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Revised RVNL's Standard Technical Specification For Material and Works Vol II (Elect.) Incorporated Upto A&c 1 DTD 22.04.2016
Revised RVNL's Standard Technical Specification For Material and Works Vol II (Elect.) Incorporated Upto A&c 1 DTD 22.04.2016
VOLUME II
ELECTRICAL WORKS
29 January 2015
RVNL/ Elect/GS/25 Machine Room Type Electric Traction Passenger Lift for
A-25 189-216
Buildings
RVNL/ Elect/GS/26 Machine Roomless & Gearless Version Electric
A-26 217-242
Passenger Lift
RVNL/ Elect/GS/27 Miscellaneous Specifications
A-27 243-248
RVNL/ Elect/GS/28
A-28 Approved Makes of Equipments and Materials 249-268
RVNL/ Elect/GS/29
A-29 Important Indian Standards 269-280
PART –A
CHAPTER: A-0
GENERAL
1.0 Introduction
All electrification works shall be carried out in accordance with Indian Electricity Rules. Railway
Regulations, BIS Specifications and Code of Practices, National Electricity Code, Energy
Conservation Building Code (ECBC), National Building Code, Energy Conservation Act 2001with
latest amendments. The specifications issued here are meant for guidelines and does not
supersede any of the rules/regulations/codes/instructions issued by Railway Board/RDSO/CORE
etc from time to time and they shall be followed accordingly. All the equipments and materials
to be supplied shall be as per the specified approved makes and laid down specifications with
latest amendments.
3.0 Standards
NOTE:
a) In case of any conflict between the above standards, the decision of Employer shall be final.
b) Henceforth in these Technical Specifications, wherever the BIS specification no. or any other
specification, Code of Practice etc. are referred to, they shall apply to the latest version
of the relevant standard, unless specifically stated otherwise.
c) Only the latest version of rules/standards/drawings/instructions shall be applicable unless
specifically stated otherwise. In case of any conflict between various instructions, decision of
the Employer shall be final. In case of any conflict/discrepancy between specifications
contained in this book and specifications as per above mentioned authorities, later shall
prevail.
Notwithstanding any approval of drawing or work by RVNL, the contractor shall be finally
responsible for following correct instructions and drawings as per latest amended details. In
case any mistake is found in the work/drawing later on which is not carried out/prepared in
accordance with laid down standards, rules and regulations, the Employer shall be free to
reject it at any stage of the work. The contractor shall be liable to dismantle/modify/redo the
rejected work without any extra cost as per directions of the Employer. The decision of the
Employer shall be final in this regard.
d) In this Technical Specification, the latest standards/drawings/instructions/letter/Code of
Practice etc. means latest of above issued up to the date 28 days prior to the deadline for
submission of bids.
3.1 Ratings of Components: All the equipments/components in the electrical system shall be of
appropriate rating of voltage/current and frequency as required. All the conductors, switches and
accessories shall be of such size as to be capable of carrying maximum current which will
normally flow through them without getting them over burdened/overheated.
4.0 Earthing
Earthing shall be provided as per Indian Electricity (IE) Rules, 1956.
5.2 The detailed instructions on safety procedures given in BIS Specifications, Indian
Electricity Rules, respective Supply Authority’s regulations and Railway Rules, shall be
applicable, all with their latest amendments.
5.3 The Electrical Contractor/ Sub-Contractor shall hold a valid and relevant Electrical
Contractor’s License for LT/HT/EHT Voltage issued by any State Government. All the work
on electrical installations shall be done under the direct supervision of persons holding valid
certificates of competency issued by any State Government.
5.5 Protective and Safety equipments such as rubber gloves, earthing rods, lineman’s safety
belt, high visibility jackets, portable artificial respiration apparatus etc., shall be provided
to all the working staff.
5.6 Caution boards such as “Man working on line”, “ Do not switch on” etc, shall be provided on
the HT/LT Panel Boards, for indication that the switch has been put to off position and
person has been allowed to work on line.
5.7 “Permit to Work” shall be got issued from the person in-charge of the installation, prior to
start of work, on energized electrical installations.
5.8 No work on live bus bar or switch boards shall be handled by a person below the rank of a
Licensed Wireman and such work shall be done in the presence of a competent Engineer.
5.9 When working on or near live installations, suitable insulated tools shall be used, and
special care shall be taken to ensure that tools do not drop on live terminals causing shock
or dead short.
5.10 The electrical switch boards/ distribution boards shall be clearly marked to indicate the
areas being controlled by them.
7.2 The inspection of the above items will be done at the manufacturer’s works or other
appropriate location decided by RVNL and inspection fees chargeable by Inspecting
Authority will be borne by the contractor as per relevant instructions/agreement. In
exigency of work or revision in Railway Board/RVNL policy, inspection authority may be
changed by RVNL. If the inspection is carried out by other than RDSO/RITES, the
inspection charges shall be recovered as per extent policy of RVNL.
7.3 OEM’s certificate and other papers, such as material challans etc. shall be furnished by the
Contractor, to establish the genuineness of the equipment/ material.
7.4 Nominated Inspector shall have free access to visit the manufacturer’s works at all
reasonable times to witness and inspect the testing of equipment/ materials. The
contractor shall provide all reasonable facilities and equipments/lab at his cost for proper
inspection of the material/equipment.
7.5 Item available as catalogued product in market like MCBs, MCCBs, wiring accessories, light
fittings, fan etc. will be acceptable on factory routine test report for the batch, certificate
from authorized dealer and manufacturer and visual inspection at site. However engineer
may decide to get any item under the scope of supply inspected by any agency
(RITES/RVNL/Rly) at manufacturer’s work if so required. And the cost of such test shall be
borne by contractor. If RVNL wants to get any special test done on any item other than at
manufacturer’s work, the cost of the same shall be borne by RVNL.
7.6 The Contractor shall ensure that all the equipments/materials supplied are tested as per
relevant BIS/ BS Specification and comply with instructions on energy star rating issued by
BEE wherever applicable. At per present RB instructions, all energy consuming equipments
should be procured with min 3 star energy rating.
7.7 The Contractor shall ensure that all the equipments/materials supplied is procured from
applicable approved list of sources. In case item is not featuring in approved list or
approved itself is not available, prior approval of RVNL/Railway shall be taken before
placing order. Detail guidelines of RNL/Railways issued from time to time shall be
applicable in this regard.
9.1 Care shall be taken by contractor to avoid damage to the building during execution of his
part of work. He shall be responsible for repairing all damages and restoring the same to
their original finish at his own cost. He shall also remove at his cost all the unwanted and
waste materials arising out of his work from the site. The Contractor shall dress up/repair
the site as per the existing surrounding ground/ floor/walls/ road surface etc. after
completion of the work and make good any damages that occurred during the execution of
works.
9.2 The work shall be carried out with minimum power shut downs. The required shut downs
from railway/other agencies will be arranged by the Engineer, with the active assistance of
Contractor, in consultation with user departments, and the charges if any & not mentioned
otherwise, shall be borne by RVNL.
The contractor shall coordinate with all other agencies so that work is not hampered due to
delay in his work. Recessed conduit and other works which directly affect the progress of
the main work should be done in time and on priority.
While working in the occupied buildings, there should be minmum inconvenience to the
occupants. Work should be programmed in coordination with the engineer and occupying
department. If required, work may have to be planned beyond normal working hours.
The contractor shall be responsible to abide by the regulations/restrictions regarding entry
into and movement within the premises.
9.5 The rates are deemed to be inclusive of all lead (except as otherwise specifically provided
in the description of the particular item), lifts ascend descend, handling, re-handling,
crossing of nullahs/streams/tracks or any other obstructions.
9.6 All enabling works for executing the work e.g. approach road to site, launching
arrangements, procuring right of way: arrangement of water and electricity etc. is to be
arranged by the contractor at his own cost and is deemed to be included in the quoted
rates.
9.7 Storage of Material: All the material at site shall be property stacked & stored so as to
facilitate inspection. The material should be properly protected from detrimental effects of
nature, fire, theft etc. The contractor shall be responsible for watch & ward and any loss or
9.8 All minor items viz. hardware items, foundation bolts clamps, termination lugs for electrical
connections etc. as required and necessary for proper working of the equipment shall be
deemed to have been included in the Bill of Quantities, whether such items are specifically
mentioned or not. All hardware & M.S components should be either Galvanized or
Electroplated.
9.9 If any activity of work is essential for the satisfactory completion of the work but is not
mentioned specifically in the Bill of Quantities or elsewhere in the bidding documents, the
same shall be deemed to be included In the scope of work and shall be executed by the
contractor within the accepted cost. The work shall be handed over in a functional manner
complete in all respects.
10.1 On award of contract, the successful bidder shall visit the site and prepare working
drawings as per site requirements. Drawings shall conform to the relevant standards and
details given in Indian Railway works Manual and prepared in Auto CAD. The drawings
which require prior approval shall be first prepared and submitted in three copies with one
soft copy as check drawings. The comments and corrections received back shall be
incorporated while preparing the final drawing on RTF sheets for signatures and approval.
10.2 The drawings of all equipments including HT/ LT panels, transformer, DG set, distribution
boards, pre-cooling/battery charging points, battery charger, wiring plan, route of laying of
cables, poles , and other items shall be got approved from the Engineer. Manufacturing of
the items can be taken in hand only after the approval of the drawings and samples. The
Contractor shall supply six copies in addition to one copy on RTF and soft copy of each of
these approved drawings before commencement of work.
After completion of the work, as erected completion drawings shall be submitted in
four copies in addition to two copies on RTF and soft copy.
11.1 After completion of work, the Contractor shall ensure that the installations have been
commissioned only after due testing and approval of the Engineer.
12.1 After completion of works, the Contractor shall submit required sets of ‘As Erected’
drawings as per para 10.2 above in respect of all the electrical installation works.
12.2 Completion Certificate, in the following format, shall be jointly signed by the Engineer and
Contractor.
Completion Certificate
I/ We certify that the installation detailed below has been installed by me/ us and tested and
that to the best of my/ our knowledge and belief it complies with Indian Electricity Rules, 1956,
Electrical installation at -----------------------------------------
Voltage and system of supply------------------------------------
Particulars of work:
(b) Motors
No Total load HP/KW Type of starting
i
ii
iii
(e) Earthing
No. Details Qty with unit
a Description of earthing electrode
b No. of earth electrodes
C Size of main lead
(h) Earth Continuity test –Maximum resistance between any point in the earth continuity
conductor including metal conduits and main earthing lead----
Ohms.
No.
i) …….. Ohms
ii) …….. Ohms
iii) ……. Ohms
iv) …. Ohms
v) …. Ohms
Note: For obtaining EIG approval for energizing HT installations, the EIG application format of the
concerned Railway shall be followed.
(a) All the foundations [except as per details given in (b)], for masts of street lighting, solar
lighting, LT/HT over head conductors, Guy wires, stays, steel/GI Tubular poles, Battery
charging poles and pedestals, protective fencing shall be as per the approved drawings of the
RVNL. In these type of foundations, normally M-10 cement concrete (except where specified
otherwise) conforming to IS-456 with 20 mm coarse aggregates shall be used. The cement to
be used shall be ordinary Portland cement of 43 grade (conforming to IS-8112) or 53 grade
(conforming to IS-12269) or PPC conforming to IS 1489(Part 1/Part 2) as approved by RVNL
based on requirement and availability and date of manufacturing shall not be older than three
months.
The contractor shall use concrete mixer, proper shuttering and vibrators for
compaction for foundations of high mast lighting system, large pumping installations etc as
directed by Engineer. For smaller foundations detailed at (a) above, manual concrete mixing
and compaction may be adopted.
------------------------------------------------------------ -----------------------------------------------
TECHNICAL SPECIFICATIONS
INTERNAL
ELECTRIFICATION
WORKS
1.0 Scope
This specification pertains to internal electrification of residential and service buildings on 3
phase, 415 volts or single phase, 230 Volts, 50 Hz Ac supply system, including provision of
conduits with accessories, metal boxes and Boards, wiring, metering, protection, switchgear,
UPS, stablizers, energy savers, provision of fans & luminaries, pre-commissioning/
commissioning tests and handing over. Separate conduits shall be laid for:
i) Emergency and non emergency circuits
ii) Power and lighting circuits
1.2 The definitions of terms shall be in accordance with IS:732-1989 ( Indian Standard Code of
Practice for Electrical Wiring), except for the definitions of point wiring, circuit, sub-main and
main wiring.
The conventional signs & symbols for technical work shall be indicated in the working and as
erected drawings.
1.4 Wiring
1.4.1 (a) Main wiring: Main wiring shall mean the wiring from one main/distribution switchboard to
another.
(b) Sub-main wiring: Sub main wiring shall mean the wiring from the distribution board to
the 1st tapping point inside the switch box, from where point wiring starts.
(c) PVC insulated, multi stranded, Heat resistant fire retardant (HRFR), low smoke, flexible
copper conductor cables of 1.1 kV grade, conforming to IS: 694/1990, ISI marked shall
be used. The size/s shall be as specified in the Bill of Quantities (BOQ).
(d) Minimum size of wiring cable/s for light and power points shall be as below:
(e) Flexible cable – Copper conductor, 3 core flexible cables shall be used for connecting
single phase appliances etc.
Sizes of single core (copper conductor) cable for point, circuit and sub main wiring, circuits,
distribution board/s, etc. for Qrs.
Nos. of points and size of wiring cables Nos. of circuits and size of wiring Size of Sub main
cables wiring cable
Size of point wiring cable Size of circuit wiring cable For For
(copper conductor) (copper conductor) L&F Power
Load load
LP TLP FP CBP EFP PP5A PP 15A GP PP32A For L&F For 5A For 15A. For For geyser
(ACP) Plug Plug 32A.
AC
Phases 1.5 sq.mm 2.5sq 4sq 6sq 6sq 2.5 sq. 4sq. 4sq.m 6sq 6 sq.mm 4 sq mm 10 sq mm
and mm mm mm m mm mm m .
neutral m mm
(i) Definition: A point (other than plug point) shall include all work necessary in complete wiring to
the following outlets from the controlling switch or MCB:
a. Ceiling rose or connector (in the case of points for ceiling/exhaust fan points, prewired
light fittings, and call bells).
b. Ceiling rose (in case of pendants except stiff pendants). Standard specification for
Electrical (General) Works
c. Back plate (in the case of stiff pendants).
d. Lamp holder (in the case of goose neck type wall brackets, batten holders and fittings
which are not prewired).
e. Main and sub-main wiring as described above.
f. Distribution boards of reputed make as required, modular switchboard, RCCBs in Main
distribution board of adequate capacity of ABB/Siemens/Legrand/L&T make.
(ii) Scope:
Point Wiring shall include:
a. Conduit/channel as the case may be, accessories for the same and wiring cables between
the switch box and the point outlet, loop protective earthing of each fan/light fixture.
b. All fixing accessories such as clips, screws, Phil plug, rawl plug etc. as required.
c. Metal or PVC switch boxes for control switches, regulators, sockets etc., recessed or
surface type, and phenolic laminated sheet covers over the same.
d. Outlet boxes, junction boxes, pull-through boxes etc. but excluding metal boxes if any,
provided with switchboards for loose wires/conduit terminations.
e. Control switch or MCB, as specified.
f. 3 pin or 6 pin socket, ceiling rose or connector as required.
g. Connections to ceiling rose, connector, socket outlet, lamp holder, switch etc.
h. Bushed conduit or porcelain tubing where wiring cables pass through wall etc.
i. Main and sub main wiring of appropriate size.
j. Pre wired MDB and DBs of ABB/Legrand/L&T make as required including MCBs. RCCBs for
MDBs will not be paid separately.
k. Earth wire run as per requirements.
All floor openings for carrying any wiring shall be suitably sealed after installation.
1.4.8 Measurements
Measurement of point wiring for light points, fan points, exhaust fan points, group points, light
plug points, power plug points & call bell points shall be done on unit basis by counting only.
Measurement of twin control point wiring shall be done on unit basis by counting.
(b) Circuit Wiring/ Sub main wiring cable/s along with earth wire cable/s shall be of the
capacity specified in Bid document/RVNL standard. Wiring of each circuit wiring/ sub/
main wiring cable/ s along with earth wire cable/s shall be drawn into an independent
conduit. Drawn boxes of suitable size shall be provided at convenient locations to
facilitate easy drawing of the circuit wiring/ sub main wiring cable/s. Cost of junction
Board/ draw Boxes are deemed to be included in the rates of circuit wiring/ sub main
wiring cables along with earth wire cable/s. Single phase circuits shall have single
earth wire whereas three-phase circuits shall be provided with two earth wires.
(c) Where sub- main, circuit wiring and point wiring cables are connected to the switch/
switchgear etc, sufficient extra length of cable/s ( not less than 150 mm ) shall be
provided to facilitate easy connection and maintenance.
1.6.1.2 Normally, concealed wiring shall be provided in all the buildings. Surface conduit wiring shall
be provided if specifically given in BOQ or where it is not practicable to provide concealed
wiring with approval of the RVNL.
1.6.1.3 Limitations
The maximum number of PVC insulated 650/1100 V grade copper conductor cables that can
be drawn in conduit pipes shall be limited to 45 % of the capacity of the conduit. Table
indicating the capacity is as under:-
1.6.1.7 Outlets :
In order to minimize condensation or sweating inside the conduit, all outlets of conduit
system shall be properly drained and ventilated, but in such a manner as to prevent the
entry of insects.
1.6.1.8 Heat may be used to soften the conduit for bending and forming joints in case of plain
conduits. As the material softens when heated, sitting of conduit in close proximity to hot
surfaces should be avoided.
Table 1
Maximum No. of single core cables in Rigid metallic/non metallic conduit
Table 2
Maximum Number of Single-Core Cables that can be Drawn into Casing and
Capping
Size of wires Size of Casing
Mm2 no. &dia 10/15mm 20mm x 25mm x 30mm x 40mm x 50mm x
x 10 mm 10 mm 10mm 10mm 20mm 20mm
1.5 1/1.4 3 5 6 8 12 18
2.5 3/1.06 2 4 5 6 9 15
4 7/0.85 2 3 4 5 8 12
6 7/1.06 2 3 4 6 9
10 7/1.40 1 2 3 5 8
16 7/1.70 1 2 4 6
25 7/2.24 1 3 5
35 7/2.50 2 4
50 19/1.80 1 3
70 1 2
1.8 Accessories
1.9 For termination of cables, crimping type cable socket/lugs shall be provided and soldered if
necessary/ instructed.
1.15 Testing
After completion of work, the entire installation shall be subjected to the following tests:
• Insulation Resistance Test.
• Earth Continuity Test.
• Earth Resistance Test.
Besides the above, any other tests specified in BIS Standards or as required by the local
Authority/ Engineer shall also be carried out.
Qty Details
For 5A Plug
For geyser
Total Ckt.
For 15A.
For 32A
of 5A 15A
PP32A
(ACP)
Plug
AC
Quat
er
&
I 6 2 2 0 0 2 2 0 0 2 1 2 0 0 5 1 Incoming MCB DP- (a) Single unit
20 Amp with RCCB Quarter --- 1 No
100 mA and O/G --
(b) two units
- 6-16amps. MCB
Quarter
SP -5 Nos. - 1 No,
Abbreviations
LP Light point with 18 watt CFL with inbuilt PP5A Light plug point complete with socket
choke. and switch
TLP Tube light point with 1x28 watt T-5 PP15A Power plug point complete with socket
Luminary complete with electronic choke and switch
and T-5 lamp.
FP Ceiling Fan point with 1200/1400 mm fan PP32A Air Conditioner point with Industrial
with 300 watts electronic regulator (ACP) type iron clad plug 32 amps & 20A DP
MCB in metal clad box
CBP Call bell point with ding dong type call bell GP Geyser point with 25 liters storage
geyser.
------------------------------------------------------------------------------------------------------------------
FOR
INDOOR/OUTDOOR
ELECTRIFICATION WORKS
CHAPTER: A-2
2.0 Scope
This specification covers supply and fixing of various electrical luminaries and other
equipments for installing inside/outside the service buildings, staff quarters, platforms,
passenger shelters, sheds, foot-over bridges (FOB) etc. The luminaries to be provided include
compact fluorescent lamps (CFL), LED Lighting System, T-5 type energy efficient luminaries,
metal halide luminaries etc. Electrical equipment includes fans, geysers, water coolers, Meter
boards etc.
b) Ceiling fans shall be continuous duty type with double ball bearings, copper wound motor,
complete with canopies, down rod, 3 blades, capacitor etc ( as per BOQ item) conforming
to IS 374/1979, suitable for operation on 230 Volt +/- 10 %, 50 Hz, A. C. supply and star
rated. Fans shall be generally off-white.
2.2 Normally 1400 mm ceiling fans shall be provided in service buildings/ passenger
shelters/waiting halls or rooms and 1200 mm sweep ceiling fans in residential buildings.
2.3 Stepped type electronic regulator ( as per BOQ item) shall be provided for control of speed of
fan at locations other than passenger shelters/ sheds as per Engineer’s decision.
2.4.2 A suitable hole shall be provided in the wall to suit the size of the frame, which shall be fixed
by means of rag bolts embedded in the wall. The size of the rack bolt and spacing shall match
with the holes on the frame of exhaust fans. The hole shall be neatly finished to the original
shape of the wall.
2.6.2 The connections and earthing of the fitting shall be done with 1.5 sq. mm single core, PVC
insulated, multi stranded, flexible copper conductor cable/s of 1.1 kV grade with FR properties
as per IS: 694/1990.
2.6.3 The fitting shall be fixed to the wall by suitable approved arrangement. The fitting, if required
to be suspended from the roof, shall be suspended with 2 numbers of 19.0 mm diameter 16
SWG MS conduit pipes ( conforming to relevant latest IS) with ball and socket arrangements,
double check nuts to hold the luminary in position, non-metallic bushing at cable entry to
prevent damage to the flexible cable. The other end of the conduit tubes shall be fitted with
the luminary.
2.6.4 Where false ceiling is being provided, the luminaries shall be recess type with mirror optic
reflector and LED / CFL / T5 lamps with complete fittings of 1 feet/ 2feet/ 4 feet length as
approved by engineer.
2.7 Street Light Type T-5 Energy Efficient Luminary with T-5 Fl. Tube Light/s
2.7.1 Weather proof, street light luminary shall be of aluminium housing with epoxy white powder
coated CRCA sheet steel tray, clear acrylic cover, pre-wired, outdoor type with degree of
protection not less than IP-54. It shall be provided with T-5 tubes and electronic ballast (as
per BOQ item) suitable to operate on 230 volt 50 c/s, AC supply system. The luminary shall
also be provided with holder/s, etc. as required and shall conform to the latest version of the
relevant BIS specification.
2.7.2 The connections of the fitting shall be done with 1.5 sq. mm single core PVC insulated, multi
stranded, flexible copper conductor cable/s of 1.1 kV grade, with FR properties as per IS:
694/1990.
2.7.3 The earthing to the fitting shall be done with 1.5 sq mm single core PVC copper conductor
cable of 1.1 kV grade, flame retardant as per IS: 694/1990.
2.7.4 The luminary shall be mounted on the pipe bracket of pole/wall and connection to luminary
shall be done from junction box of pole/over head line/ ceiling rose of point wiring etc., as the
case may be.
2.7.5 In case, the luminary is to be provided on a wall, 450/600 mm long shaped G.I. pipe bracket
of class ”B” ISI marked of diameter matching with the inlet hole of the luminary shall be
provided.
2.14 Geyser
a) Geyser (storage type water heater) shall be suitable to operate on 230 V AC, single
phase, 50 Hz supply. Geysor shall have copper/SS inner shell and fibre body outer shell.
Geyser orientation shall be of vertical / Horizontal type as per site requirement and shall
be of specified capacity (as per BOQ item) conforming to IS:2082, ISI marked of
approved make and star rated. It should be provided with inlet and outlet PVC (with steel
mesh) water connections. The geysers shall be provided with a suitable thermostat
control on which the range of temperature is indicated. The thermostat control shall have
an adjusting knob for setting the temperature of water to the desired level. The water
temperature indicator shall be available on geyser body. At the set temperature, the
thermostat shall cut off the power supply automatically. The geyser shall be provided
with an LED/ LCD lamp to indicate that the power supply is ON/ OFF. The body of the
geyser shall be provided with an earth connection to protect leakage of current.
c) The geyser shall be provided with suitable length of 3 core flexible cord and power plug of
16 A. The power supply shall be through MCB provided in the SDB to protect the geyser
from overloads and short circuits.
2.15 Water Cooler
a) Water cooler conforming to IS-1475 (Part-I)/2001 shall be complete with hermetically
sealed type, suction cooled compressor (conforming to IS 10617/Part-I/2013), with
overload protection and and star rated and all connected standard fittings, accessories,
etc. It shall be suitable to operate on 230 volt AC, single phase, 50 Hz supply.
b) Cooling capacity of water shall be 150 liter per hour or as specified in the relevant BOQ
item. The tank shall be manufactured from stainless steel of minimum 0.8 mm thickness.
The cabinet of the water cooler shall be made of stainless steel sheet not less than 1.0
mm thick. The front panel below the water outlet & drain pan shall be made of stainless
steel of 0.8 mm thickness. The bottom pedestal shall be made of thickness not less than
2.65 mm. Power factor of water cooler shall not be less than 0.85 at the rated capacity of
the cooler. The thermostat shall conform to IS 113338/1985 and the setting shall be
adjustable through rotary switch from 10 to 25 degree C which shall be marked suitably.
The thermostat control shall have an adjusting knob for setting the temperature of water
to the desired level. At the set temperature, the thermostat shall cut off power supply
automatically. The body of the water cooler shall be distinctly provided with an earth
connection to protect from leakage of current.
c) The water cooler shall be provided with a suitable length of 3 core flexible cord and a
power plug of 16 A and earthing. The power supply shall be through MCB provided in the
SDB to protect the water cooler from overloads and short circuits.
d) The water cooler shall be placed on brick masonry platform. The water connection to be
given shall be provided to the inlet port from the nearest water pipe line in order to
maintain water supply to the water cooler continuously.
e) Water cooler shall be provided with 5 KVA electronic auto voltage stabliser, suitable for
operation on single phase 160 to 260 volts input supply,with provision for time delay
start, voltmeter, instant start etc.
2.16 Meter Board
a) The meter Board shall be suitable to operate on 230/415 volts Ac, single / three phase,
50 Hz supply system (as per BOQ item) and complete with all equipments including
meter/s, MCB’s etc. (as per BOQ item).
b) The meter Board shall be out door type, weather proof, fabricated with 1.6 mm CRCA
sheet & compartmentalized for accommodating each unit. It shall be flush mounting type
with degree of protection not less than IP-54. Each compartment shall have its own door
with insulated thumb screw. MCB compartment shall be suitable to accommodate each
MCB directly mounted on DIN channel in its own chamber. Meter compartment shall be
suitable to accommodate each energy meter in its own chamber and have provision of
concealed lock for sealing the individual compartment. Suitable provision shall be made
on the front of the door to record the meter reading by providing a glass window 6 mm
thick. The provision to be made for padlock/ seal. Meter and meter box should be
provided with anti temper single use seal with sr no. Provision of suitable glass/fiber
window shall be made for meter reading with out opening the meter board.
d) Connections from bus bars to meters and from meter to MCB shall be housed in flexible
MS/ PVC conduit through cable alley.
e) The meter Board shall be provided with detachable gland plates on top & bottom with
knock outs and earthing terminal etc. as required. Bottom plate shall be provided with
cable gland for incoming cable. Suitable knock outs shall also be provided on upper
portion and on back side of MCB compartment to connect outgoing wiring/conduit.
f) The bus bar chamber, incoming and each outgoing MCB chamber shall have double
doors. It shall be possible to operate the MCBs only after opening of the outer door.
g) Neutral supply to be provided with link in the all distribution boards. No MCB or fuse
should be provided in the neutral circuit.
Meter board shall be manufactured to meet the requirement/s as per site conditions i.e. for
one/two/three/four unit blocks etc.
NOTE:
Prior to bulk manufacturing, one sample of each type of meter Board shall be got approved
from the Engineer.
(b) The air cooling system in Waiting Room and Lounge at stations shall conform to RDSO
Specification No. RDSO/2009/EM/SPEC/0001, (Rev.‘0’)Amdt-1.
(c) The air cooling system in other places like service buildings, running room and rest house
shall also generally conform to above RDSO Specification. Prior approval of RVNL should
be taken for any changes in the RDSO specification suiting to local requirement and
specific to the building.
The ENERGY SAVERS consists of Street light /High Mast controller complete with infrared
sensors, contactors and MCB, terminal board etc. for 25 KW load. Energy Pack, should be a
lighting control device for outdoor luminaries. It should optimize the switching ON/OFF cycle,
automatically, using Nature Switch having space grade infra red sensor, as per seasonal
variation of daylight. It should be suitable for automatic, group control of outdoor luminaries,
eliminating the need for any manual operation. Auto switch ‘ON’ of light at dusk Auto switch
‘OFF’ at dawn or after selected duration. No clock setting or clock tuning should be required.
It should have operating voltage range from 185 to 275 V. the enclosure shall be IP 54
protected.
2.23.1 Constructional Features
MS plates should be fixed to the housing for pole mounting. Front door shall be provided with
unique lock and key arrangement for safety.
Sr No Parameter Details
a) For Switching ON <60 lux for >30 sec (per Std. Test Procedure)
b) For Switching OFF >10 lux for >30 sec (per Std Test procedure)**
11 Selectable res. for switching off from dusk 4 Hrs to 8 Hrs with a resolution of half an hour
------------------------------------------------------------------------------------------------------------------
OVERHEAD WORKS
&
STEEL/GI TUBULAR POLES
CHAPTER: A-3
3.0 SCOPE
The scope covers overhead power lines, including stays and poles, MS cross arms (brackets),
ACSR conductors, insulators, earth wire (GI wire), guarding etc. All materials, fittings, etc,
used In the installation shall conform to relevant BIS specifications, wherever they exist. In
those cases, where there are no BIS specifications available, the items shall conform to
specifications approved by the Engineer.
* Note:-These are general guidelines. However spacing of poles should be chosen judiciously
so as to ensure specified lux levels is achieved and lighting is uniform as per RB letter
no-2004/Elect(G)/109/1 dt 18/5/2007 for station area and as per the requirement of
the Division.
3.2.1 Where distribution line and street lighting fixtures are erected on the same support, the
span shall not normally exceed 40 m.
3.2.2 Spans shall be chosen such that in a residential area adequate street lighting is
provided as per IS and as approved by Railway/Employer.
3.3.1.1 The excavation work shall be taken up after the locations of poles/stays are decided.
3.3.1.2 Every care shall be taken to see that the pits are not oversized while digging.
3.3.1.3 Suitable caution signals/boards, red lights and other protective measures, as decided
by the Engineer, shall be provided near the pit to warn the pedestrians/vehicular
traffic till such time the pit is back filled and surface leveled.
3.3.1.4 The size of the pit shall be made as per approved drawing of the foundation OR as
specified in the standard tables given below. Wherever specific depth of foundation is
not specified, the depth of the pit shall be such that normally 1/6th of the length of
pole is buried in the ground as specified in IS: 2713.
3.3.1.5 The foundation pit shall be generally excavated in the direction of the lines.
3.3.1.6 All supports shall be correctly aligned before concreting or the back filling of the pit
with excavated earth.
3.3.1.7 The pit for support/stay/strut shall be filled up or concreted only in the presence of the
Engineer.
3.4.2 The position of pit shall normally be such that the stay makes an angle within the
range of 45 degree to 60 degree with the ground. If the site conditions are such that
the angle as stated may not be possible, special stays such as foot stays, flying stays
or struts may be used.
3.4.3 The depth and size of the pit shall be suitable for the foundation of stay.
3.4.5 The stay rod shall be set in position in the excavation pit.
3.4.6 Stay rod shall be embedded in cement concrete of M-10 grade vertically with square
foundation 300 mm x 300 mm above the anchor plate lying over 15 cm thick cement
concrete base. The stay rod shall be bent only at the unthreaded portion such that the
stay wire and the bent portion of stay rod are in correct alignment. Care must be
taken to avoid sharp bend or danger to galvanization.
3.4.7 After concrete has set, back filling shall be done with excavated earth and ramming in
layers of 20 cm using water as required.
3.4.8 The surface of foundation above ground shall be finished and cured.
3.4.9 The stay clamp shall be located near about the centre of gravity of the load of the
overhead conductors.
3.4.10 One end of stay wire shall be fixed to the bow tightener of the stay grip of the stay
rod and the other end to the stay clamp fixed to the pole. By means of well spliced
joint units, GI thimbles. A strain insulator shall be provided at a height of 3 meters
above ground level. For high voltage lines, however, the stays may be directly
anchored.
3.4.11 The stay wire shall also be connected and bonded properly to the continuous earth
wire.
3.4.13 Double stays shall be provided at all dead ends and at any other place as required by
the Engineer. In such cases, these shall, as far as possible, be set parallel to each
other at a distance of approx. 600 mm or as approved by the Engineer.
