Package 8 Volume 1 of 3 Ver 5 PDF

ZESCO Limited
BIDDING DOCUMENT FOR

PROCUREMENT OF TRANSMISSION LINES AND
SUBSTATIONS
Lot 1: Woodlands 33/11kV Substation Upgrade,
Lot 2: Coventry – Kafue 33kV Overhead Line

Upgrade
and
Lot 3: Industrial – Matero 33kV Corridor Upgrade
(Volume 1 of 3)
BIDDING DOCUMENTS
Issued on: 11 January 2019
ICB No.: ZESCO/LTDRP/G/001/C2/2019
Employer: ZESCO Limited
Country: Zambia
Project: Lusaka Power Transmission and Distribution Network Project (LPTDNP)
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Bidding Document for the Procurement of Transmission Lines

and Substations:
Lot 1: Woodlands 33/11kV Substation Upgrade,
Lot 2: Coventry – Kafue 33kV Overhead Line Upgrade
and
Summary Description
SBD for Procurement of Plant Design, Supply, and Installation
PART 1 – BIDDING PROCEDURES

(Covered in Volume 1 of 3)
Section I: Instructions to Bidders (ITB)

This Section provides relevant information to help Bidders prepare their bids.
Information is also provided on the submission, opening, and evaluation of
bids and on the award of Contracts. Section I contains provisions that are
to be used without modification.
Section II. Bid Data Sheet (BDS)

This Section consists of provisions that are specific to each procurement and
that supplement the information or requirements included in Section I,
Instructions to Bidders.
Section III.Evaluation and Qualification Criteria

This Section contains the criteria to determine the lowest evaluated bid and
the qualifications of the Bidder to perform the contract.
iv
Section IV: Bidding Forms

This Section includes the forms for the Bid Submission, Price Schedules, Bid
Security, and the Manufacturer’s Authorization to be submitted completed by
the Bidder and submitted as part of his Bid.
Section V. Eligible Countries

This Section contains information regarding eligible countries.
Section VI. Bank Policy – Corrupt and Fraudulent Practices

This Section provides the Bidders with the reference to the Bank’s policy in
regard to corrupt and fraudulent practices applicable to this process. The
Covenant of Integrity will be signed and submitted with the Bid.
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PART 2 – EMPLOYER’S REQUIREMENTS (Volume 1 of 3 )
Section VII. Employer’s Requirements

This Section includes the List of Goods, Works and Related Services, the
Delivery and Completion Schedules, the Technical Specifications and the
Drawings that describe the Goods, Works and Related Services to be
procured.
Drawings: (Volume 2 of 3)
All drawings and supplementary information are included under Volume 2 of
3. The following supplementary information is provided:
1 Technical Specifications for Telecoms Optical Line Terminal / Access
Equipment
2 Technical Specifications for Optical Fibre Cables: Optical Ground Wire
(OPGW), All Dielectric Self Supporting (ADSS), Direct Buried Underground
(DUCT)
3 Environmental and Social Management Plan for The Lusaka Transmission
and Distribution Rehabilitation Project
4 Health and Safety Management Plan for The Lusaka Transmission and
Distribution Rehabilitation Project
5 Dismantling of Overhead Line and Substation Equipment Specifications
6 Waste Management Procedure
7 LTDRP SCADA Detail Design Specification
8 LTDRP Telecommunications Detail Design Specification
9 LTDRP Protection Detail Design Specification
10 111233-80-GDL-EE-0001 – Bid Document Outline
PART 3 – CONDITIONS OF CONTRACT AND CONTRACT FORMS

(Covered in Volume 3 of 3)
Section VIII. General Conditions (GC)

This Section contains the general clauses to be applied in all contracts. The
text of the clauses in this Section shall not be modified.
Section IX. Particular Conditions (PC)

This Section consists of Part A, Contract Data which contains data, and Part
B, Specific Provisions which contains clauses specific to each contract. The
vi
contents of this Section modify or supplement the General Conditions and

shall be prepared by the Employer.
Section X: Contract Forms

This Section contains forms which, once completed, will form part of the
Contract. The forms for Performance Security and Advance Payment
Security, when required, shall only be completed by the successful Bidder
after contract award.
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Standard Bidding Document
Table of Contents
PART 1 – Bidding Procedures ................................................................................................... 1

OPTION A: Single Stage Bidding............................................................................................. 3
Section I. Instructions to Bidders ........................................................................................... 5
Section II. Bid Data Sheet .................................................................................................... 33
Section III. Evaluation and Qualification Criteria (Without Prequalification) ................ 43
Section IV. Bidding Forms ................................................................................................... 77
Section V. Eligible Countries ............................................................................................. 213
Section VI. Bank Policy - Corrupt and Fraudulent Practices ............................................ 215
PART 2 –Employer’s Requirements ......................................................................................... 1
Section VII. Employer’s Requirements ................................................................................. 3
PART 3 – Conditions of Contract and Contract Forms ........................................................ 1
Section VIII. General Conditions (GC) .................................................................................. 3
Section IX. Particular Conditions ........................................................................................ 93
Section X. - Contract Forms ................................................................................................... 1
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Part 1-1
PART 1 – Bidding
Procedures
Part 1-2
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Part 1-3
OPTION A: Single Stage Bidding

Part 1-4
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Section I. Instructions to Bidders (ITB) 1-5
Section I. Instructions to Bidders
Table of Clauses
General ........................................................................................................................................... 7
1. Scope of Bid ................................................................................................................. 7
2. Source of Funds ........................................................................................................... 7
3. Corrupt and Fraudulent Practices ............................................................................... 7
4. Eligible Bidders ........................................................................................................... 8
5. Eligible Plant and Installation Services .................................................................... 10
Contents of Bidding Document ................................................................................................ 10
6. Sections of Bidding Document ................................................................................ 10
7. Clarification of Bidding Document, Site Visit, Pre-Bid Meeting .......................... 11
8. Amendment of Bidding Document........................................................................... 12
Preparation of Bids .................................................................................................................... 12
9. Cost of Bidding .......................................................................................................... 12
10. Language of Bid......................................................................................................... 12
11. Documents Comprising the Bid................................................................................ 13
12. Letter of Bid and Schedules ...................................................................................... 13
13. Alternative Bids ......................................................................................................... 13
14. Documents Establishing the Eligibility of the Plant and Installation Services..... 14
15. Documents Establishing the Eligibility and Qualifications of the Bidder ............. 14
16. Documents establishing conformity of the Plant and Installation Services ........... 15
17. Bid Prices and Discounts........................................................................................... 15
18. Currencies of Bid and Payment ................................................................................ 18
19. Period of Validity of Bids ......................................................................................... 18
20. Bid Security................................................................................................................ 18
21. Format and Signing of Bid ........................................................................................ 20
Submission and Opening of Bids ............................................................................................. 21
22. Submission, Sealing and Marking of Bids ............................................................... 21
23. Deadline for Submission of Bids .............................................................................. 21
24. Late Bids .................................................................................................................... 22
25. Withdrawal, Substitution, and Modification of Bids............................................... 22
1-6 Section I. Instructions to Bidders (ITB)
26. Bid Opening ...............................................................................................................22

Evaluation and Comparison of Bids ........................................................................................23
27. Confidentiality............................................................................................................23
28. Clarification of Bids...................................................................................................24
29. Deviations, Reservations, and Omissions ................................................................24
30. Determination of Responsiveness ............................................................................24
31. Nonmaterial Nonconformities...................................................................................25
32. Correction of Arithmetical Errors .............................................................................25
33. Conversion to Single Currency .................................................................................26
34. Margin of Preference .................................................................................................26
35. Evaluation of Bids......................................................................................................26
36. Comparison of Bids ...................................................................................................28
37. Eligibility and Qualification of the Bidder ...............................................................28
38. Employer’s Right to Accept Any Bid, and to Reject Any or All Bids ...................29
Award of Contract......................................................................................................................29
39. Award Criteria............................................................................................................29
40. Notification of Award ................................................................................................29
41. Signing of Contract ....................................................................................................30
42. Performance Security.................................................................................................31
Section I. Instructions to Bidders

General
1. Scope of Bid 1.1 In connection with the Invitation for Bids indicated in the
Bid Data Sheet (BDS), the Employer, as indicated in the
BDS, issues this Bidding Document for the procurement of
Plant and Installation Services as specified in Section VII,
Employer’s Requirements. The name, identification, and
number of lots (contracts) of the International Competitive
Bidding (ICB) are provided in the BDS.
1.2 Unless otherwise stated, throughout this Bidding Document
definitions and interpretations shall be as prescribed in the
General Conditions, Section VIII.
2. Source of 2.1 The Borrower or Recipient (hereinafter called “Borrower”)
Funds indicated in the BDS has applied for or received financing
(hereinafter called “funds”) from the European Investment
Bank (hereinafter called “the Bank”) toward the cost of the
project named in the BDS. The Borrower intends to apply a
portion of the funds to eligible payments under the contract(s)
for which this Bidding Document is issued.
2.2 Payments by the Bank will be made only at the request of the
Borrower and upon approval by the Bank in accordance with
the terms and conditions of the financing agreement between
the Borrower and the Bank (hereinafter called the Loan
Agreement), and will be subject in all respects to the terms
and conditions of that Loan Agreement. No party other than
the Borrower shall derive any rights from the Loan Agreement
or have any claim to the funds.
2.3 The Loan Agreement prohibits a withdrawal from the loan
account for the purpose of any payment to persons or entities,
or for any import of equipment, plant, or materials, if such
payment or import is prohibited by a decision of the United
Nations Security Council taken under Chapter VII of the
Charter of the United Nations.
3. Corrupt and 3.1 The Bank requires compliance with its policy in regard to
Fraudulent corrupt and fraudulent practices as set forth in Section VI.
Practices
3.2 In further pursuance of this policy, Bidders shall permit and
shall cause its agents (where declared or not), sub-contractors,
sub-consultants, service providers or suppliers and to permit

the Bank to inspect all accounts, records and other documents
relating to the submission of the application, bid submission
(in case prequalified), and contract performance (in the case of
award), and to have them audited by auditors appointed by the
Bank.
4. Eligible 4.1 A Bidder may be a private entity or a government-owned
Bidders entity—subject to ITB 4.5—or any combination of such
entities in the form of a joint venture, or association (JVA)
under an existing agreement or with the intent to enter into
such an agreement supported by a letter of intent. In the case
of a joint venture or association:
(a) unless otherwise specified in the BDS, all partners
shall be jointly and severally liable for the execution of
the Contract in accordance with the Contract terms, and
(b) the JVA shall nominate a Representative who shall have

the authority to conduct all business for and on behalf of
any and all the partners of the JVA during the bidding
process and, in the event the JVA is awarded the
Contract, during contract execution.
4.2 A Bidder, and all partners constituting the Bidder, originating

from all countries of the world is eligible to tender for works,
goods and services contracts subject to provisions of section
V. A Bidder shall be deemed to have the nationality of a
country if the Bidder is a national or is constituted,
incorporated, or registered and operates in conformity with the
provisions of the laws of that country. This criterion shall also
apply to the determination of the nationality of proposed
subcontractors or suppliers for any part of the Contract
including related services.
4.3 A Bidder shall not have a conflict of interest. All Bidders
found to have a conflict of interest shall be disqualified. A
Bidder may be considered to have a conflict of interest with
one or more parties in this bidding process, if :
(a) they have a controlling partner in common; or
(b) they receive or have received any direct or indirect

subsidy from any of them; or
(c) they have the same legal representative for purposes of

this bid; or
(d) they have a relationship with each other, directly or

through common third parties, that puts them in a
position to have access to information about or influence
on the bid of another Bidder, or influence the decisions
of the Employer regarding this bidding process; or
(e) a Bidder submits more than one bid in this bidding

process, either individually or as a partner in a joint
venture, except for alternative offers permitted under ITB
Clause 13. This will result in the disqualification of all
such bids. However, this does not limit the participation of
a Bidder as a subcontractor in another bid or of a firm as a
subcontractor in more than one bid. or
(f) a Bidder or any of its affiliates participated as a
consultant in the preparation of the design or technical
specifications of the Plant and Installation Services that
are the subject of the bid.
(g) a Bidder or any of its affiliates has been hired (or is
proposed to be hired) by the Employer or the Borrower
as Project Manager for the contract.
4.4 An individual or entity shall be ineligible to be prequalified

for, initially selected for, bid for, propose for, or be awarded a
Bank-financed contract or benefit from a Bank-financed
contract, if it has been subject to an exclusion decision as
recorded in the databases specified in the BDS.
4.5 Government-owned entities in the Borrower’s country shall be
eligible only if they can establish that they (i) are legally and
financially autonomous, (ii) operate under the principles of
commercial law, and (iii) are not dependent agencies of the
Employer or the Borrower.
4.6 Bidders shall provide such evidence of their continued
eligibility satisfactory to the Employer, as the Employer shall
reasonably request.
4.7 In case a prequalification process has been conducted prior to
the bidding process, this bidding is open only to prequalified
Bidders.
4.8 Firms shall be excluded if:
(a) by an act of compliance with a decision of the United
Nations Security Council taken under Chapter VII of the
Charter of the United Nations, the Borrower’s country

prohibits any import of goods or contracting of works or
services from that country or any payments to persons or
entities in that country.
5. Eligible Plant 5.1 The Plant and Installation Services to be supplied under the
and Contract shall have their origin in eligible source countries as
Installation defined in ITB 4.2 above and all expenditures under the
Services Contract will be limited to such Plant and Installation
Services.
5.2 For purposes of ITB 5.1 above, “origin” means the place
where the plant, or component parts thereof are mined, grown,
produced or manufactured, and from which the services are
provided. Plant components are produced when, through
manufacturing, processing, or substantial or major assembling
of components, a commercially recognized product results that
is substantially in its basic characteristics or in purpose or
utility from its components.
Contents of Bidding Document

6. Sections of 6.1 The Bidding Document consists of Parts 1, 2, and 3, which
Bidding include all the Sections indicated below, and should be read in
Document conjunction with any Addenda issued in accordance with ITB
8.
PART 1 Bidding Procedures
 Section I. Instructions to Bidders (ITB)

 Section II. Bid Data Sheet (BDS)
 Section III. Evaluation and Qualification Criteria
 Section IV. Bidding Forms
 Section V. Eligible Countries
 • Section VI Bank Policy- Corrupt and fraudulent

Practices
PART 2 Employer’s Requirements
 Section VII. Employer’s Requirements
PART 3 Conditions of Contract and Contract Forms
 Section VIII. General Conditions (GC)

 Section IX. Particular Conditions (PC)
 Section X. Contract Forms

6.2 The Invitation for Bids issued by the Employer is not part of
the Bidding Document.
6.3 The Employer is not responsible for the completeness of the
Bidding Document and its addenda, if they were not obtained
directly from the source stated by the Employer in the
Invitation for Bids.
6.4 The Bidder is expected to examine all instructions, forms,
terms, and specifications in the Bidding Document. Failure to
furnish all information or documentation required by the
Bidding Document may result in the rejection of the bid.
7. Clarification of 7.1 A prospective Bidder requiring any clarification of the
Bidding Bidding Document shall contact the Employer in writing at the
Document, Site Employer’s address indicated in the BDS or raise his
Visit, Pre-Bid enquiries during the pre-bid meeting if provided for in
Meeting accordance with ITB 7.4. The Employer will respond to any
request for clarification, provided that such request is received
no later than twenty-eight (28) days prior to the deadline for
submission of bids. The Employer’s response shall be in
writing with copies to all Bidders who have acquired the
Bidding Document in accordance with ITB 6.3, including a
description of the inquiry but without identifying its source.
Should the Employer deem it necessary to amend the Bidding
Document as a result of a request for clarification, it shall do
so following the procedure under ITB 8 and ITB 23.2.
7.2 The Bidder is advised to visit and examine the site where the
plant is to be installed and its surroundings and obtain for
itself on its own responsibility all information that may be
necessary for preparing the bid and entering into a contract for
the provision of Plant and Installation Services. The costs of
visiting the site shall be at the Bidder’s own expense.
7.3 The Bidder and any of its personnel or agents will be granted
permission by the Employer to enter upon its premises and
lands for the purpose of such visit, but only upon the express
condition that the Bidder, its personnel, and agents will release
and indemnify the Employer and its personnel and agents from
and against all liability in respect thereof, and will be
responsible for death or personal injury, loss of or damage to
property, and any other loss, damage, costs, and expenses
incurred as a result of the inspection.
7.4 The Bidder’s designated representative is invited to attend a

pre-bid meeting, if provided for in the BDS. The purpose of
the meeting will be to clarify issues and to answer questions
on any matter that may be raised at that stage.
7.5 The Bidder is requested, as far as possible, to submit any
questions in writing, to reach the Employer not later than one
week before the meeting.
7.6 Minutes of the pre-bid meeting, including the text of the
questions raised without identifying the source, and the
responses given, together with any responses prepared after
the meeting, will be transmitted promptly to all Bidders who
have acquired the Bidding Document in accordance with ITB
6.3. Any modification to the Bidding Document that may
become necessary as a result of the pre-bid meeting shall be
made by the Employer exclusively through the issue of an
Addendum pursuant to ITB 8 and not through the minutes of
the pre-bid meeting.
7.7 Nonattendance at the pre-bid meeting will not be a cause for
disqualification of a Bidder.
8. Amendment of 8.1 At any time prior to the deadline for submission of bids, the
Bidding Employer may amend the Bidding Document by issuing
Document addenda.
8.2 Any addendum issued shall be part of the Bidding Document
and shall be communicated in writing to all who have obtained
the Bidding Document from the Employer in accordance with
ITB 6.3.
8.3 To give prospective Bidders reasonable time in which to take
an addendum into account in preparing their bids, the
Employer may, at its discretion, extend the deadline for the
submission of bids, pursuant to ITB 23.2
Preparation of Bids
9. Cost of Bidding 9.1 The Bidder shall bear all costs associated with the preparation
and submission of its Bid, and the Employer shall not be
responsible or liable for those costs, regardless of the conduct
or outcome of the bidding process.
10. Language of 10.1 The Bid, as well as all correspondence and documents relating
Bid to the bid exchanged by the Bidder and the Employer, shall be
written in the language specified in the BDS. Supporting
documents and printed literature that are part of the Bid may
be in another language provided they are accompanied by an

accurate translation of the relevant passages in the language
specified in the BDS, in which case, for purposes of
interpretation of the Bid, such translation shall govern.
11. Documents 11.1 The Bid submitted by the Bidder shall comprise the following:
Comprising the
Bid (a) Letter of Bid
(b) Completed schedules as required, including Price
Schedules, in accordance with ITB 12 and 17;
(c) Bid Security or Bid Securing Declaration, in accordance
with ITB 20;
(d) alternative bids, if permissible, in accordance with ITB
13;
(e) written confirmation authorizing the signatory of the
Bid to commit the Bidder, in accordance with ITB 21.2;
(f) documentary evidence established in accordance with
ITB 14.1 that the Plant and Installation Services offered
by the Bidder in its bid or in any alternative bid, if
permitted, are eligible;
(g) documentary evidence in accordance with ITB 15
establishing the Bidder’s eligibility and qualifications to
perform the contract if its Bid is accepted;
(h) documentary evidence established in accordance with
ITB 16 that the Plant and Installation Services offered
by the Bidder conform to the Bidding Document;
(i) in the case of a bid submitted by a JVA, JVA
agreement, or letter of intent to enter into a JVA
including a draft agreement, indicating at least the parts
of the Plant to be executed by the respective partners;
(j) List of subcontractors, in accordance with ITB 16.2; and
(k) any other document required in the BDS.
(l) signed Covenant of Integrity.
12. Letter of Bid 12.1 The Bidder shall complete the Letter of Bid, including the
and Schedules appropriate Price Schedules, using the relevant forms
furnished in Section IV, Bidding Forms. The forms must be
completed as instructed in each form.
13. Alternative 13.1 The BDS indicates whether alternative bids are allowed. If
Bids they are allowed, the BDS will also indicate whether they are
permitted in accordance with ITB 13.3, or invited in
accordance with ITB13.2 and/or ITB 13.4.
13.2 When alternatives to the Time Schedule are explicitly invited,
a statement to that effect will be included in the BDS, and the
method of evaluating different time schedules will be
described in Section III, Evaluation and Qualification Criteria.
13.3 Except as provided under ITB 13.4 below, Bidders wishing to
offer technical alternatives to the Employer’s requirements as
described in the bidding document must also provide: (i) a price
at which they are prepared to offer a plant meeting the
Employer’s requirements; and (ii) all information necessary for a
complete evaluation of the alternatives by the Employer,
including drawings, design calculations, technical specifications,
breakdown of prices, and proposed installation methodology and
other relevant details. Only the technical alternatives, if any, of
the lowest evaluated Bidder conforming to the basic technical
requirements shall be considered by the Employer.
13.4 When bidders are invited in the BDS to submit alternative
technical solutions for specified parts of the facilities, such
parts shall be described in Section VII, Employer’s
Requirements. Technical alternatives that comply with the
performance and technical criteria specified for the Plant and
Installation Services shall be considered by the Employer on
their own merits, pursuant to ITB 35.
14. Documents 14.1 To establish the eligibility of the Plant and Installation
Establishing Services in accordance with ITB Clause 5, Bidders shall
the Eligibility complete the country of origin declarations in the Price
of the Plant Schedule Forms, included in Section IV, Bidding Forms.
and
Installation
Services
15. Documents 15.1 To establish its eligibility and qualifications to perform the
Establishing Contract in accordance with Section III, Evaluation and
the Eligibility Qualification Criteria, the Bidder shall provide the information
and requested in the corresponding information sheets included in
Qualifications Section IV, Bidding Forms.
of the Bidder
15.2 Domestic Bidders, individually or in joint ventures, applying
for eligibility for domestic preference shall supply all
information required to satisfy the criteria for eligibility as
described in ITB 34.
16. Documents 16.1 The Bidder shall furnish the information stipulated in Section
establishing IV, in sufficient detail to demonstrate substantial
conformity of responsiveness of the Bidders’ proposal to the work
the Plant and requirements and the completion time.
Installation
Services 16.2 For major items of Plant and Installation Services as listed by
the Employer in Section III, Evaluation and Qualification
Criteria, which the Bidder intends to purchase or subcontract,
the Bidder shall give details of the name and nationality of the
proposed Subcontractors, including manufacturers, for each of
those items. In addition, the Bidder shall include in its bid
information establishing compliance with the requirements
specified by the Employer for these items. Quoted rates and
prices will be deemed to apply to whichever Subcontractor is
appointed, and no adjustment of the rates and prices will be
permitted.
16.3 The Bidder shall be responsible for ensuring that any
Subcontractor proposed complies with the requirements of
ITB 4, and that any plant, or services to be provided by the
Subcontractor comply with the requirements of ITB 5 and ITB
15.1
17. Bid Prices and 17.1 Unless otherwise specified in the BDS, bidders shall quote for
Discounts the entire Plant and Installation Services on a “single
responsibility” basis such that the total bid price covers all the
Contractor’s obligations mentioned in or to be reasonably
inferred from the bidding document in respect of the design,
manufacture, including procurement and subcontracting (if
any), delivery, construction, installation and completion of the
plant. This includes all requirements under the Contractor’s
responsibilities for testing, pre-commissioning and
commissioning of the plant and, where so required by the
bidding document, the acquisition of all permits, approvals
and licenses, etc.; the operation, maintenance and training
services and such other items and services as may be specified
in the Bidding Document, all in accordance with the
requirements of the General Conditions. Items against which
no price is entered by the Bidder will not be paid for by the
Employer when executed and shall be deemed to be covered
by the prices for other items.
17.2 Bidders are required to quote the price for the commercial,
contractual and technical obligations outlined in the bidding
document.
17.3 Bidders shall give a breakdown of the prices in the manner
and detail called for in the Price Schedules included in
Section IV, Bidding Forms.

17.4 Depending on the scope of the Contract, the Price Schedules
may comprise up to the six (6) schedules listed below.
Separate numbered Schedules included in Section IV, Bidding
Forms, from those numbered 1-4 below, shall be used for each
of the elements of the Plant and Installation Services. The
total amount from each Schedule corresponding to an element
of the Plant and Installation Services shall be summarized in
the schedule titled Grand Summary, (Schedule 5), giving the
total bid price(s) to be entered in the Letter of Bid.
Schedule No. 1 Plant (including Mandatory Spare Parts)
Supplied from Abroad
Schedule No. 2 Plant (including Mandatory Spare Parts)
Supplied from within the Employer’s Country
Schedule No. 3 Design Services
Schedule No. 4 Installation Services
Schedule No. 5 Grand Summary (Schedule Nos. 1 to 4)
Schedule No. 6 Recommended Spare Parts
Bidders shall note that the plant and equipment included in
Schedule Nos. 1 and 2 above exclude materials used for civil,
building and other construction works. All such materials
shall be included and priced under Schedule No. 4, Installation
Services.
17.5 In the Schedules, bidders shall give the required details and a
breakdown of their prices as follows:
(a) Plant to be supplied from abroad (Schedule No. 1):
The price of the plant shall be quoted on CIP-named
place of destination basis as specified in the BDS
(b) Plant manufactured within the Employer’s country
(Schedule No. 2):
(i) The price of the plant shall be quoted on an EXW
Incoterm basis (such as “ex-works,” “ex-factory,”
“ex-warehouse” or “off-the-shelf,” as applicable),
(ii) Sales tax and all other taxes payable in the
Employer’s country on the plant if the contract is
awarded to the Bidder, and
(iii) The total price for the item.

(c) Design Services (Schedule No. 3).
(d) Installation Services shall be quoted separately
(Schedule No. 4) and shall include rates or prices for
local transportation to named place of final destination
as specified in the BDS, insurance and other services
incidental to delivery of the plant, all labour,
contractor’s equipment, temporary works, materials,
consumables and all matters and things of whatsoever
nature, including operations and maintenance services,
the provision of operations and maintenance manuals,
training, etc., where identified in the Bidding Document,
as necessary for the proper execution of the installation
and other services.
(e) Recommended spare parts shall be quoted separately
(Schedule 6) as specified in either subparagraph (a) or
(b) above in accordance with the origin of the spare
parts.
17.6 The current edition of Incoterms, published by the
International Chamber of Commerce shall govern.
17.7 The prices shall be either fixed or adjustable as specified in
the BDS.
17.8 In the case of Fixed Price, prices quoted by the Bidder shall
be fixed during the Bidder’s performance of the contract and
not subject to variation on any account. A bid submitted with
an adjustable price quotation will be treated as non-responsive
and rejected.
17.9 In the case of Adjustable Price, prices quoted by the Bidder
shall be subject to adjustment during performance of the
contract to reflect changes in the cost elements such as labour,
material, transport and contractor’s equipment in accordance
with the procedures specified in the corresponding Appendix
to the Contract Agreement. A bid submitted with a fixed price
quotation will not be rejected, but the price adjustment will be
treated as zero. Bidders are required to indicate the source of
labour and material indices in the corresponding Form in
17.10 If so indicated in ITB 1.1, bids are being invited for individual
lots (contracts) or for any combination of lots (packages).
Bidders wishing to offer any price reduction (discount) for the
award of more than one Contract shall specify in their Letter
of Bid the price reductions applicable to each package, or

alternatively, to individual Contracts within the package, and
the manner in which the price reductions will apply.
17.11 Bidders wishing to offer any unconditional discount shall
specify in their Letter of Bid the offered discounts and the
manner in which price discounts will apply.
18. Currencies of 18.1 The currency(ies) of the bid shall be, as specified in the BDS.
Bid and
Payment 18.2 Bidders may be required by the Employer to justify, to the
Employer’s satisfaction, their local and foreign currency
requirements.
19. Period of 19.1 Bids shall remain valid for the period specified in the BDS
Validity of Bids after the bid submission deadline date prescribed by the
Employer. A bid valid for a shorter period shall be rejected by
the Employer as non-responsive.
19.2 In exceptional circumstances, prior to the expiration of the bid
validity period, the Employer may request Bidders to extend
the period of validity of their bids. The request and the
responses shall be made in writing. If a bid security is
requested in accordance with ITB 20, the Bidder granting the
request shall also extend the bid security for twenty-eight (28)
days beyond the deadline of the extended validity period. A
Bidder may refuse the request without forfeiting its bid
security. A Bidder granting the request shall not be required or
permitted to modify its bid, except as provided in ITB 19.3.
19.3 In the case of fixed price contracts, if the award is delayed by
a period exceeding fifty-six (56) days beyond the expiry of the
initial bid validity, the Contract price shall be adjusted by a
factor or factors specified in the request for extension. Bid
evaluation shall be based on the Bid Price without taking into
consideration the above correction.
20. Bid Security 20.1 The Bidder shall furnish as part of its bid, a bid security as
specified in the BDS, in original form and in the amount
specified in the BDS.
20.2 If a bid security is specified pursuant to ITB 20.1, the bid
security shall be a demand guarantee in any of the following
forms at the Bidder’s option:
(a) an unconditional guarantee issued by a bank or surety;
(b) an irrevocable letter of credit;
(c) a cashier’s or certified check; or

(d) another security indicated in the BDS,
from a reputable source from an eligible country. If the
unconditional guarantee is issued by an insurance company or
a bonding company located outside the Employer’s Country,
the issuer shall have a correspondent financial institution
located in the Employer’s Country to make it enforceable. In
the case of a bank guarantee, the bid security shall be
submitted either using the Bid Security Form included in
Section IV, Bidding Forms or in another substantially similar
format approved by the Employer prior to bid submission. In
either case, the form must include the complete name of the
Bidder. The bid security shall be valid for twenty-eight days
(28) beyond the original validity period of the bid, or beyond
any period of extension if requested under ITB 19.2.
20.3 If a bid security is specified pursuant to ITB 20.1, any bid not
accompanied by a substantially responsive bid security or Bid-
Securing Declaration shall be rejected by the Employer as non
responsive.
20.4 If a bid security is specified pursuant to ITB 20.1, the bid
security of unsuccessful Bidders shall be returned as promptly
as possible upon the successful Bidder’s furnishing of the
performance security pursuant to ITB 42.
20.5 The bid security of the successful Bidder shall be returned as
promptly as possible once the successful Bidder has signed the
Contract and furnished the required performance security.
20.6 The bid security may be forfeited or the Bid-Securing
Declaration executed:
(a) if a Bidder withdraws its bid during the period of bid
validity specified by the Bidder on the Letter of Bid or
(b) if the successful Bidder fails to:
(i) sign the Contract in accordance with ITB 41; or
(ii) furnish a performance security in accordance with
ITB 42.
20.7 The Bid Security or the Bid Securing Declaration of a JVA
shall be in the name of the JVA that submits the bid. If the
JVA has not been legally constituted into a legally enforceable
JVA at the time of bidding, the Bid Security or the Bid
Securing Declaration shall be in the names of all future
partners as named in the letter of intent referred to in ITB 4.1.

20.8 If a Bid-Securing Declaration is executed in accordance with
ITB 20.7, the Employer will declare the Bidder ineligible to be
awarded a contract by the Employer for the period of time
stated in the Form of Bid-Securing Declaration.
20.9 If a bid security is not required in the BDS, and
(a) if a Bidder withdraws its bid during the period of bid
validity specified by the Bidder on the Letter of Bid
Form, except as provided in ITB 19.2, or
(b) if the successful Bidder fails to: sign the Contract in
accordance with ITB 41; or furnish a performance
security in accordance with ITB 42;
the Borrower may, if provided for in the BDS, declare the
Bidder disqualified to be awarded a contract by the Employer
for a period of time as stated in the BDS.
21. Format and 21.1 The Bidder shall prepare one original of the documents
Signing of Bid comprising the bid as described in ITB 11 and clearly mark it
“ORIGINAL.” Alternative bids, if permitted in accordance with
ITB 13, shall be clearly marked “ALTERNATIVE”. In addition,
the Bidder shall submit copies of the bid, in the number
specified in the BDS and clearly mark them “COPY.” In the
event of any discrepancy between the original and the copies,
the original shall prevail.
21.2 The original and all copies of the bid shall be typed or written
in indelible ink and shall be signed by a person duly
authorized to sign on behalf of the Bidder. This authorization
shall consist of a written confirmation as specified in the BDS
and shall be attached to the bid. The name and position held
by each person signing the authorization must be typed or
printed below the signature. All pages of the bid where entries
or amendments have been made shall be signed or initialled by
the person signing the bid.
21.3 A bid submitted by a JVA shall comply with the following
requirements:
(a) Unless not required in accordance with ITB 4.1 (a), be
signed so as to be legally binding on all partners and
(b) Include the Representative’s authorization referred to in
ITB 4.1 (b), consisting of a power of attorney signed by
those legally authorized to sign on behalf of the JVA.
21.4 Any interlineations, erasures, or overwriting shall be valid

only if they are signed or initialled by the person signing the
bid.
Submission and Opening of Bids

22. Submission, 22.1 Bidders may always submit their bids by mail or by hand.
Sealing and When so specified in the BDS, bidders shall have the option
Marking of of submitting their bids electronically. Procedures for
Bids submission, sealing and marking are as follows:
(a) Bidders submitting bids by mail or by hand shall enclose
the original and each copy of the Bid, including
alternative bids, if permitted in accordance with ITB 13,
in separate sealed envelopes, duly marking the
envelopes as “ORIGINAL,” “ALTERNATIVE” and “COPY.”
These envelopes containing the original and the copies
shall then be enclosed in one single envelope. The rest
of the procedure shall be in accordance with ITB sub-
Clauses 22.2 and 22.3.
(b) Bidders submitting bids electronically shall follow the
electronic bid submission procedures specified in the
BDS.
22.2 The inner and outer envelopes shall:
(a) bear the name and address of the Bidder;
(b) be addressed to the Employer in accordance with ITB
24.1;
(c) bear the specific identification of this bidding process
indicated in accordance with ITB 1.1; and
(d) bear a warning not to open before the time and date for
bid opening.
22.3 If all envelopes are not sealed and marked as required, the
Employer will assume no responsibility for the misplacement
or premature opening of the bid.
23. Deadline for 23.1 Bids must be received by the Employer at the address and no
Submission of later than the date and time indicated in the BDS.
Bids
23.2 The Employer may, at its discretion, extend the deadline for
the submission of bids by amending the Bidding Document in
accordance with ITB 8, in which case all rights and
obligations of the Employer and Bidders previously subject to

the deadline shall thereafter be subject to the deadline as
extended.
24. Late Bids 24.1 The Employer shall not consider any bid that arrives after the
deadline for submission of bids, in accordance with ITB 23.
Any bid received by the Employer after the deadline for
submission of bids shall be declared late, rejected, and
returned unopened to the Bidder.
25. Withdrawal, 25.1 A Bidder may withdraw, substitute, or modify its bid after it
Substitution, has been submitted by sending a written notice, duly signed by
and an authorized representative, and shall include a copy of the
Modification of authorization in accordance with ITB 21.2, (except that
Bids withdrawal notices do not require copies). The corresponding
substitution or modification of the bid must accompany the
respective written notice. All notices must be:
(a) prepared and submitted in accordance with ITB 21 and
ITB 22 (except that withdrawals notices do not require
copies), and in addition, the respective envelopes shall be
clearly marked “WITHDRAWAL,” “SUBSTITUTION,”
“MODIFICATION;” and
(b) received by the Employer prior to the deadline prescribed
for submission of bids, in accordance with ITB 23.
25.2 Bids requested to be withdrawn in accordance with ITB 25.1
shall be returned unopened to the Bidders.
25.3 No bid may be withdrawn, substituted, or modified in the
interval between the deadline for submission of bids and the
expiration of the period of bid validity specified by the Bidder
on the Letter of Bid or any extension thereof.
26. Bid Opening 26.1 The Employer shall conduct the bid opening in public, in the
presence of Bidders` designated representatives and anyone
who choose to attend, and at the address, date and time
specified in the BDS. Any specific electronic bid opening
procedures required if electronic bidding is permitted in
accordance with ITB 22.1, shall be as specified in the BDS.
26.2 First, envelopes marked “WITHDRAWAL” shall be opened and
read out and the envelope with the corresponding bid shall not
be opened, but returned to the Bidder. No bid withdrawal
shall be permitted unless the corresponding withdrawal notice
contains a valid authorization to request the withdrawal and is
read out at bid opening. Next, envelopes marked
“SUBSTITUTION” shall be opened and read out and exchanged
with the corresponding bid being substituted, and the

substituted bid shall not be opened, but returned to the Bidder.
No bid substitution shall be permitted unless the
corresponding substitution notice contains a valid
authorization to request the substitution and is read out at bid
opening. Envelopes marked “MODIFICATION” shall be opened
and read out with the corresponding bid. No bid modification
shall be permitted unless the corresponding modification
notice contains a valid authorization to request the
modification and is read out at bid opening. Only bids that are
opened and read out at bid opening shall be considered further.
26.3 All other envelopes shall be opened one at a time, reading out:
the name of the Bidder and the Bid Price(s), including any
discounts and alternative bids, and indicating whether there is
a modification; the presence or absence of a bid security or
Bid-Securing Declaration; and any other details as the
Employer may consider appropriate. Only discounts and
alternative bids read out at bid opening shall be considered for
evaluation. No bid shall be rejected at bid opening except for
late bids, in accordance with ITB 24.1.
26.4 The Employer shall prepare a record of the bid opening that
shall include, as a minimum: the name of the Bidder and
whether there is a withdrawal, substitution, or modification;
the Bid Price, per lot if applicable, including any discounts
and alternative bids; and the presence or absence of a bid
security or a Bid-Securing Declaration. The Bidders’
representatives who are present shall be requested to sign the
record. The omission of a Bidder’s signature on the record
shall not invalidate the contents and effect of the record. A
copy of the record shall be distributed to all Bidders who
submitted bids in time, and posted online when electronic
bidding is permitted.
Evaluation and Comparison of Bids

