of Earth wire (sq. mm.)
HTGS EARTH WIRE

198
165
10.98
73.64
d) Breaking load (Kg.)

Standard/Minimum
e) Resistance in Ohms per Km. at 20 deg. C.
f) Modulus of elasticity of Earth Wire (Kg/cm2)
g) Weight of Earth wire (Kg/Km)
h) Co-efficient of linear expansion (per deg. C)
3
7431/6972
2.5
19 x10 5Kg/cm2
583
11.5x10-6 /deg. C
Quality of zinc used (Specify the grading and

percentage)
Coating of zinc on wires In Gms. per sq.
mtrs.
Nos. of Dip
Oiling/greasing on Earth wire
Boiled Linseed Oil
Tolerance in standard length
Plus/Minus 5%
Zn - 99.95 %
260
3,one minute&1, half
minute
Page 110 of 116
Volume-V (Part-2)
ANNEXURE-2
GUARANTEED TECHNICAL PARTICULARS OF DISC INSULATORS
(A)
GUARANTEED TECHNICAL PARTICULARS

FOR 120KN EMS DISC INSULATORS.
S.N. Description
120 KN DISC
Single
Double
Suspension Suspension
1 Makers name, address and country

2 Size and designation of Ball & Socket and
standard to which it will conform (mm)
3 No. of insulator discs per string
20 mm IS: 2486
(Pt.II)1989
23
2*23
255
255
145
320mm
145
320mm
12237
12237
75
45
75
45
8.2 Impulse voltage 1.2/50

microsecond
a) Positive kV
110
110
b)
115
115
4 Outside dia. of the disc mm

5 Spacing mm
6 Creepage distance of the single disc-mm
7 Electro-mechanical strength of single disc
kg.
8 Withstand voltage of single disc-kVp
8.1
Power frequency
a)
Dry kV (rms)
b)
Wet kV (rms)
Negative - kV
9 Withstand voltage for

the complete string
9.1 Power frequency (with and without
Corona ring)
a)
Dry kV (rms)
720 &
b) Wet kV (rms)
680 &
9.2 Lightning Impulse voltage 1.2/50
microsecond (With and without Corona
ring)
a) Positive kVp
1600 &
b) Negative kVp
1610 &
725
720 & 725
685
680 & 685
1605 1600 & 1605

1615 1610 & 1615
10 Flashover voltage for the disc

10.1 Power frequency (with and without
Corona ring)
a)
b)
Dry kV (rms)
Wet kV (rms)
10.2 .Lightning impulse

microsecond
80
80
50
50
voltage 1.2/50
Page 111 of 116
Volume-V (Part-2)
S.N. Description
11.
12
13
14
15
15
120 KN DISC
Single
Double
Suspension Suspension
a) Positive kVp
115
115
b) Negative kVp
120
120
Flashover voltage for complete string.
11.1 Power frequency (with and
a) Dry kV (rms)
745 & 750
745 & 750
b) Wet kV (rms)
705 & 710
705 & 710
11.2 .Lightning impulse voltage
1.2/50 microsecond
a) Positive kVp
1650 & 1655 1650 & 1655
b) Negative kVp
1660 & 1665 1660 & 1665
Max. voltage (%) across any disc in the
string (with and without Corona ring)
9%
9%
P.F. Puncture Voltage of each disc
insulator
KV(rms)
125
125
Minimum corona extinction voltage of
each disc insulator KV(rms)
18
18
Max. RIV with 10 KV (rms) of each disc
insulators (Micro volts)
50
50
Weight of each disc (Kgs) (approx)
6
6
(B)
GUARANTEED TECHNICAL PARTICULARS

FOR 160KN EMS DISC INSULATORS.
S.N. Description
1 Makers name, address and

country
2 Size and designation of Ball &
Socket and standard to which
it will conform (mm)
3 No. of insulator discs per
string
4 Outside dia. of the disc mm
5 Spacing - mm
6 Creepage distance of the
single disc-mm
7 Electro-mechanical strength of
single disc kg.
8 Withstand voltage of single
disc-kVp
8.1 Power frequency
a)
Dry kV (rms)
160 KN DISC INSULATORS

ON 400 KV
Single
Double
Tension
Tension
20 mm IS: 2486(Pt.II)1989
1*24
2*24
280
280
170
170
330
330
16500
16500
75
75
Page 112 of 116
Volume-V (Part-2)
S.N. Description
b)
Wet kV (rms)

ON 400 KV
Double
Single
Tension
Tension
45
45
8.2 Impulse voltage 1.2/50

microsecond
a) Positive kV
120
120
b)
120
120
Negative - kV
9 Withstand voltage for

the complete string
9.1 Power frequency (with
and without Corona ring)
a)
Dry kV (rms)
720
720
b)
Wet kV (rms)
690
690
9.2 Lightning Impulse voltage