3.5.1 Cross arm shall be made of MS angle iron of size not less than 50 mm x 50 mm x 6
mm thick ( for LT overhead)/ MS channel iron of size not less than 75mm x 40 mm x
6.4 kgs per meter/100x50x6.4 mm for V-type cross arm ( for modification of power
line track crossings/HT lines) as specified in the BOQ item. The length of the cross arm
shall be suitable for accommodating the required number of insulators with the
spacing of the conductors being in accordance with the clearances required. A
minimum distance of 8 cm for LV/ MV lines and 10 cm for HT lines shall be left from
the centre of the extreme insulator pin hole to the end of the cross arm. The cross
arm shall be complete with clamp made of MS flat of size not less than 50mm x 6mm
with necessary bolts of 16 mm and nuts & washers. The cross arm shall have holes as
required to accommodate insulator pin etc.
3.5.2 The length of cross arm for carrying guard wire shall be such that the guard wire shall
always run not less than 30 cm beyond the outer most conductor of the configuration.
3.5.3 The cross arm and the pole clamp shall be treated with one coat of red oxide primer
before erection and finished with two coats of approved paint after erection along with
other hardware. Iron nuts and bolts shall be used for fixing of clamps.
3.5.4 The cross arms shall be clamped to the support properly, taking into consideration the
orientation of the lines.
3.6 Insulators
3.6.1 The porcelain insulator shall conform to IS 1445-1977 suitable for overhead power
lines below 1000 volts and IS 731-1971 for overhead power lines with a nominal
voltage greater than 1000 volts. The insulator shall be complete with galvanized iron
hardware etc. as required.
3.6.2 The insulators shall be of the following types as specified in the relevant BOQ item:
3.6.3 The minimum size of shackle insulator shall be 90 mm dia x 75 mm high and shall be
complete with GI clamps, nuts & bolts etc.
3.6.4 The minimum size of pin insulator shall be 65 mm dia x 100 mm high and complete
with GI pin, nuts and bolts etc.
3.6.5 Pin insulator/ shackle insulators/disc insulators shall be erected on the cross arms, as
specified in the BOQ or as directed by the Engineer.
3.6.6 Shackle insulators shall be erected on cross arms at intermediate support in case of
long lines, deviation from straight line, terminal positions, junction poles etc.
3.7.2.2 Jumpers used shall be of the same material as the line conductor and be of adequate
current carrying capacity.
3.7.3.1 The binding of conductor to insulator shall be sufficiently firm and tight to ensure
that no intermittent contacts develop.
3.7.3.2 The ends of binding wire shall be tightly twisted in a closely spaced spiral around the
conductor to ensure good electrical contact and to strengthen conductors.
3.7.5 Guarding
3.7.5.1 General
At all road crossings, crossing of overhead lines, crossing with other lines ( telephone
lines etc) and between HV and LV/ MV lines carried on the same support, guard shall
be provided.
3.7.6.1 The size of the continuous earth wire shall not be less than 8 SWG GI.
3.7.6.2 All metal supports and all reinforced and pre-stressed cement concrete supports of
overhead and metallic fittings attached there to shall be permanently and efficiently
earthed.
3.7.6.3 The continuous earth wire shall be connected to an earth. There shall be not less
than 3 connections with earth (earth electrode) per kilometer spaced equi-distantly,
as far as possible.
3.7.6.4 Where continuous earth wire cannot be provided, every pole shall be earthed and all
metal parts shall be bonded.
3.7.6.5 Junctions at terminal locations and all special structures shall be connected to earth.
3.7.6.6 The lead from earth electrode shall be suitably bonded to the continuous earth wire.
All supports carrying HV lives shall be fitted with danger notice plates conforming to
IS: 2551-1982 at suitable height from ground indicating the voltage of lines.
For preventing unauthorized persons from ascending any of the supports carrying HV
lines without the aid of a ladder, arrangement for special appliances shall be made as
directed by the Engineer. Barbed wire conforming to IS 278-1978 having 4 point
barbs spaced 75+/-12 mm apart shall be wrapped helically with a pitch of 75 mm
around the limb of the support and tied firmly, commencing from a height of 3.5m
up to a height of 5 meters or as directed by the Engineer.
3.9.1 Steel/GI tubular poles shall be swaged type with single/double bracket/s for
platform/road/level crossing lighting etc. The constructional details shall be as per IS
2713/Pt 1 to 3. The length and designations shall be as per the relevant BOQ item.
The diameter of bracket for mounting of luminary shall match with the inlet diameter
of the luminary. In case of GI pole, the pole with base plate along with the bracket
shall be hot dip Galvanized 80 to 90 microns thickness after the frabrication, as per
I.S 2629. The pole shall be with single/double arm bracket of length 1.0mtr and with
base plate complete. Dimensions of the pole shall be as per IS, reproduced in table
given at 3.9.4. Foundation bolts and base plate sizes shall be:
3.9.2 General
(a) The uncovered platform/road etc. shall be provided with swaged type stee/GI
tubular pole/s and the luminary shall be weather proof, outdoor type as specified in
the relevant BOQ item. Luminary shall be complete with control gear, lamps,
accessories, fixing arrangements etc. The make and type of luminary & lamp shall be
as specified in the BOQ item.
(b) Single core FR, PVC insulated copper conductor cable ( 2 x 1.5 sq mm size for
connections to each luminary and 1 x 1.5 sq.mm for earthing), multi stranded,
conforming to IS 694 (latest), ISI marked shall be supplied and provided for
connections from junction box/overhead/light point as the case may be. Each
luminary and junction box shall be suitably earthed.
(c) Separate wiring shall be provided for each luminary from junction box.
3.9.3 Steel Tubular pole with Canopy Type Single/Double Bracket/s (7 m for
platform lighting and 9m for Level Crossing/ circulating area
Lighting/Road lighting etc)
3.9.3.1 (a) Steel tubular pole shall be swaged type made from steel of ultimate tensile
strength 410 MPa (42 kg/mm. sq) as per IS: 2713(Pt. I,II and III) 1980 amended
up to date. The pole shall be as per IS designation 410 SP-3 for 7 meter and 410
SP-30 for 9 meter length. The portion to be inserted in the ground shall be about
1/6th of total length as per IS: 2713. Pole shall be supplied with canopy type
brackets, base plate etc. A hole of 25 mm dia and a rubber bush at required height
from the bottom of the pole shall be provided in the lower limb (above the muffing)
for drawing/taking the PVC wire from junction box to inside the pole for the
(b) MS square base plate of size 300 x 300 mm and 10 mm thick shall be welded at
the bottom of the pole. The base plate shall have a hole of dia. Approx. 50 mm in
the centre, for draining out of water.
(c) Hot dip galvanised double arm Conicle poles with foundation bolts, base plate and
bracket can also be used in above place. The pole with base plate along with the
bracket shall be hot dip Galvanized 80 to 90 microns thickness after the fabrication,
as per I.S 2629.
3.9.3.2 Bracket
Note: The drawing of canopy with pipe bracket/s, fixing arrangement and
sample shall be separately got approved from the Engineer.
(b) The junction box shall be earthed as instructed by the Engineer. Junction box
shall be mounted with pole with 2 nos. galvanized Ms flat 40 x 5 mm clamps
and Nut and bolts not less than 10 mm dia.
(c) Detachable gland plate shall be provided on the bottom of the junction box for
entry of incoming and outgoing cables.
(d) The junction box shall be fixed with the pole at a suitable height above ground
level as per instruction of the Engineer.
(e) Holes shall be suitably protected with rubber bushes to prevent entry of rain
water inside the pole.
3.9.3.4 Earthing
Earth electrode shall be provided at approved location as per IE rules. Pole/s shall
be earthed to an earth electrode with 4 mm dia. G. I. Wire/armouring of laid cable
as required.
3.9.3.5 Painting
Steel Poles shall be given 2 coats of red oxide primer and after erection painted as
under:
3.9.3.5.1 The bottom portion of poles up to a height of 1.5 m above the finished muffs shall
be painted with superior quality of black ISI marked paint.
3.9.3.5.2 The remaining portion of poles as well as the clamps shall be painted with 2 coats
of superior quality of Aluminium Paint (ISI marked).
3.9.4 Table below indicates dimensions of swaged type steel tubular pole as per
IS2713/Pt 1 to 3:
The octagonal pole shall have door of aproximate 500mm length at the elevation of 500mm
from the base plate. The door shall be weather proof to ensure safety to inside connections.
The door shall be flush with locking facility. There shall also be suitable arrangements for
earthing. The pole shall be additionally reinforced with a welded steel section so that the
section at door is unaffected and undue bucking of the cut section is prevented.
The base compartment of the built in connector control box shall have provision to have 6
mm thick Bakelite sheet of suitable size to accommodate the required electrical accessories
Height Top Dia Bottom Sheet Base Plate FOUNDATION BOLT Anchor Foundati
(Meter) (mm) Dia (A/F) Thicknes Dimensions Plate on
Bolt Pitch Bolt Project
s (A/F) (LxBxT) Thicknes
(mm) Size Circle Lengt ed
(mm) s
(no.xdi Dia. h Length
a) (mm) (mm) (mm) (mm)
(mm)
(depth)
(depth)
3.10.8 BRACKETS:
Bracket for accommodating of luminaries shall be canopy type with Galvanized single /
double arm 200mm long to suit the inlet dia of luminary as per requirement of BOQ, welded
at an angle of 15 degree (horizontal plane). Bracket shall be removable type and adjustable
in horizontal plane. Fixing arrangement with pole shall be with 4 nos. bolts & nuts of dia not
less than 10 mm. Fixing arrangements shall be suitable to bear the wind pressure. The dia. of
the bracket pipe shall match with the inlet hole of proposed luminary to be provided on the
pole.
-----------------------------------------------------------------------------------------------------------
CABLE LAYING
CHAPTER:A-4
CABLE LAYING
4.0 General
(a) LT XLPE cables shall be of 1/2/3/3.5/4 core/s (as specified in the relevant BOQ Item).
With aluminium conductor, armoured/unarmoured (as specified in the relevant BOQ
item). PVC outer sheathed, conforming to IS: 7098 Pt.1(ISI Marked).
(b) HT XLPE (earthed) cable shall be of 3 core, aluminum conductor, screened, armoured
shielded and PVC sheathed, conforming to IS: 7098/Pt 2 (latest version)(ISI Marked).
(c) IS 1255-1983 shall be followed in general for laying of cables.
4.1 The minimum safe bending radius for all types of cables shall be at least 15 times the
diameter of the cable up to 11 kV grade and 20 times the diameter for cables above 11 KV
grade.
4.2 Route
The route of the cable shall be decided before the work of cable laying is undertaken. The
drawing indicating the route of the cable shall be prepared by the contractor and got
approved from the Engineer. Cable runs/routes shall generally follow the fixed development
such as roads, pathways, track etc.
4.3 Cables of different voltage grading shall be generally laid in different trenches. In case it is
not possible to lay them in separate trenches, due to site constraint, the same trench may
be used, but adequate separation within the trench shall be ensured. Specific approval shall
be obtained from the Engineer.
4.4 There shall be adequate distance between HT & LT cables. In case it is unavoidable to
separate HT < cables, the high tension Ht cable shall be laid below LT cable.
4.5 Wherever the power and telecom cables are to cross each other the same shall be laid at
right angles to avoid interference. Wherever it is unavoidable to lay them in proximity,
horizontal and vertical clearance between the two shall not normally be less than 600 mm
b) GI/CI/RCC/HDPE pipe etc as specified in the BOQ item shall be used for the purpose.
Pipes shall be continuous with couplers etc. and clear of any debris. Before drawing of
cables, sharp edges at ends shall be smoothened to prevent injury to cable insulation
and/or sheathing.
c) In case existing property gets exposed during trenching, the same shall be temporarily
supported or propped adequately as directed by the Engineer. The trenching in such case shall
be limited to short lengths. Protective pipes shall be laid for passing the existing cables
therein, and the trench shall be refilled, in case there is a danger of collapse, or the trench is
endangering existing structure the same shall be sufficiently supported before proceeding with
the excavation work. The bottom of the trench shall be level, free from brick bats and gravel
etc.
Before and after the cable is laid, the individual cores shall be tested for continuity and
insulation resistance and ends of cables shall be sealed suitably to avoid ingress of moisture.
Surplus length of approx. 3.0 meters shall be left in the shape of a loop at each
termination/joint etc. unless otherwise approved by Engineer.
a) The cable shall be protected to provide warning to future excavators and also for avoiding any
accidental mechanical damage by pickaxe blows etc.
b) The cable shall be protected with well-burnt bricks. The bricks on face shall be so provided
that the width of the brick is in the direction of lay of cable. The bricks shall be provided
throughout the length of the cable to the satisfaction of Engineer. Wherever more than one
cable is laid I n the same trench, the protection cover for cable shall protect at least 50 mm
on the side of end cables.
c) Protective covering, sand cushioning of LT/ HT Cable & making good surface at various
locations shall be as indicated here under:
4.6.11.3 The word cables, the level of voltage, size of cable, depth shall be inscribed on the route
marker and joints.
4.6.12 Normally no joints are permitted. Under the circumstances, if joints can not be avoided,
specific approval shall be obtained from the Engineer.
The joints of two trays shall be butt construction and shall be made with the help of
coupler plates by nuts and bolts. The coupler plate and nuts and bolts shall also be properly
hot dip galvanized, where the bends of the trays are required at site the same shall be supplied
by the bidder without any extra cost.
While adopting the modules at site if cutting of any length is required the same shall
be cut at site and joined by nuts and bolts with the help of coupler plates.
The perforated cable trays shall be supported on the solid supporting arrangement
made from channel of minimum size 100x50mm and angle iron of size 50x50x6mm thick angle
approximately at a distance of 0.1 to 1.2m center to center either from ground/wall or ceiling.
However, the supporting system shall be designed by bidder suitable to bear the uniform load
of 400N per 1000mm ladder length for 300mm wide tray. The calculations in respect of this
design shall be supplied by the successful bidder during design stage. M.S. angle iron brackets
shall be further supported/anchored either to wall or ceiling/ground as per the site
requirement. The brackets and supporting system shall be painted with two coats of zinc
chromate primer followed by two coats of synthetic enamel paint of approved colour
conforming to relevant Indian standard.
Bends, tees and cross connections shall also be designed properly as per site
requirement.
The perforated trays shall be free from sharp edges and burns etc. so that joint
between two trays shall be without any clearance and matched in proper shape.
At the bends the curvature in all axis of perforated trays/racks shall be 20R or
maximum size of cable. The supporting brackets/fixing bolts size shall be so calculated that the
design load as specified in Design Requirements does not exceed. The perforated trays shall be
installed in such a way that as far as possible the cables can be laid directly in place rather
than be pulled through.
The current carrying cables as HT cables, LT cables; and DC cables shall be laid in
different tray. The cables shall be fixed in the perforated trays by means of plastic ties or
plastic coated wires etc.
The number of perforated tray shall be sufficient in order to accommodate all the
power cables indicated in the specification for cables. However, the approximate quantity of
different trays have been given under clause 2.21, which can be ensured by the bidder by
visiting the site before filling the tender.
4.7.2 EARTHING:
The perforated cable trays along with their supporting arrangements shall be properly earthed
by the contractor with nut and bolts from the earthing risers generally in the vicinity of the tray
routing. The earthing shall be as per latest I.E. rules and IS/IEC recommendation. The size of
-----------------------------------------------------------------------------------------------------------
SYSTEM
5.0 Scope
The scope covers supply and erection of the high mast lighting system of specified height
including foundation and other civil works. High Mast System includes all components and
accessories, foundation bolts with nuts, washers, anchor plates, templates, Metal Halide
luminaries (degree of protection IP65), etc. and provision of luminaries on the head frame of
high mast with manual/electrical operation arrangements to lower/raise for maintenance
purposes.
5.2 Structure
The High mast shall be of continuously tapered, polygonal cross section, presenting an
standards to give assured performance and reliable service. The structure shall be suitable for
wind loading as per IS 875 Part III of 1987.
5.4 The mast shall have fully penetrated flange, which shall be free from any lamination or
incursion. The base plate shall be of single flange and constructed with holes jig- drilled for
anchor bolts passage for fixing the high mast on to the concrete foundation. The base flange
will be provided with supplementary gussets between the bolt holes to ensure elimination of
helical stress concentration of the environmental protection of the mast. The entire fabricated
mast shall be hot dip galvanized, internally and externally, having a uniform thickness of 70
microns for the bottom section and 65 microns for the top section.
5.6 All mast components shall be hot dip galvanized, as per British Standard 729/1971 (1986).
Earthing and earthing terminal shall be provided within the access door area of each high mast.
Galvanizing shall be inspected for
(a) Adhesion (b) Mass of zinc coating and (c) Uniformity.
5.8 Foundations
The mast shall be erected on suitably designed foundation as per high mast manufacturer’s
design with following typical details:
The rate quoted for the high mast shall include the cost of testing of soil bearing capacityand
laying of foundation. The contractor shall get the foundation designed accordingly from
OEM/other reputeted firm as decided by the RVNL.
5.9.2 The mobile luminary carriage shall be designed to carry the 9/12 number of luminaries and
control gears as specified in the relevant BOQ item and shall be evenly balanced. Nylon paddle
Guide Ring shall be incorporated as a buffer arrangement between mobile luminaries carriage
and mast shaft. This is to prevent damage to mast Surface during lowering and raising
operation of mobile luminaries’ carriage.
5.10 Winch
(a) For installation and maintenance of luminaries and lamps, it is necessary to lower and raise
the luminary carriage by means of suitable winching arrangement at the base of the mast.
The speed of raising and lowering of lantern carriage ring shall be at least 3.0 meters per
minute.
Note: Pulleys made of synthetic material such as plastic or PVC shall not be accepted.
-----------------------------------------------------------------------------------------------------------
PRESTRESSED
FOR
CROSSINGS
CHAPTER: A-6
6.0 Scope
This specification covers pre-stressed concrete cement poles for modification of State
Electricity Board’s Power line crossings.
a) IS 1678 of 1998: Specification for pre-stressed concrete poles for overhead power,
traction and telecommunication lines.
b) IS 2905 of 1989: Methods for testing of concrete poles for overhead power and
telecommunication lines.
c) IS7321 of 1974: Code of Practice for selection, handling and erection of concrete poles
for overhead power and telecommunication lines.
6.5 Erection
Erection of pole/double pole structure shall include the excavation of pit 1800 mm deep and
making foundation with cement concrete as per approved drawing of SEB/Railway.
----------------------------------------------------------------------------------------------------------
MODIFICATION
OF
POWER LINE CROSSINGS
ON
RAILWAY TRACKS
7.0 General
a) The scope covers modification of existing power line crossings of Railway track as per the
regulations applicable to electrical overhead crossings and/or underground cables crossing the
railway tracks operated by the Indian Railways, Railway companies and port commissioner’s
railways, including assisted and private sidings on which rolling stock of Indian Railway may
work, unless any special section or railway tracks are exempted from these regulations by
specific written orders of the Electrical Inspector.
b) Detailed drawing of the proposed modification work of crossing shall be prepared and
approval obtained from the Railway and concerned State Electricity Authority.
c) Revised agreement as per the regulations applicable to electrical overhead crossings and/or
underground cables crossing the railway tracks shall be got signed from the concerned State
Electricity Authority.
b) Except where otherwise provided for in the regulations, the contents of relevant sections of
the Indian Electricity Act 2003, Indian Railway Act 1890 and the rules made under these and
as amended from time to time thereto and the relevant provisions of Indian Railway’s
Schedule of Dimensions (IRSOD) for Broad/ Meter / Narrow Gauges together with the latest
amendments shall apply to the modified crossings.
7.4.2 Structures
a) Steel poles/masts, fabricated steel structures or reinforced/pre-stressed cement concrete
poles either of the self supporting type or guyed type conforming in all respects to the Indian
electricity Rules, 1956 ( as amended till date) and complying with the latest editions of Codes
of Practice, IS: 800-1984 for “Code of Practice for use of Structural steel in General Building
Construction, IS: 1678 of 1998: Specification for ‘Pre-stressed Concrete Poles for Overhead
Power, Traction and Telecommunication Lines’, shall be used on either side of the track to
b) The minimum distance of the structures (supporting the crossing span) from the center of the
nearest railway track, including new proposed and considering for future, shall be as per para-
11(iv) of IRSOD-2004 and given at para 7.5.2(C)
c) The crossing span shall be restricted to 300 m or to 80% of the normal span for which the
structures are designed, whichever is less.
d) Wind pressure
The maximum wind pressure for design of the structure shall be as prescribed in IS:
802/Pt.I/1995 for loads and permissible stresses.
7.4.3 Temperature
The maximum and minimum temperatures for design of the conductors and other wires shall
be as prescribed in the latest edition of IS: 802 (pt. 1, Clause-10) with necessary correction
for maximum temperature.
Note: If, in unavoidable circumstances, the crossing span cannot be so located, the minimum
clearance between any of the crossing conductors of the crossing and the nearest traction
mast or structure shall not be less than that specified for buildings in Rule 80 of the Indian
Electricity Rules, 1956 (as amended till date). Specific permission in this regard shall be
obtained from the Employer, prior to execution of work.
7.5.1 No overhead line crossing shall be located over a booster transformer, traction switching
station, traction substation or a track cabin in an electrified area.
7.5.2 Clearance for Power Line Crossings including Telephone Line Crossings of Railway
Tracks
Following clearances should be maintained as per ACS-10 of SOD-2004 and Advance
correction slip-18/Jan-2009 to ACTM circulated vide Railway Board’s letter no.
2000/Elect.(G)/161/1 Part-III dated 19.01.2009.
(a) Clearance for Power Line Crossings in Non-Electrified & Electrified Territory:
Note:
i) All heights/clearances are in mm and under maximum sag conditions.
ii) If the crossing is provided with guarding, a minimum clearance of 2000 mm shall be
maintained between the bottom of the guard wire and highest traction conductor.
iii) Power line crossings in yard and station area shall be avoided.
iv) For new electrification works, existing crossings can continue, if dimensions are as per
Column (5) above.
7.5.2 (b) Minimum Clearance between any conductor not adequately insulated and any
railway structure under most adverse conditions-
The working of railway crane under an overhead line crossing shall normally be avoided.
If it becomes absolutely essential for a crane to work under such a crossing, the
minimum clearance required to be maintained between the highest working point of the
jib and the lower crossing conductor shall be as under:
33 1500
66 2000
110 2250
132 2500
220 3500
400 6000
500 7250
800 11500
7.6 Insulators
A double set of strain insulator strings shall be used in crossing span in conjunction with a
yoke plate where necessary. Each string of such strain insulators shall have one insulator
more than the number used in a normal span of the overhead line. The factor of safety of
each string of insulators under the worst conditions shall be not less than 2.
7.7 Guarding
a) All overhead power line crossings upto and including 33 kV shall be provided with guarding
under the power line. Guarding need not be provided for overhead power line crossings of
voltages above 33 kV if the transmission/ distribution line is protected by circuit breakers of
modern design with total tripping times of 0.20 seconds for voltage below 220 kV and 0.10
seconds for voltages of 220 kV and above, from the time of occurrence of the fault to its
clearance. Wherever, guarding is adopted for the crossing span, cradle guards shall be
provided.
b) Minimum height above rail level to the lowest level of cradle guard or guard wires under
condition of maximum sag shall not be less than the values specified in the clause 7.3.1.8
above.
c) The minimum height between any guard wire and a live crossing conductor under the most
adverse conditions shall not be less than 1.5 meters.
7.9 Earthing
(a) Each structure on either side of the crossing span supporting the transmission line conductors
shall be earthed effectively by two separate and distinct earths and connections. At least one
separate earth electrode shall be provided for each earth connection. Earth resistance of the
independent electrode shall be less than 5 ohms.
(b) All guard and stay wires shall be properly clamped to the structures connected to earth so as
to maintain proper electrical continuity to earth.
(c) Where struts are provided, they shall also be effectively connected to earth separately as well
as to the main structure earths.
(d) Where the earth resistance of the independent tower/structure is higher, the owner shall take
necessary steps to improve the earth resistance either by providing multiple earth electrodes
or by suitably treating the soil surrounding the earth electrode or by resorting to counterpoise
earthing. The method of earthing the transmission/distribution line structures etc., for the
crossing span shall be got approved from the Railway by the Engineer.
(e) The cross section of the earth conductor/ connections for the earthing system shall be
adequate for the application. They shall not be liable to be damaged or overheated or melted
while carrying the short circuit current.
Each cable crossing shall be indicated by at least two cable route markers, one at each end of
the crossing within the railway boundaries. The cable route marker shall be fixed at both ends
of the underground crossings. The following information shall be clearly displayed on the
markers.
Electrical Cable -- kV
Number of Cables -- Nos.
Danger Notice Plate -- In English, Hindi and the Vernacular language of the
District
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MEDIUM VOLTAGE
SWITCH BOARD
CHAPTER:A-8
8.1 General
(a) Medium voltage switch board shall be cubicle type, floor mounted, free standing type,
dust and vermin proof, totally enclosed & compartmentalized design of uniform height
and of multi-tier construction for indoor utilization and suitable for 3 phase, 4 wire, 415
V, 50 Hz AC, solidly earthed neutral, electric supply system complete with accessories,
inter connections, continuous GI earth strip, bus bar chamber with copper/aluminium bus
bar ( as specified I n the relevant BOQ item), ON/OFF & trip indication, all instruments,
CT’s energy meters, switchgears etc. (as specified in the relevant BOQ item) in position,
duly wired up with copper conductor cable with colour coding, code numbering etc. and
other accessories though not mentioned here but necessary to complete the work in all
respects.
(b) LT panel shall conform to IS: 8623/Pt-I/1993
(c) The panel manufacturer shall have ISO: 9001 certification with testing arrangement as
per IS: 8623 and power coating facilities in the works.
8.2 Construction
8.2.1 The panels shall be fabricated from 2.0 mm thick CRCA sheet steel. The shroud & partitions
shall be minimum 1.6 mm thick CRCA sheet steel. The panels shall be powder coated in
approved shade. The degree of protection shall not be less than IP42 as per IS: 13942/Pt. 1.
8.2.2 Height of panel shall not be more than 2200 mm and operating height of switchgears shall be
between 300 to 1900 mm. Depth of panel shall not be less than 1200 mm. Continuous GI
earth bus bar shall be of size not less than 50 x 6 mm.
8.2.4 All functional units shall be arranged in a multi-tier formation & each such unit shall be fully
compartmentalized. Vertical cable alley shall be provided. Cable alley shall have hinged doors
& suitable cable clamping arrangement. Vertical bus bars shall be housed in between two
feeder compartments in a separate bus chamber. The openings between the bus chambers &
feeder compartments shall be covered with Bakelite/hylem sheet of minimum 4.0 mm
thickness. All the interconnecting links to the feeders shall be shrouded by means of phenolic
barriers to avoid accidental contact. Each compartment shall have its own individual door with
concealed hinges & the door shall have interlocking so door can only be opened after
switching off the module.
8.3 Bus Bars
8.3.1 The bus bars shall be made of high conductivity aluminium/copper (as specified in BOQ)
conforming to the requirement of IS 5082/1998 for aluminium and IS: 1897/1983 for copper.
The bus bars shall have uniform cross section ( basis of bus bar cross section will be
maximum of 1000 A/sq. inch for copper and 630A/sq. inch for aluminium). The cross-section
of the neutral bus bar shall be same as that of the phase bus bar for bus bars of capacity up
8.3.2 Bus bars are to be provided in sections as per requirement for feeding essential/non-essential
load and domestic/commercial load as per the approved drawing.
8.3.3 Provision shall be made in the switch board to take in main bus bar trunking from
top for LT panels to be provided with transformers of capacity above 750 KVA.
8.3.4 Bus bars shall be supported on suitable non-hygroscopic,, non-combustible, material such as
DMC/SMC. The joints in the bus bars shall be provided with fish plates on either side of the
bus bars to provide adequate contact area. Bus supports shall be provided on either side of
the joints.
8.3.5 All bus bars shall be insulated with PVC tapes/tubes (heat shrink type) with colour coding
(Red/Yellow/Blue/Black) to withstand the test voltage of 2.5 kV for one minute.
8.4.2 Tripping unit shall be of thermal-magnetic type provided in each pole and connected by a
common trip bar such that tripping of any one pole operates all the poles to open
simultaneously.
8.12 Miscellaneous
Control switches shall be of the heavy-duty rotary type with plates clearly marked to show the
operating position. They shall be semi-flush mounting with only the front plate and operating
handle projecting.
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MEDIUM VOLTAGE
FEEDER PILLAR
&
SWITCH BOARD
CHAPTER:A-9
9.1.2 Digital Time switch (Timer) of suitable rating and contactors (as specified in the relevant
BOQ item) shall be provided in the feeder pillar to operate pump/street lights etc. and this
shall be controlled with independent switchgear/s.
9.1.3 Construction
9.1.3.1 The feeder Pillar shall be fabricated from 2.0 mm thick CRCA sheet steel. The shroud &
partitions shall be of minimum 1.6 mm thickness and shall be fabricated from CRCA sheet
steel. The feeder pillar shall be powder coated in approved shade by seven tank process.
The degree of protection shall not be less than IP 54 as per IS: 13942/Pt.1.
9.1.3.2 Pedestals and base frame shall be of MS angle of 75mm x 75mmx 8 mm (nominal size).
The Feeder Pillar shall have the provision of flush doors on front and back in two equal
parts with hinges and concealed lock openable with special key.
9.1.3.4All functional units shall be arranged in multi-tier formation & each such unit shall be fully
compartmentalized. Vertical cable alley shall be provided. Each compartment shall have its
own individual door with concealed hinges & the door shall have interlocking so that it can
only be opened after switching off the module.
9.1.4.2 Bus bars shall be supported on suitable non-hygroscopic, non- combustible, material such
as DMC/SMC.
9.1.4.3 Bus bars shall be insulated with PVC tapes/ tubes (heat shrink type ) with colour coding
(Red/Yellow/Blue/ Black) to withstand the test voltage of 2.5 kV for one minute.
9.1.5.1 MCCB shall be TPN of rating as specified in the relevant BOQitem and shall conform to IS-
13947/Pt-2/1993 (Ics = 100%Icuor as specified in relevant BOQ item) with thermal release
setting 70/80%-100% or fixed type ( as specified in the relevant BOQ item) with breaking
capacity of not less than 25 kA for load currents up to 200 amp. & 35 kA for load currents
above 200 amp rating. MCCBs shall be suitable for three phase, 415 Volt, AC supply.
9.1.5.2 Tripping unit shall be of thermal – magnetic type provided in each pole and connected by a
common trip bar such that tripping of any one pole operates all the poles and they open
simultaneously.
9.1.7.1Current transformers shall be in conformity with IS: 2705 (Part I, II & III). Current
transformers shall be rated for 1 kV. Current Transformer shall have rated primary current,
rated burden and class of accuracy. The rated secondary current shall be 5 A. The
acceptable minimum class of various applications shall be as given below:
Measuring : Class 1
Protection : Class 5 P10.
9.1.8.1 Cable entries shall be provided with metal glands to prevent damage to the insulation of the
cable and terminals shall be provided to suite the number, type and size of aluminium
conductor power cables.
9.1.8.2 Provision shall be made for bottom entry of cables through removable gland plates.
9.1.9.1 All routine tests shall be carried out in the presence of the inspecting Engineer.
9.1.9.2 Original test certificates of all equipments/ instrument shall be submitted by the contractor
along with the supply of panel board after the Inspecting Officer passes the feeder pillar.
9.1.11 Erection
Brick masonry platform of suitable size with 450 mm height (approximate ) shall be
constructed in the specified location and cement finish. Feeder pillar shall be erected on this
platform by grouting of pedestals as approved by the Engineer.
9.2.2 Digital time switch (Timer) of suitable rating and contactors (as specified relevant BOQ item)
shall be provided in the panel to operate pump/street lights etc. and shall be controlled with
independent switchgear/s.
9.2.3 Construction
9.2.3.1 The panel shall be fabricated fro 2.0 mm thick CRCA sheet steel. The shroud & partitions
shall be minimum 1.6 mm thickness and shall be fabricated from CRCA sheet steel. The
panel shall be powder coated in approved shade by seven-tank process. The degree of
protection shall not be less than IP 42 as per IS: 13942/Pt.1.
The following minimum clearances shall be maintained:
i) Between Phases - 32 mm
ii) Between Phases & Neutral - 26 mm
iii) Between Phases & Earth - 26 mm
iv) Between Neutral & Earth - 26 mm
9.2.3.3 All functional units shall be arranged in multi-tier formation & each such unit shall be fully
compartmentalized. Vertical cable alley shall be provided. Each compartment shall have its
own individual door with concealed hinges & the door shall have interlocking so that it can
only be opened after switching off the module.
9.2.4.2Bus bars shall be supported on suitable non-hygroscopic, non- combustible, material such as
DMC/SMC.
9.2.5.1 MCCB shall be TPN of rating as specified in the relevant BOQitem and shall conform to IS-
13947/Pt-2/1993 (Ics = 100%Icuor as specified in the relevant BOQ item) with thermal
release setting 70/80%-100% or fixed type as specified in the relevant BOQ item) with
breaking capacity of not less than 25 kA for load currents up to 200 amp. & 35 kA for load
currents above 200 amp rating. MCCBs shall be suitable for three phase, 415 Volt, AC
supply.