27. Confidentiality 27.1 Information relating to the evaluation of bids and
recommendation of contract award, shall not be disclosed to
Bidders or any other persons not officially concerned with
such process until information on Contract award is
communicated to all Bidders.
27.2 Any attempt by a Bidder to influence the Employer in the
evaluation of the bids or Contract award decisions may result
in the rejection of its bid.
27.3 Notwithstanding ITB 27.2, from the time of bid opening to the
time of Contract award, if any Bidder wishes to contact the

Employer on any matter related to the bidding process, it
should do so in writing.
28. Clarification of 28.1 To assist in the examination, evaluation, and comparison of
Bids the bids, and qualification of the Bidders, the Employer may,
at its discretion, ask any Bidder for a clarification of its bid.
Any clarification submitted by a Bidder that is not in response
to a request by the Employer shall not be considered. The
Employer’s request for clarification and the response shall be
in writing. No change in the prices or substance of the bid
shall be sought, offered, or permitted, except to confirm the
correction of arithmetic errors discovered by the Employer in
the evaluation of the bids, in accordance with ITB 32.
28.2 If a Bidder does not provide clarifications of its bid by the date
and time set in the Employer’s request for clarification, its bid
may be rejected.
29. Deviations, 29.1 During the evaluation of bids, the following definitions apply:
Reservations,
and Omissions (a) “Deviation” is a departure from the requirements
specified in the Bidding Document;
(b) “Reservation” is the setting of limiting conditions or
withholding from complete acceptance of the
requirements specified in the Bidding Document; and
(c) “Omission” is the failure to submit part or all of the
information or documentation required in the Bidding
Document.
30. Determination 30.1 The Employer’s determination of a bid’s responsiveness is to
of be based on the contents of the bid itself, as defined in ITB11.
Responsiveness
30.2 A substantially responsive bid is one that meets the
requirements of the Bidding Document without material
deviation, reservation, or omission. A material deviation,
reservation, or omission is one that,
(a) if accepted, would:
(i) affect in any substantial way the scope, quality, or
performance of the Plant and Installation Services
specified in the Contract; or
(ii) limit in any substantial way, inconsistent with the
Bidding Document, the Employer’s rights or the
Bidder’s obligations under the proposed Contract;
or
(b) if rectified, would unfairly affect the competitive
position of other Bidders presenting substantially
responsive bids.
30.3 The Employer shall examine the technical aspects of the bid in
particular, to confirm that all requirements of Section VII,
Employer’s Requirements have been met without any material
deviation, reservation, or omission.
30.4 If a bid is not substantially responsive to the requirements of
the Bidding Document, it shall be rejected by the Employer
and may not subsequently be made responsive by correction of
the material deviation, reservation, or omission.
31. Nonmaterial 31.1 Provided that a bid is substantially responsive, the Employer
Non- may waive any nonconformity in the bid that does not
conformities constitute a material deviation, reservation or omission.
31.2 Provided that a bid is substantially responsive, the Employer
may request that the Bidder submit the necessary information
or documentation, within a reasonable period of time, to
rectify nonmaterial nonconformities in the bid related to
documentation requirements. Requesting information or
documentation on such nonconformities shall not be related to
any aspect of the price of the bid. Failure of the Bidder to
comply with the request may result in the rejection of its bid.
31.3 Provided that a bid is substantially responsive, the Employer
shall rectify quantifiable nonmaterial nonconformities related
to the Bid Price. To this effect, the Bid Price shall be
adjusted, for comparison purposes only, to reflect the price of
a missing or non-conforming item or component. The
adjustment shall be made using the method indicated in
Section III, Evaluation and Qualification Criteria.
32. Correction of 32.1 Provided that the bid is substantially responsive, the Employer
Arithmetical shall correct arithmetical errors on the following basis:
Errors
(a) where there are errors between the total of the amounts
given under the column for the price breakdown and the
amount given under the Total Price, the former shall
prevail and the latter will be corrected accordingly;
(b) where there are errors between the total of the amounts
of Schedule Nos. 1 to 4 and the amount given in
Schedule No. 5 (Grand Summary), the former shall
prevail and the latter will be corrected accordingly; and

(c) if there is a discrepancy between words and figures, the
amount in words shall prevail, unless the amount
expressed in words is related to an arithmetic error, in
which case the amount in figures shall prevail subject to
(a) and (b) above.
32.2 If the Bidder that submitted the lowest evaluated bid does not
accept the correction of errors, its bid shall be declared non-
responsive.
33. Conversion to 33.1 For evaluation and comparison purposes, the currency(ies) of
Single the bid shall be converted into a single currency as specified
Currency in the BDS.
34. Margin of 34.1 No margin of domestic preference shall apply.
Preference
35. Evaluation of 35.1 The Employer shall use the criteria and methodologies
Bids indicated in this Clause. No other evaluation criteria or
methodologies shall be permitted.
Technical Evaluation
35.2 The Employer will carry out a detailed technical evaluation of
the bids not previously rejected to determine whether the
technical aspects are in compliance with the Bidding
Document. In order to reach its determination, the Employer
will examine and compare the technical aspects of the bids on
the basis of the information supplied by the bidders, taking
into account the following:
(a) overall completeness and compliance with the
Employer’s Requirements; conformity of the Plant and
Installation Services offered with specified performance
criteria, including conformity with the specified minimum
(or maximum, as the case may be) requirement
corresponding to each functional guarantee, as indicated
in the Specification and in Section III Evaluation and
Qualification Criteria; suitability of the Plant and
Installation Services offered in relation to the
environmental and climatic conditions prevailing at the
site; and quality, function and operation of any process
control concept included in the bid;
(b) type, quantity and long-term availability of mandatory

and recommended spare parts and maintenance services;
and
(c) other relevant factors, if any, listed in Section III,

Evaluation and Qualification Criteria.
35.3 Where alternative technical solutions have been allowed in

accordance with ITB 13, and offered by the Bidder, the
Employer will make a similar evaluation of the alternatives.
Where alternatives have not been allowed but have been
offered, they shall be ignored.
Economic Evaluation
35.4 To evaluate a bid, the Employer shall consider the following:
(a) the bid price, excluding provisional sums and the
provision, if any, for contingencies in the Price
Schedules;
(b) price adjustment for correction of arithmetic errors in
accordance with ITB 32.1;
(c) price adjustment due to discounts offered in accordance
with ITB 17.9 or ITB17.10;
(d) price adjustment due to quantifiable nonmaterial
nonconformities in accordance with ITB 31.3;
(e) converting the amount resulting from applying (a) to (c)
above, if relevant, to a single currency in accordance
with ITB 33; and
(f) the evaluation factors indicated in Section III, Evaluation
and Qualification Criteria.
35.5 If price adjustment is allowed in accordance with ITB 17.6,
the estimated effect of the price adjustment provisions of the
Conditions of Contract, applied over the period of execution
of the Contract, shall not be taken into account in bid
evaluation.
35.6 If this Bidding Document allows Bidders to quote separate
prices for different lots (contracts), and the award to a single
Bidder of multiple lots (contracts), the methodology to
determine the lowest evaluated price of the lot (contract)
combinations, including any discounts offered in the Letter of
Bid, is specified in Section III, Evaluation and Qualification
Criteria.
35.7 If the bid, which results in the lowest Evaluated Bid Price, is
seriously unbalanced or front loaded in the opinion of the

Employer, the Employer may require the Bidder to produce
detailed price analyses for any or all items of the Price
Schedules, to demonstrate the internal consistency of those
prices with the methods and time schedule proposed. After
evaluation of the price analyses, taking into consideration the
terms of payments, the Employer may require that the amount
of the performance security be increased at the expense of the
Bidder to a level sufficient to protect the Employer against
financial loss in the event of default of the successful Bidder
under the Contract.
35.8 In the event of identification of a potentially Abnormally Low
Bid, the Employer shall seek written clarifications from the
Bidder, including detailed price analyses of its Bid price in
relation to the subject matter of the contract, scope, proposed
methodology, schedule, allocation of risks and responsibilities
and any other requirements of the bidding document.
An Abnormally Low Bid is one where the Bid price, in
combination with other elements of the Bid, appears so low
that it raises material concerns as to the capability of the
Bidder to perform the Contract for the offered Bid Price.
After evaluation of the price analyses, in the event that the
Employer determines that the Bidder has failed to demonstrate
its capability to perform the Contract for the offered Bid
Price, the Employer shall reject the Bid.
36. Comparison of 36.1 The Employer shall compare all substantially responsive bids
Bids in accordance with ITB 35.4 to determine the lowest evaluated
bid.
37. Eligibility and 37.1 The Employer shall determine to its satisfaction whether the
Qualification Bidder that is selected as having submitted the lowest
of the Bidder evaluated and substantially responsive bid is eligible and
meets the qualifying criteria specified in Section III,
Evaluation and Qualification Criteria.
37.2 The determination shall be based upon an examination of the
documentary evidence of the Bidder’s qualifications submitted
by the Bidder, pursuant to ITB 15.
37.3 An affirmative determination shall be a prerequisite for award
of the Contract to the Bidder. A negative determination shall
result in disqualification of the bid, in which event the
Employer shall proceed to the next lowest evaluated bid to
make a similar determination of that Bidder’s qualifications to
perform satisfactorily.
37.4 The capabilities of the manufacturers and subcontractors
proposed in its Bid to be used by the lowest evaluated Bidder
for identified major items of supply or services will also be
evaluated for acceptability in accordance with Section III,
Evaluation and Qualification Criteria. Their participation
should be confirmed with a letter of intent between the parties,
as needed. Should a manufacturer or subcontractor be
determined to be unacceptable, the Bid will not be rejected,
but the Bidder will be required to substitute an acceptable
manufacturer or subcontractor without any change to the bid
price. Prior to signing the Contract, the corresponding
Appendix to the Contract Agreement shall be completed,
listing the approved manufacturers or subcontractors for each
item concerned.
38. Employer’s 38.1 The Employer reserves the right to accept or reject any bid,
Right to Accept and to annul the bidding process and reject all bids at any time
Any Bid, and prior to contract award, without thereby incurring any liability
to Reject Any to Bidders. In case of annulment, all bids submitted and
or All Bids specifically, bid securities, shall be promptly returned to the
Bidders.
Award of Contract
39. Award Criteria 39.1 Subject to ITB 38.1, the Employer shall award the Contract to
the Bidder whose offer has been determined to be the lowest
evaluated bid and is substantially responsive to the Bidding
Document, provided further that the Bidder is determined to
be eligible and qualified to perform the Contract satisfactorily.
39.2 The Contract shall not be awarded earlier than the expiry of
the Standstill Period. The Standstill Period shall be ten (10)
Days unless extended as per the BDS. The Standstill Period
commences the day after the date the Purchaser has
transmitted to each Bidder the Notification of Intention to
Award the Contract. Where only one Bid is submitted, or if
this contract is in response to an emergency situation
recognized by the Bank, the Standstill Period shall not apply.
40. Notification of 40.1 The Purchaser shall send to each Bidder the Notification of
intension to Intention to Award the Contract to the successful Bidder. The
Award Notification of Intention to Award shall contain, at a
minimum, the following information:
(a) the name and address of the Bidder submitting the successful
Bid;
(b) the Contract price of the successful Bid;

(c) the names of all Bidders who submitted Bids, and their Bid
prices as readout, and as evaluated;
(d) a statement of the reason(s) the Bid (of the unsuccessful
Bidder to whom the notification is addressed) was
unsuccessful, unless the price information in c) above
already reveals the reason;
(e) the expiry date of the Standstill Period;
(f) instructions on how to request a debriefing and/or submit a
complaint during the standstill period.
41. Notification of 41.1 Prior to the expiration of the Bid Validity Period and upon
Award expiry of the Standstill Period, specified in ITB 41.1 or any
extension thereof, and, upon satisfactorily addressing any
complaint that has been filed within the Standstill Period, the
Employer shall notify the successful Bidder, in writing, that its
Bid has been accepted. The notification of award (hereinafter
and in the Contract Forms called the “Letter of Acceptance”)
shall specify the sum that the Employer will pay the
Contractor in consideration of the execution of the contract
(hereinafter and in the Conditions of Contract and Contract
Forms called “the Contract Price”).
41.2 At the same time, the Employer shall also notify all other
Bidders of the results of the bidding, and shall publish in the
Official Journal of the European Union (OJEU), the results
identifying the bid and lot numbers and the following
information: (i) name of each Bidder who submitted a Bid; (ii)
bid prices as read out at Bid Opening; (iii) name and evaluated
prices of each Bid that was evaluated; (iv) name of bidders
whose bids were rejected and the reasons for their rejection;
and (v) name of the winning Bidder, and the Price it offered,
as well as the duration and summary scope of the contract
awarded..
41.3 Until a formal contract is prepared and executed, the Letter of
Acceptance shall constitute a binding Contract.
41.4 The Employer shall promptly respond in writing to any
unsuccessful Bidder who, after notification of award in
accordance with ITB 40.2, requests in writing the grounds on
which its bid was not selected.
42. Signing of 42.1 Promptly upon notification, the Employer shall send the
Contract successful Bidder the Contract Agreement.
42.2 Within twenty-eight (28) days of receipt of the Contract
Agreement, the successful Bidder shall sign, date, and return it
to the Employer.
42.3 Notwithstanding ITB 41.2 above, in case signing of the
Contract Agreement is prevented by any export restrictions
attributable to the Employer, to the country of the Employer,
or to the use of the Plant and Installation Services to be
supplied, where such export restrictions arise from trade
regulations from a country supplying those Plant and
Installation Services, the Bidder shall not be bound by its bid,
always provided, however, that the Bidder can demonstrate to
the satisfaction of the Employer and of the Bank that signing
of the Contact Agreement has not been prevented by any lack
of diligence on the part of the Bidder in completing any
formalities, including applying for permits, authorizations and
licenses necessary for the export of the Plant and Installation
Services under the terms of the Contract.
43. Performance 43.1 Within fourteen (14) days of signing the contract with the
Security Employer, the successful Bidder shall furnish the performance
security in accordance with the General Conditions, subject to
ITB 35.7, using for that purpose the Performance Security
Form included in Section IX, Contract Forms, or another form
acceptable to the Employer. If the performance security
furnished by the successful Bidder is in the form of a bond, it
shall be issued by a bonding or insurance company that has
been determined by the successful Bidder to be acceptable to
the Employer. A foreign institution providing a performance
security shall have a correspondent financial institution
located in the Employer’s Country.
43.2 Failure of the successful Bidder to submit the above-
mentioned Performance Security or sign the Contract shall
constitute sufficient grounds for the annulment of the award
and forfeiture of the bid security. In that event the Employer
may award the Contract to the next lowest evaluated Bidder
whose offer is substantially responsive and is determined by
the Employer to be qualified to perform the Contract
satisfactorily.

Section II. Bid Data Sheet 1-33
Section II. Bid Data Sheet

A. Introduction
ITB 1.1 The number of the Invitation for Bids is:

ZESCO/LTDRP/G/001/C2/2019
ITB 1.1 The Employer is:
ZESCO Limited
ITB 1.1 The name of the ICB is:
“Procurement of Transmission Lines and Substations”
The procurement is in 3 Lots as follows:
Lot 1: Woodlands 33/11kV Substation Upgrade
Lot 2: Coventry – Kafue 33kV Overhead Line Upgrade
and
The identification number of the ICB is:

ZESCO/LTDRP/G/001/C2/2019
The number and identification of lots (contracts) comprising this ICB is:
Three (3)
Lot 1 - ZESCO/LTDRP/G/015/C2/2019
ITB 2.1 The Borrower is:
Government of the Republic of Zambia
ITB 2.1 The name of the Project is:
Lusaka Power Transmission and Distribution Network Project
(LPTDNP)
ITB 4.1 (a) The individuals or firms in a joint venture, consortium or association shall
be jointly and severally liable.
1.34 Section II. Bid Data Sheet
ITB 4.4 Entities ineligible to receive a contract financed by EIB could be found in
the following lists:
https://www.un.org/sc/suborg/en/sanctions/un-sc-consolidated-list
https://eeas.europa.eu/topics/sanctions-policy/8442/consolidated-list-of-
sanctions_en
http://www.eib.org/about/accountability/anti-fraud/exclusion/index.htm
B. Bidding Document
ITB 7.1 For clarification purposes only, the Employer’s address is:
Attention: Project Manager – LTDRP
Street Address: Stand No. 6949, Great East Road
Floor/Room number: Procurement Office, adjacent to ZESCO
Filling Station, ZESCO Limited, Head
Office, RCC Building
City: Lusaka
ZIP Code:
Country: Zambia
Telephone: +260 211 362514 or +260 211 361358
Facsimile number: +260 211 362366
Electronic mail address: procurement@zesco.co.zm
ltdrppiu@zesco.co.zm
Requests for clarification should be received by the Employer no later

than Fourteen (14) days before date of tender closing. Requests for
clarifications must be accompanied by an electronic (email or facsimile)
copy for ease of reply.
ITB 7.4 A Pre-Bid meeting shall take place at the following date, time and place:
Date: 01 February 2019
Time: 09:00 hours
Place: Mulungushi International Conference
Centre (MICC), Lusaka
A site visit conducted by the Employer shall be held directly after the
pre-bid meeting. The Bidder will be considered to have fully informed
themselves of the conditions on the project sites. Despite the pre-bid
meeting, the basis for bid preparation and contract award
consideration will be the contents of the bid documents as issued and
any amendments or written clarifications that will be issued to all
Bidders. No further site visits will be arranged other than on the
above mentioned date.
C. Preparation of Bids
ITB 10.1 The language of the bid is:

English
ITB 11.1 (k) The Bidder shall submit with its bid the following additional documents.
Non-submission shall entitle the Employer to seek further clarification in
accordance with ITB 28. Bidders will have 5 working days to submit the
clarification information requested. The Employer reserves the right to
seek further clarification if necessary before rejecting the Bid.:
(a) In the case of an association in the form of a Joint Venture or
Consortium, non-submission of the following information will be
a cause for disqualification of a Bidder :
(i) Bidders must indicate clearly the contractual
relationship and responsibilities between the association
partners in defining the associations under a Joint
Venture or consortium.
(ii) Full information for each should be provided such as
address, nationality of the firm(s) and the firm’s
directors and shareholders.
If the Bidder is a single bidder, this additional information of the
nature of the association does not apply.
(b) For administration convenience only, an electronic copy (MS
Excel format) of the Price and Technical Schedules shall
accompany the bid in addition to the hard copy submission.
Please note that the hard copy will be considered as the official
copy and not the electronic copy. If there is a discrepancy
between the hard copy and the electronic copy, the hard copy will
prevail.
(c) Certified Copies of Type Test Reports for the Power
Transformers in accordance with the requirements of IEC 60076,
latest edition. The Type Test Reports shall meet the following
minimum requirements:
(i) Standard Type Test Certificate shall be for a similar
transformer to the transformers offered in the
Specifications. Similarity will be based on the same
manufacturer, size (MVA) and voltage ratings.
(ii) Short Circuit Type Test Certificate of a Transformer with
similar characteristics from an SO/IEC 17025 accredited,
high voltage testing facility. Similarity will be based on
the same manufacturer, vector group and voltage ratio.
(d) Certified Copies of Type Test Reports of MV Metal Clad
Switchgear in accordance with the requirements of IEC 62271,
latest edition. Copies of Type Test Reports shall meet the
following requirement:
(i) Standard Type Certificate shall be for identical switchgear
with the same manufacturer, country, type and technical
parameters as the equipment offered.
(ii) Type Tests for the Internal Arc Certification shall be for
identical switchgear with the same manufacturer, country,
type and technical parameters as the equipment offered.
(e) Certified Copies of Type Test Reports for all Medium Voltage
Cables offered in accordance with IEC 60502, latest editions.
Type Test Certificates for 132kV cable will be for the same
voltage rating and equal or higher size cable in accordance with
IEC 60840.
(f) For Mono-poles the following documentation and calculations
need to be submitted to prove the contractor’s capability:
(i) Outline drawings of the proposed structures clearly
showing all dimensions and thicknesses,
(ii) Loading trees with maximum loads for the design of the
structures in accordance with the specification,
(iii) Calculation of the maximum tip load for each of the
structure types based on the loading trees,
(iv) Type test certificate of a family of double circuit mono
pole self-supporting structures with similar tip loads.
(g) Type Test Certificates shall conform to the following minimum

requirements:
(i) Type Test Certificates shall be duly certified by a
Commissioner of Oaths that the document submitted is true
copy of the original.
(ii) Shall be carried out by a laboratory independent from the
Manufacturer. In case of the tests having been conducted
by a National Testing Laboratory/Standards Authority, a
copy of the accreditation certificate for the
laboratory/standards authority shall also be submitted in
accordance with IEC 17025 requirements.
(iii) Type Test Certificates in any language other than English
shall be accompanied by a Certified translated version.
(iv) Type Test Reports shall include all test results to meet the
requirements of applied standards as stipulated in the
Bidding Documents.
(h) Duly completed Technical Schedules “(A&B)” of Part 2: Section
VII ‒ Employer’s Requirements. Where Bidders offer multiple

suppliers, one set of Technical Schedules will be submitted for
each supplier, representing the minimum / maximum requirement
for each specific supplier and item. If a Bidder offer more than
one supplier per item, the Employer will have the right to
choose any one of the offered suppliers.
(i) Manufacturer Equipment Authorisation for specific equipment:
(i) Power transformers
(ii) HV Switchgear (Breakers and Isolators)
(iii) MV Indoor Switchgear
(iv) MV Cables
(v) Protection Relays
(vi) Telecommunication Equipment
(vii) Measuring Transformers (CTs VTs)
(viii) Earthing Resistors
(ix) Auxiliary transformers
(x) Generators
(xi) SCADA Equipment
(xii) Overhead Line Monopoles
(xiii) Overhead Line Conductor and OPGW
(xiv) Overhead Line Hardware
(j) As per instruction from the Employer, a Bid Documentation
Outline “111233-80-GDL-EE-0001 - Bid documentation
outline” as included in “Volume 2 of 3 Supplementary
Information” included in this tender document must be adhered
to by the Bidders when compiling the Bid Documents.
ITB 13.1 Alternative bids are not permitted.
ITB 13.2 Alternatives to the Time Schedule are not permitted.
ITB 13.4 Alternative technical solutions shall be permitted for the following parts of
the Plant and Installation Services:
Not allowed.
ITB 17.1 Bidders shall quote for all the requirements for each Lot as stated in the
Bidding Document. Partial bids will not be accepted. Tender prices shall
be inclusive of all duties, taxes and other levies as applicable. Please refer
to item ITB 17.6
ITB 17.5(a) Named place of destination in accordance with INCOTERMS 2010
is:
(i) CIP Lusaka: Lot 1 Woodlands 33/11kV Substation Upgrade
(ii) CIP Lusaka: Lot 2 Coventry – Kafue 33kV Overhead Line
Upgrade
(iii) CIP Lusaka: Lot 3 Industrial – Matero 33kV Corridor Upgrade
ITB Plant and equipment manufactured or fabricated within the Employer’s
17.5(b)(i) country (Schedule No. 2) shall be quoted on an EXW (ex-factory, ex
works, ex warehouse or off-the-shelf, as applicable) basis, and shall be
inclusive of all costs as well as duties and taxes paid or payable on
components and raw materials incorporated or to be incorporated in the
facilities.
ITB 17.5(d) Named place of final destination is as stated below all of them being within
20km of the Lusaka City Centre:
(i) Woodlands 33/11kV Substation

(ii) Coventry and Kafue 33kV Substations
(iii) Industrial and Matero 33kV Substations
ITB 17.6
Contracts will be awarded on CIP Lusaka.
ITB 17.7 The prices quoted by the Bidder shall be:

Lump Sum, Fixed and Firm
ITB 17.10 Bidders may submit bids for one Lot, a combination of Lots or all Lots.
ITB 18.1 Prices shall be quoted in the following currencies:
(a) Plant and equipment to be supplied from abroad shall be

quoted in USD (United States Dollars) or in a freely
convertible currency. If the Bidder wishes to be paid in a
combination of amounts in different currencies, it may quote
its price accordingly, but use no more than three freely
convertible currencies.
(b) Plant and equipment to be supplied from within the

Employer’s country shall be quoted in a freely convertible
currency. If the Bidder wishes to be paid in a combination of
amounts in different currencies, it may quote its price
accordingly, but use no more than three freely convertible
currencies.
(c) Design and installation services shall be quoted in USD

(Unites States Dollars) or in a freely convertible currency. If
the Bidder wishes to be paid in a combination of amounts in

different currencies, it may quote its price accordingly, but
use no more than three freely convertible currencies.
ITB 19.1 The bid validity period shall be 120 days.

ITB 20.1 Bid shall include a bid security (issued by bank or surety) for each lot.
If a bid security shall be issued by the Bank (Bid Security), it must be in
the form of an unconditional bank guarantee, an irrevocable letter of credit
or a Cashier’s cheque. The amount of the bid security shall be at least two
percent (2%) of the total bid price in a freely convertible currency.
If a bid security shall be issued by the Surety (Bid Bond) from an
Insurance firm, the amount shall be at least three percent (3%) of the total
bid price. A bid securing declaration will not be allowed.
ITB 20.3 (d) Other types of acceptable securities:
None.
ITB 20.10 Not Applicable.
ITB 21.1 In addition to the original of the bid, the number of copies is:
Three (3)
One Bid document will be submitted for all Lots. A Bid Security,
Qualification, Pricing and Technical Schedules will be submitted for
each individual Lot that the Bidder chooses to Bid on. Bidders should
refer to 111233-80-GDL-EE-0001 – BID DOCUMENT OUTLINE
included under Volume 2 of this tender document as a guideline for
submitting tender documents: Supplementary Information on the
format and sequence of their Bid Submission.
ITB 21.2 The written confirmation of authorization to sign on behalf of the Bidder
shall consist of:
Resolution of the Board of Directors or Power of Attorney issued by
an Attorney or authorization from Directors.
D. Submission and Opening of Bids
ITB 22.1 Bidders shall not have the option of submitting their bids electronically.
ITB 22.1 (b) Not Applicable.
ITB 23.1 For bid submission purposes only, the Employer’s address is:
Attention: Senior Manager Procurement and Stores
Street Address: ZESCO Limited, Stand No. 6949, Great East
Road
Floor/Room number: Tender Box located in Procurement Offices,

adjacent to the Filling Station, RCC Building,
ZESCO Limited
City: Lusaka
ZIP Code:
Country: Zambia
The deadline for bid submission is:

Time: 10:30 hours, local time.
ITB 26.1 The bid opening shall take place at:
Street Address: ZESCO Limited, Stand No. 6949, Great East
Road
Floor/Room number: Procurement Offices, Conference Room,
RCC Buildings, Adjacent to ZESCO Filling
Station
City : Lusaka
Country: Zambia
Time: 10:30 hours, local time.
ITB 26.1 If electronic bid submission is permitted in accordance with ITB 22.1, the
specific bid opening procedures shall be:
Not Applicable.
E. Evaluation, and Comparison of Bids
ITB 33.1 The currency that shall be used for bid evaluation and comparison
purposes to convert all bid prices expressed in various currencies into a
single currency is:
United States Dollars (USD)
The source of exchange rate shall be:
Bank of Zambia (Central Bank of Zambia)
The date for the exchange rate shall be:
Fourteen (14) days before the submission
ITB 35.5 The Purchaser’s evaluation of a bid will exclude and not take into account:
(a) Plant manufactured in the Purchaser’s Country, sales and other

similar taxes, which will be payable on the goods if a contract is
awarded to the Bidder;
(b) Plant manufactured outside the Purchaser’s Country to be

imported, customs duties and other import taxes levied on the
imported Plant, sales and other similar taxes, which will be
payable on the Plant if the contract is awarded to the Bidder.

Section III. Evaluation and Qualification Criteria 1-43
Section III. Evaluation and Qualification

Criteria
(Without Prequalification)
This Section contains all the criteria that the Employer shall use to evaluate bids and qualify
Bidders. In accordance with ITB 35 and ITB 37, no other factors, methods or criteria shall
be used. The Bidder shall provide all the information requested in the forms included in
Wherever a Bidder is required to state a monetary amount, Bidders should indicate the USD
equivalent using the rate of exchange determined as follows:
-For construction turnover or financial data required for each year - Exchange rate
prevailing on the last day of the respective calendar year (in which the amounts for
that year is to be converted) was originally established.
-Value of single contract - Exchange rate prevailing on the date of the contract.
Exchange rates shall be taken from the publicly available source identified in the ITB 33.1.
Any error in determining the exchange rates in the Bid may be corrected by the Employer.
1-44 Section III. Evaluation and Qualification Criteria
1 EVALUATION
1.1 Technical Evaluation

In addition to the criteria listed in ITB 35.2 (a) – (c) the following factors shall apply:
a) Schedules of Technical Compliance:
Incomplete or improperly completed Technical Schedules will be considered as
an omission and subjected to further clarification in accordance with ITB 28.
Where Bidders offer multiple suppliers, one set of Technical Schedules will be
submitted for each supplier, representing the minimum / maximum requirement
for each specific supplier and item. If a Bidder offer more than one supplier per
item, the Employer will have the right to choose any one of the offered suppliers.
b) Type Test Certificates:
Type Test Certificates will be evaluated to check conformity to the instructions
provided under ITB 11.1 (k). Non-conforming Type Test Certificates will not be
considered for evaluation. Conforming Type Test Certificates will be evaluated
in terms of the Schedule of Technical Compliance. Any Type Test Certificates
submitted for equipment that does not meet the minimum / maximum
requirements specified in the Schedule of Technical Compliance, shall be
subjected to further clarification in accordance with ITB 28.
1.2 Economic Evaluation
The following factors and methods will apply:
a) Multiple Contracts
If permitted under ITB 35.4, will be evaluated as follows:
Lots: Bidders have the option to Bid for any one or more lots. Bids will be
evaluated and awarded on an individual lot basis, taking into account
unconditional discounts offered. Where Bidders offer a discount for the award of
multiple Lots, the most economical combination of Lots will be considered for
award.
b) Completion time
Not applicable.
c) Operating and Maintenance Costs

Capitalisation of power transformer losses for evaluation purposes will be done
on the following basis:
The equivalent total annual ownership cost of the power transformers shall be
calculated as follows:
AC = 0.12*C + 511*Fe + 154*Cu

Where: AC = Annual Cost (US$)
C = Capital Cost of Unit (US$)
511 = a US$/kW factor for this application
Fe = Total Iron Loss (kW)
154 = a US$/kW factor for this application
Cu = Total Copper Loss (kW)
NPV cost of losses (20 Yr) = 9.82 X (511*Fe + 154*Cu)
Bid prices will be adjusted with the calculated NPV cost of losses for purpose of
comparative evaluation to arrive at an “Evaluated Bid Price.” Bid prices quoted
by bidders shall remain unaltered.
d) Functional Guarantees of the facilities
In accordance with all Specifications and Technical Schedules.
e) Work, services, facilities, etc., to be provided by the Employer
Where bids include the undertaking of work or the provision of services or
facilities by the Employer in excess of the provisions allowed for in the bidding
document, the Employer shall assess the costs of such additional work, services
and/or facilities during the duration of the contract. Such costs shall be added to
the bid price for evaluation.
f) Specific additional criteria
The relevant evaluation method, if any, shall be as follows:
Any adjustments in price that result from the above procedures shall be added, for
purposes of comparative evaluation only, to arrive at an “Evaluated Bid Price.”
Any missing unit prices in the “Schedule of Rates and Prices” may be completed
(if the Employer defines that this is not material non-conformity) by using the
highest unit prices from the other Bidders. Bid prices quoted by bidders shall
remain unaltered except for the correction of mathematical errors.
1.3 Technical alternatives

Not applicable.
2 QUALIFICATION
LOT 1 Construct Woodlands 33/11kV Substation
Factor
2.1 Eligibility
Criteria
Bidder
Sub-Factor Single Entity Joint Venture, Consortium or Association Documentation
Requirement Required
(other than a sub-contractor)
All partners Each At least one
combined partner partner
2.1.1 Nationality Existing or
Form ELI –1.1 and
Nationality in accordance with Must meet intended JVA Must meet
N/A 1.2, with
ITB 4.2. requirement must meet requirement
attachments
requirement
2.1.2 Conflict of Existing or
Interest No- conflicts of interests as Must meet intended JVA Must meet
N/A Letter of Bid
described in ITB 4.3. requirement must meet requirement
requirement
2.1.3 Bank Not having been declared Existing JVA
Must meet Must meet
Ineligibility ineligible by the Bank as must meet N/A Letter of Bid
requirement requirement
described in ITB 4.4. requirement
2.1.4 Government Form ELI –1.1 and
Compliance with conditions of Must meet Must meet Must meet
Owned Entity N/A 1.2, with
ITB 4.5 requirement requirement requirement
attachments
2.1.5 Ineligibility Not having been excluded as a
Existing JVA
based on a European result of EU, EIB or UN Must meet Must meet
must meet N/A Letter of Bid
Union, EIB or United sanction list, in accordance with requirement requirement
requirement
Nations sanction list. ITB 4.8
Factor
2.2 Historical Contract Non-Performance
Criteria
Bidder
Sub-Factor Documentation
Requirement Joint Venture, Consortium or Association Required
Single Entity All partners Each At least one
2.2.1 History of non- Must meet Must meet Form CON – 2
Non-performance of a contract
performing contracts requirement by requirement by
did not occur within the last Letter from lawyer
itself or as itself or as
five (5) years prior to the N/A N/A stating the
partner to past partner to past
deadline for application company’s
or existing or existing
submission.1 performance history.
JVA JVA
2.2.2 Suspension based Must meet Must meet
on Execution of Bid Not under suspension based on requirement by requirement by Letter from lawyer
Securing Declaration by execution of a Bid Securing itself or as itself or as stating the
N/A N/A
the Employer. Declaration pursuant to ITB partner to past partner to past company’s
20.9. or existing or existing performance history.
JVA JVA
2.2.3 Pending All pending litigation shall in Must meet Must meet Form CON – 2
Litigation total not represent more than requirement by requirement by
forty percent (40%) of the itself or as itself or as Letter from lawyer
N/A N/A stating the
Bidder’s net worth and shall be partner to past partner to past
treated as resolved against the or existing or existing company’s litigation
Bidder. JVA JVA status.
1
Non performance, as decided by the Employer, shall include all contracts where (a) non performance was not challenged by the contractor, including through referral to the dispute resolution
mechanism under the respective contract, and (b) contracts that were so challenged but fully settled against the contractor. Non performance shall not include contracts where Employers decision was
overruled by the dispute resolution mechanism. Non performance must be based on all information on fully settled disputes or litigation, i.e. dispute or litigation that has been resolved in accordance
with the dispute resolution mechanism under the respective contract and where all appeal instances available to the applicant have been exhausted.
Factor
2.3 Financial Situation and Performance
Criteria Documentation
Required
Sub-Factor Bidder
Requirement Joint Venture, Consortium or Association

Single Entity All partners At least one
Each partner
combined partner
2.3.1 Historical Submission of audited balance
Financial sheets or financial statements
Performance acceptable to the Employer, for
the last five (5) years to
Must meet Must meet Form FIN – 3.1 with
demonstrate the current N/A N/A
requirement requirement attachments
soundness of the Bidder’s
financial position and its
prospective long term
profitability.
2.3.2 Average Minimum average annual
Annual Turnover construction turnover of US
$8,000,000.00US (Eight Must meet Must meet
million USD) calculated as Must meet Must meet fifty percent Fifty percent Form FIN –3.2
total certified payments requirement requirement (50%) of the (50%) of the
received for contracts in requirement requirement
progress or completed, within
the last five (5) years
Factor
Required
Sub-Factor Bidder
Requirement Joint Venture, Consortium or Association