1.2/50 microsecond (With and
a) Positive kVp
1700
1700
b)
1700
1700
Negative kVp
10 Flashover voltage for the disc

a)
Dry kV (rms)
80
80
b)
Wet kV (rms)
50
50
125
130
125
130
740
710
740
710
1750
1750
1750
1750
125
125
18
18

voltage 1.2/50 microsecond
11.
12
13
14
a) Positive kVp
b) Negative kVp
complete string.
a) Dry kV (rms)
b) Wet kV (rms)
voltage 1.2/50 microsecond
a) Positive kVp
b) Negative kVp
Max. voltage (%) across any
disc in the string (with and
P.F. Puncture Voltage of
each
disc
insulator
KV(rms)
Minimum corona extinction
voltage of each disc insulator
Page 113 of 116
Volume-V (Part-2)
S.N. Description

ON 400 KV
Double
Single
Tension
Tension
KV(rms)
15 Max. RIV with 10 KV (rms)
of each disc insulators (Micro
volts)
15 Weight of each disc (Kgs)
16 Electromechanical strength
of complete string (kgs.)
50
50
16500
2 x 16500
Page 114 of 116
Volume-V (Part-2)
ANNEXURE-3
LIST OF SAMPLE DRAWINGS
S.No.
Particulars
Outline drawing of 400kV 23 unit single suspension insulator

string.
Outline drawing of 400kV 2x23 unit double suspension

insulator string.
Outline drawing of 400kV 1x24 unit single tension insulator

string.
Outline drawing of 400kV 2x24 unit double tension insulator

string.
Central Hanger shackle
Details of earthing arrangement for towers
Armour Grip Type Spacer for conductor
Rigid Spacer for Jumper
Midspan joints
10
Repair sleeve
11
Vibration damper
12
T-Connector
Groundwire Accessories:
13
Suspension Clamp Assembly
14
Tension Clamp
15
Midspan joint
16
Vibration damper for earthwire
17
Copper earth bond
18
Number plate for 400kV transmission line
Page 115 of 116
Volume-V (Part-2)
19
Phase plate for 400kV transmission line
20
Danger Board for 400kV transmission line
21
Anticlimbing Device for 400kV Towers.
Page 116 of 116

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Volume V

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MADHYA PRADESH POWER TRANSMISSION CO. LTD.

SHAKTI BHAWAN RAMPUR: JABALPUR

TECHNICAL SPECIFICATION FOR SUPPLY

O/o CHIEF ENGINEER (PROCUREMENT)

Common Technical Requirement . 1

Technical Specifications for Towers ..

Technical Specifications for Conductor .

Technical Specifications for Earth wire .... 45

Technical Specifications for Disc Insulators 52

Technical Specifications for Hardware fittings for

Technical Specifications for Accessories for Conductor

Technical Specifications for erection of transmission

Technical Particulars of ACSR Conductors & Earth 129

The equipments and materials shall be suitable for satisfactory

Location in the state of

Maximum ambient air temperature

Minimum temperature in shade (0C )

Maximum relative humidity (%)

Average daily ambient air

ISOCERANIC Level (days/year)

Wind Zone as per IS 802(Part-I)1995

Max. Altitudes above mean sea level

Seismic level (Horizontal acceleration)

NOTE: Moderately hot and humid tropical climate conducive to rust

ACCEPTANCE OF OTHER AUTHORITATIVE

DISCREPANCY IN TECHNICAL PARTICULARS:

The bidders will have to furnish confirmation in regard to

The bidders shall have to submit the documentation from the

PERFORMANCE GUARANTEE PERIOD:

DRAWINGS AND DOCUMENTS:

failure by the Contractor to rectify the drawings in good time shall

In no case the approval by the EMPLOYER of any document does

QUALITY ASSURANCE PROGRAM:

Statement giving list of important raw materials, names

Information and copies of test certificates as in (i)

List of manufacturing facilities available.

Levels of automation achieved and list of areas where

List of areas in manufacturing process, where stage

Special features provided in the equipment to make it

(vii) List of testing equipment available with the

INSPECTION AND TEST CERTIFICATES:

1.14.01 EMPLOYER expects that participating bidder will take all

STORE FOR SUPPLY OF MATERIAL:

The Contractor shall supply the Material at selected destination set

Commencement of following activities is subject to prior and

Items for which prior approval

Inspection of Proto Assembly of

Submission of Quality Assurance

Acceptance test and issue of test

Items for which prior approval

Quality Assurance Plan for erection.

RESPONSIBILITY FOR OBTAINING

Whenever any information or clarifications

PERMITS AND PRIORITIES:

1.18.01 Necessary permits, if any, required for the execution of

(iii) Forest clearance

USE OF PRIVATE ROADS/APPROACH ROAD TO SITE:

1.20.01 The purchaser will help in getting necessary permission