9.2.5.2 Tripping unit shall be of thermal – magnetic type provided in each pole and connected by a
common trip bar such that tripping of any one pole operates all the poles and they open
simultaneously.
9.2.7.1 Current transformers shall be in conformity with IS: 2705 (Part I, II & III). Current
transformers shall be rated for 1 kV. Current Transformer shall have rated primary current,
rated burden and class of accuracy. The rated secondary current shall be 5 A. The
acceptable minimum class of various applications shall be as given below:
Measuring : Class 1
Protection : Class 5 P10.
9.2.7.2 The VA rating of the CTs shall be not less than 5 VA.
9.2.8.2 Provision shall be made from bottom for entry of cables through removable gland plates.
9.2.9.1 All routine tests shall be carried out in the presence of the inspecting Engineer.
9.2.9.2 Original test certificates of all equipments/ instrument shall be submitted by the contractor
along with the supply of panel board after the Inspecting Officer passes the feeder pillar.
9.2.10 Testing and Commissioning at Site
Following tests shall be carried out prior to Commissioning:
a) Insulation test
b) Trip Tests & Protection Tests
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DISTRIBUTION BOARD
CHAPTER:A-10
DISTRIBUTION BOARD
10.0 GENERAL
a) Distribution boards for power and light circuit distribution shall be pre-wired, factory built, duty
powder coated and complete with copper bus bars, MCB/MCCB/RCBO/RCCB etc. (as specified
in the relevant BOQ item) and shall be suitable for 415 V, 3 – phase or 230 V, single-phase
supply (as per BOQ item). The distribution boards shall conform to IS: 8623 and IS: 13032 as
applicable
b) However, if none of the types readily available from the approved makes meets the
requirements, alternative makes may be offered with technical literature and test certificates,
for approval of the Engineer.
c) Separate distribution board shall be provided for light and power circuits in quarters
of category Type- IV and above & in service buildings, as approved by the Engineer.
10.1 Type
The Distribution Board shall be single/double door type (as specified in the relevant BOQ item)
suitable for flush installation. The boards shall be of cabinet design, totally enclosed and shall
have a degree of protection not less than IP42 (indoor type) and IP54(outdoor type ) as per IS:
13947/Part1/1993.
10.2.2 Three phase MCBs shall have common trip bar so that all the poles make and break
simultaneously. Miniature circuit breakers shall be quick make & quick break type with trip
free mechanism. They shall have thermal & magnetic short circuit protection.
10.3 Residual Current Circuit Breakers (RCCB), Residual Current Circuit Breaker with
Overload, short circuit & earth leakage Protection (RCBO)
10.3.1 RCCB/RCBO shall be used in distribution boards as per BOQ item. The RCCB/ RCBO shall be
rated for 30/100/300 mA fault circuit tripping as specified in the relevant BOQ item or as per
site requirement. RCCB and RCBO shall conform to relevant IS.
10.4.1 Tripping unit shall be of thermal-magnetic type provided in each pole and connected by a
common trip bar such that tripping of any one pole results in simultaneous operation of all
the poles.
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EARTHING SYSTEM
CHAPTER-11
Tech. Spec. No.-RVNL/Elect/GS/11
EARTHING SYSTEM
11.0 GENERAL
The earth system shall conform to IS: 3043 and as per approved drawing of the Zonal Railway.
Types of earth systems:
a) Pipe Earth Electrode: Shall be normally provided for earthing of installations other than
sub-station equipments.
b) Plate Earth Electrode : Shall be normally provided for earthing of sub-station equipments.
11.1.2 The pipe electrode shall be buried in the ground vertically with its top nearly 200 mm below
the top of the enclosure.
11.1.3 A funnel with mesh shall be provided on top of this pipe for watering. Funnel attachment shall
be housed in the masonry enclosure.
11.1.4 The top of pipe electrode shall be housed in a masonry enclosure (finished) of not less than
400mm x 400 mmx300mm (internal size). The covers of the masonry enclosures shall be of
concrete with handle for lifting.
11.1.5 Normally an earth electrode shall not be situated less than 1.5m from any building. Care shall
be taken that the excavation for the earth electrode may not affect the column footings or
foundations of the building. In such cases, the electrode may be located further away from
building. The location of earth shall be such that the soil has reasonable chances of remaining
moist. Building entrances, pavements, roads etc. shall be avoided for location of earth
electrodes.
11.1.6 Earth resistance shall be reduced by artificial chemical treatment of the soil with sodium
chloride (common salt) mixed with soft coke or charcoal in suitable proportion in layers of
150mm. When this treatment is resorted to, the electrode shall be surrounded by the mixture
of charcoal/coke and salt.
11.1.7 The earth lead from earth electrode to equipment/pole/main switch etc. shall be of GI wire of
size (8 SWG or 25mm X 4mm GI strip). The earth lead for LT panel/feeder pillars shall be of
GI strip of size (25mm X 4mm GI strip). Earthing of internal wiring (point wiring, power plug
wiring, SDB etc) shall be done by means of PVC sheathed copper wire of same size as that of
wire used for relevant point wiring.
11.1.8 Earth lead shall be connected to pipe earth electrode by means of galvanized bolts, nuts,
washers & cable sockets.
11.1.9 All materials used for connecting the earth lead with electrode shall be of GI.
11.1.11 The earth lead from electrode shall be suitably protected from mechanical injury and shall be
buried in ground at minimum 300mm depth when located outdoors. The portion within the
building shall be recessed in walls/floors at adequate depth.
11.1.12 No earth electrode shall have resistance greater than 5 ohms. In rocky soil, the resistance
may be up to 8 ohms.
11.1.13 Locations having more than one electrode shall be connected in parallel to reduce the
resistance.
11.1.14 In locations where the full length of pipe electrode is not possible to be installed due to
meeting a water table, hard soil or rock, the electrode may be of reduced length, provided the
required earth resistance result is achieved with or without additional electrodes, or any
alternative method of earthing may be adopted, with the prior approval of the Engineer-in-
charge.
a) Substation equipments shall be earthed using Plate Earth Electrode. Metallic frame of all
equipments such as transformers, HT/LT switchgears/DG sets etc. shall be earthed at two
distinct points with GI Plate earth electrodes and neutral points of the transformer/s and DG
set/s shall be earthed at two distinct points with copper plate electrodes.
For earthing HT/LT equipments/DG sets, GI plate earth. Electrode shall be 600mmx
600mmx6mm thick and shall be held vertical in ground with its top not less than 3.0 m below
ground level. The earth plate shall be embedded in alternate layers of coke and salt of 150mm
thickness so as to avail earth resistance not greater than 1.0 ohm.
11.2.2 A watering pipe of 20mm dia of medium class GI pipe shall be provided and attached to the
electrode. A funnel with mesh shall be provided on top of this pipe for watering the earth. The
watering funnel attachment shall be housed in masonry enclosure of not less than 40cm x 40
cmx30 cm inner size and shall be provided with hinged MS sheet/CI plate 10 mm thick and
having locking arrangement.
11.2.3 One end of GI earth strip of size 40mmx6mm or as specified in the relevant BOQ item shall be
securely bolted on the GI earth plate with two bolts, nuts, check nuts and washers, all
CADMIUM PLATED. Other end shall be brought above ground level vertically. The portion of
this strip that runs in ground shall be buried 500 mm below ground level to guard against
mechanical damage. The portion within the building shall be recessed in walls/floors at
adequate depth.
11.2.4 The strip shall be connected to the earth terminals of various HT/LT equipments/DG sets etc.
by means of cadmium plated nuts, bolts and washers.
11.3.1 For earthing of neutral of transformers/DG sets, 600mm x600mmx3mm thick copper plate
earth electrode shall be held vertical in ground with its top not less than 3.0 m below ground
level. The earth plate is embedded in alternate layers of coke and salt of 150mm layers each,
to avail earth resistance less not greater than 1.0 ohm.
11.3.2 A watering pipe of 20mm dia of medium class GI pipe shall be provided and attached to the
electrodes. A funnel with mesh shall be provided on top on this pipe for watering the earth.
The watering funnel attachment shall be housed in masonry enclosure of not less than 400
mm x 400mm x300mm inner size and shall be provided with hinged MS sheet/CI plate 10mm
thick and having locking arrangement.
11.3.3 One end of copper strip of size 40x5mm or as specified in the relevant BOQ item shall be
securely bolted on the copper earth plate by means of two nos. of tinned brass bolts, nuts,
check nuts and washers as required. Other end shall be brought above ground level vertically
through GI pipe of 50 mm dia. or as specified in the relevant BOQ item. The portion of this
strip that runs in the ground shall be taken through medium class GI pipe 50 mm dia or as
specified in the relevant BOQ item, buried 500 mm under ground level to guard against
mechanical damage. The portion within the building shall be recessed in walls/floors at
adequate depth.
11.3.4 The strip shall be connected to the neutral terminals of transformer/DG set by means of
tinned brass bolts, nuts and washers, as required. To bring down the earth resistance, every
earth electrode shall be surrounded by charcoal and salt.
11.4 Every individual earth electrode shall be allotted a serial number and an earth plate of size
10x22 cm of 14 SWG sheet steel (painted black) fixed in a conspicuous position near the
earth. The following information shall be displayed with white or yellow paint on the earth
plate.
i) Earth No……………………………….
ii) Individual earth resistance…………….ohms.
iii) Overall earth resistance…………………ohms.
iv) Date of testing………………………………..
11.5 The following tests shall be carried out before the installation is commissioned.
i) Earth resistance test.
ii) Earth continuity test.
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ELECTRICAL DRIVEN
SUBMERSIBLE PUMPS
12.2.2 The material used in all the parts of the pump and casing shall be suitable to withstand
corrosive action of the liquid to be handled by the pump and shall be designed for long
service.
12.2.3 All bearings/bushes used in the pumps shall be of water lubricating, high loading capacity,
synthetic thrust type. The sleeve bearings shall be of special lead bronze having a high
bearing load capacity.
12.2.4 The pump shall be complete with a suitable brass strainer at the suction side to prevent any
hard material from entering the pump.
12.3 Motor
12.3.1 The motor shall be squirrel cage type induction motor, suitable for operation with the pump,
capable of running on 230V, single phase or 415 V, 3 phase, 4 wire, 50 Hz, Ac supply
system(as specified). The motor shall be suitably rated to withstand any overload due to
higher discharge at a lower head and reduction in head up to 25 % of the specified head
without getting over loaded.
12.3.2 The motor shall be of “wet type” according to manufacturer’s standard design and generally
conforming to IS: 325.
12.3.4 The motor shall be assembled on hardened stainless steel shaft and supported on antifriction
thrust bearings of synthetic molecular insulation. The sleeve bearings shall be of special
bronze make. All the end thrust bearings shall be constructed from such material as to
ensured trouble free service and be water lubricated.
12.3.5 The motor shaft shall be fitted with synthetic rubber sealing rings and sand guard to prevent
sand and impurities from entering the motor. The motor shall be directly coupled to the pump
and shall be provided with a suitable device to prevent uncoupling when the motor is started
occasionally in the wrong direction.
12.3.6 The motor shall be equipped with suitable compensative device in order to protect the water
inside the motor from getting mixed up with well water which may contain some quantity of
sand etc. In the event of slight expansion of water inside the motor, the device shall give a
spongy action, to accommodate it and return to normal when the motor is not working.
12.3.7 The electrical cable shall be connected to the motor by means of perfectly watertight sealing
gland, to prevent water from entering the motor. The cable shall be protected by a strong
cable guard plate. Waterproof cable of suitable size and length shall be supplied.
12.4.1 Starter
The starter for the motor shall be push button operated type with under voltage and over load
release for direct on line starting and conforming to IS: 8544.
12.4.2 Indicator lamps for input supply for each phase, output supply
12.4.3 Suitable ammeter and voltmeter for each phase shall be provided.
12.4.4 Suitable electronic/microcontroller based motor protection relay with over/under voltage
protection, phase sequence, locked rotor, earth fault, over current protection, dry run
protection, single phase preventor, suitable timer control and measurement for running time
of pump.
12.5 Accessories
12.5.1 The submersible pump shall be supplied with the following accessories:
(a) Non-return valve streamlined for minimum friction and integral in each pump set. The
cone of the valve shall be fully quoted on the periphery valve seating shall be renewable
rubber ring type.
(b) Pressure gauge of suitable size and graduated in kg/sq.cm on the delivery side.
12.6 Pump and control panel should be suitably provided with two independent earthing system.
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POWER DISTRIBUTION
TRANSFORMER
CHAPTER:A-13
13.0 General
The transformer shall be suitable for operation in tropical climate and for mixed load and for
continuous operation. It shall be natural cooled, outdoor/indoor type (as specified in the
relevant BOQ item) and star rated. The PF at full load shall not be less than 0.8 lagging. It
Distribution transformers shall conform to IS: 2026 ( Pt. I to Pt. IV)/1997 for more than 100
KVA rating and IS:1180 upto 100 KVA rating. The efficiency of the transformer shall not be less
than 98% at full load. It shall be supplied with first filling of inhibited mineral oil conforming to
IS: 12463-1988 capable of withstanding 50 kV (rms) voltage as per IS: 6792/1972.
13.5 WINDINGS:
The winding shall be with double copper wound delta connected on primary, star with neutral
brought out for earthing purpose on secondary. The copper wires conforming to IS 7404 (Part 1
and 2)/1974 or the latest version for paper covered conductors shall be used for HV and LV
coils. The insulation of the conductors of the HV as well as LV coil shall be double paper
coverage (DPC).The vector group unless other wise stated in the appendix 'A', shall be DY 11.
Class of insulation for winding shall be 'A' class.
The LV wiring shall be circular and concentric with HV winding on the outside. Vertical duct shall
be provided for both HV and LV windings. The arrangements of the windings must be such that
there is no electrical and magnetic balance under conditions of operation. The design shall
permit free circulation of oil to ensure absence of hot posts. All similar coils shall be inter-
changeable. It is essential that the windings are subjected to a thorough shrinking and
seasoning process during manufacture so that no further shrinkage of windings occur during
early years of service. Adjustable screws shall be provided for taking up possible shrinkage of
13.7 TANK:
The transformer tank shall be rectangular and shall be fabricated with tested MS plates of not
less than 5mm thickness at sides top and bottom suitably reinforced and stiffened with ribs etc.
All joints of the transformer tank shall be welded both inside and outside in such a way that
they are fully hot oil type and such that no bulging occurs during service. The tank plates shall
be of such strength that the complete transformer filled with oil can be lifted bodily by means of
lifting lugs provided on the tank and the lifting lugs should be of adequate strength to cater for
this. This tank design shall be such that core and the windings can be lifted together freely out
of the tank with minimum dismantling.
The tank cover shall also be provided with suitable lifting lugs. The tank cover and
bushing joints shall be provided with superior quality oil resistant gaskets to render the tank full
watertight. In case of outdoor transformers, the cover design shall be such that rain water
drains out automatically. The cooling arrangement whether with circular or electrical tubes or
with radiators offered for the transformer shall be indicated in Appendix 'B'.
13.8 CONSERVATOR:
Conservator with its oil gauge filling and drain plugs breather shall be fixed to the transformer
tank cover. Air release device on the tank cover is necessary unless the conservator is so
located has to eliminate the possibility of air being trapped within the main time. Necessary
quantity of transformer oil sufficient for the transformers shall be filled along with the
transformer.
13.9 FINISH
The exterior of transformer tank and outer ferrous fitting shall be thoroughly cleaned, scrapped
and given a primary coat and two finishing coats of durable oil and weather resistance enamel
paint. The colour coats shall be dark admiral gray conforming to No.63 of IS 5/1961 for colours
for ready mixed paints or its latest version.
2.
Specifications- Volume II (Electrical Works) RVNL
13.11 Tests
13.11.1 Routine Test
Tests as per Clause 16.1.2 of IS: 2026 (Pt.1)/1977 shall be witnessed at manufacturer’s
works by the nominated Inspecting Officer.
13.12 Earthing
The star point on the low voltage side shall be brought out for solid earthing with copper plate
using copper strip of suitable length as per earthing specifications enclosed.
Transformer body shall also be provided with independent earthing system other
than star point as specified in earthing specification enclosed.
13.13 Installation
Installation of transformers shall be done as per IS 10028 (Pt. II/1981). Suitable concrete
work for foundation or mounting arrangements on pole shall be done as directed by engineer
for erection of transformer.
f Frequency 50 Hz +/- 3%
g) Type of insulating and cooling medium Inhibited Mineral oil to IS 12463:1988 with latest amndts.
h) Service Outdoor
ii) For outdoor type transformers 3 bushings on HV side and 4 bushings on LV side suitably
marked
Note: a) Rods, nuts, washers etc. of all HV and LV bushing must be of brass only.
b) All bushings shall conform to IS 2099/1973 or its latest version.
Suitable foundation, fencing for the transformer shall be provided as specified in the BOQ. The
typical details for foundation and fencing (wherever required) shall be as under:
(i) Foundation
M10 type foundation shall be constructed with 20mm coarse aggregate.The size of foundation
shall be as per the approved drawing based on Transformer dimensions but shall not be less
than 2 x1.5mt Length x breadthX 600mm (height above ground level) duly plastered and finished
surface. Curing shall be done as per code applicable. Excavation shall be done complying with
Code of Safety as per IS 3764/1992(Latest Version).
(ii) Fencing
Fabrication of enclosure for housing transformer shall be made in rectangular formation as
required with M.S. angle iron 50x50x8mm spaced at about 2 meters and 12 SWG GI wire. The
design of the fencing panel shall be as approved by RVNL. MS strip not less than 15x3mm size
shall be provided and welded above the GI wire along the angle frame to hold the GI wire
(iii) Iron gate: Iron gate shall be fabricated with M.S. angle 50x50x8mm iron frame with iron
grill etc as approved. The size of the gate shall be 2.0 m height X 3.5 m width and fabricated
in two parts of aprox size 1.75m each. Gate shall be provided with suitable sliding lock with
padlock. Gate shall be fixed on channels of size not less than 100 X 50 mm (weight 7.90
kg/m). Channels shall be erected on foundation constructed of size 300mm X 500mm deep
with M10 grade cement concrete.
(iv) Painting: MS portions of enclosure (fencing and gate etc) shall be painted with two coats of
red oxide primer and two coats of enamel paint of approved shade.
(vi) Approval of Drawing of Enclosure:
Drawing of the enclosure with gate etc shall be got approved from the Engineer prior to start
of the work.
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14 General
14.1 The DG set shall work as a single unit for catering to mixed load comprising electrical power
and for charging battery, average power factor of load being 0.8 (lagging). The set shall be
suitable for operation as per specified site conditions.
14.1 (a) Any equipment/accessory not specifically mentioned herein but essentially required for the
equipment to meet the site requirement shall be deemed to be included in the DG set.
14.1 (b) All the equipments shall conform to the latest version of BIS Specifications including the
following:
14.4 A fuel tank for storing the fuel oil with a capacity corresponding to 12 hrs. consumption of the
DG set shall be provided. The fuel piping shall be free from leakage and air locks. The fuel tank
shall be supplied with a level gauge to indicate the oil level in the tank and the tank shall be
marked to indicate the quantity of diesel oil in the tank.
14.5 Fuel tank shall be in built within an acoustic enclosure OR separately provided at a higher level.
14.6 The engine shall be suitable to run on Diesel Fuel Oil grade ‘ A’ to IS: 1460/2005.
14.7 Governor
The engine shall be supplied with an inbuilt electronic governor to maintain the engine speed at
varying loads. The governor shall conform to Class A-1 or G3 as per relevant BS/ IS
specification.
b) The DG set shall start automatically on full load current within 10 seconds of the supply
failure and on restoration of main supply shall stop within 3 minutes after making the
changeover from DG set supply to main supply.
f) Main supply air break contactor, four pole, of rating as under and provided with
suitable HRC fuses for short circuit protection- 1 set.
g) Alternator (DG set) Air break contactor of rating as above shall be provided with
separate overload relay for overload protection and provided with suitable HRC fuses
for short circuit protection – 1 set.
h) Main supply voltage monitor – 1 no.
i) DG control relays & timer for start/stop/three attempt starting facilities and failure to
start and lock.
j) Audio alarm hooter in case of low lube-oil pressure, high coolant temperatures, DG set
fails to start - 1 no.
k) Earth fault relays to cut off the field supply of the alternator.
l) Copper Bus bar of rating as under for phases and neutral on the basis of 1000
amp./sq. inch:
SN DG Set Capacity Bus bar for Phases Bus bar for Neutral
1 82.5 KVA 250 amps 200 amps
2 160 KVA 400 amps 200 amps
3 250 KVA 800 amps 400 amps
SN DG Set Capacity 4 pole MCCB ( Ics = 100% Icu) with thermal release
setting 70/80%-100%
1 82.5 KVA 160 amps
2 160 KVA 400 amps
3 250 KVA 800 amps
n) Provision shall be made to operate the DG set both on auto and manual mode.
o) Size of Cable
14.13 Arrangement
The engine shall be directly coupled to the alternator through flexible coupling and both the
units including the radiator shall be mounted on a rigid fabricated bed plate. Base plate shall
have threaded holes for holding of down bolts for mounting engine and alternator.
14.14 Foundation/Plinth
Complete DG set shall be fixed on the proper designed plinth as specified by OEM or as per
RVNL approved foundation drawing.
14.15 Tests
The generating sets shall be tested at the manufacturer’s works for:
a) Guaranteed fuel –consumption
b) Over load Capacity
c) Proper operation of protective devices provided for safety of the generating set and AMF
Panel.
-------------------------------------------------------------------------------------------------------
Tech.Spec.No.RVNL/Elect/GS/15
11 kV VCB HT PANEL
CHAPTER:A-15
Technical Spec.No.RVNL/Elect/ GS/15
11 kV Vacuum Circuit Breaker HT Panel
15.1 Scope
This specification covers manually operated, HT switchgear panels, suitable for 11000 volts, 50
Hz, 3- phase, 3-wire, alternating current, solidly earthed, electric supply system, complete with
all accessories. The panel shall be complete with interlocking feature, automatic safety shutters,
internal connections for inter-connections of panels, bus bar chamber, ON&OFF indicators, earth
sockets, with all the instruments and relays in position and duly wired up with copper conductor
cables and any other accessories though not specifically mentioned here but necessary to meet
the site requirements in all respects. HT panel shall be fabricated from CRCA steel sheet, 14
SWG, with anti-corrosive coating and powder coated finish of approved colour.
Note: The above mentioned tripping and measuring facilities should be provided in a single multi
function numerical relay cum meter to the extent feasible.
Note: The abovementioned tripping and measuring facilities should be provided in a single multi
function numerical relay cum meter to the extent feasible
15.7.4 Voltmeter
Voltmeter shall be digital type of size not less than 96x 96 mm, square, flush mounted and
shall conform in all respects to the relevant BIS specification. The voltmeter shall be suitable
for use in conjunction with the 11 kV/ 110 V PTs being offered. All meters shall be tested at
2000 V for one minute.
15.7.5 Ammeter
Ammeter shall be digital type, of size not less than 96x96mm, square, flush mounted and
shall conform in all respects to the relevant BIS specification. The voltmeter shall be suitable
for use in conjunction with the CTs being offered.
ii) The panels are required to be installed indoors. They shall comprise copper HT bus bars,
VCB, auxiliary equipments and HT cable box etc. The panels shall be fabricated from CRCA
sheet steel not less than 2 mm thick. The panel shall be of self standing type and fixed to
bolts grouted in the foundation.
iii) The cubical shall be finished uniformly with powder coating of specified colour.
iv) All the equipments viz. VCB, bus bars, PTs, CTs, relays, measuring instruments, auxiliary
terminals blocks, HT cable in let and outlet, earth points etc. Shall be properly arranged
within the cubicles so as to facilitate easy maintenance and replacement. The measuring
instruments and operating switches shall be suitably arranged on the front cover of the
panel.
v) Suitable interlocking arrangements shall be provided between the front covers and the VCB
switches so that the front cover is openable only when the respective VCB is in OFF
position.
vi) All the Ht connections shall preferably be arranged at the bottom of the cubicles.
vii) Proper double earth of the non-current carrying parts of all equipments and unit enclosures
shall be provided with GI strip of not less than 50 mm x 6mm size.
viii) The drawing of the HT panel shall be got prepared by the manufacturer and got approved
from the Engineer, by the contractor.
15.7.9 Space Heaters:
The Switchgear Panel shall have thermostatically controlled space heaters in each panel,
with a controlling 12 Amp, 230 V switch socket outlet, to eliminate condensation.
15.7.10 Power Pack
Suitable capacity power pack shall be provided for tripping circuits.
15.7.11 Type Test Certificates
Copies of type test certificates, successfully carried out on similar type of Vacuum Circuit
Breakers, complying with the relevant Indian Standards, from a recognized Test House/
CPRI shall be furnished.
-----------------------------------------------------------------------------------------------------------
CORRECTION (APFC)
PANEL
CHAPTER:A-16
16.0 General
The APFC panel shall be totally enclosed, made of mild steel sheet 14 SWG, free standing, floor
mounting, indoor type, with degree of protection not less than IP42. The panel shall be
compartmentalized, fixed type, manufactured as per IS 8623 Pt. I & II/1993 & powder coated
with specified colour. The panel shall be suitable for operation on 3-phase, 4-wire, 415V, 50 Hz,
AC supply system, with automatic or manual switching arrangement for 10 step power factor
correction, to achieve power factor near unity. The capacitor bank shall be complete with inter-
connections. A continuous GI earth bus bar shall run at the bottom. It shall comprise of the
following items: (However, any other item, not specifically listed below, but required for
meeting the site requirement, shall also be deemed to be included.)
(1) Incomer shall be double the rating of panel i.e. 250A for 125 kVAR, 50 kA, MCCB 4 pole (Ics
= 100% Icu) conforming to IS 13947/ Part II.
(2) Microprocessor based Automatic Power Factor Control Relay of not less than 12 steps with
display of electrical parameters- i.e. power factor, current, voltage, etc. with following
specifications:
a. 415 V 50 Hz
b. Capacity 5 Amps
c. Intelligent type
d. Built in Automatic and manual control
e. Low current cut out relay,
f. Relay shall function even at low loads
g. It shall have data logging facility and sufficient memory back-up to log the data for 30
days or above.
(3) Indicating Lamp for incoming power supply with suitable back up protection.
(5) Configuration of capacitor output – 10 steps x 12.5 kVAR each with switching ratio 1:2:3:4
(6) Knife type HRC fuses with base of suitable capacity for back up protection of capacitor duty
contactor for each capacitor bank.
(8) Capacitor shall be low loss, self-healing type for Ac power system having rated voltage 650
V & conforming to IS13340/1993 & IEC 60831.
(9) TPN copper bus bars of 400 amp rating for phase and 200 amp rating for neutral, fitted on
insulators and PVC sleeves and duly colour coded.
(11) Inter connection of capacitor duty contactors to bus bars with suitable size PVC copper
conductor cable of 1.1 kV grade, with suitable lugs. Lugs, wherever required, for control
wiring of relays, meters, equipments and indicating light etc. Inter connection from MCCB with
suitable size copper bus bars, as required.
(12) LT XLPE armoured cable conforming to IS7098/Pt.1/1988 for connection of control panel to
main bus bar of LT switchboard. The cable shall be connected with suitable size of lugs and
glands.
(13) LT Current Transformer (CT) conforming to IS2705/Part I to IV, of suitable CTR, for
incoming feeder/s complete with four terminal at input side and two terminal at output side
including connection from incoming CTs to summation CT and APFC relay with suitable size
copper conductor cable with proper wiring arrangement.
(14) Suitable metering, indication and other accessories, as per site requirement.
---------------------------------------------------------------------------------------------------------
BATTERY CHARGERS
FOR
COACHING APPLICATIONS
CHAPTER: A-17
Tech. Spec. No. RVNL/ Elect/GS/17
17.0 General
The battery charging sets shall be natural air cooled type with full wave bridge connected silicon
rectifier stack and chokes for automatic limiting of variation of charging current due to mains
voltage fluctuation. The silicon rectifier diodes shall be of capacity such that when 6 diodes are
used for 3 phase rectification, the normal capacity of the bridge shall not be less than 175% of
rated rectification capacity. The silicon diodes shall be rated for 200 PIV or more. The silicon
rectifier equipment shall conform to IS4540/1968 of rating class-B/air cooled. The maximum
permissible temperature rise on winding shall not be more than 850 C. Battery charger for
following applications shall conform to RDSO specifications listed below:
(b) Pole mounted battery chargers for train lighting applications- EL/TL/52 (Provisional)
17.1 A maximum of 5% ripple shall be allowed. Surge suppressors and HRC fuses shall be provided
for protection of the rectifier diodes. Chokes shall be wound with copper conductors.
17.2 The rating of transformer provided in the battery charging set shall match the rating of
associated rectifier set. The transformer shall be double wound with copper conductor, naturally
air cooled, as per IS:2026 with class-F insulation, suitably impregnated to withstand moist
tropical climatic conditions. SFU/FSU incorporating HRC fuses and MCCB matching the
characteristics of diodes, shall be provided for the control of incoming AC supply. The SFU/FSU
& knife switch shall be mounted firmly on a steel frame work below panel sheets. Rewirable
fuses shall be provided for pilot lamps and indicating instruments. Two nos. of suitable capacity
knife switches shall be incorporated for the control of outgoing DC supply in addition to diode
protection type HRC fuses of suitable capacity. (2 nos. of knife switches, each of 200 amp.
Capacity, shall be provided for 2 nos. of outgoing cables).
17.3 The silicon rectifier battery charging set shall be capable of giving the rated DC output over the
entire range of 125 to 150 volts. The output voltage shall be capable of adjustment in this
range, for which purpose, coarse, medium and fine control, in not less than 4 steps, shall be
provided through suitable rotary control switches incorporated on the transformers.
17.4 The arrangement of silicon rectifier stacks, transformers and chokes shall be such that each
item can be dismantled independently, without disturbing the other equipments.
17.5 The battery charging sets are required for indoor use and shall be portable with 4 wheels. The
set shall consist of transformers, chokes, silicon rectifier, control switches, ON/OFF switches. DC
Voltmeter, Ammeter of moving coil type, flush pattern, of suitable range and interconnections
etc. Cabinet shall be of 14 SWG CRCA sheet steel and powder coated. The bus bars and inter
connections shall be of copper conductors.
17.6.2 The transformer rectifier unit shall be such that on short circuiting the DC side of the rectifier
bridge, the short circuit current does not exceed 300% of the nominal rating of the rectifier
unit.
17.8.0 Tests
17.8.1 Type Tests: The manufacturer shall submit type test certificates for tests successfully carried
out on similar type of sets, to the inspecting authority.
17.8.1.1 The following routine tests shall be carried out by the inspecting authority and results
witnessed:
a) Insulation Resistance Test- Insulation resistance shall not be less than 2 ohm before
and after the high voltage test. The AC and DC side of rectifier set shall be short
circuited while testing.
b) Load Characteristic- The battery charger shall give 200 A at 150V Dc.
c) High Voltage Test- 1 kV shall be applied for 60 sec. and rectifier AC/DC side shall be
short circuited before applying the high voltage.
d) Load Test-The battery charger shall be connected to variable resistance of water
rheostat and measure the output voltage and current. Check the transformer and
temperature after 2 hours run. Check up the core noise or poor lamination or heating.
-----------------------------------------------------------------------------------------------------------
BATTERY CHARGING
AND
18.1.2 Battery charging points shall be cubicle type, weather proof, out door type, dust & vermin
proof, conforming to IS-8623 with degree of protection not less than IP54. It shall be suitable
for operation on 150V Dc supply system and fabricated with 14 SWG galvanized CRCA sheet
with pedestal of MS channel of size 100 x 50 mm (weight 7.914 kg/m), 1200 mm long, 2 nos.
aluminum bus bars of size 40x10mm, complete with one no. incoming MCB DP 63 Amps (DC
series) 10 KA. Detachable plate shall be provided on bottom for entry of incoming and
outgoing cables with suitably sized gland/s. Channel shall be fixed /welded with the enclosure
on back side in the centre of the enclosure at a specified distance from the top.
18.1.3 EFT (as per RDSO drawing already in use in Train Lighting system) feeding terminals shall be
of galvanized mild steel, suitably mounted on ebonite/Teflon sheet (approx. 12 mm thick),
fixed on the sheet of enclosure.
18.1.4 The feeding terminals shall be marked Red & Black for polarity (“+ve” and “-ve”). Suitable
space shall be provided between terminals.
18.1.5 The incoming connections from bus bars to MCB and from MCB to the feeding terminal (EFT)
shall be done with single core, 10 sq. mm, copper conductor cable, with suitably sized
galvanized Ms bolts, nuts and washers.
18.1.6 Enclosure and channel shall be powder coated and of the specified colour. Enclosure shall have
double earth terminals.
18.1.7 Erection
The channel of the battery charging point shall be grouted vertically in ground 300 mm deep
with cement concrete as per para 13.0 CH-1A. The clearance between the channel and edge
of foundation shall be minimum 200 mm and it shall be duly finished and cured. The muffing
shall be 200 mm above ground level.