Single Entity All partners At least one
Each partner
combined partner
2.3.3 Financial The Bidder must demonstrate
Resources access to, or availability of,
financial resources such as
liquid assets, unencumbered
real assets, lines of credit, and
other financial means, other
than any contractual advance
payments to meet:
(i) Construction cash flow Must meet fifty Must meet
requirements estimated as Must meet Must meet percent (50%) fifty percent
Form FIN –3.3
US $2,000,000.00 (Two requirement requirement of the (50%) of the
Million USD) for the project. requirement requirement
(ii) The Applicant shall also
demonstrate, to the satisfaction
of the Employer, that it has
adequate sources of finance to
meet the cash flow
requirements on works
currently in progress and for
future contract commitments.
Factor
2.4 Experience
Criteria
Bidder
2.4.1 General Please note, Bidder's need to
Construction demonstrate their capability to
Experience design/engineer, procure and
construction (EPC) for this
contract. Demonstrate experience
under contracts in the role of Must meet Must meet Must meet
N/A Form EXP-2.4.1
contractor, subcontractor, or requirement requirement requirement
management contractor for at
least the last five (5) years prior to
the applications submission
deadline, and with activity in at
least nine (9) months in each year.
2.4.2 Specific (a) Participation as contractor,
Construction management contractor, or
Experience subcontractor, in at least two (2)
contracts within the last five (5)
years , each with a value of at
least US $3,000,000.00 (Three
million USD), that have been
Must meet
successfully and substantially Must meet
requirements for N/A N/A Form EXP 2.4.2(a)
completed and that are similar to requirement
all characteristics
the proposed Plant and
Installation Services. The
similarity shall be based on the
physical size, complexity,
methods/technology or other
characteristics as per 2.9.2 b)
below.
Factor
2.4 Experience
Criteria
Bidder
2.4.2 Specific (b) For the above or other
Construction contracts executed during the Must meet
Experience period stipulated in 2.9.2(a) requirements
above, a minimum experience in for their area of
the following key activities: expertise.
(i) For assessment purposes, It can be a
each of the contracts shall specialist
include successful Contractor for:
completion of at least a
i) Protection,
33kV or higher
Control and
Substation, with
Must meet Must meet Automation
associated power N/A Form EXP-2.4.2(b)
Transformers, requirements requirements ii) Design of
Switchgear, Protection Electric Utility
and Communications projects
Equipment.
iii)
(ii) Installation and Construction of
termination of 33kV or Electric Utility
higher underground projects
power cables.
iv) Supply of
iii) Substation automation Power System
using IEC 61850 Equipment
protocols.
Letter of Good
For the above completed
Standing detailing
2.4.3 Letter of contracts or works handed over, a Must meet Must meet Must meet Must meet
valid contact
Good Standing Letter of Good Standing from the requirements requirements requirements requirements
information of the
Client for the two largest projects.
authorised Client’s
Factor
2.4 Experience
Criteria
Bidder
Project Manager /
Representative.
Contact information
(Name, phone
number and official
email address must
be provided
otherwise
experience will not
be considered.
2
Substantial completion shall be based on 80% or more works completed under the contract.
3
For contracts under which the Applicant participated as a joint venture member or sub-contractor, only the Applicant’s share, by value, shall be considered to
meet this requirement.
Factor
2.5 Environmental, Health, Safety and Quality
Criteria
Bidder
2.5.1 Health and Certified by an accredited Proof of
Safety Certification certification body for OHSAS Must meet Must meet Certification
18001 N/A N/A Body’s
requirements requirements
Accreditation and
proof of own
Factor
Criteria
Bidder
Certification.
2.5.2 Environ- Certified by an accredited Proof of

mental Certification certification body for ISO Certification
14001:2004. Must meet Must meet Body’s
N/A N/A
requirements requirements Accreditation and
proof of own
Certification.
2.5.3 Quality Certified by an accredited Proof of
Management certification body for ISO9001 Certification
Certification Must meet Must meet Body’s
N/A N/A
proof of own
Certification.
2.5.4 Professional Proposed Project Manager
Project registered as a Professional Proof of PM’s
Management Project Manager with an Accreditation.
Must meet Must meet
accredited certification body N/A N/A Include a Detailed
Minimum Requirements: CV for nominated
- Experience on 2 similar projects PM.
- 10 years relevant experience
2.5.5 CV’s of Key Key Personnel as defined under Must provide Must provide CV’s indicating
Personnel Paragraph 2.23: Personnel below. appropriate appropriate N/A N/A relevant specific
resources resources working experience
Factor
2.5 Quality and Project Management
Criteria
Bidder
Single Entity All partners Each partner At least one
combined partner
2.5.6 Local If the Bidder intends using a Local
Construction Construction Contractor, evidence
Contractor will be provided to confirm:
Memorandum of
i) The Subcontractor is familiar
Agreement between
with the Scope of Work
Must Comply Must Comply N/A N/A Bidder and Local
ii) Relationship and responsibility
Construction
split between the Main Contractor
Contractor
and the Subcontractor
iii) Maximum amount to be
subcontracted: 70% of Schedule 4
LOT 2 Coventry – Kafue 33kV Overhead Line Upgrade
Factor
2.6 Eligibility
Criteria
Bidder
Form ELI –1.1 and
N/A 1.2, with
attachments
requirement
Interest No- conflicts of interests in Must meet intended JVA Must meet
N/A Letter of Bid
accordance with ITB 4.3. requirement must meet requirement
requirement
2.6.3 Bank Existing or
Not having been declared
Ineligibility Must meet intended JVA Must meet
ineligible by the Bank in N/A Letter of Bid
requirement must meet requirement
accordance with ITB 4.4.
requirement
attachments
2.6.5 Ineligibility Not having been excluded as a Existing or
based on a European result of EU, EIB or UN Must meet intended JVA Must meet
N/A Letter of Bid
Union, EIB or United sanction list, in accordance with requirement must meet requirement
Nations sanction list. ITB 4.8 requirement
Factor
Criteria
Bidder
Joint Venture, Consortium or Association
Single Entity
performing contracts. requirement by requirement by
submission. performance history.
JVA JVA
N/A N/A
JVA JVA
N/A N/A stating the
mechanism under the respective contract, and (b) contracts that were so challenged but fully settled against the contractor. Non performance shall not include contracts where Employers decision
was overruled by the dispute resolution mechanism. Non performance must be based on all information on fully settled disputes or litigation, i.e. dispute or litigation that has been resolved in
accordance with the dispute resolution mechanism under the respective contract and where all appeal instances available to the applicant have been exhausted.
Factor
Required
Bidder
Sub-Factor Joint Venture, Consortium or Association
Requirement (other than a sub-contractor)
Single Entity At least
All partners
Each partner one
combined
partner
profitability.
Annual Turnover construction turnover of
Must meet at
US $1,000,000.00 (One million Must meet
least fifty
USD) calculated as total Must meet Must meet Fifty percent
percent (50%) Form FIN –3.2
certified payments received for requirement requirement (50%) of the
of the
contracts in progress or requirement
requirement
completed, within the last five
(5) years.
Factor
Required
Bidder
All partners
Each partner one
combined
partner
payments to meet:
Must meet at Must meet at
(i) Construction cash flow
least fifty least fifty
requirements estimated as Must meet Must meet
percent (50%) percent Form FIN –3.3
US $400,000.00 (Four Hundred requirement requirement
of the (50%) of the
Thousand USD) for the project.
meet the cash flow
Factor
2.9 Experience
Criteria
Bidder
Sub-Factor Joint Venture, Consortium or Association Documentation
Single Entity
All partners Each partner At least one
combined partner
contract. Bidder’s also need to
demonstrate experience under
Must meet Must meet
contracts in the role of Prime N/A N/A Form EXP-2.4.1
Contractor, Joint Venture
Member or Sub-Contractor for at
least the last Five (5) years prior
to the applications submission
Factor
2.9 Experience
Criteria
Bidder
Single Entity
combined partner
2.9.2 Specific (a) Participation as Prime
Construction Contractor, Joint Venture
Experience Member3 or Sub-Contractor3, in
at least two (2) contracts within
the last Five (5) years, each with a
value of at least US $400,000.00
(Four Hundred Thousand USD),
Must meet
that have been successfully and Must meet Must meet Form EXP
N/A requirement for
substantially2 completed and that requirement requirements 2.4.2(a)
one project
are similar to the proposed Plant
and Installation Services. The
below.
Factor
2.9 Experience
Criteria
Bidder
Single Entity
combined partner
2.9.2 Specific (b) For the above or other
Construction contracts executed during the
Experience period stipulated in 2.4.2(a)
above, a minimum experience in
the following key activities: Must meet
requirements for
(i) Construction of 33kV their area of
Overhead Lines. expertise.
For assessment purposes, It can be a
each of the contracts shall specialist
include successful Contractor for:
completion of 33kV, or
higher, overhead line with i) Protection,
OPGW. Control and
Must meet Must meet Automation Form EXP-
N/A
For each project shown, a requirements requirements 2.4.2(b)
copy of the certificate of ii) Design of
the completion of works Electric Utility
must be provided. The projects
construction of 33kV iii) Construction
overhead monopole lines of Electric
will be an added Utility projects
advantage
iv) Supply of
Power System
Equipment.
Factor
2.9 Experience
Criteria
Bidder
Single Entity
combined partner
Letter of Good
Standing
detailing valid
contact
information of
the authorised
Client’s Project
Manager /
For the above completed Representative.
2.9.3 Letter of contracts or works handed over, a Must meet Must meet Must meet Must meet Contact
Good Standing Letter of Good Standing from the requirements requirements requirements requirements information
Client for the two largest projects. (Name, phone
number and
official email
address must be
provided
otherwise
experience will
not be
considered.
2
3
Factor
Criteria
Bidder
Safety Certification certification body for OHSAS Certification
18001 Must meet Must meet Body’s
N/A N/A
proof of own
Certification.
2.10.2 Environ- Certified by an accredited Proof of
mental Certification certification body for ISO Certification
14001:2004. Must meet Must meet Body’s
N/A N/A
proof of own
Certification.
Management certification body for ISO9001 Certification
Certification Must meet Must meet Body’s
N/A N/A
proof of own
Certification.
2.10.4 Professional Proposed Project Manager
Project registered as a Professional Proof of PM’s
Management Project Manager with an Accreditation.
Must meet Must meet
accredited certification body N/A N/A Include a Detailed
Minimum Requirements: CV for nominated
- Experience on 2 similar projects PM.
- 10 years relevant experience
Factor
Criteria
Bidder
Memorandum of
Agreement between
Construction
Contractor
LOT 3 – Industrial – Matero 33kV Corridor Upgrade

Factor
2.11 Eligibility
Criteria
Bidder
Form ELI –1.1 and
N/A 1.2, with
attachments
requirement
Interest No- conflicts of interests in Must meet intended JVA Must meet
N/A Letter of Bid
accordance with ITB 4.3. requirement must meet requirement
requirement
2.11.3 Bank Existing or
Not having been declared
Ineligibility Must meet intended JVA Must meet
ineligible by the Bank in N/A Letter of Bid
requirement must meet requirement
accordance with ITB 4.4.
requirement
attachments
2.11.5 Ineligibility Not having been excluded as a Existing or
based on a European result of EU, EIB or UN Must meet intended JVA Must meet
N/A Letter of Bid
Union, EIB or United sanction list, in accordance with requirement must meet requirement
Nations sanction list. ITB 4.8 requirement
Factor
Criteria
Bidder
Joint Venture, Consortium or Association
Single Entity
performing contracts. requirement by requirement by
submission. performance history.
JVA JVA
N/A N/A
JVA JVA
N/A N/A stating the
1
mechanism under the respective contract, and (b) contracts that were so challenged but fully settled against the contractor. Non performance shall not include contracts where Employers decision
was overruled by the dispute resolution mechanism. Non performance must be based on all information on fully settled disputes or litigation, i.e. dispute or litigation that has been resolved in
accordance with the dispute resolution mechanism under the respective contract and where all appeal instances available to the applicant have been exhausted.
1
Bidder to use as appropriate
Factor
Required
Bidder
All partners
Each partner one
combined
partner
profitability.
Annual Turnover construction turnover of
Must meet at
US $4,000,000.00 (Four Must meet
least fifty
million USD) calculated as Must meet Must meet fifty percent
percent (50%) Form FIN –3.2
total certified payments requirement requirement (50%) of the
of the
received for contracts in requirement
requirement
progress or completed, within
the last five (5) years.
Factor
Required
Bidder
All partners
Each partner one
combined
partner
payments to meet:
Must meet at Must meet at
(i) Construction cash flow
least fifty least fifty
requirements estimated as Must meet Must meet
percent (50%) percent Form FIN –3.3
US $1,000,000.00 (One million requirement requirement
of the (50%) of the
USD) for the project.
meet the cash flow
Factor
2.14 Experience
Criteria
Bidder
Single Entity
combined partner
contract Demonstrate experience
under contracts in the role of Must meet Must meet
N/A N/A Form EXP-2.4.1
Prime Contractor, Joint Venture requirement requirement
Member or Sub-Contractor for at
least the last Five (5) years prior
to the applications submission
2.14.2 Specific (a) Participation as Prime
Construction Contractor, Joint Venture
Experience Member3 or Sub-Contractor3, in
at least two (2) contracts within
the last Five (5) years, each with a
value of at least US
$1,200,000.00 (One million Two Must meet
Must meet Must meet
Hundred Thousand USD), that N/A requirement Form EXP 2.4.2(a)
requirement requirements
have been successfully and for one project
substantially2 completed and that
are similar to the proposed Plant
and Installation Services. The
Factor
2.14 Experience
Criteria
Bidder
Single Entity
combined partner
below.
2.14.2 Specific (b) For the above or other Must meet
Construction contracts executed during the requirements
Experience period stipulated in 2.16.2(a) for their area
above, a minimum experience in of expertise.
the following key activities:
It can be a
(i) Construction of 33kV specialist
Overhead Lines. Contractor
For assessment purposes, for:
each of the contracts shall
i) Protection,
include successful
Control and
completion of 33kV, or
Automation
higher, overhead line with Must meet Must meet
OPGW. N/A ii) Design of Form EXP-2.4.2(b)
Electric
For each project shown, a
Utility
copy of the certificate of
projects
the completion of works
must be provided. The iii)
construction of 33kV Construction
overhead monopole lines of Electric
will be an added Utility
advantage projects
iv) Supply of
Power System
Equipment
Factor
2.14 Experience
Criteria
Bidder
Single Entity
combined partner
Letter of Good
Standing detailing
For the above completed
valid contact
2.14.3 Letter of contracts, a Letter of Good Must meet Must meet Must meet Must meet
information of the
Good Standing Standing from the Client for the requirements requirements requirements requirements
authorised Client’s
two largest projects.
Project Manager /
Representative
2
3
Factor
Criteria
Bidder
Safety Certification certification body for OHSAS Certification Body’s
Must meet Must meet
18001 N/A N/A Accreditation and
proof of own
Certification.
2.15.2 Environ- Certified by an accredited Must meet Must meet Proof of
mental Certification certification body for ISO N/A N/A
requirements requirements Certification Body’s
Factor
Criteria
Bidder
14001:2004. Accreditation and
proof of own
Certification.
Management certification body for ISO9001 Certification Body’s
Must meet Must meet
Certification N/A N/A Accreditation and
proof of own
Certification.
Memorandum of
Agreement between
Construction
Contractor
2.16 Personnel
The Bidder must demonstrate that it will have the personnel for the key positions that
meet the following requirements:
Lot 1
Total Similar
Total Work
Work
No. Position Experience
Experience
(years)
(years)
1 Project Manager 15 10
2 Senior Substation Design Engineer 15 10
3 Senior Electrical Transmission/Distribution 15 10
Design Engineer
4 Senior Protection and Control Engineer 15 10
5 Senior SCADA and Communication Engineer 15 10
6 Senior Civil Engineer 15 10
7 Senior Site Supervisor 15 10
Lot 2
Total Similar
Total Work
Work
Experience
(years)
(years)
2 Senior Overhead Line and Design Engineer 15 10
4 Civil Engineer 15 10
Lot 3
Total Similar
Total Work
Work
Experience
(years)
(years)
Design Engineer
5 Senior SCADA and Communication Engineer 15 10
6 Senior Civil Engineer 15 10
The Bidder shall provide details of the proposed personnel and their experience
records in the relevant Forms included in Section IV, Bidding Forms.
2.17 Assessment of adequacy of Technical Proposal with Requirements.
Evaluation of the Bidder’s Technical Proposal will include an assessment of the

Bidder’s technical capacity to mobilize key equipment and personnel for the contract
consistent with its proposal regarding work methods, scheduling, and material
sourcing in sufficient detail and fully in accordance with the requirements stipulated
in Section VII (Employer’s Requirements).
Specific attention will be given to the conformance to the following:
i) Bidder’s capability to provide the Turnkey Contract,
ii) Bidder’s understanding of the specific site conditions and challenges,
iii) Completeness of the proposed project schedule, clearly demonstrating the
Bidder’s capability to complete the project with the given timeframe,
iv) Where the Bidder intends using a Subcontractor for local construction works
as indicated on the form in Section IV, a memorandum of agreement will be
included clearly indicating the relationship and responsibility split between
the Main Contractor and the Subcontractor.
v) Manufacturers for the following major items of supply or services:
a) Power transformers
b) HV Switchgear (Breakers and Isolators)
c) MV Indoor Switchgear
d) EHV and MV Cables
e) Protection Relays
f) Telecommunication Equipment
g) Measuring Transformers (CTs VTs)
h) Earthing Resistors
i) Auxiliary transformers
j) Generators
k) SCADA Equipment
l) Overhead Line Monopoles
m) Overhead Line Conductor and OPGW
n) Overhead Line Hardware
must meet the following minimum criteria, herein listed for that item:
a. All manufacturers are required to have been certified to ISO 9001
for their quality assurance systems, and have been manufacturing
similar products for at least 10 years. Failure to comply with this
requirement will result in rejection of the manufacturer.
b. In the case of a Bidder who offers to supply and install major items
of supply under the contract that the Bidder did not manufacture or
otherwise produce, the Bidder shall provide the manufacturer’s
authorization, using the form provided in Section IV, showing that
the Bidder has been duly authorized by the manufacturer or
producer of the related plant and equipment or component to
supply and install that item in the Employer’s country. The Bidder
is responsible for ensuring that the manufacturer or producer
complies with the requirements of ITB 4 and 5 and meets the
minimum criteria listed above for that item.
vi) Project Management and Contract Management activities. The

Contractor’s representative and/or any deputy must be professionally
registered as a project manager at an international recognised institution.
Certified copies of this registration need to be submitted with this Bid.
It is a specific requirement that the Contractor’s Representative, Site
Manager and Safety Official must be fluent in English and the language
of the Contractor's personnel. The above shall be in accordance with the
General Conditions.
The Project Manager must be competent in Microsoft Project and have a
full understanding of the critical path.
Where there is more than one site, a site supervisor shall be dedicated to
each site.
vii) Equipment available to the Construction Contractor as indicated in the
Form under Section IV.

Section IV. Bidding Forms 1-77
Section IV. Bidding Forms

Table of Forms
Letter of Bid ................................................................................................................................ 78
Letter of Bid – Single Stage Bidding .................................................................................... 78
Schedules of Rates and Prices................................................................................................... 81
Schedules of Rates and Prices................................................................................................. 121
Schedules of Rates and Prices................................................................................................. 144
Price Adjustment ...................................................................................................................... 179
Technical Proposal ................................................................................................................... 180
Site Organization .................................................................................................................. 181
Method Statement ................................................................................................................ 182
Mobilization Schedule ......................................................................................................... 183
Construction Schedule ......................................................................................................... 184
Plant 185
Contractor’s Equipment ....................................................................................................... 186
Personnel 188
Proposed Subcontractors for Major Items of Plant and Installation Services .................. 190
Others - Time Schedule ....................................................................................................... 191
Bidder Information Sheet ....................................................................................................... 192
Party to JVA Information Sheet ............................................................................................ 193
Historical Contract Non-Performance.................................................................................. 194
Current Contract Commitments / Works in Progress ....................................................... 195
Financial Situation ................................................................................................................... 196
Historical Financial Performance........................................................................................ 196
Average Annual Turnover ................................................................................................... 198
Financial Resources ............................................................................................................. 199
Experience - General Experience........................................................................................... 200
Specific Experience.............................................................................................................. 201
Specific Experience in Key Activities ................................................................................ 203
Covenant of Integrity ............................................................................................................... 210
1-78 Section IV. Bidding Forms
Letter of Bid
Letter of Bid – Single Stage Bidding

Date:
ICB No.:
Invitation for Bid No.:
To: _______________________________________________________________________
We, the undersigned, declare that:
(a) We have examined and have no reservations to the Bidding Document, including
Addenda issued in accordance with Instructions to Bidders (ITB) 8 ;
(b) We offer to _________________________, in conformity with the Bidding Document, the

following Plant and Installation Services:
(c) The price of our Bid, excluding any discounts, Duties and Taxes offered in item (d)
below is the sum of: ____________________________, (____________________________), and
__________________, (___________)
(d) The discounts offered and the methodology for their application are:
(e) Our bid shall be valid for a period of ____________________________ days from the
date fixed for the bid submission deadline in accordance with the Bidding Document,
and it shall remain binding upon us and may be accepted at any time before the
expiration of that period;
(f) If our bid is accepted, we commit to obtain a performance security in accordance with
the Bidding Document;
(g) We, including any subcontractors or manufacturers for any part of the contract , have or
will have nationalities from eligible countries, in accordance with ITB-4.2;
(h) We, including any subcontractors or manufacturers for any part of the contract, do not
have any conflict of interest in accordance with ITB-4.3;
(i) We are not submitting more than one bid in this bidding process as a Bidder, either
individually or as a partner in a joint venture, in accordance with ITB-4.3, except for
alternative offers permitted under ITB Clause 13;
(j) We, along with any of our subcontractors, suppliers, consultants, manufacturers, or
service providers for any part of the contract, are not subject to, and not controlled by
any entity or individual that is subject to, a temporary suspension or a debarment
imposed by the European Investment Bank . Further, we are not ineligible pursuant to a
decision of the United Nations Security Council or the European Union;
(k) We are not a government owned entity/ We are a government owned entity but meet the
requirements of ITB-4.5;1
(l) We have paid, or will pay the following commissions, gratuities, or fees with respect to
the bidding process or execution of the Contract:
Name of Recipient Address Reason Amount
(If none has been paid or is to be paid, indicate “none.”)
(m) We understand that this bid, together with your written acceptance thereof included in
your notification of award, shall constitute a binding contract between us, until a formal
contract is prepared and executed; and
(n) We understand that you are not bound to accept the lowest evaluated bid or any other bid
that you may receive.
Name In the capacity of _
Signed
Duly authorized to sign the bid for and on behalf of
Dated on ________________________________ day of _______________________, _____
2
The amount of the Bond shall be denominated in the currency of the Purchaser’s country or the equivalent
amount in a freely convertible currency.

Schedules of Rates and Prices

LOT 1 - Woodlands 33/11kV Substation

Section IV Bidding Form Part 1-83
Schedule of Rates and Prices
Lot 1 – WOODLANDS 33/11kV SUBSTATION and SWITCHING

STATIONS
1 Task 1 -Relocate existing 33 & 11 kV distribution line termination structures
2 Task 2 - Construct New Woodlands 33/11 kV Substation
3 Task 3 - Intergrade existing 33 & 11kV cables into new Woodlands Substation
4 Task 4 - Dismantle Existing Woodlands 33/11 kV Substation

Name of Bidder
Signature of Bidder _________________________
Lot 1 Rev 5
Part 1-84 Section IV Bidding Forms
____________________________________________________________________________________________________________________________________________
Instructions to Bidders
Modification of any part of the Pricing Schedules might result in the misplacement of information which is crucial for successful Bid evaluation. Bidders
should follow and adhere to the following rules and guidelines in completing the Pricing Schedules:
1 Make sure it is the latest Revision of the Pricing Schedules which might have been submitted as an Addendum.
2 Bidders need to keep the format of the Pricing Schedules exactly the same as the original:
a. Do not add, delete or insert any columns
b. Do not add, delete or insert any rows. Make use of the space provided under Additional Items which can be
found in the different sections of this Pricing Schedules
c. Do not change any fonts or formatting
3 Do not change any quantities. Please add quantities under the Additional Items sections provided if necessary.
4 Do not change any headings or equipment descriptions. Use the Additional Items sections if necessary.
5 Do not change any Worksheet names or add delete/add any Worksheets
6 Do not change the name of the Spreadsheet.
7 Check and confirm that all formulas are giving the correct answers.
8 Do not use Unit pricing with more than two decimals for example $1000.23 and not $1000.2345
This Pricing Schedule must be submitted in Excel format with the Bidding Documents. The Schedules must be submitted on flash disk in a clearly marked
envelope indicating the following information: Tender number, LOT number, Description and Bidder's name. The envelope must be attached to the cover
page of Volume 1.
Before the Pricing Schedules are submitted make sure of the following:
9 Make sure all prices are unique to this Pricing Schedule document and not linked to other documents.
10 There are no passwords in the Excel document which prevents the contents of the document from being opened
11 The Bidder's Name is provided in the space provided at the bottom of each of the Schedules (Front Page, Schedule 1 to Schedule 6)
12 The CD or memory stick used for the submission is clearly marked with the Bidder's name
13 The CD or memory stick is properly attached to the Bidding document
Lot 1 Rev 5
Section IV Bidding____________________________________________________________________________________________________________________________________________
Form Part 1-85
Schedule No. 1. Plant and Mandatory Spare Parts Supplied from Abroad (Lot 1)
1) Bidders shall enter a code representing the Country of origin of all imported plant and equipment.
2) Specify currency(ies)
Supplied from abroad (CIP) Supplied from abroad (CIP)
2 2
CURRENCY 1 : CURRENCY 2 :
1 QTY
ITEM DESCRIPTION CODE UNIT
(1) CIP CIP
TOTAL PRICE TOTAL PRICE
(Unit Price (Unit Price
[(1) x (2)] [(1) x (3)]
Excluding Taxes) Excluding Taxes)
(CIP) (CIP)
(2) (3)
Concrete poles
1.1 Supply 14m self-supporting concrete poles 8 each - -
Single circuit self-supporting concrete structures - -

The unit rate for the structures must make provision for any strain or intermediate line
- -
hardware, any fastening equipment, jumpers and crossarms etc.
1.2 Supply 11kV, Vertical terminal structure as per typical drawing MKU-No8 1 each - -
1.3 Supply 33kV, Vertical terminal structure as per typical drawing MKU-No8 2 each - -
1.4 Supply 33kV, Horizontal terminal structure as per typical drawing G11392 1 each - -
1.5 Supply 33kV, Shielded Horizontal terminal structure as per typical drawing G11392 2 each - -
- -
Cables - -
The unit rate for the cable terminations must make provision for all hardware, fastening
- -
equipment, jumpers, crossarms etc.
1.6 Supply 240mm² 6.35/11kV 3C XLPE Cu SWA cable 132 m - -
1.7 Supply joint for 240mm² 6.35/11kV 3C XLPE Cu SWA cable 1 each - -
Supply 11kV outdoor cable termination for single pole as per typical drawing MAZ-ALB-
1.8 1 each - -
DM-08-G-12190
Install indoor cable termination for 240mm² 6.35/11kV 3C XLPE Cu SWA for new 11kV
1.9 1 each - -
switchgear panel
1.10 Supply 240mm² 19/33kV 3C XLPE Cu SWA cable 660 m - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________
CURRENCY 12: CURRENCY 22:
QTY
ITEM DESCRIPTION CODE1 UNIT
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.11 Supply joint for 240mm² 19/33kV 3C XLPE Cu SWA cable 7 each - -
Supply 33kV outdoor cable termination for single pole for 240mm² 19/33kV 3C XLPE Cu
1.12 3 each - -
SWA cable as per typical drawing ZAM-GEN-41-G-12827
Supply 33kV outdoor cable termination for H-pole for 240mm² 19/33kV 3C XLPE Cu SWA
1.13 2 each - -
cable as per typical drawing GH9709
Install outdoor cable termination for 240mm² 19/33kV 3C XLPE Cu SWA for new 33kV
1.14 5 each - -
overhead feeder bays cable termination structures
1.15 Supply 450mm (200micron) danger tape 792 m - -
1.16 Supply 900 x 300 x 65 mm cable concrete protection slab 55 each - -
1.17 Supply 100-250mm water pipe repair kit(joints and 1m pipe if required) 10 each - -
1.19 Supply LV cable repair kit(joints and 1m cable if required) 10 each - -
1.20 Supply MV cable repair kit(joints and 1m cable if required) 10 each - -
1.21 Supply MV/LV heat shrinkable zip-sleeve repair 20 each - -
1.22 Supply Type A concrete cable route markers 30 each - -
1.23 Supply 24 Core duct armoured fiber cable 600 m - -
1.24 Supply 40mm fiber duct 600 m - -
1.25 Supply fiber outdoor termination box and sub-soil draw boxes 1 lot - -
Surge arrestors - -
The unit rate for the surge arrestors must make provision for any hardware, fastening
- -
equipment, jumpers, crossarms and earthing material for a 5m crowsfoot
1.23 Supply complete 11kV drop-out surge arestor assembly for single concrete pole 1 each - -
1.24 Supply complete 33kV drop-out surge arestor assembly for single concrete pole 2 each - -
1.25 Supply complete 33kV drop-out surge arestor assembly for concrete H-pole 3 each - -
1.26 Supply earthing material for 5m crow's foot 6 each - -
- -
Labels - -
Note: The labelling of structures is to be in accordance with the standard for the labelling
- -
of high voltage equipment and must make provision for any fastening equipment.
1.27 Supply of circuit designation labels 6 set - -
1.28 Supply Phase Identification Disk (RYB) 6 set - -
Lot 1 Rev 5
Form Part 1-87
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.29 Supply Temporary traffic control signage during road crossings 1 lot - -
- -
1.30 Dismantle and remove existing 11 & 33kV overhead structures 1 lot - -
- -
2 Task 2 - Construct New Woodlands 33/11 kV Substation - -
Primary Equipment - -
33kV Outdoor Yard - -
2.1 Supply 33kV Line Isolator with Earth Switch 6 each - -
2.2 Supply 33kV Busbar Isolator 8 each - -
2.3 Supply 33kV Bus section Isolator 2 each - -
2.4 Supply 33kV Feeder Current Transformers 24 each - -
2.5 Supply 33kV Bus section Current Transformers 6 each - -
2.6 Supply 33kV Feeder Circuit Breaker 8 each - -
2.7 Supply 33kV Bus Section Circuit Breaker 1 each - -
2.8 Supply 33kV/110V 1Ph Voltage Transformer 24 each - -
2.9 Supply 33kV Station Class Surge Arrester 24 each - -
2.10 Supply 33kV Post Insulators 60 each - -
2.11 Supply 66kV Post Insulators 6 each - -
Supply 33/11kV 30MVA Dyn1 Transformer, complete with tap changer, surge arrestor
2.12 2 each - -
brackets and accelometer.
2.13 Supply 11kV Station Class Surge Arrester 6 each - -
2.14 Supply 11kV Neutral Earthing Resistor 2 each - -
33 kV Yard - Small Materials

2.15 Supply Clamps and Fittings for the 33 & 11kV tubular busbars and stringers 1 lot - -
2.16 Supply Miscellaneous Material and Consumables 1 lot - -
2.17 Supply 80mm x 4mm Al tubes for outdoor 33 & 11k transformer yard 16 each - -
2.18 Supply AAC Centipede Conductor 500 m - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.19 Supply AAC Hornet Conductor 40 m - -

2.20 Supply 11kV 120mm² 1C XLPE Armored Cu Cable 30 m - -
2.21 Supply 11kV 630mm² 1C XLPE Armored Cu Cable 1,200 m - -
2.22 Supply 11 kV Cable clamps, lugs and terminations complete, XLPE, Cu, 1C 120mm² 4 set - -
2.23 Supply 11 kV Cable clamps, lugs and terminations complete, XLPE, Cu, 1C 630 mm² 36 set - -
33kV Yard - Steel Structures

All exposed steel must be hot dipped galvanized according to ISO1461 and ISO 9001
Quality specification before entring into Zambia
2.24 Supply 33kV Isolator Structure 16 each - -
2.25 Supply 33kV Current Transformers 10 each - -
2.26 Supply 33kV Circuit Breaker 9 each - -
2.27 Supply 33kV Voltage Transformers 2 each - -
2.28 Supply 33kV Cable Ends With VT & SA 6 each - -
2.29 Supply 33/11kV Cable Ends - Transformers 2 each - -
2.30 Supply 33kV Busbar Support Structure 4 each - -
2.31 Supply 11kV Neutral Earthing Resistor 2 each - -
2.32 Supply 21m Lighting/Lightning Masts 4 each - -
Common Yard
2.33 Supply 400W Led Floodlights 16 each - -
2.34 Supply All safety signs, labels and and nameplates with fixing equipment 1 lot - -
2.35 Supply 110mm PVC Sleeves 320 m - -
2.36 Supply 160mm PVC Sleeves 60 m - -
2.37 Supply 200mm Concrete sleeves 130 m - -
2.38 Supply 300mm Dia Concrete Pipes for oil containment system 25 m - -
2.39 Supply 5,000l Water tanks with steel support structure 2 each - -
Lot 1 Rev 5
Form Part 1-89
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Earth Grid
Supply Copper rod 10.0mm annealed for earth grid (1m below ground level) and earthing
2.40 1,740 m - -
columns
2.41 Supply 50mm x 3mm Flat copper for earth tails to the foundations. 350 m - -
2.42 Supply 50mm x 3mm Flat copper for earth-tails to the fence and fence corner gate post 100 m - -
2.43 Supply 50mm x 3mm Flat copper for earth-tails for building earthing of panels. 150 m - -
2.44 Supply 50mm x 3mm Flat copper for earth-tails battery room 50 m - -
2.45 Supply Main earth grid bonding 10mm to 19/2.91 braced or cadweld 200 each - -
2.46 Supply Main earth bonding to earth tails diameter 10mm dia to 50mm x 3mm flat 245 each - -
2.47 Supply 60kg Sacrificial railway track earth 1 each - -
2.48 Supply 1.8m Cu Earth electrodes for each lightning mast. 32 each - -
Woodlands Substation Main 11KV Switchboard

2.49 Supply incomer panels 2 each - -
2.50 Supply bus section / bus riser panels 1 set - -
2.51 Supply local feeder panels 13 each - -
2.52 Supply fused isolator panel for Aux transformer 2 each - -
2.53 Supply VT panel 2 each - -
2.54 Supply floor support frame 1 lot - -
2.55 Supply trench support frame ( if required ) 1 lot - -
2.56 Supply galvanized metal sheet fixed to the floor in front of board 1 lot - -
2.57 Supply material to bond all panels to main trench earth. Lugs and conductor included 1 lot - -
2.58 Supply complete set of drawings and documentation as per specification 1 lot - -
Auxiliary Supply
2.59 Supply 11kV/400V 200kVA Auxiliary transformer 2 each - -
2.60 Supply 50kVA 400V 3ph Generator 1 each - -
2.61 Supply 1kV 120mm² 4C PVC Armored Cu Cable 140 m - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.62 Supply 11kV 120mm² 3C XLPE Armored Cu Cable 100 m - -

2.63 Supply 1kV Cable clamps, lugs and terminations complete, PVC, Cu, 4C 120mm² Armored 6 set - -
Supply 11kV Cable clamps, lugs and terminations complete, XLPE, Cu, 3C 120mm²
2.64 4 set - -
Armored
Fire Protection
2.65 Supply SCADA interactable fire detection system with audible alarm 1 lot - -
2.66 Supply ABC Dry power fire extinguishers 10 each - -
2.67 Supply Automatic condensed aerosol generator (CAG) flooding with manual overrides 2 lot - -
2.68 Supply ABC trolley-mounted fire extinguishers 2 each - -
Fencing
2.69 Supply Outer fence pedestrian gates 1 each - -
2.70 Supply Inner fence pedestrian gates 2 each - -
2.71 Supply Outer fence 5m double-leaf lecurity gate 3 each - -
2.72 Supply Inner fence 5m double-deaf security gate 3 each - -
2.73 Supply 6m Transformer removable panels 2 each - -
2.74 Supply Welded square mesh fence complete with gates, dig barrier and razor mesh overhang 230 m - -
2.75 Supply Razor mesh Inner Fence 70 m - -
Protection, Control and Telecommunication Equipment

Protection
2.76 Supply 33/11kV Transformer Protection Panel 2 each - -
2.77 Supply 33kV Outdoor Incomer Protection scheme 2 each - -
2.78 Supply 33kV Outdoor Feeder Protection scheme 4 each - -
2.79 Supply 33kV Bus Section Protection scheme 1 each - -
2.80 Supply 33kV Low Impedance Bus Zone Protection Scheme 1 each - -
Lot 1 Rev 5
Form Part 1-91
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.81 Supply 11kV Transformer Incomer Onboard Protection scheme 2 each - -

2.82 Supply 11kV Bus Section Onboard Protection scheme 1 each - -
2.83 Supply 11kV Local Feeder Onboard Protection scheme 13 each - -
2.84 Supply 11kV Arc Onboard Protection Scheme 1 lot - -
SCADA and Telecommunications

Supply remote terminal unit utilizing IEC 61850 (with necessary connectors) as per SCADA
2.85 1 lot - -
specification
Supply complete substation LAN on IEC 68150 (components and necessary connectors and
2.86 1 lot - -
wiring) as per SCADA specification
2.87 Supply complete GPS time server system as per SCADA specification 1 lot - -
2.88 Supply SCADA panel as per specifications for equipment 1 each - -
Supply Ethernet switches (components and necessary connectors and wiring) as per SCADA
2.89 1 lot - -
specification
2.90 Supply SCADA spares 1 lot - -
Supply SDH/PDH/PCM multiplexer (components and necessary connectors and wiring) as
2.91 1 lot - -
per specifications
Supply 19inch communication cabinet (frame with all ports and necessary connectors) as per
2.92 1 lot - -
specifications
Supply digital distribution frame (frame with all ports and necessary connectors) as per
2.93 1 lot - -
specifications (21 ports)
Supply substation phones (components and necessary connectors and wiring) as per
2.94 2 lot - -
specifications
2.95 Supply telecommunications panel as per specification for equipment 1 each - -
2.96 Supply telecommunication spares 1 lot - -
2.97 Other equipment to complete the SCADA & Communication systems (specify items) 1 each - -
Other
2.100 Supply Statistical Meters installed in the 11kV local feeder panels 13 each - -
2.101 Supply Statistical Meters for transformers installed in metering panel (6 meters per panel) 2 each - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.102 Supply Tarrif Meters for 33kV feeders installed in metering panel (6 meters per panel) 6 each - -
2.103 Supply 33kV Metering panel 19" panels to house the meters 2 each
2.104 Supply 400V AC three-way automatic change over panel 1 each - -
2.105 Supply 230V AC distribution panel 1 each - -
Supply 110V DC Supply System inclusive of distribution panel, dual paralleled battery
2.106 1 lot - -
chargers, with NiCad batteries
Supply 48V DC Supply System inclusive of distribution panel, single battery charger, with
2.107 1 lot - -
NiCad batteries
2.108 Supply CT Junction boxes with terminals 1 lot - -
2.109 Supply VT Junction boxes with terminals 1 lot - -
2.110 Supply Transformer 3-phase Socket Supply box and plug (one per two transformers) 1 lot - -
Supply all secondary cabling for a comprehensive design. This includes but is not limited to
2.111 multicore control, fibres and small power cables complete with terminations (Ferrule, cable 1 lot - -
glands, cable shrouds, etc.)
3.1 Supply 120mm² 6.35/11kV 3C XLPE Cu SWA cable 1,500 m - -
3.2 Supply transition joint for 70/120mm² 6.35/11kV 3C XLPE/XLPE Cu SWA cable 2 each - -
3.3 Supply joint for 120mm² 6.35/11kV 3C XLPE/XLPE Cu SWA cable 3 each - -
3.4 Supply joint for 120mm² 6.35/11kV 3C XLPE/PILC Cu SWA cable 4 each - -
3.5 Supply 11kV indoor cable termination for 120mm² 6.35/11kV 3C XLPE Cu SWA cable 11 each - -
3.6 Supply 185mm² 6.35/11kV 3C XLPE Cu SWA cable 1,500 m - -
3.7 Supply joint for 185mm² 6.35/11kV 3C XLPE Cu SWA cable 5 each - -
3.8 Supply 11kV indoor cable termination for 185mm² 6.35/11kV 3C XLPE Cu SWA cable 2 each - -
3.9 Supply 450mm (200micron) danger tape 3,000 m - -
3.10 Supply 900 x 300 x 65 mm cable concrete protection slab 55 each - -
3.13 Supply LV cable repair kit(joints and 1m cable if required) 10 each - -
Lot 1 Rev 5
Form Part 1-93
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
3.14 Supply MV cable repair kit(joints and 1m cable if required) 10 each - -

3.15 Supply MV/LV heat shrinkable zip-sleeve repair 20 each - -
3.17 Supply 1000x250x1mm plastic interlocking cable protection cover 3,000 m
4 Re-routing of existing cables

4.1 Supply 185mm² 6.35/11kV 3C XLPE Cu SWA cable 300 m
4.2 Supply joint for 185mm² 6.35/11kV 3C XLPE Cu SWA cable 5 each
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
6 Lot 1 Schedule 1 Additional Items

Any additional item(s), not shown in the schedules, which the tenderer consider essential and
wish to detail and price. (Provide full details)
6.1 - -
6.2 - -
6.3 - -
6.4 - -
6.5 - -
6.6 - -
6.7 - -
6.8 - -
6.9 - -
6.10 - -
6.11 - -
6.12 - -
6.13 - -
6.14 - -
6.15 - -
6.16 - -
6.17 - -
6.18 - -
6.19 - -
6.20 - -
6.21 - -
6.22 - -
6.23 - -
6.24 - -
Lot 1 Rev 5
Form Part 1-95
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
6.25 - -
6.26 - -
6.27 - -
6.28 - -
6.29 - -
6.30
Total Plant and Mandatory Spare Parts Supplied from Abroad Schedule 1 (Carried forward to Schedule No 5 Grand Summary) - -
¹Specify the currency(ies) in accordance with the specifications in Bid Data Sheet under ITB 18.1 in Single Stage Bid or ITB 30.1 in Two Stage Bid
Name of Bidder
________________
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________
Schedule No. 2. Plant and Mandatory Spare Parts Supplied from Within the Employer’s Country (Lot 1)
2 2
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.1 Plant and Mandatory Spare Parts Supplied from within the Employers Country - -
Total Plant and Mandatory Spare Parts Supplied from within the Employers Country (Carried forward to Schedule No 5 Grand
- -
Summary)
Name of Bidder
________________
Lot 1 Rev 5
Form Part 1-97
Schedule No. 3. Design Services (Lot 1)

2 2
QTY CURRENCY 1 : CURRENCY 2 :
ITEM DESCRIPTION CODE¹ UNIT
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.1 33 & 11 kV Structure design 1 lot - -
1.2 Sag and tension of 33 & 11 kV lines 1 lot - -
1.3 Surge arrestor earthing desing 1 lot - -
- -
2.1 Substation Civil Works
2.1.1 Substation Civil Design 1 lot - -
2.1.2 Substation Earthing Design 1 lot - -
2.1.3 Substation Stormwater and Drainage Design 1 lot - -
2.2 Primary Plant
2.2.1 Substation Electrical Design 1 lot - -
2.3 Protection
2.3.1 Protection & Control Designs 1 lot - -
2.4 SCADA and Telecommunications
2.4.1 Compile SCADA Functional Design Specification (FDS) 1 lot - -
2.4.2 Compile Telecommunication Functional Design Specification (FDS) 1 lot - -
2.4.3 Overall SCADA Detail Design 1 lot - -
2.4.4 Overall telecommunication Detail Design 1 lot - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CURRENCY 12: CURRENCY 22:

(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.5 Other
2.5.1 Metering Design 1 lot - -
2.5.2 AC/DC Equipment Design 1 lot - -
No items
No items
Total Design Services Schedule 3 (Carried forward to Schedule No 5 Grand Summary) - -
Name of Bidder
Lot 1 Rev 5
Form Part 1-99
Schedule No. 4. Installation and Other Services (Lot 1)

2 2
QTY CIP CIP

ITEM DESCRIPTION CODE¹ UNIT TOTAL PRICE TOTAL PRICE
(1) (Unit Price (Unit Price
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1 Preliminary and General

Contractual Requirements 1 lot - -
Site establishment and the provision of a site office for use of the contractor, client and
1.1 1 lot - -
engineer, water and sanitary facilities, first aid services
Allow for attendance to all site meetings and inspections, transport and time, related to such
1.2 1 lot - -
meetings and inspections.
1.3 Removal of all site facilities after completion of the project 1 lot - -
Other Fixed Charge Additional Items (Specify)
1.4 - -
1.5 - -
1.6 - -
1.7 - -
1.8 - -
1.9 - -
1.10 - -
1.11 - -
1.12 - -
1.13 - -
Time Related items
1.14 Contractual requirements 12 month - -
1.15 Operating and maintenance of site facilities 12 month - -
1.16 Supervision and co-ordination of sub-contractors 12 month - -
1.17 Company costs and overheads 12 month - -
Other Time Related Additional Items (Specify)
1.18 - -
1.19 - -
1.20 - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.21 - -
1.22 - -
1.23 - -
1.24 - -
1.25 - -
1.26 - -
1.27 - -
Security
1.28 24 Hour security for the duration of the project 12 month - -
Permits and Notices
Allow for obtaining all necessary permits and approvals from statutory bodies (electricity,
water, telecoms, roads, aviation) and local authorities for:
- Transport of equipment
1.29 - Giving of notices to any other authority or institute involved. 1 lot - -
- Co-operation agreements with other traders/contractors involved with
the project.
- Approvals of line design, service and road crossings.
Labor Act Requirements
1.30 Allow for compliance with the requirements of the Construction Regulations 1 lot - -
1.31 Health and Safety Compliance 1 lot - -
Drawings
Allow for marking-up a full set of drawings to show the exact positions of cables, cable
joints, road crossings etc. These "As Built" drawings must be handed to the engineer at
1.32 1 lot - -
commissioning of the equipment. Also all maintenance manuals, including all technical
literature, test certificates and wiring diagrams as per specification.
Specialised Services
Provisional amount for services rendered by a specialist on request or instruction by the client
1.33 1 lot 50,000.00 50,000.00 -
or engineer (equivalent of USD 50'000.00).
Additional Items
Allow for attendance to all factory inspections and acceptance tests for primary plant
1.34 1 lot - -
equipment outside Zambia, such as travel expenses, accommodation and per diem. (give a
Any additional item(s), not shown in the schedules, that the tenderer consider essential and
1.35 - -
Lot 1 Rev 5
Form Part 1-101

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.36 - -
1.37 - -
1.38 - -
1.39 - -
1.40 - -
1.41 - -
1.42 - -
1.43 - -
1.44 - -
Concrete poles
2.1 Install 14m self-supporting concrete poles 8 each - -
Single circuit self-supporting concrete structures

The unit rate for the structures must make provision for any strain or intermediate line
hardware, any fastening equipment, jumpers and crossarms etc.
2.2 Install 11kV, Vertical terminal structure as per typical drawing MKU-No8 1 each - -
2.3 Install 33kV, Vertical terminal structure as per typical drawing MKU-No8 2 each - -
2.4 Install 33kV, Horizontal terminal structure as per typical drawing G11392 1 each - -
2.5 Install 33kV, Shielded Horizontal terminal structure as per typical drawing G11392 2 each - -
Cables
The unit rate for the cable terminations must make provision for all hardware, fastening
equipment, jumpers, crossarms etc.
2.6 Install 240mm² 6.35/11kV 3C XLPE Cu SWA cable 132 m - -
2.7 Install joint for 240mm² 6.35/11kV 3C XLPE Cu SWA cable 1 each - -
Install 11kV outdoor cable termination for single pole as per typical drawing MAZ-ALB-DM-
2.8 1 each - -
08-G-12190
2.9 Install 240mm² 19/33kV 3C XLPE Cu SWA cable 660 m - -
2.10 Install joint for 240mm² 19/33kV 3C XLPE Cu SWA cable 7 each - -
Expose by hand and re-route 240mm² 6.35/11kV 3C XLPE Cu SWA cable to new 11kV
2.11 100 m - -
switchgear panel
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Install indoor cable termination for 240mm² 6.35/11kV 3C XLPE Cu SWA cable to new
2.12 1 each - -
11kV switchgear panel
Install 33kV outdoor cable termination for single pole for 240mm² 19/33kV 3C XLPE Cu
2.13 3 each - -
SWA cable as per typical drawing ZAM-GEN-41-G-12827
Install 33kV outdoor cable termination for H-pole for 240mm² 19/33kV 3C XLPE Cu SWA
2.14 2 each - -
cable as per typical drawing GH9709
Expose by hand and re-route 240mm² 19/33kV 3C XLPE Cu SWA cable to new 33kV
2.15 500 m - -
overhead feeder bays cable termination structure
Install outdoor cable termination for 240mm² 19/33kV 3C XLPE Cu SWA cable on new
2.16 5 each - -
33kV overhead feeder bays cable termination structure
2.17 Install 450mm (200micron) danger tape 1,392 m - -
2.18 Install 900 x 300 x 65 mm cable concrete protection slab 55 each - -
2.19 Install 100-250mm water pipe repair kit(joints and 1m pipe if required) 10 each - -
2.21 Install LV cable repair kit(joints and 1m cable if required) 10 each - -
2.22 Install MV cable repair kit(joints and 1m cable if required) 10 each - -
2.23 Install MV/LV heat shrinkable zip-sleeve repair 20 each - -
2.24 Install Type A concrete cable route markers 30 each - -
2.25 Install 24 Core duct armoured fiber cable 600 m - -
2.26 Install 40mm fiber duct 600 m - -
2.27 Install fiber outdoor termination box, termination and sub-soil draw boxes 1 lot - -
2.28 Import backfill material from a commercial source 587 m³ - -
2.29 Remove rubble from site to a licensed facility 587 m³ - -
Excavate, backfill and compact trench in: -

2.30 Dense soil (Per hand) 905 m - -
2.31 Soft Rock (Mechanical) 278 m - -
2.32 Hard rock (Drill and blast) 209 m - -
2.33 Trench cross cut 16 each - -
Surge arrestors
The unit rate for the surge arrestors must make provision for any hardware, fastening
equipment, jumpers, crossarms and earthing material for a 5m crowsfoot
2.34 Install complete 11kV drop-out surge arestor assembly for single concrete pole 1 each - -
Lot 1 Rev 5
Form Part 1-103

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.35 Install complete 33kV drop-out surge arestor assembly for single concrete pole 2 each - -
2.36 Install complete 33kV drop-out surge arestor assembly for concrete H-pole 3 each - -
2.37 Install earthing material for 5m crow's foot 6 - -
Labels
Note: The labelling of structures is to be in accordance with the standard for the labelling
of high voltage equipment and must make provision for any fastening equipment.
2.38 Install of circuit designation labels 6 set - -
2.39 Install Phase Identification Disk (RYB) 6 set - -
2.40 Temporary traffic control signage during road crossings 1 lot - -
Dismantle existing 11 & 33kV overhead structures

2.41 Remove H-pole structure and deliver material to Zesco farm 2 each - -
2.42 Remove single pole structure and deliver material to Zesco farm 4 each - -
2.43 Cutt and roll-up conductor and deliver material to Zesco farm 1,080 m - -

Civil Works
Plarform Bulk Earthworks
3.1 Geotechnical Investigation for Platform and Access Road 1 lot - -
3.2 Bush Clearing for Platform 3,000 m² - -
3.3 Removal and dispose of trees 3 each - -
3.4 Grub and Clear to Spoil (300mm deep) 900 m³ - -
3.5 Rip level and Compact in situ 300 deep 3,000 m² - -
Supply, spread, water and compact G6 material for platform to 600mm above NGL in
3.6 5,850 m³ - -
150mm layers
3.7 Supply and install 80mm interlocking brick paving for access road to parking 330 m² - -
3.8 Supply and Install kerbing around the substation fence 230 m - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Supply and install a storm water drainage system on and around the terrace on all the places
3.9 where storm water will accumulate on the platform as well as a concrete lined stormwater 1 lot - -
trench between the old and the new platforms
3.10 Rock breaking including drilling and Blasting - Chemical expansion type 150 m³ - -
Access Road Bulk Earthworks

3.11 Grub and Clear to Spoil (300mm deep) 102 m³ - -
3.12 Rip level and Compact in situ 300 deep 340 m² - -
Supply, spread and compact G6 material for access road to 600mm above NGL in 150mm
3.13 381 m³ - -
layers
3.14 Grade secondary road between main road and platform 340 m² - -
3.15 Supply and install an open channel storm water drainage system roads as per specification 50 m - -
Supply and install a vehicle crossing points with headwalls over open channel storm water
3.16 33 m - -
drainage system
3.17 Rock breaking including drilling and Blasting - Chemical expansion type 20 m³ - -
Fencing and Yard Cover

3.18 Install Outer fence pedestrian gates 1 each - -
3.19 Install Inner fence pedestrian gates 2 each - -
3.20 Install Outer fence 5m double-leaf lecurity gate 3 each - -
3.21 Install Inner fence 5m double-deaf security gate 3 each - -
3.22 Install 6m Transformer removable panels 2 each - -
3.23 Install Welded square mesh fence complete with gates, dig barrier and razor mesh overhang 230 m - -
3.24 Install Razor mesh Inner Fence 70 m - -
3.25 Supply and Install Crushed Stone Ground Cover 200 m³ - -
3.26 Supply and Install 1.2m steel reinforced concrete bollards 33 each - -
Switchgear and Control Building

Supply material and construct a new building all inclusive off but not limited to all
3.26 excavations, concrete footings, brickwork, all finishes, main/ standby/outside lights, all 240 m² - -
modes of ventilation, trench covers, outside walkway and all cable racking.
Lot 1 Rev 5
Form Part 1-105

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Office Building
Guard House
modes of ventilation, outside walkway as per ZESCO Specification and drawings)
Planning Office
Substation Facilities
Supply and Install 120 liter wheeled plastic bins marked Paper and Cardboard, Plastic, Metal
3.30 4 each - -
and General Waste
One equiped borehole and two 5,000l tanks on 6m stand supplying the community including
3.31 1 lot - -
all piping, connectors, water level sensors integrated with existing water system.
Supply and Install substation utilities - Substation desk, Bench at desk, Notice board, White
board, First aid kit, Danger notices, Primary equipment lables, Operating and maintenance
3.32 1 Lot - -
manuals, Mounted single line diagram, Durable frame for emergency numbers, Key box, Wall
mounted console desk for logbook
3.33 Supply and Install Covered parking 3m wide, 7m long 4 each - -
Fire Protection
3.34 Install SCADA interactable fire detection system with audible alarm 1 lot - -
3.35 Install ABC Dry power fire extinguishers 10 each - -
3.36 Install Automatic condensed aerosol generator (CAG) flooding with manual overrides 2 lot - -
3.37 Install ABC trolley-mounted fire extinguishers 2 each - -
3.38 Supply and Install material for a fire wall between transformers 1 each - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
132kV Yard - Reinforced concrete foundations including all formwork, excavations, reinforcing and anchor bolts
Install 30 MVA Transformer Plinth complete with bund wall and galvanized rectangular steel
3.39 2 each - -
grid
3.40 Install 33kV Isolator Structure 16 each - -
3.41 Install 33kV Current Transformers 10 each - -
3.42 Install 33kV Circuit Breaker 9 each - -
3.43 Install 33kV Voltage Transformers Busbar 2 each - -
3.44 Install 33kV Cable Ends With VT & SA 6 each - -
3.45 Install 33/11kV Cable Ends and busbar supports (Transformer) 2 each - -
3.46 Install 33kV Main Busbar Supports 4 each - -
3.47 Install 11kV Neutral Earthing Resistor 2 each - -
3.48 Install 11kV/400V 200kVA Auxiliary transformer 2 each - -
3.49 Install 50kVA 400V 3ph Generator 1 each - -
3.50 Install 21m Lighting/Lightning Masts 4 each - -
3.51 Supply and Install material for a heavy duty reinforced concrete platform road. 200 m² - -
3.52 Supply and Install material for a heavy duty reinforced concrete substation access road. 270 m² - -
Supply 150x150x150mm moulds, prepare cubes and have the cubes tested at an independent
3.53 1 lot - -
authority
4 Primary Equipment
33kV Outdoor Yard
4.1 Install 33kV Line Isolator with Earth Switch 6 each - -
4.2 Install 33kV Busbar Isolator 8 each - -
4.3 Install 33kV Bus section Isolator 2 each - -
4.4 Install 33kV Feeder Current Transformers 24 each - -
4.5 Install 33kV Bus section Current Transformers 6 each - -
4.6 Install 33kV Feeder Circuit Breaker 8 each - -
4.7 Install 33kV Bus Section Circuit Breaker 1 each - -
4.8 Install 33kV/110V 1Ph Voltage Transformer 24 each - -
4.9 Install 33kV Station Class Surge Arrester 24 each - -
4.10 Install 33kV Post Insulators 60 each - -
4.11 Install 66kV Post Insulators 6 each - -
Lot 1 Rev 5
Form Part 1-107

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Install 33/11kV 30MVA Dyn1 Transformer, complete with tap changer, surge arrestor
4.12 2 each - -
brackets and accelerometer.
4.13 Install 11kV Station Class Surge Arrester 6 each - -
33 kV Yard - Small Materials

4.15 Install Clamps and Fittings for the 33 & 11kV tubular busbars and stringers 1 lot - -
4.16 Install Miscellaneous Material and Consumables 1 lot - -
4.17 Install 80mm x 4mm Al tubes for outdoor 33 & 11k transformer yard 16 each - -
4.18 Install AAC Centipede Conductor 500 m - -
4.19 Install AAC Hornet Conductor 40 m - -
4.20 Install 11kV 120mm² 1C XLPE Armored Cu Cable 30 m - -
4.21 Install 11kV 630mm² 1C XLPE Armored Cu Cable 1,200 m - -
4.22 Install 11 kV Cable clamps, lugs and terminations complete, XLPE, Cu, 1C 120mm² Armored 4 set - -
Install 11 kV Cable clamps, lugs and terminations complete, XLPE, Cu, 1C 630 mm²
4.23 36 set - -
Armored
33kV Yard - Steel Structures

4.24 Install 33kV Isolator Structure 16 each - -
4.25 Install 33kV Current Transformers 10 each - -
4.26 Install 33kV Circuit Breaker 9 each - -
4.27 Install 33kV Voltage Transformers 2 each - -
4.28 Install 33kV Cable Ends With VT & SA 6 each - -
4.29 Install 33/11kV Cable Ends - Transformers 2 each - -
4.3 Install 33kV Busbar Support Structure 4 each - -
4.32 Install 21m Lighting/Lightning Masts 4 each - -
Common Yard
4.33 Install 400W Led Floodlights 16 each - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
4.34 Install All safety signs, labels and and nameplates with fixing equipment 1 lot - -
4.35 Install 110mm PVC Cable Sleeves 350 m - -
4.36 Install 160mm PVC Cable Sleeves 60 m - -
4.37 Install 200mm Concrete Cable sleeves 165 m - -
4.38 Install 300mm Dia Concrete Pipes for oil containment system 25 m - -
4.39 Install 5,000l Water tanks with steel support structure 2 each - -
4.40 Supply and Install material for Manholes for oil containment 3 each - -
4.41 Supply and Install French drain with 2,000 liter septic tank with sludge pumping facility 1 lot - -
Supply and Install material for Oil Containment System With Sumps, Manholes, Pipes,
4.42 1 lot - -
Oil/Water Separator And Oil Holding Dam
Supply and Install material for Sensing And Pumping System For Oil Containment System
4.43 1 lot - -
Including Sensors, Piping, Pumping Equipment And Electrical Installation With Control Box
4.44 Supply and Install material for Cable Trenches 900mm wide with covers 35 m - -
4.45 Supply and Install material for Cable Trenches 600mm wide with covers 85 m - -
Earth Grid
Excavate and install 10mm copper rod for earth grid (1m below ground level) and earthing
4.46 1,740 m - -
columns
4.47 Excavate and install 50mm x 3mm Flat copper for earth tails to the foundations. 350 m - -
Excavate and install 50mm x 3mm Flat copper for earth-tails to the fence and fence corner
4.48 100 m - -
gate post
4.49 Excavate and install 50mm x 3mm Flat copper for earth-tails for building earthing of panels. 150 m - -
4.50 Excavate and install 50mm x 3mm Flat copper for earth-tails battery room 50 m - -
4.51 Main earth grid bonding 10mm to 19/2.91 braced or cadweld 200 each - -
4.52 Main earth bonding to earth tails diameter 10mm dia to 50mm x 3mm flat 245 each - -
Excavate and install 60kg Sacrificial railway track earth, Silbraloy connected to the main
4.53 1 each - -
earth grid
Drilled holes 100mm diameter, 20m deep, one at each corner of the substation complete with
4.54 4 each - -
electrode and backfilled with conductive concrete
1.8m Cu Earth electrodes installed at each lightning mast. Two in series per connection to
4.55 32 each - -
main earthmat
Woodlands Substation Main 11KV Switchboard
Lot 1 Rev 5
Form Part 1-109

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
4.56 Install incomer panels 2 each - -

4.57 Install bus section / bus riser panels 1 each - -
4.58 Install local feeder panels 13 each - -
4.59 Install fused isolator panel for Aux transformer 2 each - -
4.60 Install VT panel 2 each - -
4.61 Install floor support frame 1 each - -
4.62 Install trench support frame ( if required ) 1 lot - -
4.63 Install galvanized metal sheet fixed to the floor in front of board 1 lot - -
4.64 Install material to bond all panels to main trench earth. Lugs and conductor included 1 lot - -
4.65 Install complete set of drawings and documentation as per specification 1 lot - -
Auxiliary Supply
4.67 Install 11kV/400V 200kVA Auxiliary transformer 2 each - -
4.68 Install 50kVA 400V 3ph Generator 1 each - -
4.69 Install 1kV 120mm² 4C PVC Armored Cu Cable 140 m - -
4.70 Install 11kV 120mm² 3C XLPE Armored Cu Cable 100 m - -
4.71 Install 1kV Cable clamps, lugs and terminations complete, PVC, Cu, 4C 120mm² Armored 6 set - -
4.72 Install 11kV Cable clamps, lugs and terminations complete, XLPE, Cu, 3C 120mm² Armored 4 set - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
5 Protection, Control and Telecommunication Equipment

Protection
5.1 Install 33/11kV Transformer Protection Panel 2 each - -
5.2 Commission 33/11kV Transformer Protection Panel 2 each - -
5.3 Install 33kV Incomer Protection scheme 2 each - -
5.4 Commission 33kV Incomer Protection scheme 2 each - -
5.5 Install 33kV Outdoor Feeder Protection scheme 4 each - -
5.6 Commission 33kV Outdoor Feeder Protection scheme 4 each - -
5.7 Install 33kV Bus Section Protection scheme 1 each - -
5.8 Commission 33kV Bus Section Protection scheme 1 each - -
5.9 Install 33kV Low Impedance Bus Zone Protection scheme 1 each - -
5.10 Commission 33kV Low Impedance Bus Zone Protection scheme 1 each - -
5.11 Install 11kV Transformer Incomer Onboard Protection scheme (Included in Schedule 1 rates) 2 each - -
5.12 Commission 11kV Transformer Incomer Onboard Protection scheme 2 each - -
5.13 Install 11kV Bus Section Onboard Protection scheme (Included in Schedule 1 rates) 1 each - -
5.14 Commission 11kV Bus Section Onboard Protection scheme 1 each - -
5.15 Supply 11kV Feeder Onboard Protection scheme (Included in Schedule 1 rates) 13 each - -
5.16 Commission 11kV Feeder Onboard Protection scheme 13 each - -
5.17 Supply 11kV Arc Onboard Protection Scheme (Included in Schedule 1 rates) 1 lot - -
5.18 Commission 11kV Arc Onboard Protection Scheme 1 lot - -

5.19 Install SCADA system 1 lot - -
5.20 Commission SCADA system 1 lot - -
5.21 Install telecommunication system 1 lot - -
5.22 Commission telecommunication system 1 lot - -
Other
5.23 Install Statistical meters in the 11kV local feeder panels 13 each - -
5.24 Commission Statistical meters in the 11kV local feeder panels 13 each - -
5.25 Install Statistical Meters for transformers in metering panel (6 meters per panel) 2 each - -
5.26 Commission Statistical Meters for transformers in metering panel (6 meters per panel) 2 each - -
Lot 1 Rev 5
Form Part 1-111

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
5.27 Install tarrif Meters for 33kV feeders in metering panel (6 meters per panel) 6 each - -
5.28 Commission tarrif Meters for 33kV feeders in metering panel (6 meters per panel) 6 each - -
5.29 Install 400V AC three-way automatic change over panel 1 each - -
5.30 Commission 400V AC three-way automatic change over panel 1 each - -
5.31 Install 230V AC distribution panel 1 each - -
5.32 Commission 230V AC distribution panel 1 each - -
Install 110V DC System inclusive of distribution panel, dual paralleled battery chargers, with
5.33 1 lot - -
NiCad batteries
Commission 110V DC System inclusive of distribution panel, dual paralleled battery
5.34 1 lot - -
chargers, with NiCad batteries
Install 48V DC System inclusive of distribution panel, single battery charger, with NiCad
5.35 1 lot - -
batteries
Commission 48V DC System inclusive of distribution panel, single battery charger, with
5.36 1 lot - -
NiCad batteries
5.37 Install CT Junction boxes with terminals 1 lot - -
5.38 Install VT Junction boxes with terminals 1 lot - -
5.39 Install Transformer 3-phase Socket Install box and plug (one per two transformers) 1 lot - -
Witnessing of each scheduled Factory Acceptance Test by three Engineers per discipline
5.40 1 lot - -
(protection, SCADA and telecommunication) as the representatives of the client
5.41 Site Acceptance Tests, as per specifications, for protection, SCADA and telecommunications 1 lot - -
5.42 Training, as per specifications, for protection, SCADA and telecommunications 1 lot - -
5.43 Testing and commissioning of all protection, SCADA and telecommunication works 1 lot - -
Install all secondary cabling for a comprehensive design. This includes but is not limited to
5.44 multicore control, fibres and small power cables complete with terminations (Ferrule, cable 1 lot - -
6 Task 3 - Intergrade existing 33 & 11kV cables into new Woodlands Substation - -
6.1 Install 120mm² 6.35/11kV 3C XLPE Cu SWA cable 1,500 m - -
6.2 Install transition joint for 70/120mm² 6.35/11kV 3C XLPE/XLPE Cu SWA cable 2 each - -
6.3 Install joint for 120mm² 6.35/11kV 3C XLPE/XLPE Cu SWA cable 3 each - -
6.4 Install joint for 120mm² 6.35/11kV 3C XLPE/PILC Cu SWA cable 4 each - -
6.5 Install indoor cable termination for 120mm² 6.35/11kV 3C XLPE Cu SWA cable 11 each - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
6.6 Install 185mm² 6.35/11kV 3C XLPE Cu SWA cable 1,500 m - -

6.8 Install 11kV indoor cable termination for 185mm² 6.35/11kV 3C XLPE Cu SWA cable 2 each - -
6.9 Install 450mm (200micron) danger tape 3,000 m - -
6.10 Install 900 x 300 x 65 mm cable concrete protection slab 55 each - -
6.13 Install LV cable repair kit(joints and 1m cable if required) 10 each - -
6.14 Install MV cable repair kit(joints and 1m cable if required) 10 each - -
6.15 Install MV/LV heat shrinkable zip-sleeve repair 20 each - -
6.17 Import backfill material from a commercial source 525 m³ - -
6.18 Remove rubble from site to a licensed facility 525 m³ - -
6.19 Excavate, backfill and compact trench in: - -
6.20 Dense soil (Per hand) 1,950 m - -
6.23 Trench cross cut 30 each - -
6.24 Survey proposed cable route by means of a non-invasive cable detection system 3,000 m - -
6.25 Install 1000x250x1mm plastic interlocking cable protection cover 3,000 m - -
- -
7 Re-routing of existing cables
7.1 Install 185mm² 6.35/11kV 3C XLPE Cu SWA cable 300 m - -
7.3 Expose and re-route 185mm² 6.35/11kV 3C XLPE Cu SWA cable by hand to new trench 600 m - -
Excavate, backfill and compact trench in:
7.4 Dense soil (Per hand) 585 m - -
Lot 1 Rev 5
Form Part 1-113

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
8 Task 4 - Dismantle Existing Woodlands 33/11 kV Substation - -

Supply the necessary equipment to dismantle the existing Woodlands 33/11kV substation
according to Specification 11233-40-SPE-EE-018 "Dismantling of Overhead Line and 1 lot - -
Substation Equipment Specification".
- -
9 Additional Items - -
- -
9.1 - -
9.2 - -
9.3 - -
9.4 - -
9.5 - -
9.6 - -
9.7 - -
9.8 - -
9.9 - -
9.10 - -
9.11 - -
9.12 - -
9.13 - -
9.14 - -
9.15 - -
9.16 - -
9.17 - -
9.18 - -
9.19 - -
9.20 - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________

QTY CIP CIP

[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
9.21 - -
9.22 - -
9.23 - -
9.24 - -
9.25 - -
9.26 - -
9.27 - -
9.28 - -
9.29 - -
9.30 - -
Total Installation and other Services Schedule 4 (Carried forward to Schedule No 5 Grand Summary) 50,000.00 -
Name of Bidder
Signature of Bidder
Lot 1 Rev 5
Section IV Bidding Form Part 1-115
____________________________________________________________________________________________________________________________________________
Schedule No. 5. Grand Summary (Lot 1)
ITEM DESCRIPTION CURRENCY 12: CURRENCY 22:

TOTAL PRICE (CIP) TOTAL PRICE (CIP)
(1) x (2) (1) x (3)
Total Plant and Mandatory Spare Parts Supplied from Abroad Schedule 1 (Carried forward
1 - -
to Schedule No 5 Grand Summary)
Total Plant and Mandatory Spare Parts Supplied from within the Employers Country
2 (Carried forward to Schedule No 5 Grand - -
Summary)
3 Total Design Services Schedule 3 (Carried forward to Schedule No 5 Grand Summary) - -
Total Installation and other Services Schedule 4 (Carried forward to Schedule No 5 Grand
4 50,000.00 -
Summary)
Total Installation and other Services Schedule 4 (Carried forward to Schedule No 5 Grand
50,000.00 -
Summary)
Name of Bidder
__________________
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________
Schedule No. 6. Recommended Spare Parts (Lot 1)
2 2
1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)

Tools
2.1 Tools/accessories for substation protection and control system (Bidder to list) 1 lot - -
2.2 Tools/accessories for 11kV switchboard and 33kV equipment (Bidder to list) 1 lot - -
Primary Plant
Transformer Spares
2.4 33kV bushing with metal parts and gaskets 1 each - -
2.5 11kV bushing with metal parts and gaskets 2 each - -
2.6 Tap changer motor 1 each - -
2.7 20kg silica gel 1 each - -
2.8 Starters, contactors, switches and relays for the electrical control panel (one set of each) 1 each - -
33kV Circuit Breaker Spares
2.9 Set of contacts for 1 pole 1 each - -
2.10 Set of gaskets for 1 pole 1 each - -
2.11 Breaking chamber insulator (1 No.) 1 each - -
2.12 Support insulator (1 No.) 1 each - -
2.13 Spring charge motor (1 No.) 1 each - -
2.14 Close coil (1 No.) 1 each - -
2.15 Trip coil (1 No.) 1 each - -
Lot 1 Rev 5
Form Part 1-117
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.16 Breaker control switch (1 No.) 1 each - -

2.17 Local control switch (1 No.) 1 each - -
33kV Isolator Spares
2.18 3 pole set of main live parts for main blades (1 set) 1 lot - -
2.19 Operating motor (1 No) 1 each - -
11kV Circuit Breaker
2.20 Spring charge motor (1 No.) 1 each - -
2.21 Close coil (1 No.) 1 each - -
2.22 Trip coil (1 No.) 1 each - -
2.23 Breaker control switch (1 No.) 1 each - -
Auxiliary Supply
Generator
2.24 One complete set of filters 1 lot - -
Protection, Control, Metering and Telecommunications
Protection & Control
Note: General requirement is at least 5% of the installed should be the spares.
2.25 Line differential relays 2 each - -
2.26 Transformer differential relays 2 each - -
2.27 Backup Overcurrent/Earth fault relays 2 each - -
2.28 Bay Control Units 2 each - -
2.29 Busbar protection modules 3 each - -
Metering
2.30 Meters 10 each - -
2.31 Transformer temperature gauges 5 each - -
2.32 Multifunction Transducers (P, VAR, V) 20 each - -
2.33 Panel meters - 5% of Total 1 lot - -
2.34 Main processor card for RTU/Gateway 1 each - -
Lot 1 Rev 5
____________________________________________________________________________________________________________________________________________
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.35 Communication card for RTU/Gateway 1 each - -

2.36 Power supply unit for RTU/Gateway 1 each - -
2.37 Binary input card for RTU/Gateway 2 each - -
2.38 Binary output card for RTU/Gateway 2 each - -
2.39 Analog input card for RTU/Gateway 2 each - -
2.40 Complete bay controller unit 2 each - -
2.41 Network element control processor 1 each - -
2.42 TDM switching card 1 each - -
2.43 Packet switching card 1 each - -
2.44 STM-16 optical line card 1 each - -
2.45 STM-1 optical line card 1 each - -
Lot 1 Rev 5
Form Part 1-119
QTY
CIP CIP
(1)
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.46 100/1000 Mbps Ethernet card (GFP supporting) 1 each - -

2.47 Network element cooling fan 1 each - -
2.48 24 port SM optical patch panel 2 each - -
2.49 48VDC rectifier module 1 each - -
2.50 48VDC battery bank 2 each - -
2.51 Condensed Aerosol Generators for automatic fire fighting systems 2 sets - -
Task 3 - Intergrade existing 33 & 11kV cables into new Woodlands Substation
3 No items
Task 4 - Dismantle Existing Woodlands 33/11 kV Substation
4 No items
Total Spare Parts Schedule 6 - -
Name of Bidder
________________
Lot 1 Rev 5