18.1.8 All equipments and material used shall conform to the following BIS specifications:
18.2.2 The pre-cooling point shall be manufactured from 3.15 mm CRCA sheet. Pedestals (4 nos. on
corners), shall be of MS angle of size 65x65x8 mm (900 mm long) with base frame of Ms angle
of size 40x40x5mm. MS angle pedestals (grouting portion approx. 150mm) shall be bifurcated.
The enclosure shall have double earth terminals.
18.2.3 The enclosure and pedestals shall be powder coated with specified shade.
18.2.4 (a) Pre-cooling portion shall be provided with the following, on the front for
utilization/operation without opening the front door:
b) The connections from bus bars to MCCB and from MCCB to the feeding terminal (Iron Clad
Sockets) shall be done with single core, copper conductor cable of suitable rating with
suitably sized galvanized MS bolts, nuts and washers.
18.2.5 All equipments and material used shall conform to the following BIS specifications:
18.2.6 Erection
Pedestals shall be grouted vertically 300 mm deep in ground with cement concrete as per para
13.0 CH-1A. They shall be 200 mm in diameter, duly finished and cured muffing 200 mm
above ground level.
-----------------------------------------------------------------------------------------------------------
Chapter: A-19
Tech. Spec. No.- RVNL/ Elect/GS/19
SOLAR HOME and STREET LIGHTING SYSTEM
NOTE:
a) All the item shall be as per latest MNES specifications (latest) and shall possess satisfactory
test certificate issued by Solar Energy Centre or any other approved testing centre by
MNES.
b) PV Modules manufacturer should be MNES approved.
c) The lamps should be housed in an assembly suitable for indoor use, with a reflector on its
back. While fixing the assembly, the lamp should be held in a base up configuration.
19.3.3 PV MODULE(S):
a) The PV module(s) shall contain crystalline silicon solar cells.
b) The power output of the module(s) under STC should be a minimum of 37W or 74W i.e. two
modules of 37 W each or one module of 74W should be used.
c) The operating voltage corresponding to the power output mentioned above
d) Should be 16.4 V
e) The open circuit voltage of the PV modules under STC should be at least 21.0 Volts.
19.3.5 INDICATIONS :
The system should be provided with 2 LED indicators, a green light to Indicate charging in
progress and a red LED to indicate deep discharge condition of the battery. The green LED
should glow only when the battery is actually being charged.
NOTE:
Components and parts used in solar home systems should conform to the latest BIS
specifications, wherever such specifications are available and applicable.
19.4.0 Solar Photo Voltaic (SPV) based LED street lighting system shall consists of the following
elements –
(a) SPV Module to convert solar radiation directly into electricity.
(b) 7 m height GI pole with necessary accessories.
(c) Battery bank to store the electrical energy generated by SPV panel during day time.
(d) Charge controller to maintain the battery to the highest possible State of Charge (SOC)
while protecting the battery from deep discharge (by the loads) or extended overcharge
(by the PV array).
(e) Blocking diode, preferably an Schottky diode, connected in series with solar cells and
storage battery to keep the battery from discharging through the cell when there is no
output or low output from the solar cell, if such diode is not provided with the module
itself.
(f) 15 W LED based luminaire as a light source.
(g) Interconnecting wires/cables & hardwares.
19.4.4 POLE
GI tubular pole shall be swaged type made from steel of ultimate tensile strength 410 MPa (42
kg/mm2) as per IS: 2713 (Pt. I, II and III) 1980 amended up to date. The pole shall be as per
IS designation 410 SP-3. Each pole shall be provided with 16 mm dia GI earth terminals of
suitable length for earth connection. Pole shall be suitable to wind pressure of not less than
150 KMPH. Drawing of pole shall be got approved from the RVNL Engineer.
Desi Length of Outside diameter & Base Plate FOUNDATION BOLT Anchor
gnat Sections (m) thickness of sections Dimen Plate
Foundation in mm
ion (mm) Thickne
sions
ss
(LxBxT)
Bottom Middle Top Bolt Size Pitch Bolt
Bottom
(mm)
Middle
(mm)
410- 4.00 1.50 1.50 114.3x 88.9x 76.10 220X220X 4X20 205 700 3 500x5
SP-3 5.4 4.85 x 3.25 12 00x
1250
(dept
h)
19.4.5 FOUNDATION:
Foundation for erection of pole shall be constructed at the approved location.
After excavation of pit of suitable size, cement concrete bed of approx.50mm thickness, using
cement concrete as per para 13.0 Chapter-1A, shall be first provided at the bottom of the pit.
Square foundation shall be made with cement concrete as per para 13.0 Chapter-1A of size as
specified in the above table of standard dimensions of pole up to 150mm above ground
level. Muffing shall be in level, plastered, finished & also cured. After foundation work, the pit
shall be filled with excavated earth. During back filling of earth, ramming and watering shall be
done.
19.4.6 ERECTION OF POLE:
The pole shall be erected in plumb on constructed foundation at the specified location and
bolted on a pre- casted foundation with a set of four bolts. Top of all the poles shall be at the
same level to maintain uniformity.
NOTE:
1. Components and part used in the solar street lighting systems should conform to the latest
BIS specification. Wherever such specifications are available and applicable.
2. All the item shall be as per latest MNES specification and manufacturer shall possess
satisfactory test certificate issued by Solar Energy Centre or any other approved testing
centre by MNES and same shall also be furnished at the time of inspection and copies of the
same shall be supplied with supply of material/equipment.
----------------------------------------------------------------------------------------------------------
20.2 Work includes supply, erection testing and commissioning of solar based water heating system
complete with Solar Collectors, Insulated Tank, Supporting Stand, system piping,
instrumentation, electric back up, controls, etc including CONNECTIONS UP TO UTILITY POINTS
of the existing arrangement/system as required.
20.5 GENERAL
Solar water Heater device shall be operative on Flat Plate Collector/ETC covered by an insulated
metallic box with glass sheet on top to receive sun rays and suitable for normal, hard water &
pressurized applications for heating capacity per day as specified in BOQ item/s. All systems
shall conform to BIS & MNES standards and specifications. System shall be suitable to heat
water between the ranges 60-80 degree centigrade. System output temperature shall normally
be 60 degree centigrade.
20. 9 WIRING
All control and sensing wiring shall be housed in MS conduit.
20.10 Technical Requirements
(a) Flat Plate Collectors: ISI mark (2 sq. m. absorber area per100 liter tank capacity system.
No. of tubes in a To have minimum 1 ½ sq. m. of absorber area per 100 litre tank
system capacity system. Absorber area will be calculated as follows:
Area in Meter = No. of tubes X Radius in Meter X Length in Meter.
Accordingly, 14 tubes of Dia: 47 mm & length: 1500 mm and 10 tubes
of Dia 58 mm & length: 1800 mm will be required for each 100 lpd
system.
For higher capacity systems, the no. of tubes calculated as per above
could be slightly less. For details, please refer to MNRE Circular no.
25/5/2009-10/ST dated 2nd March, 2010
Inner tank SS 304 or 316 grade min/ MS or any other material with
material anti-corrosive coating for hard water with chlorine contents.
Inner tank For SS minimum thickness will be 0.5 mm when using argon Arc or
thickness metal inert gas for welding & 0.8 mm when using other type of welding.
For MS it will be 1.5 mm. No leakage under any kind of negative or
positive pressure of water will be ensured.
Inner tank TIG / Seam/ pressurized weld (Open arc weld not permitted).
welding
Storage tank Not less than system capacity. In case of ETC based system, volume
capacity of tubes & manifold not to be included in tank capacity.
Thermal Minimum 50 mm thick CFC free PUF having density of
20.12 At places where water is hard and has larger chlorine content, if FPC based system is proposed
for installation, heat exchanger should be installed alongwith to avoid scale deposition in
copper tubes of solar collectors which can block flow of water as well as reduce its thermal
performance.
20.13 INSTALLATION
Solar collector array shall be installed at the proper tilt angle, orientation and the elevation
above roof and shall have proper exposure to sun throughout the day.
------------------------------------------------------------------------------------------------------------
,
Specifications- Volume II (Electrical Works) RVNL
LIGHTENING ARRESTER
CHAPTER:A-21
Lightening Arrester
21.0 Lightening arresters shall be provided on the buildings where large public congregates, essential
public services are concerned, lightening strokes are prevalent, or in structures which are very
tall, isolated, or are historical or cultural importance. The other buildings may also be provided
with lightening arrestors as per risk assessment analysis given in the IEC 62305 chapter-2. The
lightening arresters are governed as per IEC 62305 and BIS 2309.
21.1 Generally lightening protection in installation having nuclear or sensitive electronics are provided
with Level1 Lightening protection whereas buildings housing Data Centre and building taller
than 20 meter height in isolated location are provided level 2 lightening protection, other
buildings having electronics or human occupancy requires level 3 protection and godown having
no electronics will require level 4 lightening protection.
Air termination system is to intercept the Lightning current. It consists of vertical air terminal or
Mesh conductor or the combination. No drilling or welding is allowed in the terrace for fixing the
air terminal.
Values of Rolling sphere radius, Mesh size and protection angle as per Class of
LPL/LPS.
2 30 10*10
3 45 15*15
4 60 20*20
70
a0 60
50
40
30
IV
I II III
20
10
0
10 20 30 40 50 60
H m
If the structure height is more than 60 meters, top 20% of the height of the structure shall be
protected with a lateral air termination system. This is needed because, the probability of flashes to
the side is generally more for structures more than 60 meters in height. For structures of height
more than 120 meters, ring has to be formed for every 20 meters height of the building above 60
meters height.
21.6 Principal Components
The principal components of a lightning protective system are :-
(d) Aluminium: Aluminium, 99% pure, and with sufficient mechanical strength, and
protected against corrosion shall be used.
21.7.1 Aluminium should not be used underground, or in direct contact with walls.
21.7.2 All air terminations shall be of GI and all down conductors shall be of GI or aluminium, except where the
atmospheric conditions necessitate the use of copper or copper clad steel for air terminations and down
conductors.
21.7.3 The recommended shape and minimum sizes of conductors for use above and below ground are given in Table-
1 and 2 respectively.
21.8 Layout
The system design and layout shall be done in accordance with IS 2309: 1989 and specified in the tender
documents.
(i) The number and spacing of down conductors shall be as specified, or as directed
by the Engineer-in-charge.
(ii) Routing
If antenna, air cooler or any other electrical equipment is present above terrace level, the same
have to be protected by using vertical air terminal after calculating the safety or separation
distance. The vertical air terminal has to have suitable supports to hold it. Vertical air terminal
must be connected to horizontal air terminal by using suitable connectors.
At the crossings of the horizontal air terminals, suitable T or Cross connector has to be used for
secure connection.
21.9.4 Safety or Separation distance.
It is must to calculate safety or separation distance in order to avoid flash over to the electrical
equipment when the lightning current is passing through the vertical air terminal.
Safety/Separation distance (S) in m = ( ki * kc*L) / km
Value of coefficient km = 1
Value of L is the total distance between the equipment to be protected ( for e.g. Antenna) to the
equi-potential bonding bar situated just above the ground.
(i) The down conductor system must, where practicable, be directly routed from the air
termination to the earth termination network, and as far as possible, be symmetrically placed
around the outside walls of the structure starting from the corners. In all cases consideration to
side flashing must always be given.
(ii)(a) Practical reasons may not sometimes allow the most direct route to be followed. While
sharp bends, such as arise at the end of roof are inescapable (and hence permissible), re-entrant
loops in a conductor can produce high inductive voltage drops so that the lightning discharge
may jump across the open side of a loop. As a rough guide, this risk may arise when the length
of the conductor forming the loop exceeds 8 times the width of the open side of the loop.
(b) When large re-entrant loops as defined above cannot be avoided, such as in the case of some
cornices or parapets, the conductors should be arranged in such a way that the distance across the
open side of a loop complies with the requirement indicated above. Alternatively, such cornices or
1 10
2 10
3 15
4 20
(b) Bonds:
(i) Bonds have to join a variety of metallic parts of different shapes and composition, and cannot
(iii) The bond must be mechanically and electrically effective, and protected from corrosion in,
and erosion by the operating environment.
(iv)External metal on, or forming part of a structure, may have to discharge the full lightning
current, and its bond to the lightning protective system should have a cross-sectional area
not less than that employed for the main conductors.
(v) Structures supporting overhead electric supply, telephone and other lines must not be
bonded to a lightning protective system without the permission of the appropriate authority.
(vi) Gas pipe in no case shall be bonded to the lightning protective earth termination system.
(v) Earth electrodes should be capable of being isolated and a reference earth point should be
provided for testing purposes.
For earth termination system, 2 basic types of earth electrode arrangements are applicable:
Type A & Type B arrangement.
Earthing system should meet the requirements according to IS 3043, IEC 60364–5–54, IEC
62561–1 to 7, IEC62305 as well as UL 467. Earthing system should offer resistance less than 1
ohms throughout the year. For this purpose, earthing system vendor should do the soil testing
and provide the necessary recommendation. In places where Soil resistivity is more, multiple
earth electrodes are to be installed to get the required value. In case of multiple earth rods,
vendor should provide possible resistance value of each earth pit. This value remains without
any change for at least one year. Recommended value should be less than 10 ohms. In places
where resistance of each pit is more than 10 ohms, special care needs to be taken. In such
cases, Earth Enhancing compound need to be used for the vertical rods as well as horizontal
conductors.
A hole of 100 to 125 mm dia. shall be augured / dug to a depth of about 2.8 meters.
It will be penetrated into the soil by gently driving on the top of the rod. Here natural soil is
assumed to be available at the bottom of the electrode so that min 150 mm of the electrode
shall be inserted in the natural soil.
Earth Enhancing material (min. approx. 30 to 35 KG) shall be filled in to the augured /dug ole in
slurry form and allowed to set. After the material gets set, the diameter of the composite
structure (earth electrode + Earth Enhancing material) shall be of minimum 100 mm dia.
covering entire length of the hole.
Remaining portion of the hole is filled with backfill soil which is taken out during auguring /
digging
In places where short-circuit level is more than 10 KA, (eg all panel boards, body) a copper
strip of 25 mm * 6 mm with a minimum length of 150 mm need to be exothermically welded to
the solid rod. All further connections need to be done to this copper flat.
For interconnection of earth pits, SOLID copper conductors with a size of 25* 3 mm flat or 10
mm copper bonded round steel conductors are to be used for Lightning Protection/ General
purpose. In places where short circuit currents of more than 10 KA are expected, copper flats of
25 *6mm or 50 * 6 mm need to be used depending upon the expected short circuit level. In
places where short circuit current requirements are more than 10 KA, Exothermic /
Aluminothermic welding are only allowed for jointing earth electrode with round / Flat
conductor. Connections with nut and bolt need to be completely avoided in applications under
ground level, instead exothermic / aluminothermic welding need to be performed.
21.10 Lightening STRIKE recorder with six digit with min current sensitivity of 0.15 KAmps through
to a maximum of 220 KA @ 8/20 Micro Second impulse and operates by means of an inductive
pick up loop. With a polycorbonate IP67 protection. The complete system should have earth
resistance less than less than 10 ohm.
TABLE-1
Shapes and Minimum Sizes of Conductors for Use Above Ground
Sr No Material and Shape Minimum size
1
Round copper wire or copper clad steel wire 6 mm diameter
2 50 sq. mm or (7/3.00 mm dia)
Stranded copper wire
TABLE-2
Shapes and Minimum Sizes of Conductors for Use below Ground
1
Round copper wire or copper clad steel wire 8 mm diameter
2 32 mm x 6 mm
Copper strip
3 32 mm x 6 mm
Galvanized iron strip
4 10mm X 6 mm
Round Galvanized iron wire
5 25 mm x 3 mm
Aluminium strip
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(a) Control switch board shall be cubicle type, mast mounted, dust and vermin proof, totally
enclosed & compartmentalized design of uniform height for outdoor utilization and suitable for
1-phase, 2 wire, 415V, 50Hz AC, solidly earthed neutral, electric supply system complete with
accessories, inter connections, bus bar chamber with copper bus bar, ON/OFF & trip indication,
duly wired up with copper conductor cable with colour coding etc.
(b) Switch board shall conform to IS:8623/Pt.1/1993 (LATEST).
(c) The switch board manufacturer shall have ISO: 9001 certification with testing arrangement as
per IS: 8623 and powder coating facilities in the works.
(d) Drawing shall be got approved from RVNL’s Engineer.
22.1 CONSTRUCTION
a) The panels shall be fabricated from 1.6 mm thick CRCA sheet steel. The shroud & partitions
shall be of minimum 1.6 mm thick CRCA sheet steel. The panels shall be powder coated in
approved shade. The degree of protection shall not be less than IP: 65 as per IS: 13942/Pt.1
(LATEST). The bus bar chamber/s and MCCB chamber shall have double doors. It shall be
possible to operate the MCCB only after opening of the outer door. The Switch board shall be in
vertical formation. Switch board shall be compartmentalized for accommodating bus bars on top
& on bottom and MCCB in centre with individual compartment. Each compartment shall have its
own door with insulated thumb screw. Each compartment/s shall have provision of concealed
lock.
b) Upper side (on top) bus bar compartment shall be for incoming cable from AT to bus bar.
Termination from bus bars to incoming terminals of MCCB shall be with 35 sq.mm copper
conductor single core FRLS PVC insulated cable.
c) Lower side (on bottom) bus bar compartment shall be for outgoing cable for feeding supply to
load. Termination from outgoing terminals of MCCB to bus bars shall be with 35/70 sq.mm (for
10 KVA) & 70 sq.mm (for 25 KVA) copper conductor single core FRLS PVC insulated cable.
d) Cable glands with detachable gland plates shall be provided on Lower side (on bottom) bus bar
compartment for incoming and outgoing cable entry.
e) Earthing terminal as required shall be provided.
22.4 MCCB
a) MCCBs (Ics=100%Icu) shall conform to IS: 13947/Pt -2/1993(LATEST).Tripping unit shall be of
thermal-magnetic type provided in each pole and connected by a common trip bar such that
tripping of any one pole operates all the poles to open simultaneously.
22.7 ERECTION
Control switch board shall be fixed with the mast at suitable height /location and arrangement shall
be as approved by the Engineer. Base shall be of Galvanized Mild steel angle of size 50x50x6mm
and holding clamps shall be of Galvanized Mild steel flat of size 50x6mm. Nut & bolt shall not be
less than 12 mm dia.
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Chapter: A-23
Tech. Spec. No.- RVNL/ Elect/GS/23
SPECIFICATION FOR LED TYPE LUMINARIES
23.0 General:
This specification covers for the LED fitted luminaries used for outdoor and indoor applications
for working at 220+/-10% , 50 Hz +/- 3% , Single phase input system. The luminaries are used
at Railway Stations , Circulating Areas, buildings and offices etc. It consist of:
a) Fixture
b) LED
c) Driver and Electronics
(a) Fixture:
The fixture should conform to applicable IS 10322/IEC 60598( All parts & amendments) and
should have the associated LM-79 report(for Electrical and photometric test methodology for
LED lighting) from accredited lab. Test report shall be submitted along with relevant
catalogues. The fixture should have a surge protection of 2 KV.
High lumen efficacy LEDs suitable for the application along with following features shall be
used:
(i) LED Efficacy at the chip level shall >120 lumen/watt (For High power LED)
(ii) The efficiency of the LED at 85 Degree C junction temperature shall be more than 85%.
(iii) The system luminous efficacy of LED luminaire’ shall be as under:
a) Efficacy > 60 lumen/watt for low wattage luminaries (<45W): and
b) Efficacy > 80 lumen/watt for a high wattage luminaries (>45W).
(iv) Adequate heat sink with proper thermal management shall be provided.
(v) Minimum view angle of the LED shall not be less than 120*.
(vi) Power factor of complete fitting shall be more than 0.9
(vii) LED shall be surface mounted type duly soldered to PCB by Reflow system of COB Type.
The Solder used shall be ROHS compatible for environment friendliness.
(viii) Colour rendering index CRI >=70 as specified in the item description.
(ix) Correlated colour Temperature shall be in the range of 3000 K-6500 K as specified in
item description.
23.4 General
The lumen maintenance of the LED lightings shall not be less than 70% after 50,000 hours i.e.
L70 (B50). The supplier shall provide evidence that the LED chipset manufacturer has the
patent right to produce the supplied LED chipset to avoid infringement of white LED patent.
Free warranty shall commence after delivery and end at 60 months after delivery. The
warranty of replaced item shall re-start from date of attending defect/replaced.
Chapter: A-24
Tech. Spec. No.- RVNL/ Elect/GS/24
24.1 Description
Air conditioning (VRF System): The scope of work includes supply, installation, of all parts
mentioned or not in the schedule as per specification and testing, commissioning of complete
work as turnkey.
24.1.1 The VRF system shall typically consist of an outdoor unit with multiple digital scroll
compressors and different types of indoor units for different zones and electronic
control center / microprocessor.
24.1.2 The Variable Refrigerant Flow (VRF) system shall have Digital/ Inverter Scroll
Compressor to modulate the refrigerant flow to meet the varying cooling loads and to
deliver enormous savings on electricity bills.
24.1.3 The VRF system should be capable of performing cooling during summer / monsoon
season to achieve temperatures of 22°C to 28°C in the conditioned rooms as set by the
occupant.
24.1.4 The VRF system shall be provided with sophisticated electronic control center to enable
zone wise climate control.
24.1.5 The VRF system shall have tropicalized outdoor units, which can operate at ambient
temperatures as high as 520C.
24.1.6 The outdoor unit shall have following features:
(a) Polyester powder-coated sheet metal housing for longer life.
(b) Anti-corrosion blue fins in condenser coil for longer life.
(c) Built-in oil separator, accumulator and liquid receiver for oil, liquid and gas balance of
the entire system.
(d) Low noise external rotor fan
(e) Shall operate at high ambient temperatures as high as 520C.
24.2 Compressor:
The compressor(s) shall be combination of highly efficient hermetically sealed fixed scroll and
digital scroll type and should be capable of varying the capacity from 10% to 100% by
modulation technology which allows an external control to switch the compressor rapidly
between its loaded and unloaded states including crank case/oil heaters complete in all respect.
24.6.3 The address of the indoor unit shall be set automatically in case of individual and group
control.
24.6.4 In case of centralized control, it shall be set by liquid crystal remote controller.
24.6.5 The fan / blower shall be aerodynamically designed turbo, multi blade type, statically
and dynamically balanced to ensure low noise and vibration free operation of the system.
The fan shall be directly driven type, mounted directly on motor shaft having support
from housing except for floor standing ducted type in this case the blower shall be belt
driven.
24.6.6 The evaporator coil shall be constructed with refrigeration grade soft annealed copper
tubes mechanically bonded to aluminum fins to form a cross fin coils.
24.6.8 Each indoor unit shall have computerized PID (Program index) control for maintaining
design room temperature.
24.6.9 Each unit shall have cordless Remote Controller (RC) as specified in “SOR”.
24.7 Controllers:
24.7.1 Salient Features Cordless Remote Controller:
- On / Off control on individual unit
- Set temperature
- Mode settings -Fan / Cool / Heat / Dry
- Air flow direction -Auto swing or fixed angle mode for louvers (applicable only
for Cassette Type)
- On / off timer.
24.11 Makes: The acceptable make for VRF system shall be Blue Star, Voltas, Mitsubishi, Toshiba and
Daikin. Minor change in standard design shall be acceptable from approved makes only.
24.12 Air Handling Unit:
AHU shall be double skin screw less & sturdy construction for low noise and better thermal
insulation. Double skin panel construction shall allow easy inspection, service and maintenance
and reduce the risk of dirt and bacteria accumulation. Pre-filter provided shall be of synthetic
non-woven type supported with aluminum and HDPE. Filter efficiency shall be 90% for 10%
micron. Control panel shall be provided with powder coated control box to house isolator single
phasing preventer and contactors for starting of the motor. Control panel shall be compatible
with BMS having open protocol. On-off trip indications and luminous push buttons shall be
provided. Provision shall also be made to connect control value, fire dampers, modulating motor
and door switch. Fan and motor shall be mounted on aluminum extruded slide rail base frame
to adjust belt tension without disturbing motor alignment. Fan section shall be provided with an
access door for ease to service, view port shall be provided at fan door panel, which would help
monitoring fan and motor status. Door limit switch shall be provided to automatically trip fan
with the door is open. Every AHU shall be supplying with a factory fitted GI powder coated
volume, control damper to facilitate balancing. All AHU shall be Horizontal/vertical/suspended
type so as to occupy lesser floor space. Selection of the type of AHU vertical or ceiling
suspended or horizontal shall be based on the rating and the site condition. The fan section
shall be provided with an access door for ease serviceability of fan and motor. Aluminum die
cast powder coated hinges shall be provided. The unit shall be complete in all respect.
Item No. 4 This item work is mainly consisting of Design and Installation of Insulation of latest
improved quality CFC free insulating material in coating form. This should be efficient and good
looking.
Description Specification
AHU
Make Voltas, Carrier, Blue Star
Note: (1) Minor change in standard design shall be acceptable from approved makes only.
(2) Project is turn-key in nature and the contractor’s scope of work is to ensure proper
functioning and commissioning of the complete system.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------
The scope includes design, manufacturing, supply at site, erection, testing, commissioning and
handing over in satisfactory working condition of Machine room type motor operated Electric
traction passenger lift to the requirements as given in BOQ as per details of Annexure
‘A’,under the operational and environmental conditions encountered during service, complete
with all accessories. Specifications and other stipulations are given below. The salient points
pertaining to safety shall also be complied by the Supplier/Contractor. All the items mentioned
here are general in nature and any item (s) required for proper and safe functioning of the lift
shall be supplied with the lift without any extra cost even if not specifically mentioned here.
25.1 General.
The Machine Room type Lift shall be governed by relevant International Standards and
International Codes of Practice such as European code of safety EN 81,American National
Standard Safety Code for Elevators (ANSI) A117.1 , IS: 14665 or latest and IEC 60364 for
Electrical Installations of buildings. The traction machine, over speed governor, ropes, brake
gear controls and other safety equipment even though corresponding to specification EN 81 and
ANSI A117.1 should under all conditions of operations at least match with IS code of
specification for passenger Lifts viz. IS: 14665 or latest. This has to be ensured by Lift
manufacturers primarily and the manufacturer should have appropriate Quality Assurance
accreditation ISO 9000 / ISO 14001. The installations shall be to the highest standard as
expected of a fully experienced contractor. The manufacturer shall also comply with the
provision of Indian electricity act and rules in vogue and shall be taken over only if and when
they fully comply with all their requirements. The lift installation shall also be designed to
produce a safe working environment for Engineers and auxiliary workers to work on or around.
If the Supplier/Contractor intends to use the intellectual property rights of another party in
performing the Supplier/Contractor’s obligations under the contract, appropriate licenses shall
be obtained from the relevant beneficial owners.
Where any software is provided in the works, the Supplier/Contractor shall submit
documents showing that appropriate permission or License have been obtained from relevant
beneficial owners of intellectual property rights for the use of the software free of all fees for
the whole operating life of the Works.
Where O&M manuals and as-built drawings are submitted, the Supplier/Contractor shall obtain
appropriate permission or licence from relevant beneficial owners of intellectual property rights
to allow the Supervising Officer, the Employer and the subsequent owners or occupiers of the
25.4 Specifications:
25.4.1 Geared Machine:
The lift machine shall be smooth in operation with minimum noise/vibration and of worm
gear reduction type with traction motor, electromechanical brake, worm gearing, driving
sheaves and suitable to work on 400/440 Volts AC 3 Phase with neutral at 50 cycles per second
supply with VVVF (Variable Voltage Variable Frequency) type of control. The traction motor
shall be energy efficient induction type with minimum of BEE’s three star rating and in
accordance to BS 4999 and BS 5000:part 99.The motor shall be designed to operate for an
unlimited period according to the expected duty of the lift.
25.4.2 Sheaves:
The driving sheave and pulleys should be of hard alloy constructed from fabricated cast steel or
S.G iron or suitable wear resistant material and free from cracks, sand holes and other defects
with truly machined surface in order to ensure perfect alignment of all bearings and prevent
transmission of sound to the building. They shall have machined rope grooves. The traction
sheave shall be grooved to produce proper traction and shall be of sufficient dimension to
provide for wear in the groove. The deflector sheave shall be grooved so as to provide a smooth
bed for the rope. The deflector or secondary sheave assemblies where used shall be mounted in
a proper alignment with the traction sheave. Such deflector sheaves shall have grooves larger
than the rope diameter as specified in clause 8 of IS:14665 (part-4,Sec.3):2000 or latest. The
size of all the sheaves shall be in accordance with clause 8.4 of IS: 14665 (part-4, Sec.3):2001
or latest. Wherever necessary, suitable protective guards may be provided.
25.4.4 Brake:
A suitable electro magnetic brake, preferably of the direct acting type integrated with motor
operating on AC/DC shall be provided, with two brake shoes which are automatically applied by
means of a strong compression springs to a brake wheel of large diameter when the circuit is
broken and released by means of an electro-magnet.
The brake mechanism must incorporate provision to allow for minimum wear of brake lining. It
shall also have an emergency quick release device to open the brake without affecting its
adjustment so that the car can be lowered or raised manually in the event of electric supply
failure. The electric solenoid shall be rated to withstand continuous Lift duty.
25.4.6 Doors:
Landing doors and car door shall be of 2 panel centre opening sliding closed, stainless steel
powder coated or hairline stainless steel finish panels as approved by the Employer’s project
authority in charge, power operated independent drive with adjustable automatic opening and
closing speeds for door. The clear opening should be 900 mm wide x 2000 mm height. The door
shall have a fire resistance rating of one hour as per EN 81-58 and ground switch/switches at
ground floor level shall be provided on all the lifts to enable the fire service to ground the lifts.
The car doors shall be fitted with a Memco 3D curtain safe edge to detect and open the doors in
the event of obstruction/infringement while the doors are closing.
The door open time to be made programmable for time delay set in the system.
The lift shall be designed to go out of service if the doors are kept open for a long time as
programmed.
A delay to the start the lift after the doors is closed (say 0.2 to 2.0 seconds) also to be
programmable.
The landing doors shall be provided with electro-mechanical inter-locks to prevent operation of
the Lift unless all the doors are closed and positively locked. The inter-lock shall also prevent
the opening of any door until the car has reached the respective landing zone. In the event of
failure of Memco 3D curtain suitable mechanical system should be provided to open the doors in
the case of obstruction.
Any projections on or recesses in the exposed parts of the car doors or landing doors shall be
kept to a minimum in order to avoid finger trapping between sliding parts of the door and any
fixed part of the car or landing entrance.
The clearance between panels or between panels and any fixed part of the car or landing
entrance shall not exceed 6 mm.
Sliding car and landing doors shall be guided on door tracks and sills for the full travel of the
doors. The distance between the car and landing sills shall not exceed 35 mm.
The clear height of all entrances on car and landings shall not be less than 2 m.
Supplier/Contractor shall provide full door sticker of approved quality and design with adhesive
as approved them by employer’s project authority in charge.
25.6 Governor:
The car safety shall be operated by speed governor which shall be in accordance with clause 4
of IS: 14665 (part-4, Sec.3):2001 or latest and shall be adjustable to actuate the safety gears.,
located overhead and driven by governor rope suitably connected to the car and mounted on its
own pulleys. The governor shall be of “V” groove wheel design. The rope shall be maintained in
tension by means of weighted or spring loaded tension sheaves located in the pit. The governor
rope shall not be less than 10mm in dia and shall be made up of steel and as specified in Clause
25.7 of this Specification.
25.12 Buffers:
Buffers shall be in accordance with clause 5.15 of IS: 14665 (part-2, Sec.2):2000 or latest.
Hydraulic/spring buffers of tested design shall be installed as a means of stopping the car and
counter weight at the extreme limits of travel. Buffers in the pit shall be mounted on the steel
frame, which shall extend between both the car and counter weight guide rails. Energy
accumulation type buffers shall only be used if the rated speed of the lift does not exceed 1 m/s
All wordings shall be engraved in both English and Hindi characters. The material for the control
station shall be stainless steel with a thickness of not less than 2.5 mm. The control station
shall be fixed onto the car panel by stainless steel screws of secret-head type.
(b) Additional Control Station:
For passenger lifts of 21 persons capacity or larger, two car control station, one on either side
of the car doors, shall be provided such that one shall have the above functions 1, 2 and 3 only
and one shall have all the functions 1 to 7.
The indicators shall be mounted onto the back of at least 2.5 mm stainless steel faceplates
by weld studs and screws flush fit.
25.17 Interphone:
An interphone for the use in case of emergencies shall be installed in the car for direct
communication with the rescue personnel in the control room/machine room or top of the car.
The interphone shall be such that it is activated by simply pressing the interphone button on the
car operating panel.
25.23 Handicap:
It is special for those people who are handicapped, which include Voice anunciator with hand rails,
back mirror and horizontal push button station with Braille buttons.