LOT 2 - Coventry – Kafue 33kV Overhead Line Upgrade

Section___________________________________________________________________________________________________________________________________________________
IV Bidding Forms Part 1-123
LTDRPP4
Schedule of Rates and Prices (Lot 2)

LOT 2: Coventry – Kafue 33kV Overhead Line Upgrade
Task 1: 33kV OHL and cable feeders from Coventry Substation to Kafue Substation
Task 2: 33kV feeder bays at Coventry Substation and Kafue Substation
Name of Bidder
Lot 2 Rev 5
____________________________________________________________________________________________________________________________________________
page of Volume 1.
Lot 1 Rev 5
Section IV Bidding___________________________________________________________________________________________________________________________________________________
Forms Part 1-125

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1 Task 1: 33kV OHL and cable feeders from Coventry Substation to Kafue Substation
1.1 Double circuit steel monopole
1.1.1 Supply intermediate Steel Monopole 33kV (10m CAH, wind span 250m, Weight span 450m) 2 each - -
1.1.3 Supply 60⁰ Strain Steel Monopole 33kV (12m CAH, wind span 250m, Weight span 450m) 1 each - -
1.2 Steel Monopole hardware strain assembly
Supply all the material as per drawing 111233-000-DRG-CE-DE-0001 for a phase conductor
1.2.1 36 each - -
strain assembly
1.2.2 18 each - -
jumper support assembly
1.2.3 Supply all the material as per drawing 111233-000-DRG-CE-DE-0005 for a OPGW strain 6 each - -
1.3 Steel Monopole hardware intermediate assembly
Supply all the material as per drawing 111233-000-DRG-CE-DE0002 for a phase conductor
1.3.1 54 each - -
intermediate assembly
Supply all the material as per drawing 111233-000-DRG-CE-DE-0004 for a OPGW
1.3.2 9 each - -
1.4 Conductor stringing
1.4.1 Supply ACSR Bear Conductor, 14,000 meter - -
1.4.2 Supply 24 core OPGW equal to a 19/2.64 shield wire 2,310 meter - -
1.4.3 Supply Bear midspan joints 8 each - -
1.4.4 Supply 24 core OPGW joint boxes with a slack reel complete with all hardware. 2 each - -
1.4.5 Supply Bear repair sleeves 8 each - -
1.5 Earthing material
Supply foundation earth as per AUR-OHL-EAR-MP-001
1.5.1 14 each - -
This includes the all the clamps and conductor in the foundation as well as the 1m earth lead.
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________
2
CURRENCY 1 : CURRENCY 22:
1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Supply additional earths per AUR-OHL-EAR-MP-001
1.5.2 14 each - -
This includes the 15m BCEW counterpoise, all the clamps as well as the 1.5m earth spike
Supply substation bonding
1.5.3 100 meter - -
This includes the 50x3mm Cu strap as well as all the clamps/welding required
Supply all material for a distribution surge arrestor installation. The unit rate must make
1.5.4 provision for surge arrestors, mounting brackets, earthing conductors and rods, clamps, bonding 12 each - -
leads and fixing materials per H-pole structure.
1.6 Labelling
Note: The labelling of structures is to be in accordance with the standard for the labelling of
high voltage equipment:
1.6.1 Supply of circuit designation labels 28 each - -
1.6.2 Supply Phase Identification Disk - Set 4 each - -
Road/Rail Crossings, supply of temporary stays and structures. Including costs of traffic
1.6.3 3 each - -
control/signage and work outside normal work hours
1.7 Wooden pole structures
1.7.1 Supply 14m 225mm pole top wooden pole 8 each - -
Supply al material as per drawing GH9727 for a H-pole terminal structure. The unit rate must
1.7.2 make provision for the strain cross arm, three phase-conductor strains and all fixing material. 4 each - -
Poles and stays measured elsewhere
1.7.3 Supply al material as per drawing ZAM-GEN-DE-G-12831 for a complete stay. 8 each - -
1.7.4 Supply of circuit designation labels 1 lot - -
1.8 Cable installation
1.8.1 Supply 19/33kV 500mm² 1C AWA Cu XLPE cable with clamps every 300mm. 13,200 m - -
1.8.2 Supply joint kit for 19/33kV 500mm² 1C AWA Cu XLPE cable 44 each - -
1.8.3 Supply outdoor cable termination for a 19/33kV 500mm² 1C AWA Cu XLPE cable. 24 each - -
1.8.4 Supply 450mm (200micron) danger tape 2,000 m - -
1.8.5 Supply 160mm sleeves 720 m - -
1.8.6 Supply 900 x 300 x 65 mm cable concrete protection slab 200 each - -
1.8.7 Supply 100-250mm water pipe repair(joints and 1m pipe if required) 20 each - -
1.8.8 Supply 250-400mm water pipe repair(joints and 1m pipe if required) 20 each - -
1.8.9 Supply LV cable repair(joints and 1m cable if required) 40 each - -
1.8.10 Supply MV cable repair(joints and 1m cable if required) 40 each - -
1.8.11 Supply MV/LV heat shrinkable zip-sleeve repair 40 each - -
1.8.12 Supply TYPE A concrete cable route markers 100 each - -
Lot 2 Rev 5
Forms Part 1-127
2
1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Supply cable support structures. The unit rate must make provision for all, clamps, protective
1.8.13 8 each - -
pipes, support chanels where required, all fixing material for all cable teminations.
2 Task 2: 33kV feeder bays at Coventry Substation and Kafue Substation
2.1 33kV Equipment
2.1.1 Supply 33kV line Isolator with Earth Switch 3 each - -
2.1.2 Supply 33kV busbar Isolator 3 each - -
2.1.3 Supply 33kV feeder Current Transformer 9 each - -
2.1.4 Supply 33kV Feeder Circuit Breaker 3 each - -
2.1.5 Supply 33kV/110V 1Ph voltage transformer 9 each - -
2.1.6 Supply 33kV station class surge arrester 9 each - -
2.1.7 Supply 33kV post insulators 27 each - -
2.2 33kV Yard - Small Materials for three line bays
2.2.1 Supply clamps and fittings (busbars, stringers, cable terminations and portable earths) 1 lot - -
2.2.2 Supply miscellaneous material and consumables not specifically mentioned 1 lot - -
2.2.3 Supply centipede conductor 300 m - -
2.2.4 Supply hornet conductor(VT & SA) 30 m - -
2.2.5 Supply 50mm x 3mm flat copper for earth tails 180 m - -
2.2.6 Supply 10mm copper rod for main earth grid 660 m - -
2.2.7 Supply main earth bonding (Cadweld) 1 lot - -
2.2.8 Supply portable earths 95mm² stranded conductor with UV stable PVC covering 3 each - -
2.2.9 Supply all equipment labels and safety signs and fixing equipment for new line bays 1 lot - -
2.3 33kV Yard - Steel Structures
2.3.1 Supply 33kV busbar isolator support 3 each - -
2.3.2 Supply 33kV line isolator support with earth switch 3 each - -
2.3.3 Supply 33kV circuit breakers support 3 each - -
2.3.4 Supply 33kV current transformer support 3 each - -
2.3.5 Supply 33kV combination cable termination, voltage transformer and surge arrestor 3 each - -
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________
2
1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.4 Protection, Control and Telecommunication Equipment
2.4.1 Protection
Supply equipment and material to integrate the existing protection panels with the new line bay
2.4.1.1 1 lot - -
equipment
2.4.1.2 Supply 33kV tariff metering on both end of the line 1 lot - -
2.4.2 SCADA and Telecommunications
Supply all equipment and material necessary to integrate the new feeder bay equipment and
2.4.2.1 1 lot - -
existing protection and control panels into the existing SCADA and telecommunication
2.4.3 Other
2.4.3.1 Supply equipment to integrate the new equipment into the existing AC/DC distribution panel 1 lot - -
2.4.3.2 Supply CT Junction boxes with terminals 1 lot - -
2.4.3.3 Supply VT Junction boxes with terminals 1 lot - -
Supply all secondary cabling for a comprehensive installation. This includes but is not limited to
2.4.3.4 multicore control, fibres and small power cables complete with terminations (Ferrule, cable 1 lot - -
Re-routing of existing cables
2.4.3.5 Supply 185mm² 6.35/11kV 3C XLPE Cu SWA cable 300 m - -
2.4.3.6 Supply joint for 185mm² 6.35/11kV 3C XLPE Cu SWA cable 5 each - -
2.4.3.7 Supply Type A concrete cable route markers 10 each - -
Lot 2 Rev 5
Forms Part 1-129
2
1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
3 Additional items
3.1 - -
3.2 - -
3.3 - -
3.4 - -
3.5 - -
3.6 - -
3.7 - -
3.8 - -
3.9 - -
3.10 - -
Total Plant and Mandatory Spare Parts Schedule 1 (Carried forward to Schedule No 5 Grand Summary) - -
Name of Bidder
Signature of Bidder
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Summary)
- -
Name of Bidder
Signature of Bidder
Lot 2 Rev 5
Forms Part 1-131

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.1 Line design - Survey, Profiling & Templating 1 lot - -
1.2 Right of Way study including demolishing of infrastructure 1 lot
1.3 Structure design 1 lot - -
1.4 Foundation design 1 lot - -
1.5 Vibration Damping study 1 lot - -
1.1 Equipment support structure design 1 lot - -
1.2 Protection design 1 lot
1.4 Earthing design 1 lot - -
Total Design Services (Carried forward to Schedule No 5 Grand Summary) - -
Name of Bidder -
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________
2 2
QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1 ALL TASKS
1.1 Preliminary and General
1.1.1 Contractual Requirements 1 lot - -
1.1.2 1 lot - -
1.1.3 1 lot - -
1.1.4 Removal of all site facilities after completion of the project 1 lot - -
1.2 Other Fixed Charge Additional Items (Specify)
1.2.1 - -
1.2.2 - -
1.2.3 - -
1.2.4 - -
1.2.5 - -
1.2.6 - -
1.2.7 - -
1.2.8 - -
1.2.9 - -
1.2.10 - -
1.3 Time Related items
1.3.1 Contractual requirements 12 month - -
1.3.2 Operating and maintenance of site facilities 12 month - -
1.3.3 Supervision and co-ordination of sub-contractors 12 month - -
1.3.4 Company costs and overheads 12 month - -
Lot 2 Rev 5
Forms Part 1-133

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.4 Other Time Related Additional Items (Specify)
1.4.1 - -
1.4.2 - -
1.4.3 - -
1.4.4 - -
1.4.5 - -
1.4.6 - -
1.4.7 - -
1.4.8 - -
1.4.9 - -
1.4.10 - -
1.5 Security
1.5.1 24 Hour security for the duration of the project 12 month - -
1.6 Permits and Notices
1.6.1 - Giving of notices to any other authority or institute involved. 1 lot - -
the project.
1.7 Labour Act Requirements
1.7.1 Allow for compliance with the requirements of the Construction Regulations 1 lot - -
1.7.2 Health and Safety Compliance 1 lot - -
1.8 Drawings
Allow for marking-up a full set of drawings to show the exact positions of cables, cable
joints, road crossings etc. These "As Built" drawings must be handed to the engineer at
1.8.1 1 lot - -
1.9 Specialised Services
1.9.1 1 lot 50,000.00 50,000.00 -
1.10 Additional Items
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Allow for attendance to all factory inspections and acceptance tests outside Zambia, such as
1.10.1 1 lot - -
travel expenses, accommodation and per diem. (give a detailed breakdown)
Geotechnical Studies (Professional registered Geotechnical Engineer for soil Type
1.10.2 1 lot - -
nominations)
1.10.3 Compliance with local occupational health and safety requirements 1 lot - -
1.10.4 Compliance with local environmental management requirements 1 lot - -
1.10.5 EIA 1 lot - -
1.10.6 Survey 1 lot - -
Note: Any additional item(s), not shown in the schedules, which the tenderer consider
essential and wish to detail and price. (Provide full details)
1.10.7 - -
1.10.8 - -
1.10.9 - -
1.10.10 - -
1.10.11 - -
1.10.12 - -
1.10.13 - -
1.10.14 - -
1.10.15 - -
1.10.16 - -
1.10.17 - -
Lot 2 Rev 5
Forms Part 1-135

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.1 Bush clearing
2.1.1 Clear the servitude according to specification 2 km - -
2.2 Foundations and excavations
Note: Supply materials and construct the foundations for the following structures: Actual soil
types and foundation designs will be determined by the contractor during construction. The
types indicated below are only estimates
2.2.1 Intermediate Steel Monopole 33kV: Soil Type 2 1 each - -
2.2.4 Intermediate Steel Monopole 33kV: Soil Type Rock 6 each - -
2.2.5 Strain Steel Monopole 33kV angle 0-30 degree: Type 2 0 each - Rate only
2.2.8 Strain Steel Monopole 33kV angle 0-30 degree: Type Rock 0 each - Rate only
2.2.9 Strain Steel Monopole 33kV angle 30-60deg: Type 3 0 each - Rate only
2.2.11 Strain Steel Monopole 33kV angle 30-60deg: Type Rock 1 each - -
2.2.13 Strain Steel Monopole 33kV angle 60-90deg: Type 4 1 each - -
2.3.1 Install intermediate Steel Monopole 33kV (10m CAH, wind span 250m, Weight span 450m) 2 each - -
2.3.3 Install 60⁰ Strain Steel Monopole 33kV (12m CAH, wind span 250m, Weight span 450m) 1 each - -
2.4 Steel Monopole hardware strain assembly - -
Install all the material as per drawing 111233-000-DRG-CE-DE-0001 for a phase conductor
2.4.1 36 each - -
strain assembly
Install all the material as per drawing 111233-000-DRG-CE-DE-0003 for a phase conductor
2.4.2 18 each - -
Install all the material as per drawing 111233-000-DRG-CE-DE-0005 for a shield wire strain
2.4.3 6 each - -
assembly
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Install all the material as per drawing 111233-000-DRG-CE-DE0002 for a phase conductor
2.5.1 54 each - -
Install all the material as per drawing 111233-000-DRG-CE-DE-0004 for a shield wire
2.5.2 9 each - -
2.6.1 Install ACSR Bear Conductor, 14,000 meter - -
2.6.2 Install 24 core OPGW equal to a 19/2.64 shield wire 2,310 meter - -
2.6.3 Install Bear midspan joints 8 each - -
2.6.4 Install 24 core OPGW joint boxes with a slack reel complete with all hardware. 2 each - -
Install Bear repair sleeves 8
Install foundation earth as per AUR-OHL-EAR-MP-001
2.7.1 14 each - -
Install additional earths per AUR-OHL-EAR-MP-001
2.7.2 14 each - -
Install substation bonding
2.7.3 100 meter - -
This includes the 50x3mm Cu strap as well as all the clamps/welding required
Supply and install conductive cement
2.7.4 14 each - -
This rate will make provision for 0.25x0.25x15m material around the entire counterpoise
Install all material for a distribution surge arrestor installation. The unit rate must make
2.7.5 provision for surge arrestors, mounting brackets, earthing conductors and rods, clamps, 12 each - -
bonding leads and fixing materials per H-pole structure.
2.8 Labelling
2.8.1 Install of circuit designation labels 28 each - -
2.8.2 Install Phase Identification Disk - Set 4 each - -
Road/Rail Crossings, Install of temporary stays and structures. Including costs of traffic
2.8.3 3 each - -
Lot 2 Rev 5
Forms Part 1-137

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.9.1 Excavate hole, install 14m 225mm pole top wooden pole, backfill and compact 8 each - -
Install al material as per drawing GH9727 for a H-pole terminal structure. The unit rate must
2.9.3 Install al material as per drawing ZAM-GEN-DE-G-12831 for a complete stay. 8 each - -
2.10.1 Supply 19/33kV 500mm² 1C AWA Cu XLPE cable with clamps fevery 300mm. 13,200 m - -
2.10.2 Supply joint kit for 19/33kV 500mm² 1C AWA Cu XLPE cable 44 each - -
2.10.3 Supply outdoor cable termination for a 19/33kV 500mm² 1C AWA Cu XLPE cable. 24 each - -
2.10.4 Supply 450mm (200micron) danger tape 2,000 m - -
2.10.5 Drill underneath tarred road, Install 3 x 160mm sleeves per crossing 720 m - -
2.10.6 Install 900 x 300 x 65 mm cable concrete protection slab 200 each - -
2.10.7 Install 100-250mm water pipe repair(joints and 1m pipe if required) 20 each - -
2.10.8 Install 250-400mm water pipe repair(joints and 1m pipe if required) 20 each - -
2.10.9 Install LV cable repair(joints and 1m cable if required) 40 each - -
2.10.10 Install MV cable repair(joints and 1m cable if required) 40 each - -
2.10.11 Install MV/LV heat shrinkable zip-sleeve repair 40 each - -
2.10.12 Install TYPE A concrete cable route markers 100 each - -
Install cable support structures. The unit rate must make provision for all, clamps, protective
2.10.13 8 each - -
pipes, support chanels where required, all fixing material for all cable teminations.
2.10.14 Remove redundant 33kV cable, roll up and deliver to the ZESCO farm. 1 lot - -
2.10.15 Excavate, backfill and compact trench in: Dense soil (Per hand) 650 m³ - -
2.10.16 Excavate, backfill and compact trench in: Soft Rock (Mechanical) 200 m³ - -
2.10.17 Excavate, backfill and compact trench in: Hard rock (Drill and blast) 150 m³ - -
2.10.18 Trench cross cut 20 each - -
2.10.19 Survey proposed cable route by means of a non-invasive cable detection system 1,000 m - -
2.10.20 Cut and reinstate tarred surfaces to previous level of finish 50 m² - -
2.10.21 Remove and reinstate paving to previous level of finish 175 m² - -
2.10.22 Cut and reinstate concrete surface to previous level of finish 175 m² - -
2.10.23 Supply and install bedding/blanket material from a commercial source 54 m³ - -
2.10.24 Supply and install backfill material from a commercial source 350 m³ - -
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.10.25 Remove rubble from site to a licensed facility 350 m³ - -
2.10.26 Supply and install material for manholes at tarred road crossings per specification 10 each - -
3.1 33kV Equipment
3.1.1 Install 33kV line Isolator with Earth Switch 3 each
3.1.2 Install 33kV busbar Isolator 3 each
3.1.3 Install 33kV feeder Current Transformer 9 each
3.1.4 Install 33kV Feeder Circuit Breaker 3 each
3.1.5 Install 33kV/110V 1Ph voltage transformer 9 each
3.1.6 Install 33kV station class surge arrester 9 each
3.1.7 Install 33kV post insulators 27 each
3.2 33kV Yard - Small Materials for three line bays
3.2.1 Install clamps and fittings (busbars, stringers, cable terminations and portable earths) 1 lot
3.2.2 Install miscellaneous material and consumables not specifically mentioned 1 lot
3.2.3 Install Centipede conductor 300 m
3.2.4 Install Hornet conductor(VT & SA) 30 m
3.2.5 Install 50mm x 3mm flat copper for earth tails 180 m
3.2.6 Install 10mm copper rod for main earth grid 660 m
3.2.7 Install main earth bonding (Cadweld) 1 lot
3.2.8 Install portable earths 95mm² stranded conductor with UV stable PVC covering 3 each
3.2.9 Install all equipment labels and safety signs and fixing equipment for new line bays 1 lot
3.3.1 Install 33kV busbar isolator support 3 each
3.3.2 Install 33kV line isolator support with earth switch 3 each
3.3.3 Install 33kV circuit breakers support 3 each
3.3.4 Install 33kV current transformer support 3 each
3.3.5 Install 33kV combination cable termination, voltage transformer and surge arrestor 3 each
3.4.1 Protection
Install equipment and material to integrate the existing protection panels with the new line
3.4.1.1 1 lot
bay equipment
Lot 2 Rev 5
Forms Part 1-139

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Install all equipment and material necessary to integrate the new feeder bay equipment and
3.4.2.1 1 lot
existing protection and control panels into the existing SCADA and telecommunication
3.4.3 Other
3.4.3.1 Install equipment to integrate the new equipment into the existing AC/DC distribution panel 1 lot
3.4.3.2 Install 33kV Tariff meters on both ends of the line 2 each
3.4.3.3 Install CT Junction boxes with terminals 1 lot
3.4.3.4 Install VT Junction boxes with terminals 1 lot
Install all secondary cabling for a comprehensive installation. This includes but is not limited
3.4.3.5 to multicore control, fibres and small power cables complete with terminations (Ferrule, cable 1 lot
Re-routing of existing cables
3.4.3.6 Install 185mm² 6.35/11kV 3C XLPE Cu SWA cable 300 m
3.4.3.7 Install joint for 185mm² 6.35/11kV 3C XLPE Cu SWA cable 5 each
3.4.3.8 Expose and re-route 185mm² 6.35/11kV 3C XLPE Cu SWA cable by hand to new trench 600 m
Excavate, backfill and compact trench in:
3.4.3.9 Dense soil (Per hand) 263 m³
3.4.3.10 Soft Rock (Mechanical) 81 m³
3.4.3.11 Hard rock (Drill and blast) 61 m³
3.4.3.12 Install Type A concrete cable route markers 10 each
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Dismantle the two existing 33kV overhead single circuit lines from Coventry to Kafue
3.5
substation
The unit rate must make provision for both lines.
This will include disconnecting/removing/coiling of phase and shield wire conductors,
3.5.1 removal and crating of hardware and supports, removal and crating of insulators, dismantling 2,200 m - -
of structures and/or poles, remove foundations where applicable, disconnecting and removal
of redudnant cabling and terminations, backfilling and compacting holes as well as
Total Installation Services (Carried forward to Schedule No 5 Grand Summary) 50,000.00 -
Name of Bidder -
Lot 2 Rev 5
Section IV Bidding Forms Part 1-141
___________________________________________________________________________________________________________________________________________________
CURRENCY 12: N/A CURRENCY 22: N/A

ITEM DESCRIPTION
(1) x (2) (1) x (3)
1 Total Schedule No. 1. Plant, and Mandatory Spare Parts Supplied from Abroad - -
Total Schedule No. 2. Plant, and Mandatory Spare Parts Supplied from Within the
2 - -
Employer’s Country
3 Total Schedule No. 3. Design Services - -
4 Total Schedule No. 4. Installation and Other Services 50,000.00 -
Total (to Bid Form) 50,000.00 -
Name of Bidder -
Lot 2 Rev 5
___________________________________________________________________________________________________________________________________________________
2) Sales and other taxes payable by the Employer per line item if Contract is awarded (Sales and other taxes imposed in the employers country and payable by the employer per line item)
2 2
QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1 Task 1: 33kV OHL and cable feeders from Coventry Substation to Kafue Substation - -
1.1 Conductor
1.1.1 Bear conductor 1,000 m - -
1.2 Insulator sets - -
1.2.1 Complete strain insulator sets with all required hardware included 5 each - -
1.2.2 Complete intermediate post insulator sets 5 each - -
1.3 Line Hardware - -
1.3.1 Bear Dead ends 10 each - -
1.3.2 Bear Midspan joints 5 each - -
2 Task 2: 33kV feeder bays at Coventry Substation and Kafue Substation - -
2.2 Tools/accessories for 33kV equipment (Bidder to list) 1 lot - -
2.3 33kV circuit breaker spares for three bays
2.3.1 Set of contacts 1 lot - -
2.3.2 Set of gaskets 1 lot - -
2.3.3 Breaking chamber insulator 1 each - -
2.3.4 Support insulator 1 each - -
2.3.5 Spring charge motor 1 each - -
2.3.6 Close coil 1 each - -
2.3.7 Trip coil 1 each - -
2.3.8 Breaker control switch 1 each - -
2.3.9 Local control switch 1 each - -
Lot 2 Rev 5
Forms Part 1-143

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.4 33kV Isolator Spares for three bays
2.4.1 Set of main live parts for main blades (1 set 3pht) 1 lot
2.5 33kV Current transformers for three bays
2.5.1 One set for incomers 1 lot
Total Spare Parts - -
Name of Bidder
Signature of Bidder
Lot 2 Rev 5


LOT 3 - Industrial – Matero 33kV Corridor Upgrade

Section___________________________________________________________________________________________________________________________________________________
IV Bidding Forms Part 1-147
LTDRPP4

Lot 3: Matero 33kV Network Upgrade
Task 1 - OHL from Industrial Substation to Mungwi Substation
Task 2: OHL from Mungwi Substation to Liverpool Substation
Task 3: OHL from Liverpool Substation to Matero Substation
Task 4 –33kV feeder bay Matero Substation
Name of Bidder
Lot 3 Rev 5
____________________________________________________________________________________________________________________________________________
page of Volume 1.
Lot 1 Rev 5
Section IV Bidding Forms
___________________________________________________________________________________________________________________________________________________ Part 1-149

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1 Task 1 - OHL from Industrial Substation to Mungwi Substation
1.2 Triple circuit steel monopole
1.3.1 246 each -
strain assembly
1.3.2 123 each -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Supply all the material as per drawing 111233-000-DRG-CE-DE-0005 for a shield wire strain
1.3.3 34 each - -
assembly
1.4.1 192 each -
Supply all the material as per drawing 111233-000-DRG-CE-DE-0004 for a shield wire
1.4.2 25 each - -
1.5.2 Supply 19/2.64 Shield wire 9,440 meter - -
1.5.4 Supply Joint for 19/2.64 Shield wire 2 each - -
1.6.1 42 each - -
Supply additional earth s per AUR-OHL-EAR-MP-001
1.6.2 42 each - -
1.6.3 100 meter - -
This includes the 30x3mm Cu strap as well as all the clamps required
1.7 Labelling
1.7.2 Supply Phase Identification Disk - Set 4 each - -
1.7.3 3 each - -
1.8.1 Supply 14m 225mm pole top wooden pole 22 each
1.8.2 make provision for the strain cross arm, three phase-conductor strains and all fixing material. 6 each
Supply al material as per drawing GH9728 for a H-pole strain structure. The unit rate must make
1.8.3 provision for the strain cross arm, three phase-conductor strains and all fixing material. Poles 3 each
and stays measured elsewhere
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-151

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Supply al material as per drawing GH9729 for a H-pole intermediate structure. The unit rate
1.8.4 must make provision for the strain cross arm, three phase-conductor strains and all fixing 2 each
material. Poles and stays measured elsewhere
1.8.5 Supply al material as per drawing ZAM-GEN-DE-G-12831 for a complete stay. 24 each
1.8.6 Supply of circuit designation labels 11 each
1.9.1 Supply 19/33kV 400mm² 1C AWA Cu XLPE cable. 1800 m
1.9.2 Supply outdoor cable termination for a 19/33kV 400mm² 1C AWA Cu XLPE cable. 33 each
1.9.3 Supply indoor cable termination for a 19/33kV 400mm² 1C AWA Cu XLPE cable. 3 each
1.9.4 6 each
pipes, four support chanels per H-pole, all fixing material for all cable teminations.
1.9.5 Supply cable joint for a 19/33kV 400mm² 1C AWA Cu XLPE cable. 3 each
1.9.6 provision for surge arrestors, mounting brackets, earthing conductors and rods, clamps, bonding 6 each
leads and fixing materials per H-pole structure.
1.9.7 Supply 200mm x 6m sleeves for MV cable entry onto platform. 12 each
2 Task 2: OHL from Mungwi Substation to Liverpool Substation

2.2.1 108 each -
strain assembly
2.2.2 54 each -
2.2.3 Supply all the material as per drawing 111233-000-DRG-CE-DE0005 for a shield wire strain 18 each - -
2.3.1 90 each -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Supply all the material as per drawing 111233-000-DRG-CE-DE0004 for a shield wire
2.3.2 15 each - -
2.5.1 24 each - -
2.5.2 24 each - -
2.5.3 100 meter - -
2.6 Labelling
-
2.6.2 Supply phase Identification Disk - Set 4 each - -
2.6.3 3 each - -
Supply al material as per drawing GH9728 for a H-pole strain structure. The unit rate must make
2.7.3 provision for the strain cross arm, three phase-conductor strains and all fixing material. Poles 1 each
and stays measured elsewhere
2.8.3 3 each
pipes, four support chanels per H-pole, all fixing material per structure.
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-153

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
leads and fixing materials per structure.
2.8.6 Supply 200mm x 6m sleeves for MV cable entry onto platform 9 each
3 Task 3: OHL from Liverpool Substation to Matero Substation

3.2.1 168 each
strain assembly
3.2.2 84 each
Supply all the material as per drawing 111233-000-DRG-CE-DE0005 for a shield wire strain
3.2.3 28 each - -
assembly
3.3.1 84 each
Supply all the material as per drawing 111233-000-DRG-CE-DE0004 for a shield wire
3.3.2 14 each - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
3.5.1 28 each - -
3.5.2 28 each - -
3.5.3 100 meter - -
3.6 Labelling
3.6.2 Supply phase Identification Disk - Set 4 each - -
3.6.3 3 each - -
3.8.3 3 each
leads and fixing materials per structure.
3.8.6 Supply 200mm x 6m sleeves for MV cable entry onto platform 9 each
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-155

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
4 Task 4 –33kV feeder bay Matero Substation
4.1 33kV Equipment
4.1.1 Supply 33kV line Isolator with Earth Switch 1 each - -
4.1.2 Supply 33kV busbar Isolator 1 each - -
4.1.3 Supply 33kV feeder Current Transformer 3 each - -
4.1.4 Supply 33kV Feeder Circuit Breaker 1 each - -
4.1.5 Supply 33kV/110V 1Ph voltage transformer 3 each - -
4.1.6 Supply 33kV station class surge arrester 3 each - -
4.1.7 Supply 33kV post insulators 9 each - -
4.2 33kV Yard - Small Materials
4.2.1 Supply clamps and fittings (busbars, stringers, cable terminations and portable earths) 1 lot - -
4.2.2 Supply miscellaneous material and consumables not specifically mentioned 1 lot - -
4.2.3 Supply 80mm diameter 6mm thick aluminium tube 12m for busbar & cable termination 3 each - -
4.2.4 Supply centipede conductor (line and damper) 100 m - -
4.2.5 Supply hornet conductor(VT & SA) 6 m - -
4.2.6 Supply 50mm x 3mm flat copper for earth tails 60 m - -
4.2.7 Supply 10mm copper rod for main earth grid 120 m - -
4.2.8 Supply main earth bonding (Cadweld) 1 lot - -
4.2.9 Supply portable earths 95mm² stranded conductor with UV stable PVC covering 3 each - -
4.2.10 Supply all equipment labels and safety signs and fixing equipment for entire substation 1 lot - -
4.2.11 Supply light fittings as well as cable for new and existing lighting mast 1 lot - -
Supply all material (light fittings, wiring etc) to upgrade indoor and outdoor lighting to
4.2.12 1 lot - -
specification
Supply all equipment to provide automatic indoor CO 2 flooding systen for entire existing
4.2.13 1 lot
building
4.2.14 Supply railway track for sacraficial earth 1.5 m
Supply all materials to bond all roofing sheets and connect corners to the eartmat as per
4.2.15 1 lot
specification
4.2.16 Supply all materials to ensure the building is water and dust tight as per specification. 1 lot
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
4.3.1 Supply 14m sectional lightning mast 1 each - -
4.3.2 Supply 33kV busbar isolator support 1 each - -
4.3.3 Supply 33kV line isolator support with earth switch 1 each - -
4.3.4 Supply 33kV combination circuit breakers and current transformers 1 each - -
4.3.5 Supply 33kV combination cable termination, voltage transformer and surge arrestor 1 each - -
4.3.6 Supply 33kV busbar Support 1 each - -
4.4.1 Protection
4.4.1.1 Supply 33kV OHL protection panel 1 each - -
4.4.1.2 Supply equipment to integrate the new panels into the existing 33kV busbar protection panel 1 lot - -
Supply all equipment necessary to integrate the new feeder bay protection and control panels
4.4.2.1 1 lot - -
into the existing SCADA and telecommunication systems.
4.4.3 Other
Supply 33kV meter and intergrate into panel (add the communication module and ethernet
4.4.3.1 1 lot - -
switch)
4.4.3.2 Supply equipment to integrate the new protection panels into the existing AC/DC distribution 1 lot - -
4.4.3.3 Supply CT Junction boxes with terminals 1 lot - -
4.4.3.4 Supply VT Junction boxes with terminals 1 lot - -
Supply all secondary cabling for a comprehensive installation. This includes but is not limited to
4.4.3.5 multicore control, fibres and small power cables complete with terminations (Ferrule, cable 1 lot - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-157

1 QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
5 Additional items
5.1 - -
5.2 - -
5.3 - -
5.4 - -
5.5 - -
5.6 - -
5.7 - -
5.8 - -
5.9 - -
5.10 - -
Total Plant and Mandatory Spare Parts Schedule 1 (Carried forward to Schedule No 5 Grand Summary) - -
Name of Bidder
Signature of Bidder
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
- -
Summary)
Name of Bidder
Signature of Bidder
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-159

2 2
QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
4.1 Equipment support structure design 1 lot - -
4.2 Protection design 1 lot - -
4.4 Earthing design 1 lot - -
4.5 Lightning design 1 lot - -
4.6 Lighting design 1 lot - -
Total Design Services (Carried forward to Schedule No 5 Grand Summary) - -
Name of Bidder -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-161


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1 ALL TASKS
1.1 Preliminary and General

1.1.1 Contractual Requirements 1 lot - -
1.1.2 1 lot - -
1.1.3 1 lot - -
1.1.4 Removal of all site facilities after completion of the project 1 lot - -
1.2 Other Fixed Charge Additional Items (Specify)
1.2.1 - -
1.2.2 - -
1.2.3 - -
1.2.4 - -
1.2.5 - -
1.2.6 - -
1.2.7 - -
1.2.8 - -
1.2.9 - -
1.2.10 - -
1.3 Time Related items
1.3.1 Contractual requirements 12 month - -
1.3.2 Operating and maintenance of site facilities 12 month - -
1.3.3 Supervision and co-ordination of sub-contractors 12 month - -
1.3.4 Company costs and overheads 12 month - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.4 Other Time Related Additional Items (Specify)
1.4.1 - -
1.4.2 - -
1.4.3 - -
1.4.4 - -
1.4.5 - -
1.4.6 - -
1.4.7 - -
1.4.8 - -
1.4.9 - -
1.4.10 - -
1.5 Security
1.5.1 24 Hour security for the duration of the project 12 month - -
1.6 Permits and Notices
1.6.1 - Giving of notices to any other authority or institute involved. 1 lot - -
the project.
1.7 Labour Act Requirements
1.7.1 Allow for compliance with the requirements of the Construction Regulations 1 lot - -
1.7.2 Health and Safety Compliance 1 lot - -
1.8 Drawings
Allow for marking-up a full set of drawings to show the exact positions of cables, cable joints,
road crossings etc. These "As Built" drawings must be handed to the engineer at
1.8.1 1 lot - -
1.9 Specialised Services
1.9.1 1 lot 50,000.00 50,000.00 -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-163


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1.10 Additional Items
Allow for attendance to all factory inspections and acceptance tests outside Zambia, such as
1.10.1 1 lot - -
travel expenses, accommodation and per diem. (give a detailed breakdown)
Geotechnical Studies (Professional registered Geotechnical Engineer for soil Type
1.10.2 1 lot - -
nominations)
1.10.3 Compliance with local occupational health and safety requirements 1 lot - -
1.10.4 Compliance with local environmental management requirements 1 lot - -
1.10.5 EIA 1 lot - -
1.10.6 Survey 1 lot - -
Note: Any additional item(s), not shown in the schedules, which the tenderer consider
essential and wish to detail and price. (Provide full details)
1.10.7 - -
1.10.8 - -
1.10.9 - -
1.10.10 - -
1.10.11 - -
1.10.12 - -
1.10.13 - -
1.10.14 - -
1.10.15 - -
1.10.16 - -
1.10.17 - -

2.1 Bush clearing
2.1.1 Clear the servitude according to specification 3.6 km - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.2.5 Strain Steel Monopole 33kV angle 0-30 degree: Type 2 1 each - -
2.2.8 Strain Steel Monopole 33kV angle 0-30 degree: Type Rock 6 each - -
2.3.9 Install 90⁰ Strain Steel Monopole 33kV (14m CAH, wind span 250m, Weight span 450m) 0 each
2.4 Triple circuit steel monopole
2.4.9 Install 90⁰ Strain Steel Monopole 33kV (14m CAH, wind span 250m, Weight span 450m) 1 each
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-165