The Supplier/Contractor shall provide dry contacts of the following output signals for each lift
installation in a stainless steel cabinet to serve as the interface unit for future connection by
others:
1. Normal/Fault status
2. Duty/Standby status
3. Power Supply Normal/ Fault status
4. Normal/ Essential Power status
5. Passenger trapped alarm
This interface unit shall be located at the management office/caretaker’s room next to the lifts
monitoring panel unless otherwise specified on the Drawing or in the Specification.
The lifts shall be provided with energy recording devices and duty cycle reporting system. The
print out port with RS 232/ USB port to be provided to communicate with PC/Laptop to dawn load
energy, duty cycle, fault logs, mode of operation, battery status and other data/information etc.
The down loading software to be supplied along with one Laptop PC and printer independent of
platform as approved by employer’s project authority. The down loaded data, reports,
information shall be platform independent in alpha numeric format in English language and shall
have full compatibility and exchange with MS office.
Landing calls for the direction opposite to that in which the car is travelling shall be by-passed
but shall remain stored in the system to be answered when the car returns in the opposite
direction. When the car stops for the last call in its direction of travel, preference is given to car
For each lift car within a lift has been idling for 2 minutes with the lift doors closed, the lift car’s
ventilation shall be shut off automatically until the lift car is activated again by passenger call.
The Supplier/l Contractor or others shall be responsible for the provision of conduit facilities
for the alarm buzzers/bells and the supervisory control panel at the landing of designated point
of entry between the lift shaft and the position of the panel. The Supplier/Contractor shall
furnish sufficient information to the Supervising Officer in good time before the conduit
installation work is commenced on site. The Supplier/Contractor shall be liable for all expenses
incurred due to his failure to comply with the above requirement.
Where supervisory control panel is specified in the Particular Specification and/or Drawings, the
Supplier/Contractor shall be responsible for the provision of all cablings, visual and audible
signal components, and controls for the supervisory control panel from all lifts to the
supervisory control panel that is located in the caretaker's office at the landing of designated
point of entry unless otherwise specified.
The supervisory control panel shall include at least, but not exclusive, the following basic
facilities :-
The conduit/trunking facilities from the lift shaft at the landing of designated point of entry to
the position of the supervisory control panel shall be provided by others as in Clause (h) above.
ii) the Supplier/Contractor shall supply associated connection plugs, which shall suit the
BNC panel sockets on the lift supervisory control panel and shall not be less than the
sockets in quantity, to the security control console specialist contractor who shall then be
responsible for the wiring from the security control console to the plugs.
iii) the BNC connection plugs and sockets shall be of 75 ohm impedance type, service
voltage up to 500 V peak and frequencies up to 4000 MHz, and accept common RF cable.
The lift shall resume normal operation automatically on removal of the excessive load. The
overload device shall be inoperative while the lift car is in motion.
i. Doors accessing machine room are to be clearly labeled with BS warning signs.
ii. Within the machine room an Electric shock Notice shall be installed.
iii.Within the machine room adequate Rubber Matting shall be installed.
iv. Within the machine room RCD protected 15A socket outlet shall be installed.
v. The machine room lighting shall be by twin tube 2x28 W T-5 fittings/ adequate LED
luminaries which shall give illumination of 150 Lux. The level of illumination in a power
failure shall be a minimum of 50 Lux to floor level throughout to be maintained by
providing Emergency lights. These lights shall be back up at least 72 hours by
adequate SMF battery and shall be manually operated by a switch located at a
convenient position inside the machine room.
vi. Tool box shall be fitted in the machine room and it shall comprise of the following
minimum equipment:
▪ Release Keys
▪ Winding wheel
▪ Log card
▪ Hand Winding instruction
L< 750 7 10 12 16 18
750 <L < 10 12 17 21 24
1000
1000 <L < 12 17 22 27 32
1350
1350 <L < 15 20 27 32 38
1600
1600 <L < 17 25 32 39 46
2000
2000 <L < 25 37 47 59 70
3000
3000 <L < 33 48 63 78 92
4000
4000 <L < 42 60 78 97 115
5000
L < 5000 0.0083L+ 0.0118L+ 0.0156L+ 0.0190L+ 0.0229L+
0.5000 1.0000 0.5030 2.0000 0.5000
25.41 Finish:
All metal work supplied by the Supplier/Contractor in out of the way locations such as the lift
shaft, lift pit, machine room and on the outside of the lift car shall be properly wire-brushed,
cleaned of rust, scale, dirt and grease prior to the application of one coat of rust inhibiting
primer, with particular attention paid to the priming of outer surfaces of car doors, inner
surfaces of landing doors, metal work associated with door assemblies, the underside and the
framework of lift cars. Any part of the equipment, including guide rails, which requires greasing
or oiling and any components that are supplied unpainted by the manufacturers due to
functional reasons shall not be painted.
All normally visible metal surfaces, other than stainless steel and non-ferrous surfaces, shall be
finished with one coat of rust inhibiting primer, one under coat/finishing coat and one finishing
coat of enamel paint to a colour to be selected by the Supervising Officer.
25.52 Guarantee:
The Supplier/Contractor shall guarantee satisfactory performance of the Lift and allied
equipments over a period of 24 months in actual service from the date of handing over of the
installation to the Railway in normal working conditions. During the guarantee period the
Supplier/Contractor shall rectify free of cost of all defects which may develop due to faulty
design, material failure and bad workmanship inclusive of free replacement of defective parts.
The guarantee will get automatically extended corresponding to the periods during which the
equipment is not in use. On every occasion when the equipment goes out of service, the
duration between the date of intimation of the failure of equipment to the contractor and the
date of handing over of the equipment after repairs in good working condition duly tested and
commissioned in the presence of Purchaser’s representative, will be counted for the extension
of the guarantee period till the equipment completes actual service for a total period of 24
months. During the guarantee period the parts of the equipments requiring repairs or
replacements will be handed over to the contractor at site and the parts after repairs or
replacements shall be fitted in the equipment at site by the contractor. All expenses involved in
fulfilling the above guarantee obligations shall be borne by the contractor.
25.53 Inspection:
The materials will be inspected by purchasers’ nominated representative at manufacturer’s
premises or contractors depot as the case may be. The purchaser or his representative shall have
the right to be present during all the stages of manufacture and shall be afforded free of charge
all reasonable facilities for inspection and testing as well as to examine the stage inspection report
of the manufacturer / inspection in addition to the quality audit which the contractor may institute
I. Monthly Schedule:
2. Check level of the lubricating oil in the gearbox, any unusual sound in the gearbox.
12. Check the foundation bolts of the motor any unusual noise, vibration etc.
13. Check the input voltage & current of the motor and record it.
14. Check leveling switches, arm pivots and limit switch rollers and lubricate.
15. Check the performance of the over speed governors and adjust if necessary.
IV. In addition to the above periodical maintenance the firm has to attend the following:-
a) The firm has to attend the breakdown failure at any time during the working hours without any
delay.
b) They have to supply the required consumables, spares, to keep the Lift in good condition.
c) While attending the quarterly schedules the firm has to carry out the monthly schedules also.
d) While attending the yearly schedules the firm has to carry out the monthly and quarterly
schedules also.
e) Maintenance schedule should be carried out in consultation with
f) If the Lift remains OUT OF SERVICE for more than 48 Hours per month, Employer will have
right to impose penalty to the extent of 10% value of the contract.
17. Landing and Car : Landing doors and car door shall be of 2 panel centre opening
Doors. sliding closed, stainless steel powder coated or hairline stainless
steel finish panels, power operated independent drive with
adjustable automatic opening and closing speeds for door. The
clear opening should be 900 mm wide x 2000 mm with full
height Memco 3D curtain safe edge to detect and open the
doors in the event of Obstruction /infringement while the doors
are closing.
18. Leveling : ±5 mm irrespective of load.
19. Human interface a. Hall button with micro stroke push/touch buttons combined with
device 16 segment digital LED display position indicator.
b. Full height car operating panel with micro stroke push/touch
buttons (Located on side panel)
c. Door Open and Door Close button on the Car operating panel.
d. 2 Way inter communication system.
e. DOT matrix position indicator display integrated with in the Car
operating panel.
ANNEXURE - ‘B’
1. Machine:-
d) Type of enclosure. :
f) Output in HP. :
g) Weight. :
i) Class of insulation. :
2. Brake:-
a) Make. :
b) Type. :
d) Method of adjustment. :
3. Car:-
a) Dimension (internal). :
b) Weight (Approx.). :
c) Contract load. :
d) Maximum speed. :
e) Acceleration. :
g) Method of suspension. :
d) Method of lubrication. :
b) No. of Sections. :
5. Control Equipments:-
6. Suspension Ropes:-
a) No. of ropes. :
c) Factor of safety. :
7. Counter weight:-
a) No. of sections. :
b) Weight of each section. :
c) Type of guide shoes. :
d) Method of load equalization of ropes. :
8. Wiring:-
a) Specification of wires. :
b) Method of wiring. :
9. Finishing:-
a) Full particulars should be given. :
10. Protection devices, details provided in the
Lift:-
11. Special inclusions if any:-
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26.1.1 Scope:
The scope includes design, manufacturing, supply at site, erection, testing, commissioning and
handing over in satisfactory working condition of Machine room less & Gear less machine with
permanent magnet motor operated Electric traction passenger lift to the requirements as given
in Annexure 'A', under the operational and environmental conditions encountered during
service, complete with all accessories. Specifications and other stipulations are given below. The
salient points pertaining to safety shall also be complied by the Supplier/Contractor.
26.1.2General
The Machine Room less type Lift shall be governed by relevant International Standards and
International Codes of Practice such as European code of safety EN 81,American National
Standard Safety Code for Elevators (ANSI) A117 .1 , IS: 14665 or latest and IEC 60364 for
Electrical Installations of buildings. The traction machine, over speed governor, ropes, brake
gear controls and other safety equipment even though corresponding to specification EN 81 and
ANSI A117.1 should under all conditions of operations at least match with IS code of
specification for passenger Lifts viz. IS: 14665 or latest. This has to be ensured by Lift
manufacturers primarily and the manufacturer should have appropriate Quality Assurance
accreditation ISO 9000 I ISO 14001. The installations shall be to the highest standard as
expected of a fully experienced contractor. The manufacturer shall also comply with the
provision of Indian electricity act and rules in vogue and shall be taken over only if and when
they fully comply with all their requirements. The lift installation shall also be designed to
produce a safe working environment for Engineers and auxiliary workers to work on or around.
Annual Rain fall Ranging between 1750 to 6250 mm with thunder storm.
26.2.0 Specifications:
26.2.1 Gearless Machine:
The lift machine shall be smooth in operation with mm noise/vibration and of single wrap
traction type gearless machine with permanent magnet motor operated electromechanical brake
suitable to work on 400/440 Volts AC 3 Phase with neutral at 50 cycles per second supply with
VVVF (Variable Voltage Variable Frequency) type of control. The traction motor shall be energy
efficient induction type with a minimum of BEE's three star rating and in accordance to BS 4999
and BS 5OOO: part 99.The motor shall be designed to operate for an unlimited period according
to the expected duty of the lift. The traction machine shall be either induction machine or
synchronous machine. The driving sheave should be integrally coupled with the machine and the
assembly to be completely mounted on guide rail or on suitable rigid frame fixed to the shaft .
The driving sheave should be constructed from fabricated cast steel or S.G iron or suitable wear
resistant material with truly machined surface in order to ensure perfect alignment of all
bearings and prevent transmission of sound to the building. The motor shall be designed to
operate for an unlimited period according to the expected duty of the lift. The
Supplier/Contractor shall furnish detailed drawings showing weights to be tackled and the
disposition of various loads on the Lifts shaft and Lift well for the approval of employer.
26.2.2 Sheaves:
The driving sheave and pulleys should be of hard alloy constructed from fabricated cast steel or
S.G iron or suitable wear resistant material and free from cracks, sand holes and other defects
with truly machined surface in order to ensure perfect alignment of all bearings and prevent
transmission of sound to the building. They shall have machined rope grooves. The traction
sheave shall be grooved to produce proper traction and shall be of sufficient dimension to
provide for wear in the groove .The deflector sheave shall be grooved so as to provide a smooth
bed for the rope . The deflector or secondary sheave assemblies where used shall be mounted
in a proper alignment with the traction sheave. Such deflector sheaves shall have grooves
larger than the rope diameter as specified in clause 8 of IS:14665 (part-4 ,Sec.3):2000 or
latest. The size of all the sheaves shall be in accordance with clause 8.4 of IS: 14665 (part-4,
Sec.3):2001 or latest. Wherever necessary, suitable protective guards may be provided.
26.2.4 Brake:
A suitable electro magnetic brake, preferably of the direct acting type integrated with motor
operating on AC/DC shall be provided, with two brake shoes which are automatically applied by
means of a strong compression springs to a brake wheel of large diameter when the circuit is
broken a nd released by means of an electro-magnet.
The brake mechanism must incorporate provision to allow for minimum wear of brake lining. It
shall also have an emergency quick release device to open the brake without affecting its
adjustment so that the car can be lowered or raised manually in the event of electric supply
failure. The electric solenoid shall be rated to withstand continuous Lift duty.
26.2.5 Car and car frame:
The car enclosure shall be in accordance with clause-4 of IS:14665 (part-4,
Sec.3):2001 or latest, made up of stainless steel 1.5 mm thickness hairline finish. The Lift car
26.3.0 Doors:
Landing doors and car door shall be of 2 panel centre opening sliding closed, stainless steel
powder coated or hairline stain less steel finish panels as approved by the employer or engineer
Supplier/Contractor shall provide full door sticker of approved quality and design with adhesive
as approved them by employer or engineer in charge.
Three good quality digitally printed safety and energy saving tips/
instructions as per pictographically international signage’s pattern of size 2 feet x 3 feet
of suitable design to be supplied and fixed on wall at lift on each floor in
Hindi/English/Vernacular language (i.e. one each).
26.5.0 Governor:
The car safety shall be operated by speed governor which shall be in accordance with clause 4
of IS: 14665 (part-4, Sec .3):2001 or latest and shall be adjustable to actuate the safety gears.,
located overhead and driven by governor rope suitably connected to the car and mounted on its
own pulleys. The governor shall be of "V" groove wheel design. The rope shall be maintained in
tension by means of weighted or spring loaded tension sheaves located in the pit. The governor
rope shall not be less than 10mm in dia. shall be made up of steel and as specified in Clause
26.6.0 of this Specification.
26.10.0 Buffers:
Buffers shall be in accordance with clause 5.15 of IS: 14665 (part-2, Sec.2):2000 or latest.
Hydraulic/spring buffers of tested design shall be installed as a means of stopping the car and
counter weight at the extreme limits of travel. Buffers in the pit shall be mounted on the steel
frame, which shall extend between both the car and counter weight guide rails. Energy
accumulation type buffers shall only be used if the rated speed of the lift does not exceed 1 m/s
and Energy accumulation type buffers with buffered return movement shall only be used if the
rated speed of the lift does not exceed 1.6 m/s.
For lifts equipped with attendant control, the control station shall also incorporate:-
All push/electronic touch buttons shall be vandal-resistant design and of flush mounted
construction. The push/electronic touch buttons shall have acknowledgement of the
call by illumination. The halo shall be formed with flame retarding polycarbonate. Shock
loads due to pressing of the pressel must be borne by the body of the unit and not by the
contacts.
(f) Lift control buttons:
Essential lift controls buttons such as emergency alarm button, intercom button, door (opening
button, call buttons on landings, floor buttons in the lift car shall not be lower than 900mm or
higher than 1200mm above the finished floor level. Braille and tactile markings shall be
placed either on or to the left of the control buttons. Such markings shall be minimum 15mm in
height and 1 mm raised. All lift control buttons shall have a minimum dimension of 20 mm.
26.11.2 Fire Emergency return:
When the building's fire or smoke detectors are activated, all calls should be cancelled
automatically and the lift shall travel to the main lobby or a pre- designated floor and park
there with the door fully opened. However the Electrical signal that indicates the actuation of
the fire sensors must be supplied to the lift controller by others or the fire a larm switch
provided on the ground floor is activated. The display to be given in the car with pre-recorded
audio message so that passeng ers do not panic.
26.11.3 Car lights & Fan automatically shut off:
The lift shall be installed with an energy saving feature that automatically switches off
the car internal lighting and ventilation fans when there are no calls registered after a
predetermined (Programmable) period of time.
26.11.4 Interphone:
An interphone for the use in case of emergencies shall be installed in the car for direct
communication with the rescue personnel in the control room or top of the car. The interphone
shall be such that it is activated by simply pressing the interphone button on the car operating
panel.
26.11.5 Fault information recording:
The lift shall be provided with an automatically fault recording facility. A minimum of 50 last
fault information's are reco rded to check what happened during a break down.
26.11.6. Arrival chime:
An electronic chime to provide an audio signal to inform waiting passengers of the arrival of
the lift car at each floor shall be provided. The chime shall be mounted on the top or bottom of
(a) Construction:
The controller shall be constructed in accordance with IEC 60947 and shall be mounted in a
ventilated steel cubicle with hinged front doors and removable hinged rear panels, in which all
contactors, solenoids, relays, motor starting equipment etc., shall be fitted. All steel sheets
shall be not less than 2.5 mm thick and comply with Clause 20.0 of this Specification.
(b) General requirements:
The controller shall comply with the general requirements as stated in EN 81-1, and in
particular, the following features shall be included:
1. Materials used in the construction of the control equipment shall not support combustion.
2. The components shall be designed and mounted in a manner which will facilitate easy
inspection, maintenance, adjustment and replacement. Wirings shall be terminated in
such a way that the wires are not damaged. Accessible terminals suitably marked, shall
be provided for incoming and outgoing cables.
3. Control circuits at normal mains voltage shall be connected between phase and neutral
and shall be supplied through double wound isolating transformer.
4. Where rectifier is used it shall be of the full wave silicon type fed from a
transformer.
1. Normal/Fault status
2. Duty/Standby status
3. Power Supply Norma l/ Fault status
4. Normal/ Essential Power status
5. Passe nger trapped alarm
This interface unit shall be located at the management office/caretaker's room next to the
lifts monitoring panel unless otherwise specified on the Drawing or in the Specification.
(e) Energy consumption and Duty Cycle monitoring:
The lifts shall be provided with energy recording devices and duty cycle reporting system. The
print out port with RS 232/ USB port to be provided to communicate with PC/Laptop to dawn
load energy, duty cycle, fault logs, mode of operation, battery status and other
data/information etc. The down loading software to be supplied along with one Laptop PC and
printer independent of platform as approved by employer or engineer in charge. The down
loaded data, reports, information shall be platform independent in alpha numeric format in
English language and shall have full compatibility and exchange with MS office .
(f) Directiona l collective control for single lift:
All calls shall be stored in the system and answered in sequence regardless of the order in
which they are registered. When the car is traveling in a given direction it shall travel to the
further-most call, answering any car ca ll or landing call for the corresponding direction of
travel. Landing calls for the direction opposite to that in which the car is traveling shall be by-
passed but shall remain stored in the system to be answered when the car returns in the
opposite direction. When the car stops for the last call in its direction of travel, preference is
given to car call(s) for an adjustable period. When all calls have been answered the car remains
with doors closed at the floor to which it last traveled.
The conduit/trunking facilities from the lift shaft at the landing of designated point of entry
to the position of the supervisory control panel shall be provided by others as in Clause
26.12.0(h).
The Supplier/Contractor shall be responsible for providing all necessary harmonic filter(s) should
the THO of the installation exceed the maximum allowable values as specified in Table I.
Rated Load Maximum allowable Electrical power{kW) of Traction life Systems for
{Kg) various ranges of Rated speed {Vc) in m/s
750 <L ≤ 10 12 17 21 24
1000
1000 <L ≤ 12 17 22 27 32
1350
1350 <L ≤ 15 20 27 32 38
1600
1600 <L ≤ 17 25 32 39 46
2000
2000 <L ≤ 25 37 47 59 70
3000
3000<L ≤ 33 48 63 78 92
4000
4000 <L ≤ 42 60 78 97 115
5000
L < 5000 0.0083L+ 0.0118L+ 0.0156L+ 0.0190L+ 0.0229L+
0.5000 1.0000 0.5030 2.0000 0.5000
26.19 Finish:
All metal work supplied by the Supplier/Contractor in out of the way locations such as the lift
shaft, lift pit and on the outside of the lift car shall be properly wire -brushed, cleaned of rust,
scale, dirt and grease prior to the application of one coat of rust inhibiting primer, with
particular attention paid to the priming of outer surfaces of car doors, inner surfaces of
landing doors, metal work associated with door assemblies, the underside and the framework
of lift cars. Any part of the equipment, including guide rails, which requires greasing or oiling
and any components that are supplied unpainted by the manufacturers due to functional
reasons shall not be painted.
All normally visible metal surfaces, other than stainless steel and non-ferrous surfaces, shall
be finished with one coat of rust inhibiting primer, one under coat/finishing coat and one
finishing coat of enamel paint to a colour to be selected by the Supervising Officer.
At least four renewable guide shoes, or guide shoes with renewable linings, or sets of guide
rollers shall be provided, two at the top a nd two at the bottom of the car
frame.
26.30 Guarantee:
The Supplier/Contractor shall guarantee satisfactory performance of the Lift and allied
equipments over a period of 24 months in actual service from the date of handing over of the
installation to the Railway in normal working conditions. During the guarantee period the
Supplier/Contractor shall rectify free of cost of all defects which may develop due to any reason
including faulty design, material failure and bad workmanship inclusive of free replacement of
defective parts. The guarantee will get automatically extended corresponding to the periods
during which the equipment is not in use. On every occasion when the equipment goes out of
service, the duration between the date of intimation of the failure of equipment to the
contractor and the date of handing over of the equipment after repairs in good working
condition duly tested and commissioned in the presence of Railway's representative, will be
counted for the extension of the guarantee period till the equipment completes actual service
for a total period of 24 months. During the guarantee period the parts of the equipments
requiring repairs or replacements will be handed over to the contractor at site and the parts
after repairs or replacements shall be fitted in the equipment at site by the contractor. All
expenses involved in fulfilling the above guarantee obligations shall be borne by the contractor.
26.31 Inspection:
The materials will be inspected by purchasers' nominated representative at manufacturer's
premises or contractors depot as the case may be. The purchaser or his representative shall
have the right to be present during all the stages of manufacture and shall be afforded free of
charge all reasonable facilities for inspection and testing as well as to examine the stage
inspection report of the manufacturer/ inspection in addition to the quality audit which the
contractor may institute as a part of his Programme so as to satisfy himself the materials are
in accordance with the specification, approved drawings and designs and purchasers
prescribed Quality Assurance Standard.
S Nature of Work
No.
1. Check and attend fittings of Lift (light, fan, emergency light, failure alarm etc.)
2. Check level of the lubricating oil in the gea rbox, any unusual sound in the gearbox.
8. Check the main switch, fuses etc. (for loose connection, oscillation and ratings etc.).
4. Check the condition of the pit clean the car top and clean the gate.
5. The wire ropes should be cleaned by a stiff brush to remove old lubricant and lubricate
it again by using oil machinery medium or equivalent.
9. Measure the voltage and current at the various test points in the control system
including microprocessor control and record it.
10 Check the fixing bolts of the motor for any vibration.
Sr Nature of work.
No.
1 Overhaul the motor for bearing and alignment.
2 Check car of body supported and steel channels.
c) While attending the quarterly schedules the firm has to carry out the monthly schedules also.
d) While attending the yearly schedules the firm has to carry out the monthly and quarterly
schedules also.
e) Maintenance schedule should be carried out in consultation with user mostly on Holidays or
beyond office hours.
f) If the Lift remains OUT OF SERVICE for more than 48 Hours per month, Railways will have
right to impose penalty to the extent of 10% value of the contract .
ANNEXURE”A“
1 Capacity : …..persons.
2 Speed : ….m/sec.
19. Human interface a. Hall button with micro stroke push/touch buttons combined
device with 16 segment digital LED display positio n indicator.
h. Fireman's switch.
1.
e) Machine:-
Acceleration. :
d) Type of enclosure. :
f) Output in HP. :
g) Weight. :
i) Class of insulation. :
2. Brake:-
a) Make. :
b) Type. :
d) Method of adjustment. :
b) Weight (Approx.). :
c) Contract load. :
d) Maximum speed. :
4. Guide Rail:-
b) No. of Sections. :
d) Method of lubrication . :
c) Spacing of intermediate :
supports.
d) Method of lubrication :
5. Control Equipments:- :
a) Type. :
a) No. of ropes. :
c) Factor of safety. :
7. Counter weight:- :
a) No. of sections. :
b) Weight of ea ch section. :
8. Wiring:- :
a) Specification of wires. :
b) Method of wiring. :
9 FINISHING. :
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MISCELLANEOUS SPECIFICATIONS
CHAPTER:A-27
MISCELLANEOUS SPECIFICATIONS
Based on the tripping Characteristics, MCBs are available in B” and ‘C’ Curve to Suit different
types of applications.
‘B” Curve: For Protection of electric circuits with equipment that does not cause surge current
(lighting and socket outlet circuits). Short circuit release is set to 3-5 In
‘C” Curve : For Protection of electric circuits with equipment that cause surge current (inductive and
motor circuits). Short circuit release is set to 5-10 In
‘D” Curve : For Protection of electric circuits which cause high in rush current when they are switched
ON. Typically 15 times the normal running current (Transformers, Heavy Start Motors, 2
Pole Motors). Short circuit release is set to 10-20 In.
C Above 180°C Materials such as mica Porcelain, glass quartz and asbestos with
or without inorganic binder.
The degree of protection is specified in The first numeral indicates the degree of
accordance with DIN 40 050 and with protection against contact with live parts and
Publications of the International Electro the ingress of foreign bodies; the second
technical commission (IEC) by means of the numeral indicates the degree of protection
letters IP (International Protection) and two against water.
characteristic numerals.
First characteristic numeral. Second characteristic numeral.
Degree of protection against contact with live Degree of protection against water.
parts and the ingress of foreign bodies
First Degree of Protection. Second Degree of Protection.
characte characte
ristic ristic
Numeral numeral
0 No protection of persons against 0 No protection.
contact with live or moving parts
inside the enclosure.
No protection of equipment
against increase of solid foreign
bodies.
1 Protection against accidental or 1 Protection against drops of
inadvertent contact with live or condensate.
moving parts inside the enclosure Drops of condensate falling
body large surface of the human vertically on the enclosure shall
body as, for example, a hand, but have no harmful effect.
no protection against deliberate
access to such parts.
Protection against ingress of large
solid foreign bodies of diameters
greater than 50mm.
2 Protection against contact with live 2 Protection against drops of other
or moving parts inside the liquids.
enclosure by figures. Drops of falling liquid shall have no
Protection against ingress of harmful effect when the enclosure
medium size solid foreign bodies of is tilted any angle up to 15 from
diameters greater than 12mm. the vertical.
3 Protection against contact with live 3 Protection against rain.
or moving parts inside the Water falling as rain at an angle
enclosure by tools, wires or such equal to or less than 60 with
objects of thickness greater than respect to the vertical shall have no
2.5 mm. Protection against ingress harmful effect.
of small solid foreign bodies of
diameter greater than 2.5 mm.
4 Protection against contact with live 4 Protection against splashing liquid:
or moving parts inside the Liquid splashed from any direction
enclosure by tools , wires or such shall have no harmful effect.
objects of thickness greater than 1
mm.
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APPROVED MAKES
OF
1. All Equipments & Materials should conform to latest version of BIS or other indicated
specification as per RVNL Policy guidelines. All energy consuming equipments should have
minimum 3 star rating given by BEE, wherever applicable.
ABB
Siemens
Voltas
Volt Amp. ,
Kerala Electric and Allied Engg. Co. Ltd.,
Vijay Electricals
Indo Tech. Transformers Ltd.,
PN Engg.
Power Master Electricals, Kolkata
Automatic Electrogear, Kolkata
Alfa Transformers, Bhubaneshwar
Orissa Transformers, Pvt. Ltd.,
Bhubaneshwar
United Machinery Corporation, Kolkata,
Star Delta Transformers Pvt. Ltd.Bhopal.
XICON
Safe Systems
Shrink Fit
REPL
DENSON Yamuna
Super Seal
Birla 3M
Sub Cab
SBEE
Fine cab
Bharat Cab brand of Vardhaman cables
44 RCC Hume /HDPE Relevant Reputed make ISI mark with the
pipe/DWC Pipe approval of the Engineer
Kirloskar
Worthington Pumps India Pvt. Ltd.,
Ghaziabad
Beacon Weir Ltd.,Chennai
Mather & Platt Ltd., Pune
Jyoti Ltd., New Delhi
Luxmi Pumps
KSB
Suguna
ii) Control Panel for Relevant Original as supplied with pump by OEM
Pump
Kiron
NOTE:
1. If any item/ equipment are not included in the above list, good quality material/equipment shall
be procured, in accordance RVNL policy as stipulated.
2. If any work requires coordination and acceptance of other department of Central/State
government, the contractor shall follow approved vendor list and standards, specifications of
that department and take their approval before ordering the material/equipment.
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IMPORTANT
INDIAN STANDARDS
(IS)
Note: The following IS codes (issued by Bureau of Indian Standards) shall be referred with their
latest amendments for supply, erection, testing and commissioning of the equipments and materials.
------------------------------------------------------------------------------------------------------
PART-B
RAILWAY ELECTRIFICATION
WORKS
CHAPTER:B-1
GENERAL REQUIREMENTS FOR 25 kV AC OHE
1.1 INTRODUCTION:
This part contains general, technical and other specifications for design and erection of
complete 25 kV AC 50 Hz single phase traction overhead equipment, switching stations, booster
transformer stations, LT supply transformer stations complete with foundations, structures, return
conductors and 25 kV feeders if any. This part also gives reference to technical specifications of
materials and components, procedure for submission of designs and drawings of basic arrangements,
components and fittings designs and other typical designs relating to overhead equipment, switching
stations and booster transformer stations. A list of the standard drawings is included in the
annexure to these Technical Specifications.
The design and erection of OHE shall conform to standards and specifications, guidelines laid
down in A.C.Traction Manual, IR Schedule Of Dimension-2004, RDSO and Railway Board issued from
time to time with their latest amendments.
The details covered here are for 25 KV conventional OHE. For high rise OHE, para 1.9 may be
referred for relevant specifications of RDSO.
The specifications issued here are meant for guidelines and does not supersede any of the
rules/regulations/codes/instructions issued by Railway Board/RDSO/CORE etc from time to time and
they shall be followed accordingly.
The nominal voltage of the overhead equipment will be 25 kV AC 50 Hz, single phase. The
supply voltage may, however, rise upto 27.5 kV. One terminal of the 25 kV system will be solidly
earthed at the traction sub-station and also connected to the running rails. The other terminal will be
connected to the overhead equipment through switchgear provided at the traction sub-station and at
the feeding station.
(b)SWITCHING STATIONS
Power supply will be controlled to the different sections of traction overhead equipment by switching
stations. At these stations the switching will be effected by means of “Interrupters” which are single
pole, non-automatic circuit breakers capable of repeatedly interrupting normal full load current. There
are three types of switching stations:
Notwithstanding any approval of drawing or work by RVNL, the contractor shall be finally
responsible for following correct instructions and drawings as per latest amended details. In
case any mistake is found in the work/drawing later on which is not carried out/prepared in
accordance with laid down standards, rules and regulations, the Employer shall be free to reject
it at any stage of the work. The contractor shall be liable to dismantle/modify/redo the rejected
work without any extra cost as per directions of the Employer. The decision of the Employer
shall be final in this regard. In this technical specification, the latest standards/drawings/
instructions /letter/ Code of Practice etc means latest up to the date 28 days prior to the
deadline for submission of bids.
OVERHEAD EQUIPMENT
2.1 TRACK
(b) SPEED
The overhead equipment which shall be of the simple polygonal type and pre-sag should be
designed for a maximum speed of 160 kmph (approx. 100 miles/h)if unregulated, unless
otherwise specified in any particular section.
(c) CURVES
The minimum radius permissible is 175m (573 ft.) i.e. a 10 deg. Curve. Inside station limits,
the curvature at a 1 in 8.5 turnout is 8 degree i.e. of radius 219m (716 ft.).
(f) FORMATION
Generally sections with more than one track have common formation. In certain lengths,
however the formation for different tracks may be separate (see relevant drawing listed in the
Annexure to these Technical Specifications).
(g) DISPLACEMENT
The general design of overhead equipment shall permit a displacement of +/- 100 mm of
tracks without difficulty and any adjustment of the overhead equipment on this account shall
be of such a nature as could be done conveniently without changing any component of the
overhead equipment.
2.2 SECTIONING
(a) INSULATED OVERLAPS
Insulated overlaps are provided for facility of isolation. Some of the overlaps may be provided
with manually operated isolator switches. In addition, for connecting the overhead equipment
to booster transformers, insulated overlaps are to be indicated in the sectioning diagrams.
The overhead equipment in yards and sidings may be fed through isolator switch or
interrupter in accordance with arrangement indicated in the sectioning diagram/s.
(i) If neutral section is provided after a stop signal, the distance * between signal and neutral
section shall be such that after stopping, the train shall be able to pick up enough speed to
coast the neutral section without any risk of stalling.
(ii) If neutral section is provided before a stop signal, the distance* between neutral section
and signal shall be such that the train shall not cross the signals in an effort to cost the
neutral section.
(iii) The PTFE type short neutral section shall be located on level tangent track at least 400 m
after the stop signal and 200m before the stop signal. Where, however, modification require
to comply with these guide lines are difficult or entail heavy investment, the Chief Electrical
Engineer of the Railway may direct any other arrangement to be followed consistent with
safety and reliability. For location on graded section guidelines of para2.2 h (i),(ii) shall be
followed.
(iv) PTFE type short neutral section assembly shall be procured as per RDSO specification NO.
TI/SPC/OHE/SNS/0000(01/00) or latest.
2.3 PANTOGRAPHS:
(a) The outline of the pantograph, its dimensions and its current collecting area are shown in a
drawing listed in the Annexure to these Technical Specifications.
(b) CATENARY
The catenary wire shall be of cadmium copper 19/2.10 mm, 65 mm sq.
(c) CONTACT WIRE
The contact wire shall be grooved and made of hard drawn copper 107/150sq. mm cross
section. 65/150 sq mm OHE with 1200/1200 kgf tension shall be adopted for new
electrification in terms of RDSO L.No. TI/OHE/GA/2013 DT 30th April,2013.
(d)DROPPERS
Droppers shall be made of hard drawn round copper wire, approximately 5 mm dia. Droppers
shall be spaced not more than 9 m apart.
(e) ENCUMBRANCE
As a general rule, the nominal “encumbrance” i.e. the centre distance between the catenary
and the contact wire at the support shall be 1.40m. Deviation from this figure will be
(f) Jumpers:
All jumpers connected to OHE conductors shall be of copper only. The in –span jumpers
potential equalizer jumpers at insulated overlaps and neutral section shall be of 50 mm sq.
nominal 19/1.8 mm size. Flexible jumper of nominal section 105 mm sq., 19/7/1.06mm size
shall be used at overlaps turnouts, crossings, etc. Provision of long cross type G-jumper on
parallel run side instead of cross-over/turn out side as per RDSO drawing No ETI/OHE/G/02141
Rev ‘C’ or latest.
The jumper connecting the Aluminium Conductors to any other conductors terminal or clamp
shall be made with the aid of suitable bi-metalic clamps. All aluminium jumpers of size
19/7/1.4 mm bare ¾ hard shall be used to connect other aluminium conductors such as
return conductor. The tail ends of feeder wires from the strain clamps at the termination of a
feeder, return feeder or return conductor may be connected directly to a terminal or clamp
where feasible to avoid the use of a separate jumper wire.
(a) REGULATED
In the regulated type of overhead equipment, the tension of both the catenary and the
contact wires shall be maintained at a constant value at all temperatures by means of
automatic tensioning devices desired to take up the variation in the length of overhead
equipment due to temperature variation.
An anti creep shall be provided at a point approximately midway between two tensioning
devices and not more than 750 metres from any one of them. The general arrangement of an
anti-creep is shown in a drawing listed in the Annexure to these Technical Specifications. The
arrangement shall generally consist of the galvanized steel wire anchored on the masts
adjacent to the anti creep central mast in accordance with the relevant drawing listed the
Annexure to these Technical Specifications. Alternatively, the arrangement may consist of
anchoring the catenary on either side of the boom of a portal with the contact wire running
through and providing a jumper connection as per general arrangement shown in typical
drawing listed in the Annexure to these technical specifications. The engineer shall indicate
the type of anti-creeps to be adopted in the pegging plans. RDSO drawing No.
TI/DRG/OHE/GENL/RDSO/00001/12/0 REV ‘0’ or latest, Ref.ETI/OHE/G/02111 Rev-A
dt.23.10.2012 or latest is to be followed for use of catenary wire in place of GI wire at ACC
locations in polluted area.
(a) REGULATED
The regulated overhead equipment shall be so erected that the contact wire has the designed
sag.
(b) UNREGULATED
In the case of unregulated equipment the contact wire shall have no sag at an ambient
temperature of 35 deg. C.
(d) DROPPER
Dropper charts to be used for standard span of regulated and unregulated overhead
equipment would be supplied by the Engineer. Droppers for non-standard spans, span with
section insulators and special locations shall be calculated by the Contractor in accordance
with the method indicated by the Engineer and submitted to the Engineer for approval.
For dropper schedule of OHE having presage of 0.8mm/meter, RDSO drgs
TI/DRG/OHE/DROP/00001/10/1, TI/DRG/OHE/DROP/00002/10/1, TI/DRG/OHE/DROP/00003/
10/1 should be used [RDSO lr No: TI/OHE/SHS/2014 dt 29/9/2014].
2.7 TENSIONS:
(a) REGULATED
(i) In regulated equipment the tension in the catenary and contact wire shall be 1,000 kgf in
each conductor.
(b) UNREGULATED
In unregulated equipment the tension in the catenary and in the contact wire at 35 degree
C without wind shall be, 1,000 kgf in each conductor.
2.8 CLEARANCE:
(a) GENERAL
The distance between live parts and parts at earth potential (for parts likely to be earthed) shall
be as large as possible. In all cases the values given in the latest version of the Schedule of
Dimensions shall be observed along with any other supplementary rules, that may be issued by
the Railway Board.
Note: i) Long Duration means when the conductor is at rest and short Duration means
when the conductor is not at rest.
ii) A minimum vertical distance of 270 mm shall normally be provided between rolling
stock and contact wire to allow for a 20 mm temporary raising of the track during
maintenance. Wherever the allowance required for track maintenance exceeds 20 mm,
the vertical distance between rolling stock and contact wire shall correspondingly be
increased.
iii) Where adoption of above clearances is either not feasible or involves abnormally
high cost, Permanent Bench Mark shall be provided to indicate the level of track to be
maintained.
i) Regulated: In sections where High speed trains with 160 kmph or higher speed are likely
to be run, contact wire pre-sag shall be planned to be 0.8 mm per meter (precisely rather than
following thumb rule of 50 mm for 72m span as per RDSO letter TI/OHE/SHS/2014 dt 29/9/2014.
ii) Unregulated
- Unregulated OHE designed 5.75 m
For areas with temp. range of
4 deg.C to 65 deg. C
- Unregulated OHE designed for 5.65m
Areas with a temp. range of 15
deg. C to 65 deg. C
(b) The height may be reduced under overline structures after a clearance study. The
minimum height shall be 4.92 m for the broad gauge and 4.02 m for the metre gauge to
permit movement of “C” class ODC without physical lifting of wires. In case ”C” class ODC
movement is not required, the height could be reduced to 4.80m (BG). Height may be
further reduced to 4.65 if rolling stock higher than 4.265 m are not allowed on such lines.
(c) At electric locomotive sheds and loco inspection pits, the minimum height shall be 5.80m
for the BG and 5.50m for the MG.
(d) All level crossings, the minimum height shall be 5.50m for both broad and metre gauges.
(e) Necessary provision shall be made in overhead structure and overhead equipment, if
necessary by using longer OHE masts to permit an allowance of 275 mm for raising of
track in connection with introduction of modern track structures in future and for catering
to increased ballast cushion, larger sleeper thickness etc [para 10(f) of ACS-10 of SOD-
2004]
(f) Erection tolerance:[Para 7.3 of ACTM]
A tolerance of +/- 20mm is permissible on the height of contact wire as measured at a
point of support except on either side of an over bridge where tolerance of +/- 10 mm will
be allowed. But the difference between the heights of contact wire at two adjacent
supports shall not exceed 20mm. In spans with gradient of contact wire, this difference of
20 mm is measured over and above the approved gradient.
2.10 STAGGER:
To ensure uniform wear of contact strips of pantographs, the contact wire shall normally be
staggered in a manner given below.
a) Tangent Track
On tangent track the contact wire is normally given a stagger of 200 mm at each support
alternately on either side of the centre of the track. This is relaxed in special cases for ensuring
requisite clearances in difficult locations such as in the vicinity of signals. Subject to stagger at
midspan not exceeding the permissible values given in Drg. No. ETI/OHE/G/ 00202.
b) On tangent track, the catenary stagger is zero for masts supporting a single equipment.
The catenary is fixed vertically over the contact wire at all supports at which more than one
equipment is supported, at flexible head spans and at supports with reduced encumbrance, on
tangent as well as curved tracks.
c) Curved Track
On curves, the stagger of the contact wire at supports should not exceed 300mm. The stagger
of the catenary on curved track shall be determined with reference to Drg. No.
ETI/OHE/G/00202. The standard values adopted are 0, +200 and -200.
e) Uninsulated overlap
At uninsulated overlaps, the stagger should conform to drawing No. RE/33/G/0 2121 Sh. 1. On
non uniform curves or at other locations where staggers different from those indicated in these
drawings are adopted, the following points should be observed.
i) The stagger of the in running contact wire does not exceed to 100 mm on tangent track
and 300 mm curved track at any support, at which only one contact wire is in running.
ii) In any span of the centre of which only one of the contact wires is in running ( as in a
4-span overlap), the mid-span stagger of the in-running contact wire does not exceed
the values given in Drg. No. ETI/OHE/G/00202.
iii) The two contact wires run parallel to each other between the intermediate supports at
a distance of 200 mm from each other.
f) Insulated Overlap
At insulated overlaps, stagger should conform to Drg. No. ETI/OHE/G/02131 Sh. 1. On non –
uniform curves and other locations where stagger different from those shown in this drawing
are adopted. The points mentioned against un-insulated overlap spans also apply, with the
difference that between intermediate masts the two contact wires run parallel at a distance of
500 mm from each other.
g) Neutral Section:
The stagger at overlap type neutral sections should conform to Drg. No. ETI/OHE/G/02161,
Sheet No. 1.
i) The stagger at section insulator type neutral section should be so adopted that the stagger at
the section insulator assembly is within the limit of +/- 100 mm.
ii) PTFE type neutral section shall be erected on tangent track only. The stagger shall be zero at
support.
2.11 SPAN:
Standard spans shall be determined in accordance with following RDSO drawings:
The spans should be as large as practicable. The maximum span of the OHE in tangent track is
72 m. Spans may be reduced in interval of 4.5m based on curvature, signal locations etc keeping
in view stagger limits, signal visibility. Maximum span of OHE is also limited based on the wind
Note:
(a) On main tracks, the lengths of two consecutive spans shall not normally differ by more than
18m.
(b) The spans in case of unequal encumbrances shall be such that the axial distance between the
catenary and contact wire at the min dropper is not less than 150mm.
(c) With crossed type OHE at facing turnouts, the anchor spans shall be restricted to 54m.
(d) Where earth wire is provided, the max span over level crossings should be 58.5m.
(e) Spans should be restricted when loaded with section insulators.
2.12 TERMINATION
(a) GENERAL
Traction overhead lines shall be terminated using components as specified in RDSO Drg. The
termination may be carried forward by one or two spans if anchoring facilities so require.
(b) Terminating wires shall be electrically connected to the conductors with which they
are likely to approach closely or come into contact under normal conditions.
(c) PORTALS
In cases where the tracks in a multiple track section do not permit location of independent masts
and where automatic tensioning of overhead equipment is required, rigid portals may be used.
Also in the vicinity of points and crossings, portals may be used, provided it is not possible to
have prescribed setting with independent cantilever masts. These structures shall be equipped
with standard bracket assemblies for supporting individual equipment of different tracks. The use
of such structures is to be avoided as far as possible and for this purpose, the Engineer will
arrange to slew the tracks, if practicable. A single portal shall normally not cover more than five
tracks (See also 4.7). Portal structures shall also be employed at anti-creep central locations and
such portals will have necessary guy arrangement.
(d) FOUNDATIONS
Foundations for all structures shall be designed in an economical manner by following the
methods of design indicated by the Engineer and observing the schedule furnished by him.
The bracket assembly carrying overhead equipment shall be swivel type. The assembly shall be
such that the tubes adopted will permit easy adjustment of the whole equipment after erection to
cater for displacement of the track during maintenance up to the extent of 100 mm on either side
except as otherwise relaxed by the Engineer (see Para 2.1 g). In special locations, pull –off
arrangements may be used with the approval of the Engineer.
In sections where High speed trains with 150 kmph or higher speed are likely to be run, drop
bracket assembly as per drg No ETI/OHE/P/2360 alongwith steady arm drg ET/OHE/P/2390
should be used to give 100mm push up. [RB letter 2001/RE/170/1 dt 13/3/2007 &
2001/Elect(G)/170/1 Pt 30/6/2009].
2.15 OVERLAPS:
Overlaps shall be provided at suitable intervals such that neither the tension length exceeds
1500 m nor the fixed anchor to balance weight anchor exceeds 750m.
(a) GENERAL
The two contact wires at the overlapping zone shall be parallel to each other in a
plane parallel to the track and run separated from each other.
(b) INSULATED
In the case of insulated overlaps, the separation between the two contact and the two
catenary wires shall be 0.5m (see the Annexure to these Technical Specifications for
general arrangement drawings).
1. At National Highway having Class-I road or TVU > 1 lakh)Standard plan- Height
Gauge for level crossing (For Clear span above 7.3 m Upto 12.2 M) details of structure &
foundations Drg. No. TI/DRG//CIV/HGAUGE/RDSO/00002/05/0.
2. At State Highway having Class-I road or TVU > 1 lakh)Standard plan – Height for
level crossing (For clear span upto 7.3m) details of structure & foundations Drg. No.
TI/DRG/CIV/HGAUGE/RDSO/00001/05/0
3. At Other roads (Class-II to IV) height gauges at level crossings upto 7.30 m span
Drg. No. RE/CIVIL/S/138-04 (Mod.-R1).
(a) Bonding and earthing shall be done in accordance with the code of practice for bonding and
earthing for power supply installations as per RDSO specification No. ETI/PSI/120(2/91) with
A&C Slip No. 1 (10/93).
(i) The structure bonds shall continue to be provided. However, earth wire is not required to
be provided.
(ii) The structure bonds shall be painted with ‘high build epoxy paint’ to RDSO Specification
No. M&C/PCN/111/2006.
2.22 LIGHTENING ARRESTORS: No lightening arrestors will be provided on the traction overhead
equipment.
The neutral section assembly shall be suitable for erection symmetrically on either side of the
cantilever bracket support with regulated or unregulated conventional/composite OHE where
one point each for suspension of catenary conductor and contact wire is available as also shown
in GA drawing under the Annexure to these Technical Specifications.
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CHAPTER: B-3
FOUNDATIONS
3.0 SCOPE:
This chapter deals with the design of foundations and anchor blocks for traction structures
carrying overhead equipment (including those on bridges), structures at switching stations and
booster stations and other concrete work. It also deals with the specifications for concrete.
In case any infringement is detected at any stage of the project execution, such foundations are
liable to be rejected by RVNL not with standing any approval given or supervision done by
RVNL. Final responsibility for the work done lies with the contractor and he shall replace and re-
cast all the rejected foundation and re-erect OHE (if required) free of cost.
In the case of hard rock, a hole should be blasted in the rock, or by means of any other
drilling and pneumatic method and the mast sealed into it with concrete.
3.3 CONCRETE:
(a) Concrete for foundations shall be nominal mix of following grade:
(c) For cable trenches at switching stations/TSS, M-15 grade concrete shall be used.
Example:
For an average grading of the fine aggregate (that is zone II of Table 4 of IS: 383-1970* or
latest) the proportions shall be 1:1.5, 1:2 and 1:2.5 for maximum size of aggregate 10mm,
20mm and 40 mm respectively.
* Specification for coarse and fine aggregates from natural sources for concrete (second
revision).
“Volume Batching may be allowed only where weight batching is not practicable and provided
accurate bulk densities of materials to be actually used in concrete have earlier been
established. The quantities of fine and coarse aggregate (not cement) may be determined by
volume. If the fine aggregate is moist and volume batching is adopted. Allowance shall be made
for bulking in accordance with IS: 2386 (Part-III-1963 or latest) the mass volume relationship
should be checked as frequently as necessary, the frequency for the given job being determined
by Engineer to ensure that the grading is maintained”.
In judging the acceptability of the materials, quality of concrete and the method of work, the
Engineer will generally observe the provisions of the “ Indian Standard Code of Practice for Plain
and Reinforced Concrete, IS: 456-2000 or latest. The crushing strength of concrete shall not be
less than the limits given below (as per IS456-2000 or latest Table-2 Grade of Concrete):
NOTE: (a) Test specimen of works tests shall be taken at the site of work from mixture
of concrete ready for pouring into the foundation hole. All tests shall be
carried out in accordance with IS: 516-1959 or its latest version. The
sample of concrete from which test specimens are made shall be
representative of the entire batch.
(b) Age is reckoned from the day of casting.
Fine aggregate shall be graded from 10 mm downwards. The maximum size of aggregate for
under reamed pile foundation shall be 20 mm graded nominal size. In case river sand is not
available easily and nearby, quarry dust of appropriate grading may be used without affecting
strength of the concrete and with prior approval of competent authority.
3.6 SAND CORED FOUNDATIONS:
After erection of masts in sand-cored foundations, the core hole of the foundation blocks shall
be filled with dried sand and covered with a layer of bitumen of 80 mm thickness below 30
mm from top level of the block. A hemispherical shaped muff shall be provided on such
foundations in lieu of standard type.
Where the water-level is high, one or more sections of reinforced concrete shells may have to
be sunk before casting concrete. The size of each of shell shall be 1200 mm outside dia x 50
mm thick x 600 mm high reinforced with 6mm (1/4”) dia rods spaced 150 mm apart, both
longitudinally and circumferentially, the concrete shall be of grade M10 as per provisions of
para 3.3.
3.8 CEMENT:
The cement to be used in the construction of foundations, RCC structures shall be ordinary
Portland cement of 43 grade (conforming to IS-8112) or 53 grade (conforming to IS-12269)
as approved by RVNL based on requirement and availability.
Side bearing foundations are used for masts where the soil bearing capacity is 11000 or
21500 kgf/m sq and 300 mm wide shoulder is available on the banks. However, for overlap
iner masts and masts on the inside of curves, 550 mm wide shoulder is necessary ( Typical
Drg No. ETI/C/0023).
(a) New pure gravity foundations may be used for masts where soil bearing capacity is 5500,
8000 and 11000 kgf/m sq. or where adequate shoulder width as mentioned in above para is
not available. In such cases, it should be ensured that foundation is not exposed.
(b) Side gravity foundations may be used for masts where soil bearing capacity is 8000 and
11000 kgf/m sq or adequate shoulder width is not available. No portion of foundation should
be exposed.
(i) The foundation of the black cotton should be done preferably in dry season i.e. from
November to May. Excavations should be avoided as far as possible in case of unexpected
rains in dry season also.
(ii) In black cotton soils, WBC and NBC type of foundations are used. Primarily WBC
foundations are to be adopted where swelling/ shrinkage is not expected to take place at the
foundation level and NBC foundations have to be provided where swelling/ shrinkage is
expected to occur.
(iii) The safe bearing capacity should be determined in accordance with IS: 6403 latest.
(iv) When in doubt regarding classification BC soil as to dry or wet, it is preferable to make
NBC type foundation.
3.10 Where foundations are constructed on the slope of banks, the foundations should be so
located that generally no part of it is exposed. The top of foundations may then be brought to
the desired levels (rail level -500 mm ) by providing a super block of length and breadth equal
to the top dimension of foundation. The increase in bending moment due to increased setting
distance should be calculated and the designation of foundation to allow for this BM should be
selected.
3.11 The top of foundation should be 50-100 mm above the surrounding ground level. The
length of mast below rail level should be minimum 1850 mm for regulated OHE and 1750 mm
for un-regulated OHE. A 1350 mm embedment of mast in concrete is necessary. Concrete
cushion of 150 mm below the bottom of mast is also necessary. Where necessary, these may
be achieved by providing a supper block of length and width equal to the top dimension of
foundation. However, portion of existing pure gravity foundations corresponding to a depth of
500 mm of embankment having slope of 1:2 may be exposed.(As per ACTM para no 6.5.9 vol-
II part-II).
Giving due consideration to the above, the most economical type of foundation should be
adopted.
1. For Masts:
(i) a) Side bearing ( Type B) Drg. No. TI/DRG/CIV/FND /RDSO/ 00001/04/0
b) Side gravity ( Type:BG) Sheet 1 Mod. B for 2.8 implantation or
c)Pure gravity for black cotton soil TI/DRG/CIV/FND/RDSO/00001/12 /0 for sheet
(type: WBC) 1 for 2.9 m implantation
2. For Portals:
(i) In ordinary soil Drg. No. ETI/C/0005/68
(ii) In dry black cotton soil Drg. No. ETI/C/0063
(b) LOCATION
The location of each foundation or anchor block shall be set out correctly in accordance with
the approved structure/cross-section drawings or foundation layout drawings, as the case may
be, in the presence of the Engineer.
(d) EXCAVATION
Normally, excavation of soil for foundations or anchor blocks along side the tracks may be
done up to the length of 1 to 1.2 m and depth of 0.8 to 1m without shoring, provided the
excavated hole is concreted immediately and not left overnight. Shoring shall otherwise be
done unless the hole is re-villed with soil and tamped. In case the length of excavation is 1 to
1.2 m and depth of excavation for foundations and anchor blocks alongside the tracks is more
than 0.8 to 1m, the excavation may be undertaken only after certification by the Engineer to
be safe and concrete is cast on the same day. Shoring shall be done to the satisfaction of the
Engineer, if the excavated hole is left overnight. All water logged locations will come under the
purview of this para. In poor soil or ash banks, no excavation shall be done without adequate
shoring and piling, For large foundations and water logged locations shoring shall be done in
accordance with drawings submitted by the Contractor and approved by the Engineer. Shoring
/shuttering of the pits should be provided effectively to the satisfaction of the Engineer. Core
hole covers should be provided promptly on casting of foundation (within 48 hours) and their
edges cemented to the foundation blocks. Prior to doing so, water should be filled in the core
hole so as to assist in curing. The date of casting should be inscribed on the foundation block.
In case of platform areas and Level crossings, the core holes should be filled with sand before
provision of core hole covers. So as to prevent any injury to rail users If the core hole cover
gets damaged or is displaced. The track ballast should be restored to its original form
promptly after casting of the foundation block. The excavated earth should be removed well
clear of the area so as to avoid any mixing up with the track ballast or any obstruction to the
track drains. In case of cuttings, the earth should be thrown well away from the shoulders so
that there is no risk of its flowing back to the drain during the rains.
(e) CONCRETING
All concreting or grouting shall be done in accordance with para 3.3 with coarse aggregate
grade for the purpose specified in para 3.5. The concrete shall be poured and compacted
(f) MUFFS
All anchor blocks and foundations of structures carrying overhead equipment shall be provided
with concrete muffs. The top of these muffs shall be above the level of ground the track
formation and of adequate height of not less than 15 cm to afford reasonable protection
during rainy weather. Muffs may be installed at the same time masts are grouted or after the
mast/ structure is loaded with equipment. The foundations of structures for switching stations
need not, however, be provided with muffs. The top of such foundations shall be given a slope
of 1 in 50 towards the edge to ensure that water does not collect at the base of the structure
of the frame work of the equipment.
(g) Suitable grooves or niches shall be provided in the foundation blocks, wherever required, at
the time of casting, to enable embedment of earth strips etc. to avoid the necessity of
chipping of concrete.
(g) Conduits for cables should be embedded in the foundation blocks, wherever required, to avoid
subsequent chipping off and breaking of the foundation blocks.
(i) Shuttering
Suitable iron shuttering of proper dimensions as per type of foundation shall be used while
casting the foundations in the exposed portions or any where required as per the site
conditions so as to get proper shape and finish.
Exposed surfaces of concrete shall be kept continuously in damp or wet condition by ponding
or by covering with a layer of sacking, canvas, hessian or similar material and kept constantly
wet for atleast seven days from the date of placing concrete in case of ordinary Portland
cement.
Sampling and Testing of concrete shall be done generally as per CORE letter No:
EL/CORE/Policy/system Improvement/0272/003 dated 26/2/2003. The provisions are
summarized as under:
Record for Sieve Testing of Coarse aggregate: three samples from every supply lot:
3.17 SUPERVISION:
Constant and strict supervision of all the items of the construction is necessary during the progress of
the work, including the proportioning and mixing of the concrete. Supervision is also of extreme
importance to check the reinforcement and its placing before being covered. Before any important
operation, such as concrete or stripping of the form work is started, adequate notice shall be given to
the construction supervisor.
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CHAPTER: B-4
OHE STRUCTURES
4.1 SCOPE:
This chapter deals with the design of steel structures and steel work for overhead equipment,
switching stations, booster transformer stations and LT supply transformer stations and the
specification for steel and pre-stressed concrete trial mast.
4.2 TYPES:
Structures and gantries may consist of any or more of the following types:
(i) Broad flange beams
(ii) Rolled steel joists ( I section).
(iii) Fabricated steel Structures ( Welded/bolted).
Structure/ uprights shall generally be embedded in concrete foundation blocks in special cases
Structures may be secured by means of holding down bolts.
4.3 DESIGN:
(a) STEEL STRUCTURES
Designs for steel structures shall, except where otherwise provided, comply with the
Indian standard code of practice for use of structural steel in General Building Construction-
IS: 800-1984. The thickness of smallest steel sections used shall be 5 mm for galvanized
members.
(b) All the steel structures and small part steel for carrying overhead equipment are to be
fully galvanized after drilling and fabrication as per specification No. ETI/OHE/13 (4/84) with
A&C Slip No. 1 to 3.
(ii) The additional deflection under maximum wind pressure shall not exceed 8 cm at the level
of the contact wire.
(iii) All traction masts and structures shall be erected with the correct reverse deflection so
that they become reasonably vertical after they are loaded.
(c) TORSION
The torsional rotation of the mast due to permanent loads shall not exceed 0.1 radian.
(a) Masts at which overhead equipment will be anchored will be anchored shall also normally be of
the same type as those in other locations. Anchor masts shall normally be provided with
suitable guys but struts may be permitted in special cases.
(b) LOAD
The load shall be as detailed in para 4.4 (a) as applicable.
b) Designs of Structures on bridges to suit different locations and local conditions will be
furnished by the contractor to the Engineer.
b) On straight track and outside of curve, the standard setting shall be as per the relevant
drawing included in the Annexure to these Technical Specifications. Minimum setting of
structures shall be 2.9 m plus curve allowance as required. Whenever this distance can not be
provided, specific approval of Engineer shall be obtained before erection. The setting of portal
upright, overlap/turn-out structures, anchoring structures and other masts carrying more than
one OHE will be 3.0 m wherever possible.
e) STRUCTURES ON PLATFORM
The setting of structures on platform shall be not less than 4.75 m.
(a) SIGMA BOARDS FOR EASY IDENTIFICATION OF STOP SIGNALS DURING FOGGY
WEATHER
Sigma Boards for easy identification of stop signals during foggy weather shall be
provided as per RDSO specification No. TI/OHE/ 33A (Revision-8) and Drg. No.
TI/DRG/OHE/PLTBRD/RDSO/00036/12/0 circulated vide Railway Board letter No.
2001/Elect.(G)/170/1Pt. dated 07.05.12.
(b) For purpose of design all possible loads which may occur in the worst combination shall be
considered. The loads shall include the followings:-
(ii) Maximum tension in longitudinal feeders running parallel to the track at the switching
stations under worst conditions 150 kgf.
(iii) Tension in anchored overhead equipment in case of sectioning and paralleling stations-
2000 kgf.
Deflection under the permanent loads (at an average temperature of 35 deg. C without wind)
at the top of the fabricated structures of mast shall be limited to one eightieth (1/80) of its
height above foundation.
(e) Masts of the gantry at which feeder or overhead equipment will be anchored at the switching
stations shall normally be provided with suitable guys, but struts shall not be permitted.
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CHAPTER: B-5
5.1 GENERAL:
This chapter deals with the details and specifications of the equipment, components and
materials to be used for traction overhead equipment, switching stations, booster transformer
stations and LT supply transformer stations.
All equipments, components and fittings shall be inter-changeable and supplies shall be in
accordance with the Engineer’s designs unless otherwise specifically approved by him.
Components such as fuses, indication lamps etc. should be replaceable with substitutes
available indigenously, as far as possible.
The technical specifications included in Annexure-2 to these specifications will govern the supply
and testing of important materials, components and equipments.
(a) All components and fittings shall bear the respective identification number and a mark to
identify the source of supply except in the case of galvanized tubes, bolts and nuts and /or
any other fittings as may be agreed to by the Engineer.
(b) In case of insulators, galvanized steel tubes, stainless steel wire rope and conductors, name of
manufacturer shall be specified in “ As Erected” drawings for identification.
(a) GALVANISING
All ferrous materials and fittings shall be hot dip galvanized according to the specification
ETI/OHE/13(4/84) with A&C slip No. 1 to 3
(b) PAINTING
Some components or parts may, with the approval of the Engineer, be protected only by paint
and parts so protected shall be given two coats of composite Aluminium primer and two coats
of Aluminium paint. The second coat of Aluminium paint shall be applied after erection.
(b) BRACKET
The bracket tubes shall be of seamless cold drawn or electr4ic resistance weld steel complying
with ETI/OHE/11 (5/89) with an insulator near the support. The length of the tubes shall be
such that there is a free length of about 200 mm beyond the catenary suspension bracket to
facilitate adjustment during track maintenance (see para 7.9 (b).
Ensure projection of RT at pull off i. e. –ve stagger location to be beyond the vertical plane of
the contact wire as per RDSO drawing No. ETI/OHE/G/02106 Rev ‘C’.
The Raised Register Arm Clamp conforming to RDSO drawings ETI/OHE/P/1370-1, Revision-‘E’
or latest shall only be used.
Gap between mast fitting for hook insulators & top of the mast should be as per drawing no.
RE/33/G/0001.
Bent steady arms of aluminium alloy tube conforming to Spec. ETI/OHE/21 (9/74) shall be used
for neutral section overlap and in the central mast of a 4 span insulated overlap.
(b) LOADING
The droppers shall be able to withstand a vertical load of 200 kg at the point of attachment to
the contact wire and the clip shall not slide under a horizontal load of 120kgf.
(c) The permissible tolerance in the overall length of a dropper will be +/- 5mm.
5.11 INSULATORS:
(a) All insulators except those on return conductors and earth wires shall be of the solid core type.
Disc insulators shall be used on return conductors and earth wires or other locations as desired
by the Engineer. All solid core insulators shall conform to TI/SPC/INS/0070(04/07).
(c) INTER-CHANGEABILITY
For free inter-changeability only the following types of insulators shall be used. While the
shapes of the insulators may vary slightly from those shown in the drawings, the essential
dimension of the galvanized malleable cast iron caps as given in standard drawings shall be
adopted.
(i) Stay arm Insulators: These insulators will be used in conjunction with the tubular
stay arm of all bracket assemblies.
(ii) Bracket Insulators: These will be used at the base of each bracket assembly in
conjunction with bracket tubes.
(b) LOADING
All the parts shall be capable of withstanding without damage, a load greater than the
ultimate strength of the wires to which they are fitted. In case of threads, no damage shall
occur when they are subjected to a load equal to two third of the ultimate strength of the
wires.
(f) PG Clamps:
The Parallel grooved Clamps conforming to following RDSO drawings (or as amended) shall
only be used:
(i) Parallel Clamp (90/50) – RDSO drawing no. ETI/OHE/P/1040-3, Revision ‘B’ or latest
(ii) Contact Wire Parallel Clamp (Part Small) – RDSO drawing no. ETI/OHE/P/1041-2,
Revision ‘D’ or latest
(iii) Parallel Clamp (150/160) – RDSO drawing no. ETI/OHE/P/1050-3,Revision ‘A’
(iv) Parallel Clamp Part (150 / 105 - 150) – RDSO drawing no. ETI/OHE/P/1051-2,
Revision‘C’.
(v) Parallel clamp (105/240)-RDSO drawing No. ETI /OHE/P/1530-1 Revision” C’
(b) JUMPERS
Copper jumpers shall be of any of the followings:
(i) Large jumpers of annealed copper in accordance with specification ETI/OHE/3(2/94)
with A&C slip No. 1 of 4/95.
(ii) Small jumpers of annealed copper in accordance with the specification IS: 9968
(PT.2) -1981.
(d) FEEDERS
Feeders shall be of all Aluminium conductor 19/3.99 mm (SPIDER).
(f) The general characteristics of all wires and conductors shall be as per RDSO/CORE drawings.
(g) Earth wire shall be of steel reinforced Aluminium conductor 7/4.09 mm (RACCOON) conforming
to IS: 398-(Part-II) 1976.
(a) GENERAL
A general arrangement is shown in the standard drawings of CORE/RDSO. The regulating
equipment should have a minimum adjustment range of 950mm. Stainless steel wire rope in
accordance with TI/SPC/OHE/WR/1060 with A&C slip no. 1 & 2 shall be used in these
equipments and these shall be sufficiently flexible for the purpose.
Fixing arrangement for mast anchor fitting for anti falling device for 3- Pulley modified ATD
should be as per RDSO drg. no TI/DRG/OHE/ATD/RDSO/00009/05/0 or latest and provision
of double eye distant rod as per RDSO MI no TI/MI/0008 Rev 0 (or latest).