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.5.1 246 each
strain assembly
2.5.2 123 each
Install all the material as per drawing 111233-000-DRG-CE-DE0005 for a shield wire strain
2.5.3 34 each - -
assembly
2.6.1 192 each
Install all the material as per drawing 111233-000-DRG-CE-DE0004 for a shield wire
2.6.2 25 each - -
2.7.2 Install 19/2.64 Shield wire 9,440 meter - -
2.7.4 Install Joint for 19/2.64 Shield wire 2 each - -
2.8.1 42 each - -
Install additional earth s per AUR-OHL-EAR-MP-001
2.8.2 42 each - -
2.8.3 100 meter - -
2.8.4 42 each - -
2.9 Labelling
2.9.2 Install phase Identification Disk - Set 4 each - -
2.9.3 3 each - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
2.10 Wooden pole structures - -
2.10.1 Install 14m 225mm pole top wooden pole 22 each - -
Supply al material as per drawing GH9728 for a H-pole strain structure. The unit rate must
Supply al material as per drawing GH9729 for a H-pole intermediate structure. The unit rate
2.10.4 must make provision for the strain cross arm, three phase-conductor strains and all fixing 2 each - -
material. Poles and stays measured elsewhere
2.11 Cable installation -
2.11.1 Install 19/33kV 500mm² 1C AWA Cu XLPE cable. 1800 m - -
2.11.2 Install outdoor cable termination for a 19/33kV 500mm² 1C AWA Cu XLPE cable. 33 each - -
2.11.3 Install indoor cable termination for a 19/33kV 500mm² 1C AWA Cu XLPE cable. 3 each - -
2.11.4 6 each - -
2.11.5 Install cable joint for a 19/33kV 500mm² 1C AWA Cu XLPE cable. 3 each - -
bonding leads and fixing materials per H-pole structure.
2.11.7 Install 200mm x 6m sleeves for MV cable entry onto platform 12 each - -
Dismantle the existing 33kV overhead line from Liverpool Substation up to Mungwi
2.12 - -
Substation.
removal and crating of hardware and supports, removal and crating of insulators, dismantling
of structures and/or poles, remove foundations where applicable, disconnecting and removal 4.2 km - -
transporting of all material ZESCO Farm
3.1 Bush clearing
3.1.1 Clear the servitude according to specification 4.2 km - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-167


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
3.4.1 108 each
strain assembly
3.4.2 54 each
3.4.3 18 each - -
assembly
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
3.5.1 90 each
3.5.2 15 each - -
3.7.1 24 each - -
3.7.2 24 each - -
3.7.3 100 meter - -
3.7.4 24 each - -
3.8 Labelling
3.8.2 Install pPhase Identification Disk - Set 4 each - -
3.8.3 3 each - -
Supply al material as per drawing GH9728 for a H-pole strain structure. The unit rate must
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-169


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
3.10 Cable installation - -
3.10.3 3 each - -
bonding leads and fixing materials for all cable terminations.
Dismantle the existing Lusaka West Substation to Liverpool Substation 33kV overhead
3.11 - -
line from Liverpool Substation up to Mungwi Substation.
of structures and/or poles, remove foundations where applicable, disconnecting and removal 4.2 km - -
transporting of all material ZESCO Farm

4.1 Bush clearing
4.1.1 Clear the servitude according to specification 4 km - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
4.4.1 168 each
strain assembly
4.4.2 84 each
4.4.3 28 each - -
assembly
4.5.1 84 each
4.5.2 14 each - -

4.7.1 28 each - -

4.7.2 28 each - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-171


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
4.7.3 100 meter - -
4.7.4 28 each - -
4.8 Labelling
4.8.2 Install pPhase Identification Disk - Set 4 each - -
4.8.3 3 each - -
4.10 Cable installation - -
4.10.3 3 each - -
bonding leads and fixing materials for all cable terminations.
Dismantle the existing 33kV overhead line from Liverpool Substation up to Matero
4.11 - -
Substation.
4 km - -
of structures and/or poles, remove foundations where applicable, disconnecting and removal
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
5 Task 4 –33kV feeder bay Matero Substation - -
5.1 Bush clearing
5.1.1 Remove all weeds from platform and dispose at licenced facility 1 lot - -
5.2 33kV Yard - Supply and install all material for foundations including foundation bolts
5.2.1 14m Sectional lightning mast 1 each - -
5.2.2 33kV Busbar isolator support 1 each - -
5.2.3 33kV Line isolator support with earth switch 1 each - -
5.2.4 33kV Combination circuit breakers and current transformers 1 each - -
5.2.5 33kV Combination cable termination, voltage transformer and surge arrestor 1 each - -
5.2.6 33kV Busbar Support 1 each - -
5.2.7 Remove, set aside and reinstate existing yardstone 1 lot - -
5.2.8 Supply and install all required material for new control cable trench to match existing 37 m - -
5.3 33kV Equipment
5.3.1 Install 33kV line Isolator with Earth Switch 1 each - -
5.3.2 Install 33kV busbar Isolator 1 each - -
5.3.3 Install 33kV feeder Current Transformer 3 each - -
5.3.4 Install 33kV Feeder Circuit Breaker 1 each - -
5.3.5 Install 33kV/110V 1Ph voltage transformer 3 each - -
5.3.6 Install 33kV station class surge arrester 3 each - -
5.3.7 Install 33kV post insulators 9 each - -
5.4 33kV Yard - Small Materials
5.4.1 Install clamps and fittings (busbars, stringers, cable terminations and portable earths) 1 lot - -
5.4.2 Install miscellaneous material and consumables not specifically mentioned 1 lot - -
5.4.3 Install 80mm diameter 6mm thick aluminium tube 12m for busbar & cable termination 3 each - -
5.4.4 Install centipede conductor (line and damper) 100 m - -
5.4.5 Install hornet conductor(VT & SA) 6 m - -
5.4.6 Install 50mm x 3mm flat copper for earth tails 60 m - -
5.4.7 Install 10mm copper rod for main earth grid 120 m - -
5.4.8 Install main earth bonding (Cadweld) 1 lot - -
5.4.9 Install portable earths 95mm² stranded conductor with UV stable PVC covering 3 each - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-173


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
5.4.10 Install all equipment labels and safety signs and fixing equipment for entire substation 1 lot - -
5.4.11 Install light fittings as well as cable for new and existing lighting mast 1 lot - -
Install all material (light fittings, wiring etc) to upgrade indoor and outdoor lighting to
5.4.12 1 lot - -
specification
Install all equipment to provide automatic indoor CO2 flooding systen for entire existing
5.4.13 1 lot - -
building
5.4.14 Install railway track for sacraficial earth and connect to earthmat 1.5 m - -
Install all materials to bond all roofing sheets and connect corners to the eartmat as per
5.4.15 1 lot - -
specification
5.4.16 Install all materials to ensure the building is water and dust tight as per specification. 1 lot - -
5.5.1 Install 14m sectional lightning mast 1 each - -
5.5.2 Install 33kV busbar isolator support 1 each - -
5.5.3 Install 33kV line isolator support with earth switch 1 each - -
5.5.4 Install 33kV combination circuit breakers and current transformers 1 each - -
5.5.5 Install 33kV combination cable termination, voltage transformer and surge arrestor 1 each - -
5.5.6 Install 33kV busbar Support 1 each - -
5.5.7 Remove gantry column and beam of the unused Roma feeder and deliver to the ZESCO farm 1 lot - -
5.6.1 Protection
5.6.1.1 Install 33kV OHL protection panel 1 each - -
5.6.1.2 Install equipment to integrate the new panels into the existing 33kV busbar protection panel 1 lot - -
5.6.2 SCADA and Telecommunications - -
Install all equipment necessary to integrate the new feeder bay protection and control panels
5.6.2.1 1 lot - -
into the existing SCADA and telecommunication systems.
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________


QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
5.6.3 Other
5.6.3.1 Install 33kV meters to be installed into exisisting panel 1 lot - -
Install equipment to integrate the new protection panels into the existing AC/DC distribution
5.6.3.2 1 lot - -
panel
5.6.3.3 Install CT Junction boxes with terminals 1 lot - -
5.6.3.4 Install VT Junction boxes with terminals 1 lot - -
Install all secondary cabling for a comprehensive installation. This includes but is not limited
5.6.3.5 to multicore control, fibres and small power cables complete with terminations (Ferrule, cable 1 lot - -
Total Installation Services (Carried forward to Schedule No 5 Grand Summary) 50,000.00 -
Name of Bidder -
Lot 3 Rev 5
Section IV Bidding Forms Part 1-175
___________________________________________________________________________________________________________________________________________________

ITEM DESCRIPTION
(1) x (2) (1) x (3)
1 Total Schedule No. 1. Plant, and Mandatory Spare Parts Supplied from Abroad - -
Total Schedule No. 2. Plant, and Mandatory Spare Parts Supplied from Within the
2 - -
Employer’s Country
3 Total Schedule No. 3. Design Services - -
4 Total Schedule No. 4. Installation and Other Services 50,000.00 -
Total (to Bid Form) 50,000.00 -
Name of Bidder -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________
2) Sales and other taxes payable by the Employer per line item if Contract is awarded (Sales and other taxes imposed in the employers country and payable by the employer per line item)
2 2
QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
1 Task 1 - OHL from Industrial Substation to Mungwi Substation - -
1.1 Conductor
1.1.1 Panther conductor 1,000 m - -
1.3.1 Panther Dead ends 10 each - -
1.3.2 Panther Midspan joints 5 each - -
2 Task 2: OHL from Mungwi Substation to Liverpool Substation - -
2.1 Conductor
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________ Part 1-177

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
3 Task 3: OHL from Liverpool Substation to Matero Substation - -
3.1 Conductor
4 Task 4 –33kV feeder bay Matero Substation - -
4.2 Tools/accessories for 11kV switchboard and 33kV equipment (Bidder to list) 1 lot - -
4.3 33kV circuit breaker spares
4.3.1 Set of contacts 1 lot - -
4.3.2 Set of gaskets 1 lot - -
4.3.3 Breaking chamber insulator 1 each - -
4.3.4 Support insulator 1 each - -
4.3.5 Spring charge motor 1 each - -
4.3.6 Close coil 1 each - -
4.3.7 Trip coil 1 each - -
4.3.8 Breaker control switch 1 each - -
4.3.9 Local control switch 1 each - -
Lot 3 Rev 5
___________________________________________________________________________________________________________________________________________________

QTY
(1) CIP CIP
[(1) x (2)] [(1) x (3)]
(CIP) (CIP)
(2) (3)
4.4 33kV Isolator Spares
4.4.1 Set of main live parts for main blades (1 set 3pht) 1 lot
4.5 33kV Current transformers
4.5.1 One set for incomers 1 lot
Total Spare Parts - -
Name of Bidder
Signature of Bidder
Lot 3 Rev 5
Price Adjustment
Under this form, the prices are to remain firm and fixed for the duration of the Contract.
Price Adjustment is not applicable.
Technical Proposal
- Site Organization
- Method Statement
- Mobilization Schedule
- Construction Schedule
- Plant
- Contractor’s Equipment
- Personnel
- Proposed Subcontractors for Major Items of Plant and Installation Services
- Others
Site Organization
Method Statement
Mobilization Schedule
Construction Schedule
Plant
Contractor’s Equipment
Form EQU
The Bidder shall provide adequate information to demonstrate clearly that it has the capability
to meet the requirements for the key Contractor’s equipment listed in Section III, Evaluation
and Qualification Criteria. A separate Form shall be prepared for each item of equipment listed,
or for alternative equipment proposed by the Bidder.
Item of equipment
Equipment Name of manufacturer Model and power rating

information
Capacity Year of manufacture
Current status Current location
Details of current commitments
Source Indicate source of the equipment

 Owned  Rented  Leased  Specially manufactured
Omit the following information for equipment owned by the Bidder.
Owner Name of owner

Address of owner
Telephone Contact name and title

Fax Telex
Agreements Details of rental / lease / manufacture agreements specific to the project
Form FUNC
The Bidder shall copy in the left column of the table below, the identification of each
functional guarantee required in the Specification and stated by the Employer in para. 1.2 (c) of
Section III. Evaluation and Qualification Criteria, and in the right column, provide the
corresponding value for each functional guarantee of the proposed plant and equipment.
Required Functional Guarantee Value of Functional Guarantee of the

Proposed Plant and Equipment
1. Maximum Transformer No Load
Losses (kW)
2. Maximum Transformer Full Load
Losses at nominal tap (ONAF) (kW)
3. Minimum Transformer Efficiency (%)
Personnel
Form PER -1
Proposed Personnel
Bidders should provide the names of suitably qualified personnel to meet the specified
requirements stated in Section III. The data on their experience should be supplied using the
Form below for each candidate.
1. Title of position*
Name
Name
Name
Name
*As listed in Section III.

Form PER-2
Resume of Proposed Personnel

Name of Bidder
Position
Personnel Name Date of birth

information
Professional qualifications
Present Name of employer

employment
Address of employer
Telephone Contact (manager / personnel officer)
Fax E-mail
Job title Years with present employer
Summarize professional experience over the last 20 years, in reverse chronological order.
Indicate particular technical and managerial experience relevant to the project.
From To Company / Project / Position / Relevant technical and management experience

Proposed Subcontractors for Major Items of Plant and

Installation Services
A list of major items of Plant and Installation Services is provided below.
The following Subcontractors and/or manufacturers are proposed for carrying out the item of
the facilities indicated. Bidders are free to propose more than one for each item
Major Items of Plant and Proposed Subcontractors/Manufacturers Nationality

Installation Services
Others - Time Schedule

Not Applicable.
Form ELI 1.1
Bidder Information Sheet
Date: ______________________
ICB No.: ___________________
Invitation for Bid No.: ________
Page ________ of _______ pages
1. Bidder’s Legal Name
2. In case of JVA, legal name of each party:
3. Bidder’s actual or intended Country of Registration:
4. Bidder’s Year of Registration:
5. Bidder’s Legal Address in Country of Registration:
6. Bidder’s Authorized Representative Information

Name:
Address:
Telephone/Fax numbers:
Email Address:
7. Attached are copies of original documents of:

 Articles of Incorporation or Registration of firm named in 1, above, in accordance with ITB
Sub-Clauses 4.1 and 4.2.
 In case of JVA, letter of intent to form JVA including a draft agreement, or JVA
agreement, in accordance with ITB Sub-Clauses 4.1 and 11.1(i) Single Stage Bidding or
11.1(g) Two Stage Bidding.
 In case of government owned entity from the Employer’s country, documents establishing
legal and financial autonomy and compliance with the principles of commercial law, in
accordance with ITB Sub-Clause 4.5.
Please note that a written authorization needs to be attached to this sheet as required by ITB
21.2 Single Stage Bidding) or ITB 17.2 Two Stage Bidding
Form ELI 1.2
Party to JVA Information Sheet
Date: ______________________
ICB No.: ___________________
Invitation for Bid No.:_________
Page ________ of_ ______ pages
1. Bidder’s Legal Name:
2. JVA’s Party legal name:
3. JVA’s Party Country of Registration:
4. JVA’s Party Year of Registration:
5. JVA’s Party Legal Address in Country of Registration:
6. JVA’s Party Authorized Representative Information

Name:
Address:
Telephone/Fax numbers:
Email Address:
7. Attached are copies of original documents of:

 Articles of Incorporation or Registration of firm named in 1, above, in accordance with
ITB Sub-Clauses 4.1 and 4.2.
 In case of government owned entity from the Purchaser’s country, documents establishing
legal and financial autonomy and compliance with the principles of commercial law, in
accordance with ITB Sub-Clause 4.5.
Form CON – 2
Historical Contract Non-Performance
In case a prequalification process was conducted this form should be used only if the
information submitted at the time of prequalification requires updating
Bidder’s Legal Name: _______________________ Date: _____________________
JVA Partner Legal Name: _______________________ ___________________
ICB No.: __________________
Page _______ of _______ pages
Non-Performing Contracts in accordance with Section III, Evaluation Criteria
 Contract non-performance did not occur during the stipulated period, in accordance with
Sub- Factor 2.2.1 of Section III, Evaluation Criteria
Pending Litigation, in accordance with Section III, Evaluation Criteria
 No pending litigation in accordance with Sub-Factor 2.2.2 of Section III, Evaluation Criteria
 Pending litigation in accordance with Sub-Factor 2.2.2 of Section III, Evaluation Criteria,
as indicated below
Year Outcome as Total Contract
Percent of Contract Identification Amount (current
Total Assets value, US$
equivalent)
Contract Identification:
______ ______ Name of Employer: ___________
Address of Employer:
Matter in dispute:
Contract Identification:
______ ______ Name of Employer: ___________
Address of Employer:
Matter in dispute:
Form CCC
Current Contract Commitments / Works in Progress
Bidders and each partner to a JVA should provide information on their current commitments
on all contracts that have been awarded, or for which a letter of intent or acceptance has been
received, or for contracts approaching completion, but for which an unqualified, full
completion certificate has yet to be issued.
Name of contract Employer, Value of Estimated Average

contact outstanding completion date monthly
address/tel/fax work (current invoicing over
US$ equivalent) last six months
(US$/month)
1.
2.
3.
4.
5.
etc.
Form FIN – 3.1

Financial Situation
Historical Financial Performance
Bidder’s Legal Name: _______________________ Date: _____________________

JVA Partner Legal Name: _______________________ ICB No.: __________________
Page _______ of _______ pages
To be completed by the Bidder and, if JVA, by each partner
Financial Historic information for previous ______ (__) years

information (US$ equivalent in 000s)
in US$
equivalent
Year 1 Year 2 Year 3 Year … Year n Avg. Avg.
Ratio
Information from Balance Sheet

Total Assets
(TA)
Total
Liabilities
(TL)
Net Worth
(NW)
Current
Assets (CA)
Current
Liabilities
(CL)
Information from Income Statement
Total
Revenue (TR)
Profits Before
Taxes (PBT)
 Attached are copies of financial statements (balance sheets, including all related notes,
and income statements) for the years required above complying with the following
conditions:
(a) Must reflect the financial situation of the Bidder or partner to a JVA, and not sister
or parent companies
(b) Historic financial statements must be audited by a certified accountant
(c) Historic financial statements must be complete, including all notes to the financial
statements
(d) Historic financial statements must correspond to accounting periods already
completed and audited (no statements for partial periods shall be requested or
accepted)
Form FIN – 3.2

Average Annual Turnover
Bidder’s Legal Name: ___________________________ Date: _____________________

JVA Partner Legal Name: ____________________________ ICB No.: __________________
Page _______ of _______ pages
Annual turnover data (construction only)

Year Amount and Currency US$ equivalent
_________________________________________ ____________________
_________________________________________ ____________________
_________________________________________ ____________________
_________________________________________ ____________________
_________________________________________ ____________________
*Average _________________________________________ ____________________
Annual
Construction
Turnover
*Average annual turnover calculated as total certified payments received for work in
progress or completed, divided by the number of years specified in Section III, Evaluation
Criteria, Sub-Factor 2.3.2.
Form FIN 3.3

Financial Resources
Specify proposed sources of financing, such as liquid assets, unencumbered real assets, lines of
credit, and other financial means, net of current commitments, available to meet the total
construction cash flow demands of the subject contract or contracts as indicated in Section III,
Evaluation and Qualification Criteria
Source of financing Amount (US$ equivalent)
1.
2.
3.
4.
Form EXP 2.4.1

Experience - General Experience
Bidder’s Legal Name: ____________________________ Date: _____________________

JVA Partner Legal Name: ____________________________ICB No.: __________________
Page _______ of _______ pages
Starting Ending
Contract Identification Role of
Month / Month /
Years Bidder
Year Year
*
Contract name:
______ ______ Brief Description of the Works performed by the _________
Bidder:
Name of Employer:
Address:
Contract name:
Bidder:
Name of Employer:
Address:
Contract name:
Bidder:
Name of Employer:
Address:
Contract name:
Bidder:
Name of Employer:
Address:
Contract name:
Bidder:
Name of Employer:
Address:
Contract name:
Bidder:
Name of Employer:
Address:
*List calendar year for years with contracts with at least nine (9) months activity per year
starting with the earliest year
Form EXP – 2.4.2(a)

Specific Experience

JVA Partner Legal Name: _________________________ ICB No.: __________________
Page _______ of _______ pages
Similar Contract Number: ___ of ___ Information

required.
Contract Identification _______________________________________
Award date _______________________________________
Completion date _______________________________________
Role in Contract
  
Contractor Management Subcontractor
Contractor
Total contract amount __________________________ US$_______

__ ___
If partner in a JVA or subcontractor,
specify participation of total contract
__________% _____________ US$_______
amount
Employer’s Name: _______________________________________
Address: _______________________________________
_______________________________________
Telephone/fax number: _______________________________________
E-mail: _______________________________________
Form EXP – 2.4.2(a) (cont.)

Specific Experience (cont.)
Bidder’s Legal Name: ___________________________ Page _______ of _______ pages

JVA Partner Legal Name: ___________________________
Similar Contract No. __[insert specific Information

number] of [total number of contracts]
___ required
Description of the similarity in
accordance with Sub-Factor 2.4.2a) of
Section III:
Amount _________________________________
Physical size _________________________________
Complexity _________________________________
Methods/Technology _________________________________
Physical Production Rate _________________________________

Form EXP – 2.4.2(b)

Specific Experience in Key Activities

JVA Partner Legal Name: _________________________ ICB No.: __________________
Subcontractor’s Legal Name: ______________ Page _______ of _______ pages
Information
Contract Identification _______________________________________
Award date _______________________________________
Completion date _______________________________________
Role in Contract
  
Contractor Management Subcontractor
Contractor
Total contract amount _________________________ US$________

If partner in a JVA or subcontractor,
specify participation of total contract
__________% _____________ US$________
amount
Employer’s Name: _______________________________________
Address: _______________________________________
_______________________________________
Telephone/fax number: _______________________________________
E-mail: _______________________________________
Form EXP – 2.4.2 (b)(cont.)

Specific Experience in Key Activities (cont.)
Bidder’s Legal Name: ___________________________ Page _______ of _______ pages

JVA Partner Legal Name: ___________________________
Subcontractor’s Legal Name: __________________________
Information
Description of the key activities in
accordance with Sub-Factor 2.4.2b) of
Section III:
_____________________________
[signature(s)]
Form of Bid Security

(Bank Guarantee)
[The bank shall fill in this Bank Guarantee Form in accordance with the instructions
indicated.]
[Guarantor letterhead or SWIFT identifier code]

Beneficiary: [Purchaser to insert its name and address]
IFB No.: [Purchaser to insert reference number for the Invitation for Bids]
Alternative No.: [Insert identification No if this is a Bid for an alternative]
Date: [Insert date of issue]
BID GUARANTEE No.: [Insert guarantee reference number]
Guarantor: [Insert name and address of place of issue, unless indicated in the letterhead]
We have been informed that ______ [insert name of the Bidder, which in the case of a joint
venture shall be the name of the joint venture (whether legally constituted or prospective) or
the names of all members thereof] (hereinafter called "the Applicant") has submitted or will
submit to the Beneficiary its bid (hereinafter called "the Bid") for the execution of
________________ under Invitation for Bids No. ___________ (“the IFB”).
Furthermore, we understand that, according to the Beneficiary’s conditions, bids must be
supported by a bid guarantee.
At the request of the Applicant, we, as Guarantor, hereby irrevocably undertake to pay the
Beneficiary any sum or sums not exceeding in total an amount of ___________
(____________) upon receipt by us of the Beneficiary’s complying demand, supported by
the Beneficiary’s statement, whether in the demand itself or a separate signed document
accompanying or identifying the demand, stating that either the Applicant:
(a) has withdrawn its Bid during the period of bid validity set forth in the Applicant’s
Letter of Bid (“the Bid Validity Period”), or any extension thereto provided by the
Applicant; or
(b) having been notified of the acceptance of its Bid by the Beneficiary during the Bid
Validity Period or any extension thereto provided by the Applicant, (i) has failed to
execute the contract agreement, or (ii) has failed to furnish the performance security, in
accordance with the Instructions to Bidders (“ITB”) of the Beneficiary’s bidding
document.
This guarantee will expire: (a) if the Applicant is the successful bidder, upon our receipt of
copies of the contract agreement signed by the Applicant and the performance security issued
to the Beneficiary in relation to such contract agreement; or (b) if the Applicant is not the
successful bidder, upon the earlier of (i) our receipt of a copy of the Beneficiary’s
notification to the Applicant of the results of the bidding process; or (ii) twenty-eight days
after the end of the Bid Validity Period.
Consequently, any demand for payment under this guarantee must be received by us at the
office indicated above on or before that date.
This guarantee is subject to the Uniform Rules for Demand Guarantees (URDG) 2010
Revision, ICC Publication No. 758.
_____________________________
[Signature(s)]
Note: All italicized text is for use in preparing this form and shall be deleted from the final
product.
Form of Bid Security (Bid Bond)

[The Surety shall fill in this Bid Bond Form in accordance with the instructions indicated.]
BOND NO. ______________________

BY THIS BOND [name of Bidder] as Principal (hereinafter called “the Principal”), and
[name, legal title, and address of surety], authorized to transact business in [name of
country of Purchaser], as Surety (hereinafter called “the Surety”), are held and firmly bound
unto [name of Purchaser] as Obligee (hereinafter called “the Purchaser”) in the sum of
[amount of Bond]1 [amount in words], for the payment of which sum, well and truly to be
made, we, the said Principal and Surety, bind ourselves, our successors and assigns, jointly
and severally, firmly by these presents.
WHEREAS the Principal has submitted or will submit a written Bid to the Purchaser dated
the ___ day of ______, 20__, for the supply of [name of Contract] (hereinafter called the
“Bid”).
NOW, THEREFORE, THE CONDITION OF THIS OBLIGATION is such that if the
Principal:
(a) has withdrawn its Bid during the period of bid validity set forth in the
Principal’s Letter of Bid (“the Bid Validity Period”), or any extension thereto
provided by the Principal; or
(b) having been notified of the acceptance of its Bid by the Purchaser during the Bid
Validity Period or any extension thereto provided by the Principal; (i) failed to
execute the contract agreement; or (ii) has failed to furnish the Performance Security,
in accordance with the Instructions to Bidders (“ITB”) of the Purchaser’s bidding
document.
then the Surety undertakes to immediately pay to the Purchaser up to the above amount upon
receipt of the Purchaser’s first written demand, without the Purchaser having to substantiate
its demand, provided that in its demand the Purchaser shall state that the demand arises from
the occurrence of any of the above events, specifying which event(s) has occurred.
The Surety hereby agrees that its obligation will remain in full force and effect up to and
including the date 28 days after the date of expiration of the Bid Validity Period set forth in
the Principal’s Letter of Bid or any extension thereto provided by the Principal.
IN TESTIMONY WHEREOF, the Principal and the Surety have caused these presents to be
executed in their respective names this ____ day of ____________ 20__.
Principal: _______________________ Surety: _____________________________
Corporate Seal (where appropriate)
_______________________________ ____________________________________
(Signature) (Signature)
(Printed name and title) (Printed name and title)
Manufacturer’s Authorization
[The Bidder shall require the Manufacturer to fill in this Form in accordance with the
instructions indicated. This letter of authorization should be on the letterhead of the
Manufacturer and should be signed by a person with the proper authority to sign documents
that are binding on the Manufacturer. The Bidder shall include it in its bid, if so indicated in
the BDS.]
Date: [insert date (as day, month and year) of Bid Submission]
ICB No.: [insert number of bidding process]
Alternative No.: [insert identification No if this is a Bid for an alternative]
To: [insert complete name of Purchaser]
WHEREAS
We [insert complete name of Manufacturer], who are official manufacturers of [insert type
of goods manufactured], having factories at [insert full address of Manufacturer’s factories],
do hereby authorize [insert complete name of Bidder] to submit a bid the purpose of which is
to provide the following Goods, manufactured by us [insert name and or brief description of
the Goods], and to subsequently negotiate and sign the Contract.
We hereby extend our full guarantee and warranty in accordance with Clause 28 of the
General Conditions of Contract, with respect to the Goods offered by the above firm.
Signed: [insert signature(s) of authorized representative(s) of the Manufacturer]
Name: [insert complete name(s) of authorized representative(s) of the Manufacturer]
Title: [insert title]
Dated on ____________ day of __________________, _______ [insert date of signing]

Covenant of Integrity
to the Promoter
from a Tenderer, Contractor, Supplier or Consultant to be attached to
its Tender
(or to the Contract in the case of a negotiated procedure)
Date: __________________
ICB No.: _________________
“We declare and covenant that neither we nor anyone, including any of our directors,
employees, agents, joint venture partners or sub-contractors, where these exist, acting on our
behalf with due authority or with our knowledge or consent, or facilitated by us, has engaged,
or will engage, in any Prohibited Conduct (as defined below) in connection with the
tendering process or in the execution or supply of any works, goods or services for [specify
the contract or tender invitation] (the “Contract”) and covenant to so inform you if any
instance of any such Prohibited Conduct shall come to the attention of any person in our
organisation having responsibility for ensuring compliance with this Covenant.
We shall, for the duration of the tender process and, if we are successful in our tender, for the
duration of the Contract, appoint and maintain in office an officer, who shall be a person
reasonably satisfactory to you and to whom you shall have full and immediate access, having
the duty, and the necessary powers, to ensure compliance with this Covenant.
If (i) we have been, or any such director, employee, agent or joint venture partner, where this
exists, acting as aforesaid has been, convicted in any court of any offence involving a
Prohibited Conduct in connection with any tendering process or provision of works, goods or
services during the five years immediately preceding the date of this Covenant, or (ii) any
such director, employee, agent or a representative of a joint venture partner, where this exists,
has been dismissed or has resigned from any employment on the grounds of being implicated
in any Prohibited Conduct, or (iii) we have been, or any of our directors, employees, agents
or joint venture partners, where these exist, acting as aforesaid has been excluded by the EU
Institutions or any major Multi-lateral Development Bank (including World Bank Group,
African Development Bank, Asian Development Bank, European Bank for Reconstruction
and Development, European Investment Bank or Inter-american Development Bank) from
participation in a tendering procedure on the grounds of Prohibited Conduct, we give details
of that conviction, dismissal or resignation, or exclusion below, together with details of the
measures that we have taken, or shall take, to ensure that neither this company nor any of our
directors, employees or agents commits any Prohibited Conduct in connection with the
Contract [give details if necessary].
In the event that we are awarded the Contract, we grant the Project Owner, the European
Investment Bank (EIB) and auditors appointed by either of them, as well as any authority or
European Union institution or body having competence under European Union law, the right
of inspection of our records and those of all our sub-contractors under the Contract. We
accept to preserve these records generally in accordance with applicable law but in any case
for at least six years from the date of substantial performance of the Contract.”
For the purpose of this Covenant, Prohibited Conduct includes12,

 Corrupt Practice is the offering, giving, receiving or soliciting, directly or indirectly,
anything of value to influence improperly the actions of another party.
 Fraudulent Practice is any act or omission, including a misrepresentation, that
knowingly or recklessly misleads, or attempts to mislead, a party to obtain a financial
or other benefit or to avoid an obligation.
 Coercive Practice is impairing or harming, or threatening to impair or harm, directly
or indirectly, any party or the property of any party to influence improperly the
actions of a party.
 Collusive Practice is an arrangement between two or more parties designed to achieve
an improper purpose, including influencing improperly the actions of another party.
 Obstructive Practice is (a) deliberately destroying, falsifying, altering or concealing
of evidence material to the investigation; and/or threatening, harassing or intimidating
any party to prevent it from disclosing its knowledge of matters relevant to the
investigation or from pursuing the investigation, or (b) acts intended to materially
impede the exercise of the EIB’s contractual rights of audit or access to information
or the rights that any banking, regulatory or examining authority or other equivalent
body of the European Union or of its Member States may have in accordance with
any law, regulation or treaty or pursuant to any agreement into which the EIB has
entered in order to implement such law, regulation or treaty.
 Money Laundering is defined in the Bank’s Anti-Fraud Policy.
 Terrorist Financing is defined in the Bank’s Anti-Fraud Policy.
 Project Owner means the person designated as such in the tender documents or the
Contract.
Signed: _______________________________________
Name: ______________________________________
Title:______________________________________
Duly authorized to sign this Authorization on behalf of:

______________________________________
Dated on ____________ day of __________________, _______
Note: This Covenant must be sent to the Bank together with the contract in the case of an international
procurement procedure (as defined in article 3.3.2). In other cases, it must be kept by the promoter and available
upon request from the Bank. The Covenant is not mandatory for contracts awarded prior to Bank involvement
in the project. Nevertheless, promoters who are seeking or may seek EIB involvement in a project are advised to
include it in order to promote integrity among the tenderers/contractors. This is particularly relevant in the case
of a promoter who has already implemented a number of previous Bank-financed projects and is considering
further EIB financing
Section V. Eligible Countries 1-213
Section V. Eligible Countries
Eligibility for the Provision of Goods, Works and Non- Consulting Services in
Bank-Financed Procurement
In reference to ITB 4.2 and 5.1, for the information of the Bidders, at the present time firms,
goods and services from the following countries are excluded from this bidding process:
Under ITB 4.2(a) and 5.1: None
Under ITB 4.2(b) and 5.1: None

1-214 Section V. Eligible Countries

Section VI. Bank Policy – Corrupt and Fraudulent Practices 1-215
Section VI. European Investment Bank’s Anti-

Fraud provisions
(To be included as an annex to the bidding documents)
It is the Bank’s policy to require that promoters, as well as tenderers, contractors, suppliers
and consultants under Bank-financed contracts, observe the highest standard of ethics during
the procurement and execution of such contracts. The Bank reserves the right to take all
appropriate action in order to enforce this policy.
Moreover, the Bank is committed to ensuring that its loans are used for the purposes intended
and its operations are free from prohibited conduct (including but not limited to, fraud,
corruption, collusion, coercion1, and money laundering and terrorist financing).
In pursuance of this policy as set out in EIB’s Anti-Fraud Policy and within the framework of
its exclusion procedures (published in the Bank’s website: www.eib.org), the Bank:
• may declare an individual or an entity ineligible to be awarded a contract under any
EIB Project or to enter into any relationship with the Bank, if it determines pursuant
to its exclusion procedures that such individual or entity has engaged in any
prohibited conduct in the course of the procurement process and/or implementation of
the contract; and
• may cancel all or part of the Bank financing allocated to a contract for works, goods or
services if it, at any time, it determines, pursuant to its exclusion procedures, that an
individual or an entity has engaged in any prohibited conduct during the procurement
process or during the execution of the contract, without the promoter having taken
action satisfactory to the Bank to investigate and/or terminate the prohibited conduct
or, as the case may be, remedy the damage.
Prohibited Conduct includes corruption, fraud, coercion, collusion, obstruction, money
laundering and financing of terrorism defined as follows:
a. A corrupt practice, which is the offering, giving, receiving, or soliciting, directly or
indirectly, anything of value to influence improperly the actions of another party.
b. A fraudulent practice, which is any act or omission, including a misrepresentation that
knowingly or recklessly misleads, or attempts to mislead, a party to obtain a financial
or other benefit or to avoid an obligation.
c. A coercive practice, which is impairing or harming, or threatening to impair or harm,
directly or indirectly, any party or the property of the party to influence improperly
the actions of a party.
d. A collusive practice, which is an arrangement between two or more parties designed to
achieve an improper purpose, including influencing improperly the actions of another
party.
e. An obstructive practice is (a) deliberately destroying, falsifying, altering or concealing
of evidence material to the investigation; and/or threatening, harassing or intimidating
any party to prevent it from disclosing its knowledge of matters relevant to the
investigation or from pursuing the investigation, or (b) acts intended to materially
impede the exercise of the ElB's contractual rights of audit or access to information or
the rights that any banking, regulatory or examining authority or other equivalent
body of the European Union or of its Member States may have in accordance with
1-216 Section VI. Bank Policy – Corrupt and Fraudulent Practices
any law, regulation or treaty or pursuant to any agreement into which the EIB has
entered in order to implement such law, regulation or treaty.
Money laundering and financing of terrorism are defined in EC Directives on the
prevention of the use of the financial system for the purpose of money laundering and
terrorist financing, as amended and supplemented from time to time (hereafter
“AML/CFT Directive”), as follows:
f. Money laundering is
i the conversion or transfer of property, knowing that such property is derived
from criminal activity or from an act of participation in such activity, for the
purpose of concealing or disguising the illicit origin of the property or of
assisting any person who is involved in the commission of such activity to
evade the legal consequences of his action;
ii the concealment or disguise of the true nature, source, location, disposition,
movement, rights with respect to, or ownership of property, knowing that such
property is derived from criminal activity or from an act of participation in
such activity;
iii the acquisition, possession or use of property, knowing, at the time of receipt,
that such property was derived from criminal activity or from an act of
participation in such activity;
iv participation in, association to commit, attempts to commit and aiding,
abetting, facilitating and counselling the commission of any of the actions
mentioned in the foregoing points.
Financing of terrorism is the provision or collection of funds, by any means, directly
or indirectly, with the intention that they should be used or in the knowledge that they are to
be used, in full or in part, in order to carry out any of the offences within the meaning of
Articles 1 to 4 of the Council Framework Decision 2002/475/JHA of 13 June 2002 on
combating terrorism.
Section VII. Employer’s Requirements 2-1
PART 2 –Employer’s
Requirements
2-2 Section VII. Employer’s Requirements

Section VII. Employer’s Requirements
Contents
Scope of Supply of Plant and Installation Services by the Contractor ................................ 5

Scope of Supply of Plant and Installation Services by the Contractor ............................ 135
Scope of Supply of Plant and Installation Services by the Contractor ............................ 227
Forms and Procedures ............................................................................................................. 331
Form of Completion Certificate .........................................................................................332