The anchor height, X-Y adjustment chart and guide tube will be as per RDSO drawing
No.TI/DRG/OHE/GUYHR/RDSO/00001/13/0(Sheet-1to4),
(b) COUNTERWEIGHT
Counter weights and arrangements used shall be such that these could be accommodated
within 330 mm (13 inches) measured transverse to the track under the worst wind conditions.
The vertical upward movement shall be limited with a fixed top.
5.17 ISOLATORS:
25 kV isolator switches shall comply with specifications as indicated in para 5.5.
5.19 BUSBARS:
(a) No splicing will normally be allowed in the tubular bus-bars unless the length of the bus-bar
exceeds 6m.
(b) GENERAL
The bus-bar shall be clean, smooth, mechanically sound and free from surface and other
defects. Provision shall be made where necessary to allow for expansion and contraction of bus-
bars caused by temperature variation. The open ends of bus-bars shall be covered by suitable
tube caps, wherever the tubular bus-bars are required to be bent, the radius of the bend
shall be not less than 200 mm.
(c) JOINTS
(i) The joints in bus-bars shall be mechanically and electrically sound so that the temperature
rise under normal working condition does not exceed 40 deg. C for an ambient temperature
of 65 deg. C.
(ii) All aluminium joints shall be thoroughly cleaned and smeared with suitable. Oxidation
inhibiting joint compound before and after assembling the joint. Similar procedure shall be
5.20 CABLING:
Note: (i)In case of feeding stations which are located within the traction sub-station premises, the
cables shall be run from individual equipment and terminated inside the sub-station
control room.
(ii)Notwithstanding the sizes of cables given above, the Bidder shall assure himself that various
cables would suit the ratings of equipments offered by him.
(b) SPECIFICATION
The cables shall be resistant to decay, abrasion, acids, alkalies and other corrosive materials.
All indoor wiring on walls shall be clamped neatly on heavy PVC rigid conduit of nominal
thickness 2 mm fixed to the wall by means of PVC plug rolls. The cable run layout at a typical
switching stations is shown in the relevant drawing already included in the Annexure to these
Technical Specifications.
CHAPTER: B-6
DESIGNS AND DRAWINGS
(b) RESPONSIBILITY
It is to be clearly understood that all original designs and drawings shall be based on a
thorough study of the project site. General designs and dimensions shall be such that the
Contractor is satisfied about the suitability of the designs for the purpose. The Engineer’s
approval will be based on these considerations and notwithstanding the Engineer’s
acceptance, the ultimate responsibility for the correct design and execution of the work shall
rest with the Contractor.
(b) DEVIATIONS
Normally, deviations from the standard drawings shall not be made by the Contractor.
However, in exceptional cases where the contractor desires to suggest improvements as a
result of his experience, site requirements or any other reasons, he shall justify his proposals
with supporting explanatory notes.
(b) Such special designs shall generally be in conformity with the basic designs furnished by the
Contractor and in accordance with the specifications. If the Contractor wishes to adopt
special designs which do not conform to the general basic designs of the CORE/RDSO, he
shall submit alternative designs and drawings justifying his proposals.
(i) The run of wires in different thickness or colour in special cases and termination.
(ii) The run of wires for future wiring indicated to the Contractor in dotted lines.
(iii) Exact position of all cut-in-insulators, including section insulators.
(iv) Direction and value of stagger at each traction structure location.
(v) Clearance of live conductors to structures in the vicinity including bridges, signals
gantries etc.
(vi) Layout of feeders.
(vii) Jumper connections and connections to switches and switching stations.
(viii) List of infringements.
(ix) Kilometer numbers and type of Structures.
(x) Location and numbers of switches.
(xi) Schematic sectioning diagram drawn to convenient scale showing section insulator,
number of switches, elementary sections and connections to switches and switching
stations.
(xii) Table giving references of approved profile drawings, feeder layout plans and other
relevant drawings.
While the layout plans are being finalized, the Contractor shall submit for approval, in –so-far
as yards between outer most points and crossings are concerned, cross-section drawings for
each structure showing guy rods, if any, indicating the cross-section of the formation, height
and nature of soil, type of foundation block, structure proposed, reverse deflection of the
structure and all necessary particulars for erection of the foundation and the structures. In the
preparation of drawings, care shall be taken to show all obstructions such as signal wires,
points rods and their correct location in references to track/tracks as well as underground
obstructions like pipes cables, etc. after collecting such information from the site.
In open line sections, cross-sections shall be submitted in the following performa, separately
for each Railway line for special foundation drawings with all necessary details shall be
submitted to the Engineer. In case of side bearing foundation with extra depth, formation
details at such location and necessary details of anchor foundation will be submitted.
SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LOCATION No.
CHAINAGE
SETTING DISTANCE IN ‘m’
STEP DISTANCE IN ‘m’
B.M. CODE
SOIL TYPE & PRESSURE
FOUNDATION TYPE AND SIZE
DETAILS MAST SIZE & LENGTH IN ‘m’
MAST EMBEDDED LENGTH ‘m’
REVERSE DEFLECTION in cm
SUPER MAST LENGTH (m)
CROSS ARM LENGTH (m)
ANY OBSTRUCTION
SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LOCATION No.
CHAINAGE
1. ENCUMBRANCE
2. CONTACT WIRE HEIGHT
3. STAGGER
(i) CATENARY
ii) CONTACT
4. STAY ARM
i) (a) M
ii) CODE
5. BRACKET
i) (b) M
ii) CODE
6.REGISTER:
i) C/D (M)
ii) CODE
7. STD/BENT CODE
8. IDENTIFICATION MARK (SEE PARA (6.11)
OTHER REFERENCES/CODES FOR MISCELLANEOUS ITEMS LIKE STEEL WORK FOR STAY/BRACKET
ATTACHEMNT, MISC. SINGLE/DOUBLE CAT. ETC. WILL BE INDICATED.
NOTE: The proforma for SED at individual locations shall be as per standard proforma already
circulated and shall be adopted in consultation with the Engineer.
The Engineer shall satisfy himself about the correctness and applicability of the location plans
given by the Contractor before adopting them for detailed designs.
(i) Cross-section drawings for each switching station indicating the cross section of the
formation transverse to the track at each location of main mast and longitudinal
section parallel to the track along the centre line of the interrupters. These drawings
shall be prepared after an accurate survey at site and shall indicate the nature of the
soil, its bearing capacity, compactness and in case of loose soil, transverse section of
the parent soil. In the preparation of the drawings care shall be taken to show all
obstructions to be removed, such as signal wires, rods and their correct location with
reference to the track/s as well as under-ground constructions like pipes, cables etc.
after collection of such information from the site.
1. Employment schedule for pure gravity type of foundations for main masts for
various direct loads and bending moments;
2. Employment schedule for all other foundations for various depths of parent
soil from the datum level.
3. Sag tension charts for cross feeders for various spans and tensions.
The Contractor shall submit for approval to the Engineer drawings for booster transformer
stations and LT supply transformer stations, similar to those detailed for switching stations in
6.7 (b). The following drawings may, however, be combined together:
(a) Within one month of issue of Letter of Acceptance, the Contractor shall assess the quantities
of various items of work including various components and fittings as covered in the Bill of
Quantities and also those required to satisfactorily commission the works, and submit the
same for the approval of the Engineer as Assessment 1. Such an assessment can be revised
at suitable intervals after the first assessment is approved and till the work is completed. Such
reassessments shall be denominated as Assessment 2, Assessment 3 etc., and shall also be
submitted for approval of the Engineer.
On receipt of approval of each final layout plan from the Engineer, the followings Schedules of
quantities relating to each layout plan shall be submitted within a fortnight:
i) Schedules of number of masts, types, weight of different masts and total weight of
masts;
ii) Schedules of number of foundations, types, volume of different foundations and total
volume;
iii) Schedule of quantities of various items of work other than masts and foundation
under various Schedules
iv) Schedule of net tension lengths of contact, catenary and feeder wire lengths required
to be ordered;
v) Schedule of lengths of other wires and conductors required to be ordered and
vi) Schedules of small parts steel work to be supplied by the Contractor.
(a) The submission of designs and drawings for approval shall be done in the proper manner. In
case, the Contractor wishes to deviate from the standard drawings he should submit to the
Engineer, the revised drawings, with full details of deviation sought explaining the necessity
of deviation, calculations and other supporting documents. The Engineer, if satisfied about
the necessity and adequacy of deviations, shall refer the matter to RDSO for necessary
approval. In case of deviations on working drawings, decision shall be communicated by the
Engineer to the Contractor. The number of copies of drawings which shall be submitted are
indicated in the following sub-paras. The Engineer will return one copy of the drawings either
with approval subject to modification where necessary or with comments. The engineer shall
endeavour to return this copy within a period of fifteen days from the date of receipt and
shall normally return the copy within a month. Where drawings are returned with comments
or approval subject to modifications, the Contractor shall submit to the Engineer within
fifteen days of receipt of such advice, the revised drawings for approval taking into account
the comments or modifications. Also the contractor shall as far as possible avoid
One soft copy of each drawing (on Autocad) will also be supplied on CD.
After completion of works, all drawings and designs submitted by the contractor and approved
by the Engineer shall be made up to date by incorporating actual supply and erection
particulars, including the name and make of insulators, galvanized steel tubes, stainless steel
wire rope etc. The mark of conductors shall be specified in the “As erected” OHE layout plans,
SEDs and other relevant drawings for identification. Such drawings and schedules shall then be
verified and corrected, if necessary, by the contractor jointly with the Engineer. The verified
and corrected drawings shall be supplied in six sets, one of which shall be transparencies of
linen or film reproduction or any other durable material approved by the Engineer. One soft
copy (on Autocad) will also be supplied on CD.
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CHAPTER: B-7
PART-1: PRINCIPLES
7.1 SCOPE
This chapter deals with the methods of erection and installation of traction equipment,
including casting of foundations and erection of structures.
7.3 SECTIONING:
The entire equipment shall be erected in accordance with the finally adopted sectioning
diagram and in such a way so as to facilitate sectioning which may be required in future and
which will be indicated by the Engineer.
7.4 INSPECTION:
All erection and installation work shall be subject to inspection by the Engineer to ensure that
the work is done in accordance with the specification, approved designs and drawings, is in
line with the best industry practices and of best quality.
7.5 MEASUREMENTS:
All measurements for location of structures and foundations shall be made with the aid of
steel tapes. On curves, these measurements shall be taken on the outer rail of the middle
track in the case of odd number of tracks and on the inner rail of the first outer track from the
centre of the formation in the case of even number of tracks. Structures on curves shall be
located in the radial offset of the location as determined.
In loading transport and erection, all galvanized/painted materials shall be handled with care
to avoid damage to galvanized/painting. If galvanizing/painting is damaged in spite of all care
taken, the damaged part of component shall be put up for inspection, to obtain permission
from the Engineer to carry out repairs as per para 5.7 (c ).
(a) ERECTION
In case traction masts or structures are erected in cored foundations, till such time they are
grouted, they shall be properly wedged to prevent them leaning towards the track and
endanger safety of moving vehicles. In case traction masts or structures are erected
NOTE: Mast/uprights should be grouted on the same day they are dropped in the
foundations.
(d) INSULATORS
Before insulators are used in bracket assemblies or dispatched from the Contractor’s Depot to
work site for erection, they shall be tested as specified for routine mechanical test. NO
chipped or cracked insulators shall be installed. All insulators shall be cleaned before offering
complete wired sections for inspection and testing.
(i) - NIL-
(k) CUT-IN-INSULATORS
All insulators in and out of run shall be so positioned that they are away from the zone swept
by the pantograph and will not foul with it. The live parts of these insulators shall also be so
located that they are at least 2 m away from the structures, other than those supporting
traction overhead equipment.
(n) CONNECTIONS
All jumper connections including anti-theft jumpers shall be made properly with parallel
clamps and finished neatly without any loose wire or cables. The length of flexible jumpers
shall be adequate to avoid any disturbance to overhead equipment or restraint in the relative
movement of conductors, but the jumpers should not be excessively long. The ends of
jumpers shall be tinned including the portion inside the first parallel clamp.
(r) For wiring in large yards, the Contractor shall, prior to the execution of works, submit to the
Engineer for approval, the sequence of stringing of catenary and contact wires to arrange for
proper crossing of wires. Endeavour will be made by the Engineer to arrange for traffic blocks
to suit approved sequence of wiring.
7.10 ISOLATORS:
Isolator switches shall normally be so mounted that when the switches are being operated, the
operator faces the oncoming direction of train. The operating handles and contact blades shall
be correctly aligned for easy operation.
7.12 EARTHING:
The copper earth strips or MS flats used for earth shall be bent and shaped neatly before
connection to the structure or frame work of equipment. The connection of MS flats to steel
work shall be made at a height not exceeding 15 cm from the datum level of the switching
station. Before making earth connections, the ends shall be cleaned thoroughly and tinned for
copper strips. All junctions shall be properly secured to avoid loose contact. Portions of copper
earth strips which remain visible above the ground level should be painted with suitable paint to
make them inconspicuous.
7.13 TOLERANCES:
The permissible tolerance in dimensions for erections from those included in the appropriate
drawings or schedules for different items are given below:
(a) MEASUREMENTS
The span length shall not vary more than +/- 50 mm as measured along the appropriate rail
(see para 7.5). The cumulative error of measurement of all spans in a kilometer shall be not
more than 1000mm.
Sl No Item Limits/Tolerances
1 Register Arm tube projection - 150-200 mm in case of push off locations.
- For pull off locations, it shall project over contact
wire plane.
2 Bracket tube projection 150-200 mm
3 Dip between Register Arm Tube - 200-250 mm on tangent track (BFB Steady arm).
& Steady Arm - 250-320 mm on curves (BFB Steady arm and
bend Tubular Steady arm)
4 Encumbrance +50 mm
5 Length of 'A' dropper (1st
dropper from support) + 5 mm
6 Spacing of 'A' dropper (1st
dropper from support) + 30 mm
7 Length of other droppers + 5 mm
8 Spacing of other droppers + 50 mm
9 Stagger of Catenary wire + 30 mm
10 Height of Catenary wire + 50 mm
11 Stagger of Contact wire + 10 mm
12 Position of compensation plate It shall be in vertical plane.
13 Difference in height between 50 mm (minimum)
mainline contact wire and the
crossover contact wire at
support
7.16 In pure RE works, wiring train/crane/UTV shall be provided by RVNL but in combined works, the
contractor shall have to make their own arrangement for mast and OHE erection.
In all the works, for final checking adjustment and inspection of OHE, Tower wagon will be
provided free of cost by RVNL. Diesel, lubricant, watering and security of Tower wagon shall be
provided by contractor.
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CHAPTER: B-7(b)
This sections deals with wiring procedure which may be adopted for erections of normal
overhead equipment. The following procedure for erection of overhead equipment has been
formulated with a view to ensure that:
(i) Bracket assemblies (brackets) and regulating are correctly installed in their final position.
(ii) The conductors are correctly tensioned and
(iii) The need for final adjustments of overhead equipment immediately before energisation
and commissioning is virtually eliminated.
7.21 GENERAL
In the case of regulated overhead equipment when the regulating equipments are in action, the
tension in the conductors should remain constant, irrespective of variations in the ambient
temperature. As the regulating equipments are brought into action a few days after the
stringing of conductors the equipment is unregulated in the intervening period. Any of the
following two procedure may be followed for tensioning and clamping of conductors of regulated
overhead equipment during stringing operations i.e. before the regulating equipments are
brought into action:
(i) The catenary is tensioned to 1000kgf, the stipulated tension at the mean temperature of
35 deg. C, whatever may be the ambient temperature during the stringing operations. In
this case, at the time of clamping the catenary to the bracket, the brackets should be
placed at angular positions corresponding to temperature at the time of clamping, and
proportionate to their distance from the anti-creep.
(ii) The catenary is strained to a stringing tension corresponding to the ambient temperature
for the equipment span of the tension length. In this case, the brackets are placed in the
mean position i.e. at right angles to the track, when the catenary is clamped or the
regulating equipment commissioned.
The advantage of the second method is that once the catenary is strung at the proper
tension, there would be no necessity to adjust each bracket separately at the time of
clamping the catenary or commissioning the regulating equipment. The erection work is,
thus considerably simplified and the possibility of errors greatly reduced. This is also
applicable to erection of unregulated overhead equipment.
7.23 ANTICREEP:
The anti-creep of the tension length is then installed in its final positions.
In order to restrict the duration of traffic blocks to the minimum,in the first block, a catenary is
strained to the stringing tension with the aid of dynamometers and terminated. In the
subsequent block, the sag is checked and the tension readjusted with ladders, if necessary.
7.29 DROPPERING:
Droppers are fitted to the catenary at the correct locations. At the contact wire ends these
droppers may be provided with small pulleys or hooks to act as temporary supports when the
contact wire is strung.
Hooks made of scrap contact wire, suspended from the catenary wire, may also be used as
temporary supports.
NOTE:
(1) It should be ensured that sagging is done carefully and accurately. The adjustment of
tension in the catenary after checking of sag, if required, would be easy if a temporary turn
buckle is inserted in the temporary termination.
(2) If feasible without offering any hindrance to progress of works, the catenary may be
maintained at stringing tension for a period of 48 hours before checking sag and clamping it
to the brackets. This would ensure equalization of tension in the different spans. Before
clamping the catenary to the brackets, the sag should however, be checked in two spans as
indicated in para 7.27.
(3) If it is difficult to obtain a separate traffic block for stringing contact wire, the wire may be
paid out at the same time as the catenary, with the following precautions:
(i) The contact wire is run and suspended from independent pulleys hooked on to the
brackets, separately from the catenary pulleys, to avoid twisting together of the two
conductors.
(4)When the contact wire is under tension, creep takes place which results in an increase in
the length of wire and, consequently, the droppers and the equalizer plates would become
oblique.
Though creep may continue for a long time, may be about a year, the bulk of it would
occur during the days following stringing. If sufficient period of time is allowed, the contact
wire may be clipped to the droppers and the equalizer plates, all in the vertical position,
and the necessity for any further adjustments before energisation and commissioning of
the OHE may be reduced to a great extent. If this precaution is not taken, at the time of
energisation of the OHE, the droppers may not all be vertical and staff would have to be
detailed for shifting the dropper clips which is attendant with risk of damage to the contact
wire.
(5)Before the temporary arrangement is removed, a reference mark should be made on each
conductor. After final termination of the conductors, it should be ensured that two marks
are in the same relative longitudinal position as they were before the removal of the
temporary arrangement.
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CHAPTER: B-8
8.1 SCOPE:
This chapter deals with the inspection and testing of completely erected overhead equipment,
switching stations, booster transformer stations and LT supply transformer stations.
8.3 RESPONSIBILITY:
The general tests of overall performance stipulated below are only supplementary to other tests
on structures, foundations, equipment, components and fittings as specified. Any testing and
acceptance by the Engineer of overall performance shall be subject to the general terms of
guarantee.
(j)Tests shall then be conducted to check if the power collection performance of the overhead
equipment is satisfactory after ensuring that the contact wire is adequately clean. For this
purpose, an observation car shall be attached next to the electric locomotive. The behavior of
the overhead equipment will be watched at various speeds. Power collection shall be considered
unsatisfactory if a long blue flash is observed, indicating that the contact between the contact
wire and the pantograph is not continuous.
(a)GENERAL
As soon as a switching station, booster transformer station or LT supply transformer station is
ready for inspection and testing, the Contractor shall advise the Engineer in writing. Testing will
be carried out by the contractor at his cost jointly with the Engineer. These shall include the
tests which the Engineer may like to conduct with a view to assure himself of the soundness of
the equipments and their erection in compliance with these specification However, testing
equipments such as those indicated below and staff required for the tests shall be provided by
the Contractor free of charge:
(i) Oil testing equipment.
(ii) 2500 V & 500 V meggers.
(iii) Earth megger and accessories.
(iv) Continuity tests apparatus.
(v) Avometer;
The Contractor shall take full responsibility for these tests inter-alia his other responsibilities.
(b)VISUAL INSPECTION
Visual inspection which shall include check for satisfactory workmanship shall cover all
connections, painting, plastering, cleanliness of insulators etc. and compliance with Indian
Electricity Rules.
(d) I NSULATION
The strength of insulation of the various items of equipment and of the entire installation as
a whole shall be tested with a 2500 V/500 V megger, as required.
(g) ISOLATORS
All isolators will be tested for smooth and trouble free operation.
(h) INTERRUPTERS
Operation of trip and close coils for interrupters, shall be tested for satisfactory performance
with the respective equipments de-energised.
8.6 EARTHING:
(a)Earth wires will be checked for continuity and electrical isolation after every 1000mapprox.
(b)Clearances between earth wires and out-of –run wires of overhead equipment and signals
shall be checked.
(c)Earth resistance shall be measured separately for each earth electrode. In the case of
interconnected earth electrodes, the net resistance of the Inter-connected electrodes shall also
be measured.
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9.1 GENERAL:
This chapter deals with details and specifications for design and construction of switching
station buildings and associated electrical works.
9.2 EARTH WORK:
(a)Earth work in cutting or embankment in the premises of switching station buildings is included
in the scope of construction of building. The buildings will be adequately leveled with earth duly
consolidated in the premises or as directed by the Engineer.
(c) Excavation:
All cuttings shall be taken down carefully to the precise level and section as shown in the
drawings or as decided by the Engineer. In case the bottom of the cutting is taken down deeper
than is necessary by oversight or neglect of the contractor, the hollow must be filled up to true
depth with selected material and rammed, as approved by Engineer. Cuttings with the
formation in rock will be excavated to 15 cm below the true formation and filled up to true level
with cutting spoil to ensure that no lumps of solid rock project above formation level.
(g) The spoil heap shall be roughly but neatly dressed off to a slope of 1-1/2:1 and shall form a
continuous bund along the top of the cutting. In country where there is any cross fall sufficient
spoil shall be thrown on the uphill side of the cutting to supplement the catch water drains and
assist in keeping drainage out. This work must be done first.
(h) All material excavated from cutting suitable for pitching, ballast, masonry or any other purpose
whatever, shall be the property of the Railway, and shall be stacked, as also disposed of, as
directed by the Engineer.
(j) Blasting:
If any blasting operations are necessary, they shall be carried out by the contractor with all
safety precaution as per purchase directives.
9.3 FOUNDATIONS:
(a) Foundations shall be designed by the contractor in accordance with the tender specification. The
contractor shall get the relevant drawings approved by the Engineer. The foundation work may
involve wet excavation also, for which all due precautions by way of pumping and other
operations, preventing blowing are to be adopted.
(c) Wherever it is necessary in case of deep trenches, shoring or timbering for such trenches shall
have to be provided to avoid collapsing of earth.
(d) Apron:
For protection of plinth, an apron as specified in drawing No. RE/Civil/BS -11/95 shall be
provided.
(b) Plastering: Plastering on inside and outside surfaces shall be done with cement mortar of ratio
1:3 and shall have a thickness of 10mm.
(c)Finishing: All external surfaces shall be treated with snowmen over two coats of cement primer
of approved quality and all internal surfaces of wall and ceiling shall be white washed with three
coats.
9.6 FLOORING:
(a)Following pattern of the flooring shall be adopted:
(i)Base concrete- 100 mm thick cement concrete of ratio 1:4:8 with under layer of 100 mm
thick sand filling over well compacted earth.
9.7 ROOFING:
RCC roof, complete in all respects in accordance with RDSO drawing No ETI/C/0067 Mod.-B
shall be provided. Water proofing of roof shall be carried out by the contractor. The type of
water proofing treatment, will be got approved from the Engineer. The contractor shall ensure
at the time of hanging over of the building that roofs are leak proof and water tight. The
contractor shall also provide CI rain water pipes of specified size.
9.10 WIRING: Wiring of the substation shall be done as per RVNL standard specifications given in
Part-A.
Electrical fittings, plug points and appliances as indicated in following table shall be provided in
a switching station. The contractor shall get the locations of the electrical fittings/appliances
approved from purchaser.
TABLE
SN DESCRIPTION OF ITEM QUANTITY
1 Wiring of Light (3 nos), Fan (1 No.) Ex. Fan (1 No.) & 6 Nos.
light plug points (1 No)
2 Wiring of power plug points (16 Amp.) 2 Nos.
3 1x28 watt Surface type T-5, Energy Efficient Luminary 2 Nos. (inside the
with Tube building)
4 1x150 watt Street light Metal Halide (MH) Luminary 1 No. (outside the
with Lamp 150 watt building)
5 230Volt Ac, 450mm, 900 RPM exhaust fan. 1 No. (battery
room)
6 AC ceiling fan 1400 mm sweep complete with stepped 1 No.
type electronic regulator
7 Double Door MCB Distribution Board complete with 1 Nos. (Main)
Incoming MCB DP-32 Amp with RCCB 100 mA and O/G-
--6-16 amps. MCB SP-3 Nos. & 20 amps. MCB SP-3
Nos.
CHAPTER: B-10
GENERAL REQUIREMENTS
10.1 INTRODUCTION
This part deals with general information and criteria for design, manufacture, supply, erection
and testing of equipment at 132/25 kV (or any other rating depending on input voltage
availability from grid with output always being 25 kV AC) traction sub-stations, feeding stations
and 25 kV Shunt Capacitor Bank. These traction sub-stations are also referred to as “SUB-
STATIONS” in these technical specifications.
10.2 DEFINITIONS
The following definitions shall apply for the purpose of this specification, in addition to
definitions applicable to standard equipments.
(a) ”Grid Sub-station” means the sub-station of a power supply authority which is connected to the
grid network in the area and from which 132 kV (or any other level ) power is supplied to the
Railway for electric traction.
(b) ”Interrupter” means a single pole single phase non-automatic circuit breaker capable of
interrupting normal full load current.
(c) “Return Feeder” means the conductor of the feeder line from a traction sub-station to the
corresponding feeding station which is connected to the earth terminal of the traction
transformer secondary winding.
(d) “Traction overhead equipment” means the overhead conductors and other associated
equipment and structures erected over the track to supply power to the electric locomotives.
(e) “Traction sub-station” means a sub-station that converts the grid supply voltage to 25 kV AC to
supply power to traction overhead equipment installed on the railway track, in accordance with
this specification.
(f) “25 kV Feeder” means the conductor or feeder line from the traction sub-station to the
corresponding feeding station and which is connected to the unearthed terminal of the traction
transformer secondary winding.
(g) ”Feeding station” means the 25 kV interrupters and other associated equipment as also
structures erected near the track, within or outside the sub-station boundary, for feeding
different sections of the traction overhead equipment.
(h) ”Shunt Capacitor Bank” means shunt capacitor equipment, along with control gear, protective
relays, series reactor and accessories erected on 25 kV side of a traction sub-station for the
purpose of maintaining unity power factor and reduction of maximum demand.
10.3 FUNCTIONS
The traction sub-stations covered by this specification will be installed to supply power for
electric traction at 25 kV Ac 50 cycles single phase through the traction overhead equipment.
10.4 LOCATION
The locations of the traction sub-stations are given in the Bidding Documents.
(a) Adjacent sub-stations will normally be connected across different phases to reduce the
unbalance on the three phase power supply system. In order to keep the supply from two
adjacent sub-stations separate, a neutral section is provided on the traction overhead
equipment approximately midway between them. The neutral section is normally kept dead.
Electric locomotives coast through the neutral section with power off.
(b) The traction sub-stations, will normally be unattended and all switching operations will be
carried out by remote control from a Remote Control Center.
The different arrangements of feeders, return feeders, 25 kV along track feeders and return
conductors can be seen from the drawings listed in the Annexure.
(f) JUMPERS
All jumpers connected to OHE conductors shall be of copper only. The in –span jumpers,
potential equalizer jumpers at insulated overlaps and neutral section, shall be of 50 sq mm
nominal section, 19/1.8mm size. Flexible jumpers of nominal section 105 sq mm, 19/7/1.06
mm size shall be used at overlaps, turnouts, crossings etc.
The jumper connecting the Aluminium conductors to any other conductors, terminals or
clamps shall be made with the aid of suitable bi-metallic clamps. All aluminium jumpers of
size 19/7/1.4 mm bare ¾ hard shall be used to connect other Aluminium conductors such as
return conductor. The tail ends of feeder wires from the strain clamps at the termination of a
feeder, return feeder or return conductor may be connected directly to a terminal or clamp
where feasible to avoid the use of a separate jumper wire.
(i) At the feeding station, the 25 kV supply will be fed to different sections of the traction
overhead equipments by means of interrupters. All interrupters will be remote controlled.
(j) Normally, traction substation will be located alongside the Railway track. The feeding stations
will be located within the sub-station boundary and connected to the traction sub-station
boundary and connected to the traction sub-station by extension of the 25 kv busbars. Where
the traction sub-station is located some distance away from the track, the 25 kV supply will be
extended to the feeding station by means of two overhead feeders carried on tower/masts.
Each feeder line will comprise two conductors one called the 25 kV Feeder and the other
return feeder.
(k) A small masonry building called the control room, will be provided at each sub-station to
house the control and instrument panels, remote control equipment, batteries, battery
chargers, telecommunication terminal equipment, telephones and AC and DC LT distribution
boards, capacitor bank equipment (if required to be indoors) etc. (See relevant drawing
included in Annexure-1).
(l) For Fire protection, baffle wall shall be provided in between the two bays of the power
transformer as per RDSO Drg. No. ETI/C/0214 for wind pressure upto 112.5 kgf/sqm (brick baffle wall)
and RDSO Drg. No. ETI/C/0213 for wind pressure beyond 112.5 kgf/sqm (RCC baffle wall).
(m) The entire traction sub-station and the control room will be protected by a fenced enclosure. A
railway siding from the nearest railway station will be terminated inside each-sub-station,
where feasible, to enable unloading of heavy equipment at site. Road access will also be
provided wherever possible.
10.11 CLEARANCES
10.13 NUMBERING
Each circuit breaker, potential transformer, current transformer, Traction power transformer ,
LT Supply Transformer, Isolator and Lightning Arrestor shall carry a vitreous enameled steel
number plate of approved design (See Annexure-1). The Engineer will furnish the actual
numbers to be allotted to the various switchgear installed at the sub-station.
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CHAPTER: B-11
11.1 DESCRIPTION
Single booster station will be located on either side of the track in a double track section. In
multi-track sections where space does not permit location of a booster station, it may be
provided with cross feeders for connections to the overhead equipment and return conductors
as indicated in the relevant general arrangement drawing listed in the Annexure to these
Technical Specifications.
The low tension supply required at switching stations will be obtained through L.T. supply
transformers, mounted on steel structures and connected to the 25 kV side through rigid bus-
bars of aluminum. In special cases where the length of connection is small, 50 sq. mm copper
wire may be used for connection, with the approval of the Engineer. At locations other than at
switching stations, wherever low tension supply is required, LT supply transformer stations may
be provided along the track at isolated location.
L.T. supply transformer stations shall essentially comprise of a mast mounted transformer
connected to the traction overhead equipment through dropout fuse switches. The 240 V side
shall be connected to a distribution board located at the remote control cubicle by means of a
two-core, aluminum conductor, XLPE insulated, PVC sheathed and steel armoured heavy duty
cable of requisite size, conforming to IS 7098/Pt. I/1988 or latest (see 5.20 (a). The general
arrangement drawing for LT supply transformer stations for single/double and multi-track
sections is included in the Annexure to these Technical Specifications.
(a)Switching Staions.
The switching stations shall be complete in all respects in accordance with specifications. The
work may also include, depending on the project requirement and as specified in the Bill of
Quantities of the tender:-
11.7 NUMBERING:
Each booster transformer, interrupter, potential transformer, LT supply transformer and isolator
shall carry an enameled number plate of approved design. The Engineer will furnish the actual
numbers to be allocated to the various equipments as per specification No. ETI/OHE/53 (6/88)
with A&C slip No. 1 to 5.
11.10 CLEARANCES:
No part of the installations which is live at 25 kV shall be erected at a height less than 3 m from
the datum level. Clearance between any part live at 25 kV and any part at earth potential (or
part likely to be earthed ) shall not normally be less than 500 mm. This clearance may be
reduced under special circumstances but in no case static clearance shall be less than 320250
mm and any dynamic vertical and horizontal clearances shall be less than 250 mm and any
dynamic vertical and horizontal clearances 250 mm and 200 mm respectively. The clearance
between any part live at 3 kV and any part at earth potential (or part likely to be earthed) shall
be not less than 150 mm under static condition and 70mm under dynamic conditions.
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CHAPTER: B-12
12.1 SCOPE:
This chapter deals with the design of all structural steel work including gantry structures,
supporting structures and small parts steel work including chairs, brackets and other fabricated
steel work for mounting various equipments, bus bars, cables etc. at traction sub-stations,
feeding stations and shunt capacitor banks.
12.2 GENERAL
The steel structures may be of riveted, bolted or welded construction as convenient for
installation. The thickness of smallest steel section used shall not be less than 6 mm (or ¼”).
Legs of gantry structures/portals and supporting steel work and uprights or bus bar supports
shall generally be embedded in concrete foundation blocks and for equipment and in special
cases secured by means of holding down bolts.