Form of Operational Acceptance Certificate ...................................................................333
Change Order Procedure and Forms................................................................................334
Change Order Procedure....................................................................................................335
Annex 1. Request for Change Proposal ...........................................................................336
Annex 2. Estimate for Change Proposal .........................................................................338
Annex 3. Acceptance of Estimate .....................................................................................340
Annex 4. Change Proposal................................................................................................341
Annex 5. Change Order .....................................................................................................344
Annex 6. Pending Agreement Change Order..................................................................345
Annex 7. Application for Change Proposal.....................................................................347
Scope of Supply of Plant and Installation Services by the

Contractor
LOT 1 - Woodlands 33/11kV Substation


Section VII. Employer’s Requirements – Lot 1 Part 2-7
1. PROJECT BACKGROUND
The Lusaka Transmission and Distribution Rehabilitation Project (LTDRP) aims to strengthen the existing
transmission and distribution infrastructure in and around Zambia’s capital, Lusaka. This is achieved by,
amongst other, increasing the power intake and distribution capacity and reliability of the 132 kV ring
surrounding Lusaka. The ring currently connects Lusaka West - Roma - Leopards Hill - Waterworks - Coventry
- Lusaka West substations. During the execution of the LTDRP packages, the integrity of the ring must be
protected by avoiding the isolation of more than one section at any point in time.
1.1 OBJECTIVE
Package 8 of the LTDRP increases the 33 kV infrastructure by:
 Increase the transformer capacity at Woodlands Substation.
 Increase the 33kV transfer capacity between Coventry and Kafue Substations
 Increase the 33kV transfer capacity between Industrial, Mungwi, Liverpool and Matero Substations
1.2 OVERVIEW
The above objectives will be achieved under one contract, herein referred to as:
 Lot 1: Woodlands 33/11kV Substation Upgrade (This document)
o Task 1 – Relocate existing 33 & 11 kV distribution line termination structures
o Task 2 - Construct new Woodlands 33/11 kV Substation.
o Task 3 – Intergrade existing 33 & 11kV cables into new Woodlands Substation
o Task 4 - Dismantle Existing Woodlands 33/11 kV Substation
 Lot 2: Coventry – Kafue 33kV Overhead Line Upgrade (Separate document)
o Task 1: 33kV OHL and cable feeders from Coventry Substation to Kafue Substation
o Task 2: 33kV feeder bays at Coventry Substation and Kafue Substation
 Lot 3: Industrial – Matero 33kV Corridor Upgrade (Separate document)
o Task 1 - OHL from Industrial Substation to Mungwi Substation
o Task 2: OHL from Mungwi Substation to Liverpool Substation
o Task 3: OHL from Liverpool Substation to Matero Substation
o Task 4 –33kV feeder bay Matero Substation
1.3 DEPENDENCIES
The re-build of Woodlands Substation has no inter-project dependencies.
Part 2-8 Section VII. Employer’s Requirements – Lot 1
1.4 SCHEDULE
The typical schedule of the Package 8 Lot 1 is shown in Figure 1.
MONTHS
1 2 3 4 5 6 7 8 9 10 11 12
Package 8 Lot 1
Lead Time
Task 1
Task 2
Task 3
Task 4
Figure 1: LTDRP Package 8 Lot 1 typical schedule
1.5 NETWORK DIAGRAM

The existing Woodland Substation is shown in Figure 2. It is a 33/11kV substation with five 33kV feeder bays
connected to Waterworks, Bauleni and Chalala substations.
Figure 2: Existing Woodlands 33kV infrastructure overview

Figure 3: Woodlands 33kV infrastructure overview at the end of Package 8 works
1.6 ABBREVIATIONS
Item Description
°C Degree Celsius
°C/mW Degree Celsius per meter Watt
A Ampere
AAC All Aluminium Conductor
AC Alternating Current
ADSS All dielectric self-supporting
ANSI American national standards institute
BCEW Bare copper earth wire
BOQ Bill of quantities
BS British standard
CAD Computer added drawing
CCITT Consultative Committee International Telephone and Telegraph
Cm Centimetre
CT Current Transformer
Cu Copper
DC Direct Current
DPC Damp proof coarse
EN European norms
EPC Engineering procurement and construction
EPSG European petroleum survey group
Item Description
FAT Factory acceptance test
GA General arrangement
HDG Hot dipped galvanized
HDPE High density polyethylene
HF High frequency
HMI Human Machine Interface
HPS High pressure sodium
HV High Voltage
Hz Hertz
IEC International electrotechnical commission
IEEE Institute of Electrical and Electronics Engineers
ISO International standards organization
kA Kilo Amperes
Kg Kilogram
kg/sqm Kilogram per square metre
Kl Kilo litre
km² Square kilometre
kPa Kilo Pascal
kV Kilo Volts
LCD Liquid crystal display
LED Light emitting diode
LTDRP Lusaka transmission and distribution rehabilitation project
m/s Meters per second
MCB Miniature Circuit Breaker
MOD AASHTO Modified American Association of State Highway and Transportation Officials
mPa Mega Pascal
MV Medium Voltage
mVA Mega Volt Ampere
N/mm² Newton per square millimetre
NER Neutral earthing resistor
NRS National Reference Standard
ODF Optical distribution frame
OEM Original equipment manufacturer
OLTC Onload tap changer
ONAF Oil natural air forced
ONAN Oil natural air natural
OPGW Optical Ground Wire
Pa Pascal
PVA Poli-Vinyl Acrylic
PVC Polyvinyl Chloride
RTU Remote Terminal Unit
RYB Red-Yellow-Blue ( phase rotation)
Item Description
SANS South African National Standard
SAT Site acceptance test
SC Standard connector
SCADA Supervisory Control and Data Acquisition
TRFR Transformer
UPS Uninterruptible power supply
UTM Universal Trans Mercator
UV Ultra violet
VT Voltage Transformer
XLPE Cross linked polyethylene
ZESCO Zambia electricity supply commission
1.7 SCOPE OF WORK

The scope of work summary for Package 8 Lot 1 is separated into various tasks, which is described in the
following sections.
 Task 1 – Relocate existing 33 & 11 kV distribution line termination structures
 Task 2 - Construct new Woodlands 33/11 kV Substation.
 Task 3 – Integrate existing 33 & 11kV cables into new Woodlands Substation
 Task 4 - Dismantle Existing Woodlands 33/11 kV Substation
The substation works are divided into three disciplines, namely:
 Primary plant, which covers all high- and medium-voltage equipment,
 Protection, control and telecommunication equipment, and
 Civil works.
The work in each discipline must be planned according to the implementation methodology for the whole project,
taking careful note that disciplines are inter-dependent, with the possibility that certain personnel, equipment,
and sub-contractors will be mobilised and demobilised as required.
The work described is a summary of the work to be carried out under the different task descriptions in this
document. It does not necessarily describe all the work in detail. The prospective bidders must study the
documents and drawings and ensure that he allows for all the material required to provide a complete fully
functional installation. Bidders need to outline any significant material omissions in their Bids. It is important
to note that the scope of work is design, supply, installation and commissioning, up to final handover of the fully
functional substation, properly integrated into the Lusaka Transmission and Distribution network.
Although a functional design was conducted in preparation of this Bidding Document, the Bidder will be
responsible for the detail design within the quantities provided in the Schedule of Rates and Prices. To this
effect, the Bidder will include all equipment not specifically listed in the Pricing Schedule, but required for a
fully functional product, under the relevant section allowed for under Additional Items.
Where detail Technical Data is not provided for specific items, the successful Contractor will be required to
specify these items, supported by the necessaries calculations, in line with the standards provided, for approval
of the Engineer.
1.7.1 Task 1 – Relocate existing 33 & 11 kV distribution line termination structures

1.7.1.1 General
Currently there are a number of 33 & 11 kV lines with stayed terminal structures on the proposed site for the
new substation ABCD as indicated in Figure 4.
Each of these lines must be dismantled up to a point 10m south of Chilimbulu Road and terminated on a self-
supporting structure.
Any dismantling to be done according to “111233-40-SPE-EE-0018 - REP011 Dismantling of OHL and
Substation Equipment - Rev 2” and the material transported to the Zesco Farm.
The cables used to connect the overhead lines to the existing switchgear must be exposed and re-routed so that
it is outside of the new substation’s footprint. From there it will be jointed and extended outside the footprint of
the new site to the new termination structures. These are situated on the outside of the new substation site where
it will be terminated onto new self-supporting termination structures. The self-supporting structures must be
provided with the following:
 Cable support and fixing structures
 Outdoor terminations
 Distribution type surge arrestors with a counterpoise earthing arrangement
When the new substation has been completed these cables will be disconnected from the old substation
termination points, relocated and terminated onto the new 33 kV termination structures.
Excavate, install, backfill, joint and terminate the following power cables:
 120 m of 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Bauleni No 1 feeder.
 120 m of 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Bauleni No 2 feeder.
 120 m of 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Chalala feeder.
 120 m of 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Waterworks No 1 feeder.
 120 m of 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Waterworks No 2 feeder.
 120 m of 240 mm² 6.35/11kV XLPE SWA Cu cable for the 11kV Ngumba Yanga feeder.
Figure 4: Woodlands Substation relocation of existing 33 & 11 kV overhead lines
Existing fibre optic cables on the MV lines must be terminated onto the new self-supporting structures, jointed,
installed in a sleeve, temporarily connected to the old substation and swung over to the new termination point
once the new Woodlands Substation is completed. This must be done in consultation with Fibrecom to ensure
minimum downtime of any fibre services.
Excavate, install, backfill, joint and terminate the following fibre optic cables:
 600 m 24-core armoured duct type fibre optic cable
 600 m 40 mm fibre optic sleeve
 Supply all draw boxes, joints, terminations, slack reel and hardware for fibre and duct.
1.7.2 TASK 2 - CONSTRUCT NEW WOODLANDS 33/11 KV SUBSTATION

1.7.2.1 General
The new Woodlands Substation is located right next to the existing site (co-ordinates 15°26'42.23"S
28°20'42.56"E). The site is easily accessible from the surrounding tarred roads. The site appears to be located in
good soil conditions, but Bidders need to familiarize themselves with actual conditions on site.
Figure 5: Woodlands Substation location
Figure 6: Woodlands Substation layout
The new 33/11 kV Woodlands Substation will have a total of two 33/11 kV 30 MVA transformers which will
both be installed as part of this contract.
The 33 kV yard will consist of two transformer bays, one bus section and six feeder bays.
The 11 kV switchgear will be housed in a separate switching room within the substation. The transformers will
be connected to the MV switchgear via power cables. Figure 7 represents the single line diagram for the new
substation.
The protection at Woodlands Substation will be according to the LTDRP protection philosophy as described in
the LTDRP protection specification. The SCADA system will be IEC61850 compliant. Woodlands Substation
will form part of the existing telecommunication network.
1.7.2.2 Network diagram

The proposed single line diagram for the new Woodlands substation is shown in Figure 7 and the general
arrangement in Figure 8.
Figure 7: Single line diagram

Figure 8: General arrangement
1.7.2.3 Primary Plant

The primary plant scope of work to be completed at Woodlands Substation is provided in this section.
Note: Sufficient time should be set aside for a thorough FAT, SAT, testing and commissioning of all works.
Following the successful commissioning, supply as-built drawings, maintenance manuals, cable schedules and
other necessary drawings, as applicable, including software copies in AutoCad format (three sets of each).
1.7.2.3.1 33 kV EQUIPMENT
 Supply and construct six 33 kV feeder bays which include cable termination structures, voltage
transformers, current transformers, isolators, circuit breakers, all required clamps, conductors, busbar
and connections between the equipment.
 Supply and construct two 33/11 kV transformer bays which include current transformers, isolators,
circuit breakers, all required clamps, conductors, busbar and connections between the equipment.
 Supply and install two 33/11 kV 30 MVA transformer with NERs.
 Supply and construct one 33 kV bus section bay which includes current transformers, isolators, circuit
breaker, all required clamps, conductor, busbar and connections between the equipment.
 Supply and construct two 33 kV busbar VT bays which includes voltage transformers and all required
clamps, conductor and connections between equipment and busbar.
 Supply and construct a new 33 kV tubular busbar with all required clamps, conductors and connections.
 Supply and install stringers and droppers with Centipede and Bull conductor and required clamps,
spacers, fittings, conductor and connections.
 Supply and install lightning and lighting masts as shown in the general arrangement.
 Supply and install all necessary signs and labels as required by ZESCO for safe operation and
maintenance of the substation.
 Supply and install eighteen 6.35/11 kV 630 mm² 1C XLPE cables (three cables per phase),
approximately 1,200 m total cable length, from the two 33/11kV transformers to supply the 11 kV
switchboard.
 Supply and install 2 x 6.35/11 kV 120 mm² 1C XLPE Cu, approximately 15 m each, between the
transformers and NERs.
 Portable earths and associated fixed earth ball joints to be provided.
1.7.2.3.2 11 kV SWITCHGEAR
Supply, install and commission one 11 kV, two sectioned single busbar switchboard as per single line diagram
111233-2001-DRG-ELE-0001 in the switchgear room and as per the approved layout 111233-2001-DRG-ELE-
0003.
The board will consist of the following:
 A two-section board.
 Two incomer circuit breakers with voltage transformers.
 Two busbar voltage transformer panels.
 One bus-section breaker, and bus-risers (if required).
 Thirteen normal local feeder breakers for re-connecting to the surrounding existing networks.
 Two fused isolators for the auxiliary transformer supplies.
1.7.2.3.3 AUXILIARY SUPPLY

Supply and install the following equipment for the substation auxiliary supply:
 Two 11 kV/400 V 200 kVA auxiliary transformers.
 One 400 V 50 kVA generator.
 Supply, install and terminate two 11 kV, 120 mm² 3C XLPE Cu cables, approximately 50 m each from
the auxiliary supply transformers to the new 11 kV switchgear panel.
 Supply, install and terminate two 600/1,000 V 120 mm² 4C PVC Cu LV cables, approximately 70 m
each between the auxiliary transformers and the AC auxiliary supply panel.
 Supply, install and terminate one 120 mm² 4C PVC Cu LV cable approximately 70 m between the
generator and the AC auxiliary supply board.
1.7.2.4 Protection, control, telecommunication and metering equipment

The scope includes the design, manufacture, supply, delivery, installation and commissioning. The Contractor
will be responsible for the detail design in accordance with:
 LTDRP SCADA Detail Design Specification (111233-40-SPE-EE-0003)
 LTDRP Telecommunication Detail Design Specification (111233-40-SPE-EE-0004)
 LTDRP Protection Detail Design Specification (111233-40-SPE-EE-0005)
All design calculations and measuring transformer (CTs and VTs) specifications will be submitted to the
Engineer for approval before designs are finalized.
1.7.2.4.1 PROTECTION
 Two 33/11 kV 30 MVA transformer protection and control schemes.
 Two 33 kV incomer protection and control scheme.
 Four 33 kV outdoor feeder protection and control schemes.

 One 33 kV bus section protection scheme panel.
 One 33 kV bus zone low impedance protection scheme.
The 11kV protection schemes will be installed in the 11kV switchgear panel LV compartment.
Note: The 11kV on-board protection and switchgear installation are to be done at the same time
 Two 11kV transformer incomer protection and control schemes.
 One 11kV bus section control schemes.
 Thirteen 11kV feeder protection and control schemes.
 One 11kV arc protection scheme.
1.7.2.4.2 SCADA AND TELECOMMUNICATIONS
 Design, supply, install and commission a complete new IEC61850 compliant SCADA and
telecommunication system for the new Woodlands Substation.
 Supply and install an Ethernet II fibre based ruggedized substation LAN backbone with an appropriate
level of redundancy through the strategic use of ruggedized Ethernet II switches that will also form the
backbone of the SCADA system.
 Supply and install a telecommunication system suitable to integrate with existing and future
telecommunication systems primarily making use of SDH operating at STM-16 with PCM/PDH
capabilities for, amongst other, substation phones interconnected via PABX.
 Integrate the SCADA system with the telecommunications system to enable full RTU-based control
and monitoring of the substation from the Regional Control Centre.
 Supply and install a 19” communication cabinet with sufficient patch trays for all fibres as well as two
additional 24-way patch frames. All existing commercial telecommunication services must be
transferred to the new building.
 Supply and install a digital distribution frame with 21 E1 port pairs allowing communication speeds up
to 2Mbps.
1.7.2.4.3 METERING
 Two 33kV metering panels with meters and all auxiliary equipment (six meters per panel)
o Tariff meters for the 33kV feeder panels.
o Statistical meters on the 33kV transformer feeders.
 Thirteen statistical meters installed on the 11kV local feeder panels.
1.7.2.4.4 AC/DC SUPPLIES
 One 400V AC three-way automatic change over panel with all auxiliary equipment.
 One 48V DC distribution panel with DC circuit MCBs.
 One 110V DC distribution panel with DC circuit MCBs.
 One 400V AC distribution panel with AC circuit MCBs.
 One 110V DC supply system inclusive of panel and dual paralleled battery chargers with NiCad
batteries in accordance with LTDRP Protection Detail Design Specification (111233-40-SPE-EE-
0005).
 One 48V DC supply system inclusive of panel battery chargers with NiCad batteries in accordance
with LTDRP Protection Detail Design Specification (111233-40-SPE-EE-0005).
1.7.2.4.5 YARD JUNCTION BOXES
 Current transformer junction boxes with terminals.
 Voltage transformer junction boxes with terminals.
 400V AC 3-phase socket supply box and plug (one per two transformers).
 Supply multicore control and small power cables complete with terminations.
1.7.2.4.6 OTHER
 Factory acceptance tests (FATs), witnessed by three engineers of each discipline (protection, SCADA
and telecommunications) as the representatives of ZESCO shall be conducted according to the
specifications. Sufficient time should be set aside for a thorough FAT. As far as practically possible,
the protection and control scheme FAT will be conducted together with the SCADA system FAT.
 Site Acceptance Tests (SATs) and local and overseas training to be provided for by the contractor as
detailed in the specifications. These tests and training will be applicable to all the equipment supplied
under this contract for Woodlands Substation.
 Testing and commissioning of all works.
 Following the successful commissioning, supply as-built drawings, maintenance manuals, cable
schedules and other necessary drawings, as applicable, including software copies in AutoCad format
(three sets of each).
1.7.2.5 Substation civils

1.7.2.5.1 OUTDOOR HV YARD
The civil scope of work to be completed at the new Woodlands Substation is:
 Clear the area of vegetation and dispose.
 Cut a minimum of 300 mm from the site and dispose.
 Remove all collapsible material, any areas that was used as a dump previously as well as rock where
applicable, backfill and compact to surrounds.
 Cut the in-situ material a minimum of 300 mm deep and store for later use.
 Rip the exposed bed 300 mm deep and re-compact to 95% MOD-AASHTO.
 Backfill from stockpile and compact in layers of not more than 150 mm and compact to 95% MOD-
AASHTO.
 Supply, spread, water and compact G6 material to 95% MOD-AASHTO for the platform to 600mm
above NGL in layers of not more than 150 mm for completing the terrace as indicated on the General
Arrangement (GA) drawing. The finished compacted terrace level must be a minimum of 600 mm
above the highest point of the site. Each level must be tested for conformance to the level of compaction.
The acceptance of each layer will be a holding point before commencing with the next.
 The existing substation site is prone to severe stormwater damage. On the boundary between the old
and the new platforms the contractor must provide permanent concrete lined drainage channel properly
sized to accommodate all the stormwater from the higher ground. This channel must cover the entire
width of the new platform and must be designed as such that the stormwater does not spill over into the
new yard. For on the new platform the contractor must provide appropriate storm water drainage
systems including storm water culverts and pipes for any area of the new substation terrace where storm
water is likely to accumulate. The drains must accumulate on the lower side of the platform and
connected to an existing stormwater network or be discharged into the surrounding area without causing
damage to any existing structures.
 Install new precision welded galvanized rectangular mesh fence topped with a 600mm 45º slanted
outward galvanized razor mesh with removable panels and gates to enclose the substation. The inner
fence will be 1.8m galvanized razor mesh.
 Construct new access roads to the new substation including storm water culverts and pipes where
required as indicated in Figure 6.
 Complete installation of all primary plant equipment foundations, lighting and lightning mast
foundations, busbar support foundations and plinths for the two 30 MVA transformers. Please take note
that this is a dolomitic area and each foundation must be provided with a suitable compacted soil
mattress if so required by the geotechnical investigation.
 Provide an integrated oil drainage system for the 30 MVA transformers, which includes oil containment
bund walls with rectangular galvanized steel grid around the transformers, drainage sumps and an oil
spillage containment system complete with oil/water separator at the oil dam.
 Install earth mat across the new terrace and around the perimeter fence, connect all equipment, steel
work, building and fence poles to the main earth mat. Connect the new earthmat to the existing earthmat
when completed.
 Provide new cable trenches with covers between the yard and control building.
 Install concrete kerbing around the outside perimeter of the substation security fence at a distance of
1,000 mm.
 Install clean crushed granite, with a minimum thickness of 100 mm to cover the full extent of the
substation terrace and kerbing around outside the perimeter fence.
1.7.2.5.2 CONTROL AND SWITCHGEAR BUILDING
 Build a new combined control and 11 kV switchgear room of approximately 34.8 m x 6.8 m as typically
indicated in .
Figure 9 : Proposed control and office building layout for Woodlands Substation
1.7.2.5.3 OFFICE BUILDING

 Build a new office building approximately 6.8 m x 9.5 m. The typical layout of the building is shown
in .
Figure 10: Proposed office building layout for Woodlands Substation
1.7.2.5.4 GUARD HOUSE

 Construct a new guard house in accordance with the ZESCO standard. The typical layout of the building
is shown in .
Figure 11: Proposed guard house layout for Woodlands Substation
1.7.2.5.5 PLANNING OFFICE

Construct a new planning office in accordance with the ZESCO standard. The typical layout of the building is
shown in
Figure 12: Proposed planning office layout at Woodlands Substation
1.7.2.5.6 SUBSTATION FACILITIES

The following substation facilities must be provided:
 Potable water by means of a borehole and two 5,000 litre tanks, one tank for the substation and one
tank for the local community.
 The disposal of waste water and sewage by means of a 2,000 litre tank and French drain if there is no
utility connection nearby. If there is a utility connection nearby it will replace the septic tank and French
drain.
 Solid waste disposal in designated bins.
 Covered and uncovered parking.
 Security and access control.
 Acid evaporation pond.
1.7.2.5.7 FIRE PROTECTION

The following fire protection must be provided:
 Fire extinguishers for inside and outside the buildings.
 Fire barriers between the new and future transformers.
 Each room in the entire building will be protected by means of automatically activated fire protection
system.
 The proposed solution should be environmental friendly, non-corrosive, non-conductive and nontoxic.
The system should not require any pipe work and must be easy to maintain. The system should utilize
the latest fire chain inhibiting technology by creating a fire extinguishing compound through
exothermic oxidation or condensed aerosol generators (CAG).
 The product must have no Ozone Depletion Potential (ODP) or Global Warming Potential (GWP)
 Each protected room will have a manual override control inside room at access door.
 Each room in the building must be equipped with fire and smoke detection. Each detector must be
relayed to a control panel that will be mounted in the telecoms room. The control panel must have the
functionality to sound an audible alarm as well as to be integrated into the SCADA where all signals
and alarms must be made available to the control centre. An automatic CAG system will typically
consist of, but not be limited to, the following:
 Easy to install and maintain.

 Fire and smoke detection censors in each room wired to the control panel in the telecoms room.
 Spare cartridges must be included in spares
 Control panels connected to the SCADA including all wiring and cabling
1.7.3 TASK 3 – INTERGRATE EXISTING 33 & 11kV CABLES INTO NEW WOODLANDS
SUBSTATION
1.7.3.1 Existing 11 kV cable feeders

There are 11 x 11kV cable feeders connected to the existing Woodlands 11kV switchgear. There is a certain
amount of PILC cables present in the surrounding networks that will be connected to the new switchgear with
XLPE cables. The contractor must confirm the type of cable being jointed onto and provide a XLPE/PILC
transition joint.
Disconnect from the old switchgear, exposed by hand, re-route, join to new cables and terminate onto the new
11kV switchgear the following:
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Chilenje No 1 feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Ngumba Yanga feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Lake Road feeder.
 1,500 m of 185 mm² 6.35/11kV XLPE SWA Cu cable for the Chilimbulu Road feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Chindo Road feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Mutende Road feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Benangombe feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Musakashela feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Elm Road feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Woodlands Extention feeder.
 120 m of 120 mm² 6.35/11kV XLPE SWA Cu cable for the Chilenje No 2 feeder.
1.7.3.2 Existing 33 & 11kV overhead lines

The existing 33 & 11kV overhead lines of which the terminal structures were re-located under Task - 1 must
now be disconnected from the existing switchgear, the cables exposed re-routed and terminated onto the new
switchgear constructed under TASK – 2. The lines in question are indicated in Figure 13 as follows:
 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Bauleni No 1 feeder.
 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Bauleni No 2 feeder.
 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Chalala feeder.
 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Waterworks No 1 feeder.
 240 mm² 19/33kV XLPE SWA Cu cable for the 33kV Waterworks No 2 feeder. This overhead line is
redundant with the inclusion of the UTH 33kV cable feeder but it will not be dismantled. Instead the
cable connected to the existing switchgear must be exposed and coiled up and buried to outside the
substation fence and properly capped for, later use.
 240 mm² 6.35/11kV XLPE SWA Cu cable for the 11kV Ngumba Yanga feeder.
Any of the cables that is left over after terminating the onto the new substation equipment must be capped on
both ends with heat shrink cap, rolled up and transported to the ZESCO Farm.
Figure 13: Overhead line connection to Woodlands Substation
1.7.4 TASK 4 – DISMANTLE WOODLANDS 33/11KV SUBSTATION

This task comprises dismantling the existing Woodlands 33/11 kV Substation and rehabilitating the site as
detailed in Specification document 111233-40-SPE-EE-018. The existing Woodlands 33/11 kV Substation is
located at 15°26'42.19"S 28°20'42.50"E and is shown in Figure 14.
Figure 14: Location of Woodlands 33/11 kV Substation
A photo of the existing 33 kV yard is shown in Figure 15.
Figure 15 Existing Woodlands 33/11 kV Substation.

2. SPECIFICATION
The Specification for this Lot corresponds to the tasks in the Scope of Work. Functional requirements for design
and construction are described below, which must be read in conjunction with the ZESCO Standard
Specifications (Section VII Works Requirements – Supplementary Information) and Technical Schedules
(Section X Contract Forms).
2.1 REFERENCE STANDARDS
The design shall be in accordance to the latest version of the local ZESCO codes & standards, British Standards
(BS) or relevant IEC standards listed in the table below:
NB: The specifications in this document take precedence. In the absence of specifications in this
specification, Local codes and standards, British Standards (BS) or relevant IEC standards shall take
precedence. Where there is any conflict between the requirements of the Specification and the Specification of
Equipment, then the Specification shall take precedence. Where there is any conflict between the requirements
of this Specification and International Standards, then this Specification shall take precedence, unless otherwise
agreed to, in writing, by the Engineer.
Where Bidders choose to submit more than one supplier for the same equipment, the Employer has the right to
choose which equipment the Bidder should supply.
2.1.1 ZESCO SPECIFICATIONS
Reference Document No: Title
VOLUME 1
SP - CSS – 000 CIVIL WORKS

1 SP - CSS – 001 Civil Works Substation General
SP - ECA - 000 CABLES ( CA )
2 SP - ECA – 001 Cables and Accessories
3 SP - ECA – 002 Cable Joints
4 SP - ECA – 003 Installation of small wiring & Trunking
5 SP - ECA – 004 Power Cable Installation
SP - ECO - 000 CONDUCTOR ( CO )
6 SP - ECO – 001 Overhead line & Earth Conductor
7 SP - ECO – 002 Aerial Bundled Conductors
SP - EIN – 000 INSTRUMENTS ( IN )
8 SP - EIN – 001 Metering Equipment
9 SP - EIN – 002 Credit Dispensing Units
SP - EGE - 000 ELECTRICAL MISCELLANEOUS ( GE )
10 SP - EGE – 001 Small Power Distribution Unit (Ready Board)
SP - ESC – 000 SYSTEM CONTROL
11 SP - ESC – 001 SCADA System for Regional Control Centre
SP - ESG – 000 SWITCHGEAR ( SG )
12 SP - ESG – 001 Unit Substation Switchgear
13 SP - ESG – 002 Surge Arresters
14 SP - ESG – 003 Pole Mounted Equipment
15 SP - ESG – 004 Auto Recloser (Pole Mounted)
16 SP - ESG – 005 Distribution Pillars, Fuses and Fuselinks
17 SP - ESG – 006 33kV Outdoor Switchgear
18 SP - ESG – 007 33kV & 11kV Metal Enclosed Indoor Switchgear

19 SP - ESG – 008 Control Relays & Ancillary Equipment
VOLUME 2
SP - ESS – 000 SUBSTATION GENERAL ( SS )

1 SP - ESS – 001 Substation Auxiliary’s
2 SP - ESS – 002 Unit Substations
3 SP - ESS – 003 Substation Earthing - Lightning Protection & NER
4 SP - ESS – 004 11kV & 0.4kV Reticulation System Earthing
SP - ESU – 000 SUPPORTS ( SU )
5 SP - ESU – 001 Supports and Foundations
6 SP - ESU – 002 Wood Pole Supports
7 SP - ESU – 003 Tubular Steel Poles and Ancillary Equipment
8 SP - ESU – 004 Overhead line Insulators
9 SP - ESU – 005 Stays
10 SP - ESU – 006 Installation of 0.4-33kV OHL & ABC System
SP - ETR – 000 TRANSFORMER ( TR )
11 SP - ETR – 001 Distribution Transformers
12 SP - ETR – 002 Power Transformers
13 SP - ETR – 003 Current & Voltage Transformers
SP - GGE - 000 GENERAL REQUIREMENTS
14 SP - GGE – 001 General Technical requirements
15 SP - GGE – 002 Works & Site Tests for S/S Equipment
16 SP - GGE – 003 Unit Substation Installation
17 SP - GGE – 004 Drawings/Operations & Maintenance Instructions
18 SP - GGE - 005 Overhead Line Construction Drawings
SP - GTE - 000 TEST EQUIPMENT (TE )
19 SP - GTE – 001 Test Equipment
SP - GTO - 000 TOOLS ( TO )
20 SP - GTO – 001 Tools and Equipment
SP - GVE - 000 MOTOR VEHICLES ( VE )
21 SP - GVE – 001 Vehicles Trucks Tractors & Portable Equipment
22 SP - GVE – 002 Cable Test and Fault Location Vehicle
23 SP - GVE – 003 Mobile Insulating Oil Treatment Plant
2.1.2 IEC STANDARDS
No Title Reference
1. POWER TRANSFORMERS
1.1 Quality Management Systems ISO 9001

1.2 Power Transformers IEC 60076
1.3 Insulating oil for transformers IEC 60296
1.4 Bushings for alternating Voltage above 1000V. IEC 60137
Insulating liquids – Determination of the breakdown voltage at
1.5 IEC 60156
power frequency
1.6 Current Transformers. IEC 60044
1.7 Three phase Induction motors. IEC 60034
1.8 Thermal evaluation and classification of electrical insulation. IEC 60085
Degree of protection provided by enclosures for low voltage IEC 60529
1.9
switchgear and control. IEC 60947
1.10 Guide for loading of oil immersed transformers. IEC 60354
1.11 On-load tap-changers IEC 60214
1.12 Application Guide for OLTC IEC 60542
1.13 Method of measurement of Transformer Sound levels. NEMA-TR1
1.14 Methods of High Voltage Testing IEC 60060
1.15 Methods for Partial Discharge Measurements IEC 60270
1.16 Insulation Coordination IEC 60071
1.17 Short Circuit Current – calculation of effects IEC 60865
Shunt Reactors, Neutral/Earthing Reactor and Arc Suppression
1.18 IEC 60289
Coil
1.19 Insulating oils for transformers/reactors and switchgears IEC 60296
Supervision and Maintenance guide for Mineral Insulating Oil in
1.20 IEC 60422
Electrical Equipment
1.21 Method of Sampling of Liquid dielectrics IEC 60475
Guide for the Sampling of Gases and of Oil from Oil-filled
1.22 IEC 60567
Electrical Equipment for the Analysis of Free and Dissolved Gases
1.23 Digital Recorders and Software for High Voltage Impulse testing IEC 61083
1.24 Communication network and systems in substations IEC 61850
2. HIGH VOLTAGE BREAKERS
2.1 Quality management systems – Requirements ISO 9001:2008

High-voltage switchgear and control gear – Part 100: Alternating
2.2 IEC 62271-100:2011
current circuit-breakers
2.3 High voltage test techniques IEC 60060:2010
No Title Reference
3. HIGH VOLTAGE ISOLATORS AND EARTH SWITCHES

High-voltage switchgear and control gear – Part 103: Switches for
3.2 IEC 62271-103:2011
rated voltages above 1 kV up to and including 52 kV
3.3 IEC 62271-104:2015
current switches for rated voltages higher than 52 kV
Tests on indoor and outdoor post insulators of ceramic material or
3.4 IEC 60168:1994
glass for systems with nominal voltages greater than 1000 V
4. CURRENT TRANSFORMERS

4.2 Instrument transformers – Part 2: Current transformers IEC 61869-2:2012
4.3 IEC 60168:1994
5. VOLTAGE TRANSFORMERS

5.2 Instrument transformers – Part 3: Inductive voltage transformers IEC 61869-3:2011
5.3 Instrument transformers – Part 4: Capacitive voltage transformers IEC 61869-5:2011
6. HIGH VOLTAGE SURGE ARRESTORS

Surge arresters – Part 4: Metal-oxide surge arresters without gaps
6.2 IEC 60099-4:2014
for AC systems
6.3 IEC 60168:1994
Polymeric insulators for indoor and outdoor use with a nominal
6.4 voltage >1 000 V – General definitions, test methods and IEC 62217:2012
acceptance criteria
2.1.3 BRITISH STANDARDS
No Title Reference
1. GENERAL
1.1 Fire Extinguishing Installations BS 5306
2.1.4 EUROPEAN STANDARDS
No Title Reference
1. GENERAL
Masonry cement - Part 1: Composition, specifications and
1.1 EN 413-1
conformity criteria
2.2 PERSONNEL REQUIREMENTS

The Bidder must demonstrate that it will have the personnel for the key positions that meet the following
requirements:
Total Work In Similar Works

No. Position Experience - minimum minimum Experience
(years) (years)

Design Engineer
5 Senior SCADA and Communication 12 10

Engineer
The Bidder shall provide details of the proposed personnel and their experience records.
Project Management and Contract Management activities. The Contractor’s representative and/or any deputy
must be professionally registered as a project manager at an international recognised institution. Certified copies
of this registration need to be submitted with this Bid.
Monthly Progress Meetings will be held on site and must be attended by at least the Contractor’s Representative
and the Site Manager. The Contractor’s Representative will be duly authorised to make decisions on behalf of
the Contractor.
It is a specific requirement that the Contractor’s Representative, Site Manager and Safety Official must be fluent
in English and the language of the Contractor's personnel. The above shall be in accordance with the General
Conditions.
2.3 REQUIRED DOCUMENTATION SUBMISSION

The successful Bidder will be required to submit the following information during the execution of the contract
for approval as a minimum requirement:
No. Position
Detailed project schedule showing all planned activities including starting and completion dates
for:
a. Project commencement
b. Data Collection
c. Design
d. Design Approvals
1 e. Procurement,
f. Factory Acceptance Tests
g. Delivery of material
h. Preparation works for construction
i. Construction
j. Testing and Commissioning and
k. Handover.
No. Position
Detailed designs and drawings for substations, switching stations and associated plant including
the following:
a. Single Line Diagrams

b. Site Layouts
c. General Arrangement
d. Foundations Layouts including trenches, roads, plinths
e. Drainage Designs
f. Fencing and gate designs
g. Clamp schedule
h. Structural steel layouts
i. Earthing Designs
j. Sections
k. Lighting Layouts
2 l. Lightning layouts.
m. Fire protection designs
n. Control Buildings, roof trusses and building finishes
o. Switchgear Buildings
p. Guard Houses
q. Oil Holding Dams
r. Fire Walls
s. Water tanks
t. Septic tank soak away.
u. Borehole and water testing reports
v. Cable trenches
w. Access and Internal road designs
x. All relevant protection and metering designs
y. All relevant SCADA, Telecommunication and Substation automation designs
All relevant design reports:
a. Cable and conductor ratings for relevant applications

b. Surge arrestor application
c. Structural steel design strength
3
d. Foundations designs
e. Earthing designs
f. Substation AC and DC loadings
g. Requirements for batteries and chargers
h. Generator design load
i. Protection settings
Submission and approval of Technical details for all equipment listed in the Technical Schedules
4
prior to ordering.
5 Geotechnical studies and soil analysis of substation site area and quarries.
6 Samples of building material where applicable e.g concrete blocks and brick cube tests.
7 Transformer and oil testing reports