12.3 DESIGNS
(a) All the steel structures like gantries/portals, other supporting members, small part steel work
etc. shall be galvanized after fabrication with a minimum value of average mass of zinc coating
being not less than 610 g/m sq as per RDSO’s specification No. ETI/OHE/13 (4/84) with A&C slip
No. 1 to 3.
(b)All designs for special steel work shall be furnished by the contractor for the approval of the
Engineer. Designs for steel structures shall, except where otherwise provided, comply with the “
Indian Standard Code of Practice for use of Structural steel in General Building Construction” –
IS: 800-1984 or latest other relevant IS specifications and statutory regulations.
(c)For purposes of design, all possible loads which may occur in the worst combination shall be
considered.
(d)Steel Structures
For calculation of wind load on structures, conductors and equipment, the basic wind pressure
shall be taken as per wind zone of the area indicated in the IS-875 Part-3 1987.
(e)For purposes of design of gantries, the tension in the 220 kV incoming/outgoing lines shall be
taken as 200 Kg. at 4 degree C ( without wind) in each conductor and 150 Kg. at 4 deg. C (
without wind ) in the earth wire. The tension in the 66 kV strung bus-bars and earth screen wire
at 66/25 kV sub-stations shall not exceed 200 kg. At 4 degree C ( without wind)
(g) Notwithstanding the provisions contained in I.S. and other regulations referred to in para
12.3(b) above regarding permissible deflection, the following should apply.
• The deflection at the top of the mast or structure shall be limited to one eightieth (1/80) of
its height above foundation.
(h)The torsional rotation of the mast due to permanent loads shall not exceed 0.1 radian.
12.4 STEEL
Steel conforming to IS: 2062-1992 or latest shall be used for all fabricated steel work. Steel
should be to designation ST: 42-S.
(b)For purpose of design, all possible loads which may occur in the worst combination shall be
considered. The loads shall include the following:-
i) Weight of insulators, instrument transformers, isolator switches, bus- bars, and their
accessories.
ii) Loads caused by feeders, along and across tracks, return feeders etc.
(iii) Loads caused by anchorage due to guying of anchored masts (where applicable).
(iv) Pull or push on the structures due to anchorage and radial tension (where applicable).
(v) Wind load on the different structures, conductors and equipment. The wind pressure shall
be taken as that indicated in the bidding documents.
(vi) Weight of men working on the structures.
(ix) Any other load or loads which may occur due to special equipment wherever they occur.
(c)TENSION OF CONDUCTORS
For purpose of designs, the maximum tension of different conductors, without wind load, shall
normally be as under:-
(i) Maximum tension in the cross feeders at switching stations under worst loading conditions:-
(ii) Maximum tension in longitudinal feeders running parallel to the track at the switching
stations under worst conditions. 1,500 kgf.
(d) Masts of the gantry at which feeder or overhead equipment will be anchored at the switching
station shall normally be provided with suitable guys, but struts shall not be permitted.
13.1 GENERAL
This chapter deals with details and specifications of the equipments, components and materials
to be used at the traction sub-station, feeding station and shunt capacitor bank. It does not
cover foundations and structures which are dealt with in separate Chapters. The detailed
specifications for various items of equipment and materials issued by the Railway may be
bought separately from Research Design and Standards Organisation, Lucknow.
Service Voltage
--------------------------------------------------------
220 kV 132 kV 110 kV 66kV 25 kV
-------------------------------------------------------
i) Power frequency 1 min. wet with 460 275 230 160 95
stand test- in kV(rms)
13.4 INSPECTION
All equipment, material etc, shall be inspected by RITES and the inspection charges
shall be borne by the contractor.
13.5 NIL
13.9 INTERCHANGEABILITY
Parts and components of similar equipments and all fittings shall be fully interchangeable.
General requirements for the supply of metals and metal IS: 1387-1993
products
Tin bronze castings IS:306 -1983 (grade
G-2)
All aluminium conductor IS: 398 ( Part-I)-
1996
Aluminium conductors galvanized steel reinforced IS: 398(Part-III)
1976
Aluminium conductors galvanized steel reinforced hard IS:398( Part-III)-
drawn stranded aluminium and steel –code aluminium 1976
conductors for over head power transmission purposes. IS:398(Part-I)-1996
Disc Insulators IS: 3188-1980
IS: 731-1971
Aluminium and steel cored Aluminium conductors for IS:2121-1981(Part I
overhead power lines. &II)
Aluminium alloy for clamps and fittings, for connectors IS: 617-1994(A-6-M)
Control cables (PVC insulated) IS:1554(Part-I)-1988
Structures and steel work IS:800-1984
Structural steel ( standard quality). IS: 2062-1992
Code of practice for General Construction of plain & IS: 456-2000
reinforced concrete.
Method of tests for strength of concrete IS:516-1959
Hard-drawn standard aluminium and steel-cored Al IS: 398(Part- I)1996
conductors for overhead power transmission purposes
Coarse and fine aggregate from natural sources for IS: 383-1970
concrete.
a) Galvanising
All ferrous components and fittings shall be hot-dip galvanized according to specification No.
ETI/OHE/13 (4/84).
b) Rectification at site
If minor modifications, which would damage the protective coat, become necessary at site,
these shall be carried out with the approval of the Engineer and in a manner to be specified by
him in accordance with specification ETI/OHE/13(4/84) with A&C slip No. 1 to 3.
13.12 BUSBARS
a) ACSR Conductors
ACSR conductors used as bus bars or bus bar connectors shall be of ZEBRA ACSR size 61/3.18
mm (28.62 mm dia ) at 220/25 kV traction Sub-station.
b) Aluminium tubes
Aluminium tubes used as bus bars or bus bar connectors shall be of dia 50x39 mm for traction
sub-station and shunt capacitor banks of size 36mm x 28mm for feeding stations. The
aluminium tubes shall be made of alloy 63401 to IS: 5082-1998 or latest and IS: 6051-1970
or latest or its equivalent. The maximum manufacturing tolerance on diameter and thickness
of the tubes shall not exceed the values specified under Class-I of IS: 2673-1979.
d) General
The bus bar shall be clean, smooth mechanically sound and free from surface and other
defects. No splices will be allowed in the bus bars unless the length of bus bar exceeds 6 m.
The ends of the tubular bus bars shall be covered with suitable end caps. Provision shall be
made where necessary to allow for expansion and contraction caused by temperature
variation.
e) Joints
The joints in bus bars where unavoidable, shall be mechanically and electrically sound, so that
the temperature rise under normal working conditions does not exceed 40 degree C for a
maximum ambient temperature of 45 degree C.
13.14 INSULATORS
The pedestal insulators for service voltage of 132 kV shall be of solid core type conforming to
specification as indicated in Annexure-1. The pedestal insulators for service voltage of 25 kV
shall be of the solid core type conforming to specification as indicated in Annexure-1.
13.15 NOMENCLATURE
All components/fittings supplied by the Contractor to Railway’s standard designs shall bear the
standardized nomenclature and identification numbers, if any.
13.16 CABLES
a) Cables for LT supply
240 V Ac supply from 10 KVA LT supply Transformer shall be brought and terminated on the
LT AC distribution board in the Control room by a 2 core 70 sq.mm. Aluminium conductor
cable. The cables shall be XLPE insulated, PVC sheathed and armored cables of 1100 V grade
complying with IS:7098/Pt.I.1988 or latest.
b) Control Cables
All control cables shall be of copper conductor 1100 V grade and PVC insulated (heavy duty),
complying with IS: 1554(part-I)-1988. The sizes and number of cores of various control cables
required are given in the table below for copper cables.
b) COPPER JUMPERS
Copper jumpers shall be of any of the following type:
ii) Small jumpers of annealed copper in accordance with specification IS: 9968 (Pt.2)- 1981 or
latest
c) ALUMINIUM JUMPERS
Aluminium jumpers wherever used, shall be of all Aluminium stranded conductor 19/7/1.4 mm
bare ¾ H generally conforming to IS: 8130:1984 or latest
d) FEEDERS
Feeders shall be of all aluminium conductor 19/3.99 mm (SPIDER).
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b) The type designs shall be as few as possible to cover the largest field of application consistent
with economic considerations.
c) In all drawings, as far as possible only internationally accepted symbols shall be used.
b) It is to be clearly understood that all original designs and drawings shall be based on a thorough
site study. General designs and dimensions, shall be such that the contractor is satisfied about
the suitability of the designs for the purpose. The Engineer’s approval will be based on these
consideration and notwithstanding the Engineers acceptance, the ultimate responsibility for the
correct design and execution of the work shall rest with the Contractor.
The Contractor for his use and reference shall obtain reproducible transparent film (50 microns)
each of such standard basic arrangement, components and fittings drawings, equipment
drawings, employment schedule etc., from Chief Electrical Engineer, Railway Electrification,
Allahabad on payment as per prescribed rates.
b) Deviations- Normally deviations from the standard drawings of the Railway will not be
accepted. However, in exceptional cases where the contractor desires to suggest improvements
as a result of his experience, specific site conditions or any other developments, he shall justify
his proposals with supporting explanatory notes.
i) Position of incoming lines on the gantries to be erected inside the traction sub-station.
ii) Location of switching station gantry showing where the 25 kV outgoing feeders will be
terminated.
iv) Position of the control room with respect to the traction sub-station.
iii) Arrangement of cross feeders and longitudinal feeders to be anchored on the gantry if any,
including jumper connections to the overhead equipment.
v) Position of the remote control cubicle with respect to the feeding stations.
B) Contractor’s responsibility- The contractor shall satisfy himself about the correctness and
applicability of the location plans before adopting them for detailed designs.
14.6 DETAILED DRAWINGS
(A) FOR TRACTION SUB-STATION, FEEDING STATIONS AND SHUNT CAPACITOR BANK
The contractor shall submit the following drawings for approval of the Engineer:
a) Cross section drawings
Cross section drawings shall indicate the transverse and longitudinal cross-section of the soil
along the center line of the equipments, bus bar supports and cable trenches. These drawings
shall be prepared after an accurate survey at site and shall indicate the nature of the soil, its
bearing capacity, compactness and in case of loose soil, cross-section of the parent soil. In the
preparation of the drawings, care shall be taken to show all obstructions to be removed, such
as telegraph posts, underground pipes, cables etc. after collection of such information from the
site.
c) Structural drawings
Structural drawings shall be prepared for each supporting steel frame work or pedestal. The
drawing shall include one elevation view of the steel frame work assembly from behind, a
transverse cross section and plan view. In the assembly each component member shall be
marked with its reference number. The drawing shall also have a schedule of components
members along with drawing references of various members. The weight of the component
members shall also be indicated. The drawings shall be made for each component and this
shall include all fixing bolts, nuts and washers whose sizes will be mentioned on the drawing.
Unit weight of the components shall also be given in the drawing.
d) Foundation layout and cross section drawings: Foundation layout and cross section
drawings for each traction sub-station shall indicate layout of all foundations in plan,
longitudinal and transverse cross-sections of various foundations through centre line of
gantry/portal legs, various equipment/bus bar supports, fencing uprights and cable trenches. All
foundations shall be marked serially on the drawing indicating the volume of concrete for each
foundation block.
i) Miscellaneous Drawings
These drawings shall include the drawings or sketches made for study of clearances, isolator
alignment details, number plates of various equipments, caution or instruction boards, non-
standard bus bar connectors, clamps and U- bolts for cable mounting etc.
j) Schedule of Quantities
On receipt of approval of relevant drawings for each traction sub-station, the following
schedules of quantities relating to each traction sub-station shall be submitted by the
Contractor within a fortnight of receipt of approval.
ii. Schedule of steel work, indicating types, weights of each member and total weight.
iii. Schedule of type and number, weight of different types of masts for each gantry,
iv. Schedule of quantities of those items of Bill of Quantities that are not included in items(i) &
(ii) above.
v. Any other items required to satisfactorily commission the works but not included in the Bill of
Quantities.
14.7 SUBMISSION OF DESIGNS AND DRAWINGS
a) The submission of designs and drawings for approval shall be done in the manner indicated
below . In every case the Contractor shall send all correspondence calculations, explanatory
notes, other documents and drawings, in triplicate to the Design Office of the Engineer. In case
Contractor wishes to deviate from standard drawings he should submit to the Engineer revised
drawings with full details of deviation sought explaining the necessity of deviation, calculations
and other supporting documents. The Engineer, if satisfied about the necessity and adequacy of
deviations, shall refer the matter to RDSO for necessary approval. In case of deviations on
working drawings decision shall be communicated by the Engineer to the Contractor. In respect
of working drawings prepared on the basis of approved typical drawings other special drawings
and schedules, all the three copies shall be submitted to the Design office of the Engineer. The
Engineer will return one copy each of their drawings either with approval, subject to
modification where necessary, or with comments. The Engineer shall endeavor to return this
copy within a period of 15 days from the date of receipt and shall normally return the copy
within a month. Where drawings are returned with comments or approved subject to
modifications, the Contractor shall submit to the Engineer within 15 days of receipt of such
advice, revised drawings for approval taking into account the comments or modifications. Also
the Contractor shall, as far as possible, avoid correspondence on such comments and shall
endeavor, to settle any difference or opinion on the comments by discussions with the
Engineer’s Engineers. No drawings shall be re-submitted without incorporating the modifications
required by the comments of the Engineer, unless the Engineer has agreed to the deletion of
such comments.
In all the above cases, the Contractor has the option to supply only five copies of the approved
drawings provided one of them is a transparent paper print.
c) Drawings approved by the Engineer shall not be modified without prior consent in writing from
the Engineer. Drawings incorporating approved modifications shall be resubmitted for formal
approval of the Engineer in the same manner as original drawings.
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CHAPTER: B-15
ERECTION AND INSTALLATION OF EQUIPMENTS-PSI
15.1 SCOPE
This chapter deals with the method of erection and installation of equipments, including casting
of foundation and erection of structures.
15.3 INSPECTION
All erection and installation work shall be subject to inspection by the Engineer to ensure that
the work is done in accordance with specifications, approved designs and drawings and is of the
best quality suitable for the purpose.
15.4 MEASUREMENT
All measurements for location of structures and foundations shall be made with the aid of the
steel tapes.
15.7- FOUNDATIONS
a) Soil Sampling
The Contractor shall carry out soil pressure tests in accordance with the method approved by
the Engineer to determine permissible bearing pressure of various representative types of soils
in the presence of the Engineer’s representative during pegging out or site inspection. He shall
adopt only accepted values for the design of foundations.
b) Location
The location of each foundation shall be correctly set out in accordance with the approved
foundation layout drawings in the presence of the Engineer’s representative.
c) Method of installation
The foundation bolts for erection of gantries, portals and other supporting frames, if any, shall
be grouted into the foundation in cored holes left in foundation blocks. Cored holes shall be left
in foundation blocks for gantry legs or other steel work to be embedded. In any case, the
method of casting foundation blocks and erection of gantries, portals and other supporting
frames shall be subject to the approval the Engineer.
d) Concreting
j) Equipment
Pedestals for power transformers shall be made of mass concrete with base resting on
consolidated soil. Foundations for Circuit Breakers supported on steel structures and for other
items of equipment such as isolators, instrument transformers, bus bar support insulators etc.
shall be of the pure gravity type, the base of which shall rest on consolidated soil, and shall be
left with core holes into which the legs of the supporting structures shall be suitably fixed by
grouting.
k) Cable trenches
The reinforced concrete cable trench shall rest on original ground if the depth of unconsolidated
soil is less than 0.5 m. If the depth of the unconsolidated soil is more than0.5 m the cable
trench shall be supported at suitable intervals on concrete pillars. Cable trench details are
shown in a drawing included in Annexure-1 to these technical specifications.
l) Fencing posts
Foundations for fencing posts shall rest on consolidated soil if the depth of unconsolidated soil is
less than 1.5m below the datum level and shall be rectangular parallel-piped in shape. If the
depth of the unconsolidated soil is more than 1.5m the foundation block shall rest on reinforced
concrete piles cast-in-situ or reinforced concrete foundation may be adopted as desired by the
Engineer.
15.8 Structures
a) Erection
The structures shall be embedded in the foundation blocks for the correct length specified in
approved drawings.
b) Alignment
The legs of gantries and other supporting frames shall be carefully aligned to enable easy and
good assembly of top booms and other fabricated steel work.
c) Alignment of Mast at Gantries
The main masts of gantries shall be carefully aligned to enable easy and good assembly of
fabricated steel work.
15.9 Equipment
The installation of the equipment shall be carried out strictly in accordance with the instructions
issued by the Manufacturer. The equipment shall be leveled carefully before being fixed finally
The tubular Aluminium busbars shall be supported at a uniform height through out. Wherever
tubular busbars are required to be bent, the radius of the bend shall not be less than 375 mm.
b)All aluminium bus bar joints shall be made carefully, The contact surfaces of the bus-bars and
the connectors shall be cleaned vigorously either by hand with a dry coarse emery cloth or by
power driven wire wheel brush. The surfaces shall be smeared with a suitable corrosion
inhibiting joint compound approved by the Engineer. The joint closed-up as soon as possible
thereafter and a final light application of joint compound shall be made. Similar procedure shall
be followed while connecting the equipment terminals to be bus-bar by means of bi-metallic
connectors.
15.11CABLING
a) Laying of Cables
All cables provided out-door shall be either laid in trenches or neatly clamped to the structures
as approved by the Engineer. If it becomes necessary to take the cable connections along the
steel supports for the equipment, the cables shall be laid through bent or shaped GI pipes
embedded in concrete while the foundations are being cast. All cables in the cable trenches and
along the structures shall neatly secured with proper clamping arrangement at suitable
intervals. Each cable in the cable trench/on the structure shall also be provided at suitable
intervals with identification labels of durable material bearing indelible engraved or punched
markings to facilitate easy identification.
b) Termination of cables
The cables shall be terminated neatly and the cores arranged and dressed properly. Suitable
terminal strips and ferrules made of PVC or other durable materials shall be provided on
terminals and wire ends respectively to facilitate identification. The marking on the terminals
strips and ferrules shall be either engraved or punched so as to be indelible.
c) Indoor wiring
As far as possible all cables shall be laid in the trenches/pipes provided for the purpose in the
Control Room. Wherever necessary indoor wiring on walls shall be clamped neatly on MS flats
fixed to the wall by means of rag bolts grouted in the wall. The typical clamping arrangement is
shown in the relevant drawing listed in Annexure-1.
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CHAPTER: B-16
INSPECTION AND TESTING of TRACTION SUB-STATION
16.1 GENERAL
a) This chapter deals with the inspection and testing of completely erected sub-stations.
b) Reasonability
The general tests of overall performance are only supplementary to other tests on structures,
foundations, equipments, components and fittings as specified elsewhere in these specifications
or in standard specifications and are to be complied with. Any testing and acceptance by the
Engineer of overall performance shall be subject to general terms of guarantee, which shall
continue to be valid as provided for in the Bidding Documents.
(A) SUB-STATION
(a) General
As soon as a sub-station is ready for inspection and testing, the Contractor shall advise the
Engineer in writing. Tests will be carried out by the Engineer jointly with the Contractor. These
shall include the tests which the Engineer may like to conduct with a view to assure himself of
the soundness of the equipments and their erection in compliance with these specifications.
Testing equipments such as these indicated below and staff required for the tests shall be
provided by the Contractor free of charge.
The Contractor shall take full responsibility for these tests inter-alia his other responsibilities.
(b) Visual Inspection
Visual inspection which shall include check for satisfactory workmanship shall cover all
connections, painting, plastering, cleanliness of all insulators etc. and compliance with Indian
Electricity Rules.
(c) Correctness of connections
Correctness of connections of relays, alarm circuits, annunciator indications etc., shall be
thoroughly checked.
(d) This test will be conducted on every individual item of equipment such as Circuit Breakers,
Isolators, Relays etc. to ensure that the equipment as whole is functioning properly and is
mechanically sound, e.g. in the particular case of Isolators the fixed contact and knife blade
have been correctly aligned and operation does not cause undue strain on the equipment. The
operation tests will be carried out with the high tension installation disconnected from the
(f) The di-electric strength of the oil of instrument transformers (except if they are of sealed
construction) auxiliary transformers and Circuit breakers at each sub-station shall be tested
before commissioning.
(g) Isolators
All Isolators will be tested for smooth and trouble-free operation. Correct functioning of inter-
locking devices shall also be checked.
v) Avometer;
The Contractor shall take full responsibility for these tests inter-alia his other responsibilities.
(d) INSULATION
The strength of insulation of the various items of equipment and of the entire installation as a
whole shall be tested with a 2500 V/500 V meager, as required.
(e) ISOLATORS
All isolators will be tested for smooth and trouble free operation.
(f) INTERRUPTORS
Operation of trip and close coils for interrupters, shall be tested for satisfactory performance
with the respective equipments de-energised.
(b)Visual Inspection
Visual inspection which shall include check for satisfactory workmanship shall cover all
connections, painting, plastering, cleanliness of all insulators etc., and compliance with Indian
Electricity Rules.
(c)Correctness of Connections
Correctness of connections of relays, alarm circuits, annunciator indications etc. shall be
thoroughly checked.
(d)Operation test
These test will be conducted on every individual item of equipment such as circuit breakers,
current transformers, potential transformers, isolators, relays etc. to ensure that the equipment
as whole is functioning properly and is mechanically sound, e.g. in the particular case of
isolators the fixed contact and knife blade have been correctly aligned and operation does not
cause undue strain on the equipment. The operation tests will be carried out with the high
tension installation disconnected from the supply, but by actuating power devices where such
(e)Insulation
The strength of insulation of the various items of equipment, cabling and of the ensure
installation as a whole shall be tested with 5000/2500/500 V megger as required.
(f)The di-electric strength of the oil of instrument transformers (except if they are of seated
construction) shall be tested before commissioning.
(g)Isolators
Isolators will be tested for smooth and trouble free operation. Correct functioning of inter-
locking devices shall also be checked.
(h)Instrument transformer
Tests shall be conducted to check the polarity of current and potential transformers.
16.3 EARTHING
Earth resistance will be measured separately for each earth electrode and when they are
connected together and to the equipment at each sub-station, feeding station and shunt
capacitor bank.
16.5 Measurement of contact resistance and opening/closing time of CBs/BMs during commissioning
of TSS/switching post shall be done as per ACTM para 20908 and OEM. This is to be done as
per pre-commissioning test.
EARTHING
b) Earthing System
At each substation, two separate earth circuit will be provided, one for earthing the HT
Equipment and the other for earthing the LT Equipment inside the control room.
c) HT earthing grid
A combined resistance of earthing system, in any sub-station shall not be more than 0.5 Ohms.
To ensure this, the Ht earthing grid shall be formed by means of bare mild steel rods of
appropriate size as indicated in Clause (d) below buried at a depth of about 600 mm below the
ground level and connected to earth electrodes by means of two separate and distinct
connections made with 75mmx 8mm Ms flats. The connection between the Ms flat and Ms rod
shall be made by welding, while that between, the earth electrodes and the Ms flats through Ms
links by bolted joints. As far as possible the earthing grid conductor shall not pass through the
foundation block of the equipments. All crossings between longitudinal conductors and
transverse conductors shall be jointed by welding. The transverse and longitudinal conductors
of the earthing grid shall be suitably spaced so as to keep the step and touch potentials within
acceptable limits. The overall length of the earthing grid conductor shall not be less than the
calculated length as per the code of practice. The earth electrodes shall be provided at the outer
periphery of the grid as indicated in the sketch enclosed in Specification No. ETI/PSI/120(9/91)
with A&C slip No.1. The earth electrodes shall be embedded as far away as possible from each
other. Mutual separation between them shall usually be not less than 6 m. The contractor shall
submit detailed design calculation for the earthing system and obtain approval of the
design/drawings.
e) Earth Electrodes
The earth electrodes shall normally be of mild steel galvanized perforated pipe of not less than
40 mm nominal bore of about 3 m length provided with a spike at one end and welded lug
suitable for taking directly Ms flat of required size at other end. The pipe shall be embedded
vertically into the ground as far as possible except in case of hard rock, where it may be buried
inclined, the inclination being limited to 30 degree from the vertical. The connection of Ms flats
to each electrode shall be made through Ms links by bolted joints. A typical drawing number of
one earth electrode installation is included in Annexure-1. If the value of earth resistance
specified may not be achieved with a reasonable number of electrodes connected in parallel
such as in rocky soil or soil of high resistivity, the earth surrounding the electrodes shall be
chemically treated by alternative layers of finely divided coke, crushed coal or charcoal and salt
at least 150mm all around. However, coke treatment shall be used only where absolutely
necessary and such electrodes shall not be situated within 6 m of other metal work. In high
embankments, use of electrodes longer than 3 m shall be considered so as to reach the parent
soil to achieve earth resistance as specified.
g) System earthing
One terminal of the secondary winding of each traction transformer shall be earthed directly by
connecting it to the earth grid by means of a 75 mm x 8 mm Ms flat and to the buried rail by
means of another 75 mm x 8 mm Ms flat. One designated terminal of the secondary of each
potential, current and Lt supply transformer shall also be connected to earth grid by means of
two separate distinct earth connections made with 50 mm x 6mm MS flat.
h) Equipment earthing
The metallic frame work of all outdoor equipments such as transformers, circuit breakers,
Interrupters & Isolators, as well as steel structures shall be connected to the earth grid by
means of two separate and distinct connections made with MS flat of size 50 mm x 6 mm up to
10000 MVA and by 75 mm x 8 mm MS flats above 10000 MVA upto 20000 MVA. Equipments on
the secondary side of the traction power transformer and steel structures shall be connected to
the earth grid by means of two separate and distinct connections made with Ms flats of size 50
mm x 6 mm. One connection shall be made with the nearest longitudinal conductor while the
other shall be connected with the transverse conductor.
l) Method of Jointing
All the joints between the MS flats, Ms rods or between Ms flat and Ms rods shall be made by
welding only. No soldering shall be permitted. For protection against corrosion, all the welded
joints shall be treated with red lead and afterwards thickly coated with bitumen compound.
m) Painting of Ms Flats
For protection against corrosion, all the exposed surfaces of earthing connections (MS flats)
above ground level shall be given all around two coats of painting to colour black of IS: 5/2004
or latest.
n) EARTH SCREEN
The area covered by outdoor sub-station equipment shall be shielded against direct strokes of
lightning by an overhead earth screen comprising 45 tonne quality 7/9 SWG, 19/2/5 mm
galvanized steel stranded wire strung across pinnacles of the metallic structures as indicated in
the drawings included in Annexure-1. The earth screen wires shall be fixed not less than 2.5 m
above the live conductors so as to provide an angle of protection, not exceeding 30 degree to
the equipment/busbar below and shall be solidly connected to the sub-station earth circuit by
means of 50 mm x 6mm Ms flats.
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18.1 HIGH RISE OHE FOR RUNNING DOUBLE STACK CONTAINERS UNDER ELECTRIFIED
ROUTE (WITH SPEED POTENTIAL OF 140 KMPH)
Design, installation and erection of High Rise OHE shall conform as per RDSO’s Design
document No-TI/DESIGNS/OHE/2013/00001 (July 2013). Further RDSO has issued drawings
for 11.4 meter masts, Portals, TTC, Employment Schedule, Foundations, Anchor Arrangement
etc which shall be followed while executing the work.
1. The type of foundations shall remain same. However, the work to be done as per the
relevant drawings issued by RDSO. Payment shall be made in cum under relevant BOQ.
2. Structures: RDSO has issued the drawings of 11.4m high masts, which shall be paid under
relevant BOQ items. However, the additional erection rate shall be paid as NS item as per
condition of agreement.
16 G-Type Portal Special Upright and End Piece For TI/DRG/CIV/G- PORTAL/00001/13/0
High Rise OHE dtd 06.05.2014
18 Special BFB portal Details of Upright Part ‘A’ For TI/DRG/CIV/BFB- PORTAL/00001/13/0
High Rise OHE Sh 2 dtd 06.05.2014
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CHAPTER: B-19
Drawing Mod.
S No. Brief Description
Series Number No.
1 2 3 4 5
Typical location plan and general
1. TI/DRG/PSI/TSSLO/RDSO/ 006 E
arrangement for a feeding station
46.
Details of structure for 132kv Current
ETI/C 330 F
transformer
51.
Part Plan for Details of position of feeder
ETI/PSI/SK 272 NA /Nil
Bus coupling interrupter at TSS
52.
Terminal connector for 220kV equipments
ETI/PSI/SK 324 NA/Nil
(Typical drawing)
54.
Details of Beam B/1 for 132/25 KV TSS ETI/C 201 D
64. Drilling schedule for S-5 mast (11.4m long) -do- 0042 E
81. Typical number plate for circuit breaker ETI/PSI/P 7523 Nil
94. 0225
Control Room for Traction substation ETI/C Nil
Sheet-1
97. TI/DRG/PSI/CPROOM/
Typical layout of control room at TSS 00001/01 0
RDSO
106.
Typical cable run layout of a sectioning and
-do- 302 C
paralleling station
107.
General arrangement & details of fencing 0186
-do- E
panels & gate for switching station Sh.1
118.
36mm Aluminum flexible bus splice -do- 6550 B
123. Operating pole for 25kV drop out fuse switch ETI/PSI 039 B
LAST
S.No. DESCRIPTION SPECIFICATION NO.
REV.
24 Power transformer 21.6 MVA, single ETI/PSI/118 (10/93) with A&C Slip 10
phase 50 Hz, 220/132/110/66/27 kV for No.1 to 10 (08/12) or latest
traction substation.
25 Code of practice for earthing of power ETI/PSI/120 (2/91) with A/c Slip 1
supply installation for 25 kV. AC. 50 Hz No1 (10/93)
single phase traction system.
36 Metal oxide gapless type lightning ETI/PSI/137 (8/89) with A&C Slip 7
arresters for use of 220/132/110/66 kV No.1 (1/90), 2(2/91), 3(12/91),
side of railway ac traction substation. 4(8/94) 5 & 6 (9/05) &
7(07/2007)
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CHAPTER: B-20
ANNEXURE-2
LIST OF STANDARD DRAWINGS AND SPECIFICATIONS FOR OHE WORKS
All references to drawings charts schedules of specifications given in this Annexure shall be
taken to the latest version of such drawings, charts, and schedules of specifications as issued
by the purchaser.
201 Drilling schedule of OHE mast 8.5m & 9 m long RSJ) ETI/OHE/G 04202 C
and BFB respectively. Sh.1 C
Sh.2
202 Schematic arrangement of (regulated) tramway type ETI/OHE/G 04203 C
OHE
203 Arrangement of bracket assembly for Tramway Type ETI/OHE/G 04204 B
OHE (Regulated)
204 Arrangement for anti-creep for Tramway Type OHE ( ETI/OHE/G 04205 B
Regulated)
205 Arrangement of anti-creep for Tramway OHE ETI/OHE/G 04206 B
(regulated alternative arrangement )
206 Arrangement of section Insulator for Tramway Type ETI/OHE/G 04207 B
OHE (regulated) Sh.1
207 Small parts steel for supporting section insulator ETI/OHE/G 04207 B
assembly for regulated tramway type OHE. Sh.2
208 General arrangement of turnouts for Tramway type ETI/OHE/G 04208 B
OHE ( regulated)
209 Adjustment chart for Tramway type OHE (regulated) ETI/OHE/G 04209
210 Bridle wire clamp (6 mm) ETI/OHE/P 1070-1 B
211 Large suspension clamp 20 mm (with armour rod) ETI/OHE/P 1580 -
Sh-2
212 Hook bracket ETI/OHE/P 2380 C
213 BFB steady arm assembly for Tramway OHE ETI/OHE/P 2540-1 -
(Regulated)
214 Anti wind clamp for tramway OHE (regulated) ETI/OHE/P 2550-3 E
215 Counterweight assembly (light) ETI/OHE/P 5090-3 F
216 Counter weight assembly with pulley type regulating ETI/OHE/P 5090-6 B
equipment (3:1 ratio)
217 Employment schedule for tramway type regulated ETI/C 0705 A
OHE without RC and EW(WP 112.5 kgf/sqm)
218 Protective screen at FOB/ROBs. ETI/C 0068 H
219 i) standard plan –height gauge for level crossing( for TI/DRG/CI 00001/0 -
clear span upto 7.3m) details of structure & V/HGAUGE 5/0
foundation. /RDSO
ii) standard plan –height gauge for level crossing(for TI/DRG/CI 00002/0 -
clear span above 7.3m upto 12.2 m) details of V/HGAUGE 5/0
structure & foundation. /RDSO
(iii) Span length 7.3m for Class-II to IV roads and CORE dwg 38-04
TVU<1 Lakh No:RE/CIV (Mod
IL/S1 R1)
Sl. LAST
DESCRIPTION SPECIFICATION NO.
No. REV.
OR
ETI/OHE/14(9/94)
with A&C slip No.1 of
9/95,2 of
1/97,3(8/99)4
of(12/99) & 5 of
(10/2001).
25. Principles for OHE layout plans and sectioning ETI/OHE/53(6/88) with 5
diagrams for 25 kV ac traction. A&C slip no.1 of (6/88), 2 of
(6/88), 3 of (6/90), 4 of
(8/92) & 5 of (11/2006)
33 Specification for continuous cast copper wire rods. ETI/OHE/65(8/87) with A & 3
C Slip No 1 to 3
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