2.4 NEW SUBSTATIONS

2.4.1 AMBIENT CONDITIONS
The following ambient and environmental conditions will be used in the design of all lines and substations which
form part of this contract. For some components, more onerous design criteria than the ambient conditions are
specified in later sections.
Table 1: Ambient Conditions
Altitude ≤1,400m Above sea level

Ambient Temperature
Absolute Max. 45ºC
Annual Average Max. 36ºC
Annual Average Min. 3ºC
Absolute Min. 2ºC
Lightning conditions High with an average lightning ground flash density of
10 -15 flashes per km² per annum
Relative Humidity
Maximum 86%
Minimum 39%
Atmosphere Medium pollution atmosphere.
Average Annual Rainfall 850 to 1,200mm
Extreme Wind Speed 28 m/s
Hail Occasional
Sand Storm Occasional
2.4.2 CIVIL WORK

Contractors should familiarise themselves with site conditions and price accordingly. Please take note that this
is a dolomitic area with a possibility of underground dolomite spires.
Embankments and fills shall be compacted in layers not exceeding a compacted thickness of 150 mm, provided
that the minimum relative density specified is achieved throughout the layer when compacted. The contractor
shall obtain the Project Manager’s approval of the previous layer before the next layer is spread. If the Contractor
wishes to continue placing fill before density test results are available, he may do so entirely at his own risk and,
should tests fail, then the Contractor must remove both the layer being tested and those placed above it, all at his
own expense. Unless otherwise specified, embankments and fills shall be compacted to a minimum relative dry
density of 91% Mod AASHTO. Embankments must be protected against storm water erosion
Embankments shall be constructed as far as is reasonable in layers parallel to the formation and to the full width
corresponding to the height at which the work is being carried out from time to time. In no circumstances may
a narrow portion of the embankment be constructed first and material "side-tipped" to make up the specified
width.
Density tests must be taken on every layer at a frequency of one for every 1000 m² of area. The specified density
is a minimum so the Contractor must aim to achieve a higher density than the minimum specified.
2.4.2.1 Terrace and Drainage

A complete new terrace must be constructed. The terrace for the new buildings and equipment must be a
minimum of 600mm higher than the highest point of the surrounding natural ground level with suitable drainage
ditches must be provided on the higher side of the terrace in order to channel water away from the terrace towards
the existing infrastructure therefore. The drainage system must prevent water from the surrounding areas to flow
onto the terrace. Stormwater will under no circumstances be allowed to pool anywhere on the platform and must
be dispersed in such a manner that it does not result in erosion of the area around the substation as well as cause
flash floods at the lowest point of the substation that borders at an existing tarred road. This might include the
installation of a sub-soil drainage system.
Clear all the area of vegetation and dispose.
Cut a minimum of 300 mm from below nominal ground level and dispose.
Remove all collapsible material, any areas that was used as a dump previously and rock where applicable.
Cut the in-situ material to a minimum of 300 mm deep and store for later use.
Rip the exposed bed 300 mm deep, level out if required and re-compact to 95% MOD-AASHTO.
Backfill from stockpile and compact in layers of not more than 150 mm and compact to 95% MOD-AASHTO.
Import additional material as required and compact in layers of not more than 150 mm to 95% MOD-AASHTO
for completing the terrace as indicated on the General Arrangement (GA) drawing. The finished terrace level
must be a minimum of 600 mm above the highest point of the site. Fill material must be of G5 to G7 material
with a neutral Ph. value and a low electrical resistivity ≤100Ωm. The use of dump rock from mining activities
will not be accepted. The finished terrace shall have a bearing pressure of not less than 150kPa.
Provide appropriate stormwater drainage systems including storm water culverts and pipes for any area of the
new substation terrace where storm water is likely to accumulate. The terrace shall have a slope of 0.5%
minimum and 1% maximum along its longer axis (orthogonal to the 33kV busbar) for water run-off. Where
roads and trenches create obstacles to free rain water drainage, measures which include channels, pipes and
sumps must be employed to prevent water from damming on the platform. The drains must accumulate on the
lower side of the platform and connected to an existing storm water network or be discharged into the
surrounding area without causing damage to any structures.
All embankments lower than 1m must be protected against erosion by means of seeding the embankment with
indigenous grass. These embankments must be watered regularly to ensure that the seeding is successful.
Install new high security perimeter fence with removable panels and gates to enclose the substation.
Install new platform fence with removable panels and gates to enclose the substation.
Construct a new access road to the new substation including storm water culverts and pipes across existing
drainage channels where required.
Complete installation of all primary plant equipment foundations, lighting and lightning mast foundations,
busbar support foundations and plinths for the two 30 MVA transformers. Please take note that this is a dolomitic
area and each foundation must be provided with a suitable compacted soil mattress if so required by the
geotechnical investigation.
Provide an integrated oil drainage system for the 30 MVA transformers, which includes oil containment bund
walls with rectangular galvanized steel grid around the transformers, drainage sumps and an oil spillage
containment system complete with oil/water separator at the oil dam.
Install earth mat across the new terrace and around the perimeter fence, connect all equipment, steel work,
building and fence poles to the main earth mat.
Provide new cable trenches with covers between the yard and control building.
Install concrete kerbing around the outside perimeter of the substation security fence at a distance of 1 000 mm.
Install clean crushed granite, with a minimum thickness of 100 mm to cover the full extent of the substation
terrace and kerbing around outside the perimeter fence. The existing substation has been damaged by stormwater
in the past. Please consider the following and include in stormwater design.
Shortcoming Typical Mitigation
Flooded battery room floor

Consider installing cut-off drains diagonally across the path of
the stormwater. All stormwater drains must be channelled
towards the main stormwater infrastructure on the pavement.
No airbricks allowed.
Flooded switchroom floor

Consider installing cut-off drains diagonally across the path of
the stormwater. All stormwater drains must be channelled
towards the main stormwater infrastructure on the pavement.
No airbricks allowed.
Building floors are lower than the NGL.

Floors of all buildings must be at least 600mm higher than the
platform.
Cable entries into the building must be sealed after
commissioning of the substation.
Any water accumulating on the outside of the building must be
able to drain away from the building un-assisted. Do not
include any structures that will tend to dam the water up
Non-draining substation roads.

Transformer road must also be higher than the platform sloped
towards the street typically with a cut-off drain on its higher
side.
Stormwater from the area surrounding the new platform shall
not be allowed to dam anywhere on the platform.
2.4.2.2 Geo-technical and Environmental

It will be the responsibility of the Contractor to perform the necessary geotechnical tests on the terrace with
special emphasis on the building, transformer and termination gantry positions. The results of this study must be
submitted to the Engineer for scrutiny.
The Geotech study must be done by a professionally registered competent person and must contain mitigation
actions for the different adverse conditions regarding structure and building foundations on site.
The Contractor shall base his designs on these results and proposed mitigation actions. All calculations must be
submitted for acceptance.
The contractor shall allow for rock drilling and breaking if necessary.
Any material to be imported, which is required to create the terrace, must be obtained from an approved borrow
pit. The material must be of G5 – G7 quality with a neutral PH value and a low electrical resistivity.
2.4.2.3 Concrete works

All cement will conform to the EN 413-1 specification and all the sub-clauses contained therein.
It is preferred that any mass pour concrete (large single volumes) be from a commercial ready-mix supplier
against the specifications requested as it can be poured in one go and will provide consistency throughout the
volume as part of a foundation cannot be rejected, it has to be the entire foundation.
Smaller batches for small foundations can be mixed on site on condition that the design of the mix of each
specific volume be made available for scrutiny and records are kept and signed off regarding material proportions
used, the intended foundation it is for and that cubes are prepared for that batch.
Under no circumstances will any concrete be mixed by hand.
The concrete shall be mechanically vibrated once poured to ensure there will be no honeycombs in the concrete
and that proper compaction of the concrete is attained. Over-vibration of concrete will cause segregation of the
concrete and weaken it.
Concrete shall not be poured directly into a hole deeper than 1.5m without a chute to prevent segregation of the
concrete.
The concrete that has started to set without being finally placed must be discarded. Adding water to make it
workable will not be allowed.
If the outside air temperature is less than 5°C, concrete shall not be mixed or poured as the cold will cause the
water to freeze.
All concrete shall be thoroughly mixed by machine with only sufficient water to ensure a workable
mix. Consistency tests shall be made when required by the Project Manager. The slump in a truncated cone
300 mm high and of standard dimensions shall be between 25 and 50 mm, corresponding to a stiff plastic
consistency. This must be done for each new batch delivered to site and the results written down.
Concrete shall not be poured directly into a hole deeper than 1.5m without a chute to prevent segregation of the
concrete. The concrete shall be mechanically vibrated once poured to ensure there will be no honeycombs in
the concrete and that proper compaction of the concrete is attained. Over-vibration of concrete will cause
segregation of the concrete and weaken it. The concrete shall not stand for periods of time and then have water
added to it to make it workable as it weakens the concrete.
The grading of the fine aggregates for concrete will be as indicated in Table 2.
Table 2 Specification for fine aggregates for concrete
Class
Property Fine aggregate from natural Fine aggregate from
disintegration mechanical crushing
Grading mass percentage passing

sieves with square apertures of
nominal sizes:
5,000µm
92 – 100
4,750µm
90 – 100
150µm
5 - 25
Dust content for material passing
through a 75 µm sieve mass 5 10
percentage
Methylene blue adsorption(max) 0.7
Clay content particles smaller
2
than 5µm mass percentage(max)
Fineness modules 1.2 - 3.5
Pre-stressed concrete: 0.01
Chloride(Cl) content mass
Reinforced concrete: 0.03
percentage
Non-reinforced concrete: 0.03
The colour of the liquid above
the fine aggregate shall not be
darker than the colour of the
reference solution, except that
Organic impurities this requirement shall not be -
applicable if the fine aggregate
complies with the requirement
for soluble deleterious
impurities.
Free from sugar unless the fine
aggregate complies with the
Presence of sugar -
requirement for soluble
deleterious impurities.
The strength of specimens
made with the fine aggregate
shall be at least 85 % of that of
Soluble deleterious impurities the specimens made with the -
same fine aggregate after it has
been washed, except that this
requirement shall not be
Class
complies with the requirements
both for organic impurities and
for the presence of sugar.
The grading of the coarse aggregates for concrete will be as indicated in Table 3.
Table 3 Specification for coarse aggregates for concrete
Requirement
Property
Nominal size of aggregate (mm)
Grading1), mass
percentage of material
that passes sieves2) of 75.0 53.0 37.5 26.5 19.0 13.2 9.5 6.7
nominal aperture size,
mm
75.0 100 100 100
53.0 0-50 85- 98-100
50.0 0-43 100 85-100 100
37.5 0-25 70- 15-55 90-100
28.0 0-7 85 0-50 85-100
26.5 0-5 0-50 0-28 15-55 100
20.0 0-28 0-25 0-50 90-100
19.0 0-25 0-7 0-28 85-100 100
14.0 0-7 0-5 0-25 15-55 90-100
13.2 0-5 0-7 0-30 85-100 100
10.0 0-5 0-28 15-55 90-
9.5 0-25 0-55 100 100
7.1 0-9 0-30 85- 90-100
6.7 0-5 0-25 100 85-100
5.0 0-7 25- 25-58
4.75 0-5 58 0-55
2.36 0-55 0-28
2.0 0-28 0-25
1.18 0-25 0-5
1.0 0-5 0-4
0-4
Dust content for
material passing
through a 75 µm 2
sieve mass
percentage
Aggregate crushing 29
value (ACV)3), of
Requirement
Property
less than 13,2 mm
and more than 9,5
mm fraction (dry),
mass percentage,
max.
10 % FACT value, of
less than 13,2 mm
Coarse aggregate for use in concrete subject to surface abrasion,
and more than 9,5
structural elements of reinforced or prestressed concrete (or both): 110
mm fraction (dry),
kN, min.
Flakiness index, max.
35 Flakiness index, max. 35
2.4.2.4 Concrete test cubes

All testing of concrete shall be carried out in accordance with the requirements of BS CP 114, clause 601 and
BS 1881. During mixing of concrete for each section of the work and at such other times as directed by the
Project Manager.
Consistency and bleeding tests and such other preliminary tests as the Project Manager may direct, shall be taken
as often as directed by the Project Manager. No concrete of any type or class shall be used in the works before
the preliminary tests have shown specified compressive strength and workability.
Concrete cubes must be prepared for every new batch of concrete in the following manner:
 Prepare 3 specimens for each test age. Moulds should be made of a non-absorbent
material150x150x150mm. The mould construction must be such that the specimen can be easily
removed. Three cubes shall be tested after 7 days, another three at 14 days and the remaining 3 cubes
after 28 days.
 Put in each mould +- 50mm well mixed concrete, compact with a tampering rod and ensure the layer
is uniform. Do not over compact as it might cause laitance and segregation.
 Repeat for layers 2 and 3 taking care that the already compacted layer beneath is not disturbed.
 After the third layer take a steel trowel and smoothen the exposed surface.
 Cover all the specimens with an impervious sheet, followed by wet matting, sacks, or similar material,
and then store them in a place that is free from vibration, excessive draughts, direct sunlight and low
temperatures for 20 h to 24 h.
 Demould the specimens and immerse them in portable water that is preferably maintained at 22 °C to
25 °C, until they are transferred to the test facility.
 During curing the cubes must be well protected against damage and/or vibration.
2.4.2.5 Buildings
2.4.2.5.1 Substation Main Control and Switchgear Building
The building must be furbished to Zesco standards. The inside and outside walls must be painted as well as the
floors. The doors, window frames and burglar proofing must also be painted. The following facilities must be
available:
 Relay room with operator control desks
 Telecommunication terminal equipment room
 Auxiliary power supplies room
 Battery room with wooden battery stands, eye bath, shower, wooden bench for maintenance
 Workshop, typically 3m x 4m, equipped with small power- and hand-tools only.
 11kV indoor switchgear room with self-levelling epoxy.
All 33kV feeder panels, the bus-zone protection panel, 33/11kV transformer control panels, 11kV switchgear
and associated equipment will be housed in the building.
The complete internal electrical installation will be in accordance with the latest international standards and must
be included as part of the building construction.
Heavy duty, non-slip, 300mm x 300mm, ceramic tiles at least 10mm thick must be used on all the floors except
for the new switchgear building which will have epoxy. Samples must be submitted for approval.
All secondary plant protection and control cabling will be top entry.
Tile skirtings shall be used in all rooms.
Each room with heat generating equipment must be vented by means of louvre door as well as air-conditioners
mounted in such a position that it will promote cross ventilation.
All outside doors will be provided with tamper proof locking mechanisms as per the design except for the
emergency exit.
The building will be constructed strictly according to international best practices as well as governing local
building standard and bylaws.
All material shall be new.
The contractor must appoint a registered civil engineer to do all structural and foundation designs. All new
foundations must be designed according to the mitigation measures provided by the geotechnical engineer for
the prevailing soil conditions and signed-off by the appointed civil engineer.
The main roof of the building will be a steel reinforced self-supporting concrete roof up to the edge of the
building. As an alternative to the steel reinforced in-situ concrete roof the contractor may consider using
wafflecrete pre-cast slabs. The final product chosen must have a trap door placed in such a place that it is the
maximum distance from any electrical equipment. Any concrete beams required for this roof must be housed in
the roof cavity. The building will furthermore be provided with a false roof on top of the concrete roof in the
form of IBR Chromadek roof sheets with steel trusses. The roof will be a standard pitched roof with overhangs
as per the typical building layout. A roofing certificate must be provided for the installation.
A waterproofing membrane must be installed between the trusses and the roof sheeting.
The finished floor level of all buildings will be a min of 600mm above finished terrace level. All ground on the
outside of the buildings will be sloped to promote drainage away from the buildings.
Vertical DPC to be installed for the cable trench.
All newly plastered surfaces on the inside of the building (walls and concrete roof) must be treated with two
coats high quality washable white acrylic PVA paint after a plaster primer has been applied.
It must first be treated with a plaster primer and painted with two coats white acrylic paint.
Power cable trench will be 1.5(d) x 2.25(w) m. Cable trench will be plastered, treated with primer coat and
painted white two coats white acrylic paint.
Install galvanized removable checker plate trench covers with lifting handles with support structures.
Install cable ladders for easy trench access.
All protection and control cabling will be top entry installed on a ceiling mounted cable tray.
The internal floors will be steel reinforced concrete and will be tiled with 300x300mm industrial grade non-slip
ceramic tiles with the same for the skirting.
External brickwork shall be done by using face bricks and internal walls with stock bricks.
Table 4 Compressive strength for masonry bricks
Individual
Nominal compressive
Class compressive Dimensions
Strength
Strength mm
MPa
MPa (min)
Hand-molded face
12 9 Length:190
brick
Width:90
Engineered face brick 17 12.5
Height:90
Non-facing brick 7 5.5
Brickforce will be installed on all new buildings as follows:

 Brickforce shall comprise hard-drawn wires that consist of two main wires of diameter not less
than 2,8 mm and not more than 3,55 mm spaced a constant distance apart, and 2,5 mm diameter
cross wires spaced at longitudinal intervals that do not exceed 300 mm in ladder-type brickforce
and at twice the distance between the longitudinal wires in truss-type reinforcement.
 Where required in terms of the specification data, brickforce shall be manufactured from pre-
galvanized wire, galvanized in accordance with the requirements of ISO 1461, or be made of
stainless steel wire.
 For walls install 180mm galvanized brick force every fourth course above the foundation to
under the wall plate.
 For walls above doors install 180mm galvanized brick force every second course above door to
under the wall plate. Together with this install typically 2 x R8 reinforcing bars the entire width
of the in and outside walls one brick layer above the door.
 For gables install 180mm galvanized brick force every fourth course to under the ridge,
 If the contractor utilizes the concrete column and beam method of construction, the brick-force
must be imbedded into the columns prior to casting the columns
Brick joints must typically be 10mm thick and rake to a depth of the same,
Expansion joints in walls will typically be between 10 and 20 mm wide and will be sealed by installing bitumen
impregnated soft board in the gap and closing the gap with a suitable acrylic sealer.
Building mortar must have a cement/sand mixture (1-4). It shall be mixed in small enough batches so that it can
be used up in a working day. Any leftover quantity must be discarded and are not to be used the next day.
The plaster must be maximum 15mm thick and must have a cement/sand mixture (1-5). Mortar shall be mixed
in small enough batches so that it can be used up in a working day. Any leftover quantity must be discarded and
are not to be used the next day.
All doors and door frames will be galvanised steel. Any air-conditioned rooms will have a solid galvanised steel
door. Forced ventilated rooms will have galvanised louvre doors with an insect screen. Any internal doors will
be solid galvanised steel. The auxiliary transformer rooms will be naturally vented by means of louvre door
which will have insect screening. The switchgear room will also be naturally vented by means of louvre doors
with removable dust filters as well as a 600mm (min) turbine ventilator mounted on the roof in such a position
that it will promote cross ventilation. The active part must be higher than the roof line. It must be provided with
flexible ducting to be able to vent the room and not the roof cavity.
All outside doors will be provided with tamper proof locking mechanisms as per the design except for the
emergency exits.
Used and un-used sleeves will be sealed and must be watertight and must be vermin proof.
The platform road to the parking for the office block will be paved with 80mm interlocking paving bricks sloped
away from the building for storm water management. The paving must be provided with an edge restraint in the
form of river sand and cement mixture surround. After the paving is installed it must be compacted with a
mechanical plate compactor. Fill the joints with dry sand by means of a broom. Wet thoroughly.
Any items, not measured separately under the civil works BOQ for the new buildings, must be provided for in
the unit rate for the building. This will include but not be limited to the site preparation, excavations, concrete
and false roof, walls, doors, plaster, reinforcement, inside and outside lights, foundations, inside and outside
finishes, natural and forced ventilation and or cooling, small power distribution and cable racking.
Entry into the stands will be by means of a road of the same specifications as the transformer road to be able to
handle weight of the transformer deliveries as well as to have a big enough turning circle. The road must have a
steady incline from the tarred road level op to the new platform level. Part of this inclined section will be a
headwall construction on both sides connected by a steel reinforced concrete pipe to facilitate storm water during
the rainy season. Any pipes installed and channels built must be similar in size than the existing systems and
must be able to dispose of the expected amount of storm water safely.
Water used for any Cementous mixes must be clean and free from injurious amounts of acids, alkalis, organic
matter, and other substances that may impair the strength or durability of concrete. All cement will conform to
the EN 413-1 specification and all the sub-clauses contained therein. The grading of the fine aggregates for the
plaster and mortar will be as indicated in Table 5
Table 5 Specification for fine aggregates for plaster and mortar
Type
Property
Fine aggregate for plaster Fine aggregate for mortar
Grading mass percentage
passing sieves with square 100
apertures of nominal sizes:
90 – 100
4,750µm
100 70 – 100
2,360 µm
90 – 10 40 – 100
1,180 µm
70 – 0 5 – 85
600 µm
40 – 10 5 - 35
300 µm
5–0
150µm
5 - 90
Type
Property
Fine aggregate for plaster Fine aggregate for mortar
65
20
Dust content for material
passing through a 75 µm sieve 7.5 12.5
mass percentage
Methylene blue
0.7
adsorption(max)
2
than 5µm mass percentage
Organic impurities The colour of the liquid above the fine aggregate shall not be
darker than the colour of the reference solution, except that this
requirement shall not be applicable if the fine aggregate complies
with the requirement for soluble deleterious impurities.
Soluble deleterious impurities The strength of specimens made with the fine aggregate shall be
at least 85 % of that of the specimens made with the same fine
aggregate after it has been washed, except that this requirement
shall not be applicable if the fine aggregate complies with the
requirements both for organic impurities and for the presence of
sugar.
Dry shrinking of mix (% max) 0.1 0.12
2.4.2.5.2 Office building

The office building will be done to the same standards and finishes as the control/switchgear building and will
consist of the following rooms:
 Filing facilities for drawings and manuals.
 Ablution facilities for male and female, with toilets and showers.
 Kitchenette.
 Storeroom for earthing gear and spare parts.
 Supervisor office with filing for drawings and manuals
2.4.2.5.3 Guard House

A guard house must be built in accordance with the standard ZESCO drawings and must be constructed in a
similar fashion as the control building as far as materials and finishes are concerned.
The Guard house shall be situated inside the substation perimeter fence, close to the main gate. The following
shall be provided:
 Separate personnel and vehicle access, to ensure that only authorised vehicles are granted entry.
 Direct communication facilities to a National or Regional Control Centre and to the local law
enforcement agency.
 Access control desk where the access control register can be completed and access permits issued.
 Display facilities for safety induction posters or audio-visual presentation.
 Security monitoring equipment, such as the alarm fence panel, fire protection system panel, intruder
detection system panel, and video surveillance terminal.
 Ablution facilities for guards and visitors, with toilet and shower.
2.4.2.5.4 Planning Office

The planning office will be done to the same standards and finishes as the control/switchgear building and will
consist of the following rooms:
 Ablution facilities for male and female.
 Kitchenette.
 Storeroom.
 Office with filing for drawings and manuals.
 Meeting room
2.4.2.5.5 Cable access - buildings

Except for medium-voltage power cables, all cables will run at high level in racks or cableways within the
buildings. The entry of cables into buildings from cable trenches shall be by way of an external cable column,
with vermin-proofed cable entries at a high level.
Cables to all outlets, switches, luminaires and other fittings shall be protected by running them in conduits,
power skirting, or other suitable surface-mounted cable management system. The use unprotected cables and
electrical mounting adhesive is not acceptable. Data and power shall be in separate cables and in separate
conduits or cableways throughout.
Medium-voltage power cables shall run in trenches to the switchgear. The trenches shall be wide enough and
deep enough to accommodate the minimum allowable bending radii of the cables. Cable entries into the building
shall have a suitable seal at the entry to prevent moisture ingress. Furthermore, the cable trench shall have a
sump at the lowest point that drains completely to the exterior of the building.
It is the responsibility of the contractor to determine sufficient weight and sizing for access on the cable racks
and at the entrance to the building.
Cable entry into the building will be through 160mm PVC sleeves installed at the same level as the bottom of
the cable trench inside the building. The entry or exit sleeves must typically start or stop a 1 000mm from the
outside wall of the building. If there are roads and or paving that will obstruct trenching for these cables to the
outside of the stand, the sleeves must be extended underground past the obstructions. The sleeves will be installed
on the centre line of each panel. The sleeve entry point into the building must be sealed both in and outside of
the building with an appropriate acrylic waterproofing sealant. Spare sleeves will be sealed with a waterproof
endcap. All cable entry point into the sleeves, used or un-used, will also be sealed the waterproofing sealant.
2.4.2.5.6 Electrical installations

Each building shall be supplied from a separate, wall-mounted, distribution board in accordance with the
applicable electrical installation regulations. There shall be earth leakage protection for all circuits feeding
socket outlets. The EPC Contractor shall obtain a certificate of compliance for the electrical installation from
the applicable inspection authority.
Socket outlets shall be British Standard, rectangular pin, outlets suitable for fused 15 A plugs. There shall be at
least:
 2 individually switched, double outlets in the supervisor’s office.
 Individually switched, double outlets in the control room.
 2 individually switched, double outlets in the kitchenette.
 2 individually switched, double sockets in the workshop.
 2 individually switched, double sockets in the gate house.
The kitchenette shall have a 30A stove switch / connection point.

Hot water shall be provided in the ablution facilities and kitchenette using locally-available, off-the-shelf, solar
hot water heaters with electrical back-up heating element and controller.
2.4.2.5.7 Indoor Lighting

The illumination required in various applications is given in Table 6. Indoor lighting shall be provided by
luminaires with covered, 2 m long, fluorescent tubes. Luminaires with bare tubes are not acceptable.
The lights will be controlled with an ON/OFF switch located on the inside of each door.
The light fittings will be mounted horizontally against the walls at 1m from the ceiling.
The fittings will have clear polycarbonate covers.
Outside lights will typically be a waterproof bulkhead with a 70W HPS on each side of the building. These lights
will be controlled by means of a daylight switch mounted against the building.
Table 6: Required illumination
LEVEL
LOCATION
(LUX)
Offices and control desks 800
Control room in front of panels 300
Control room at rear of panels 150
High voltage yard around transformers 20
High voltage yard in general 10
Emergency lighting 5
2.4.2.5.8 Emergency Lighting

The emergency lighting design must be done according to IEC standards to the following levels:
 The minimum lux level under emergency conditions shall be 5 lux.
Emergency lights will be of the same kind as the normal lights
The lights will be controlled with an ON/OFF switch located on the inside of each door. The switch must be
distinguishable from the normal light switch.
The light fittings will be mounted horizontally against the walls at 1m from the ceiling.
The fittings will have clear polycarbonate covers.
The lighting in each room shall be provided with a separate emergency light switch and timer, 0 – 30 minutes.
This timer shall only switch the emergency lights.
Emergency lights shall be self-contained units, fitted with internal power packs and inverters to operate
independently from the emergency switch. The batteries in the lights shall be charged under normal power
conditions.
2.4.2.5.9 Lightning protection

The buildings must be provided with a lightning protection system according to the standards hereunder typically
as follows:
STANDARD DESCRIPTION
IEC 62305 (ALL PARTS) Protection against lightning
SP-ESS-003 Substation earthing
The switching station building will be provided with a lightning protection system according to IEC62305 as
well as SP-ESS-003 typically as follows:
 Aerial termination rods will be installed on the roof to provide shielding.
 The termination rods will be bonded together as well as to the steel roof trusses.
 Install from each corner of the building and connected to the steel roof trusses a down conductor, of
typically 35mm² BCEW, and connect to the corresponding earth rod.
 The down conductor will be fixed to the wall with a saddle at intervals of not more than 500mm.
 Where there is a change in direction of the down conductor, the fixing intervals will be brought down
to maximum 200mm.
 The building will be provided with an earth ring conductor in the form of a 10mm copper rod installed
at a depth of 1m deep and 2m from foundation.
 The earth ring conductor together with the down conductor will be connected to 1.8m Cu plated earth
rods installed on each corner.
 Care should be taken when dissimilar metals are connected together.
 The contractor must submit as design to prove that the building will be covered.
 The design of a lightning protection and earthing system for the switching stations must be provided
for under schedule 3 “Design services”
2.4.2.5.10 Telecommunication facilities

Telephone sockets shall be provided in:
 Supervisor office.
 Relay room.
 Telecommunications room.
 Gate house.
The relay room shall be provided with an HF base-station radio, with outdoor antenna mounted on a suitable
antenna mast, according to ZESCO standards
2.4.2.5.11 Finishes
2.4.2.5.11.1 Toilets
The following facilities shall be provided in toilets:
 Toilet bowl – vitreous porcelain, plastic cistern, porcelain urinal in male toilet.
 Basin – vitreous porcelain.
 Framed mirror above basin with shelf for soap dispenser and towel loop.
 Bathroom tiles – ceiling to floor, ceramic tiles on floor.
 Shower – brick or toughened glass enclosure, with curtain or hinged door (sliding doors are not
acceptable).
2.4.2.5.11.2 Kitchenette
The kitchenette shall be fitted with stainless-steel laboratory sink and kitchen tiles shall be from the ceiling to
floor. Floors shall be covered with ceramic tiles.
All tiles shall be submitted to the Engineer for approval.
2.4.2.5.11.3 Furniture
The following furniture shall be supplied:
 Relay room – 2 x desks with chair, telephone / HF radio (mast and antenna).
 Supervisor office – desk, chair, telephone, conference table with 6 chairs, bookshelf, filing cabinet,
drawing cabinet.
 Gate house – control desk, chair, telephone.
 Kitchenette – laboratory bench with sink, (staff to provide own appliances).
2.4.2.5.12 Ventilation and/or air-conditioning
Air-conditioning shall be installed in the Supervisor’s office, relay room, telecoms room and the auxiliary power
supplies room. Forced ventilation shall be utilised in the battery rooms. These are only typical installations. The
Contractor must evaluate the equipment in his offer and install additional air-conditioning where required to
dissipate the heat generated.
Natural ventilation will be used in the toilet, store room, workshop and 11kV switchgear room of which the
switchgear room will have dust and insect filters.
2.4.2.6 Outdoor Lighting

The required lighting levels is specified in Table 6. Outdoor lighting shall be provided by luminaires with LED
lamps, installed on lighting towers. There shall be ladders on the lighting towers to access the luminaires, with
a safety cage around the ladder above 2 m. Emergency lights are not required, since the lights will be supplied
by the emergency generator.
The outdoor yard lighting must comply with international standards. A detailed lighting study must be performed
by the Contractor to provide the appropriate lux levels in the substation yard. The required lighting levels should
be 20 lux on the operating positions and a general average lighting level of the yard must be approximately 10
lux.
The yard lighting will be installed on the new 21m lighting mast to be installed in the yard as indicated on the
drawing. The lighting supply must be taken from the outdoor AC distribution board where the control mechanism
for the lighting must be housed.
The power supply cable to the masts is to be buried, and the steel armouring is only to be earthed on one side of
the cable to prevent circulating currents in the armouring. The foundation must have two sleeves at opposite
ends of the foundation to make provision for the supply cable.
The contractor must prove that the combined positioning of the masts will provide cover.
2.4.2.7 Lightning Cover

The positioning of lightning masts must be evaluated by the contractor according to the rolling ball method as
set out in IEC 62305 all parts.
The masts shall be positioned as indicated on the approved general arrangement drawing, and must be bonded
to the earth mat.
Shield wires will be strung between the gantry columns to provide full coverage over the electrical equipment.
Earth peaks will also be installed on top of the columns to further assist with lightning cover.
2.4.2.8 Fire protection
The General technical requirements in Standard SP-GGE-001 will be applicable in terms of fire protection.
2.4.2.8.1 Indoor
A fire detection system covering entire building, control panel at entrance of main building with audible alarm
and integration via SCADA shall be installed.
Install Class A (for trash, wood and paper) Class B (for liquid and gasses) and Class C (for energized electrical
sources) type dry power fire extinguishers mounted on wall near each door, in accordance with ZESCO standard
in normally occupied rooms e.g. relay room, offices, gate house.
The proposed solution should be environmental friendly, non-corrosive, non-conductive and nontoxic. The
system should not require any pipe work and must be easy to maintain. The system should utilize the latest fire
chain inhibiting technology by creating a fire extinguishing compound through exothermic oxidation or
condensed aerosol generators (CAG) type with manual override inside room at access doors shall be used in
normally unoccupied rooms e.g. 11kV switchgear; auxiliary power supplies; telecommunication equipment
room;
Any pressurizing or extraction ventilation fans must be interlocked with the triggering of the automated gas
system.
2.4.2.8.2 Outdoor
ABC trolley-mounted fire extinguishers shall be used in covered cubicles adjacent to the substation building,
the number dependent of substation configuration.
2.4.2.8.3 Transformers Fire Wall and Oil Drainage

Active fire protection system should be included in the bills of quantities as a Priced Option.
Transformers must be separated by fire barriers. Fire barriers must be constructed by means of cast concrete or
brick walls.
Bund walls must be installed around all transformers and should be able to contain 20% of the transformer oil
volume. The bund wall must be provided with knock out sections on the substation road side in the event that
transformers need to be removed.
The area between the bund wall and the plinth must be provided with rectangular galvanized steel grid that is
level with the ground. Transformer protection and control cables will be installed on top of the steel grid in a
suitable sized galvanized channel.
The bricks to be used for the bund shall match that of the control room.
The oil drainage system will consist of 300mm diameter fireproof pipes which will be installed between the
transformers and an oil dam capable of retaining 120% oil of the largest transformer.
An oil-water separator system must be installed with water conserved for treatment. Pumping will not be
allowed directly into the environment. An alarm will be initiated in the conservancy tank when the water level
reaches 30% to indicate pumping is required.
The oil-water separator system must be designed to allow for water overflow when the alarm and pumping
system fails. No oil will be allowed to drain from the oil-water separator system at any time whatsoever.
The separation distances between transformers shown in Table 7 shall be used for the placement of transformers.
Table 7: Transformer spatial separation distances
Volume of oil Separation distance

(kl) (m)
>60 23
30-60 15
10-30 10
2-10 7.5
<2 1.5
2.4.2.9 Substation facilities

2.4.2.9.1 Drinkable water supply
Drinkable water will be supplied by a borehole, via two 5,000 litre tanks on engineered tank-stands 6m high.
One tank will supply the requirements of the substation, and one tank will be used to supply the local community
via a standpipe and tap outside the perimeter fence near the guard house. The substation building and gate house
shall have balanced-pressure hot and cold water supplies.
The borehole shall be fitted with a suitable pump.
The tanks must be fitted with level detecting devices with auto starting and stopping of the pump once the water
level reaches set levels.
The borehole shall be fitted with casing from the top to the water level to prevent and caving in of the borehole.
The potable water supply will be supplied with all piping and connections.
Samples of the water must be tested and submitted for approval.
2.4.2.9.2 Waste water and sewerage disposal

Waste water and sewage will be disposed of by a 2,000-litre septic tank and French drain, constructed according
to ZESCO standard drawings. The tank must be positioned so that pumping of sludge is practical.
2.4.2.9.3 Solid waste disposal

Solid waste will be sorted into four 120 litre wheeled, plastic, bins that are emptied on a fortnightly basis. The
bins will be designated for:
 Paper and cardboard
 Plastic
 Metal
 General waste
2.4.2.9.4 Outdoor
Two covered parking – at least 3.0m wide, 7.0m long, and 2.4m high, suitable for typical electrical network
maintenance vehicles.
Four uncovered parking bays – at least 3m wide, 7m long
Fenced store yard for conductor, cable, and spare outdoor HV equipment – size to be determined based on
laydown requirements during construction and required spares holding.
2.4.2.9.5 Security and access control

A double barrier system for the switchyards will be used. There shall be a perimeter fence around the entire
substation property, and a separate fence around the switchyards. Where necessary for equipment maintenance
and inspection, there must be a compacted access road for maintenance vehicles between the perimeter fence
and the switchyard fence. Electric alarm fencing will not be applied.
Table 8 Security and Access Control Details
Perimeter Switchyard
1.8m razor mesh with 150 and
2.1m precision welded rectangular 300mm apertures, with a metal
Type mesh with a metal pipe imbedded pipe imbedded in concrete for
in concrete for support support, 3 wire strainers for
intermediate and bottom supports
Overhang Yes, razor mesh None.
Yes, 15cm above 60cm below
Dig barrier None.
ground level
Manual swing gates, locked from Manual swing gates, locked from
Vehicle gates
inside. outside
Personnel gates Swing gates, locked from outside. Swing gates, locked from outside.
Removable panels None 6m at transformer positions.
Gates during construction Diamond mesh sliding gate None
There will be no intruder alarm system, but there should be provision in the telecommunication and SCADA
systems for video surveillance. Cameras will be wall mounted at the gate house and main building by others.
2.4.2.10 Cable Trenches

Within switchyards, cables will run in covered cable trenches. The trenches shall be wide enough and deep
enough to accommodate the minimum allowable bending radii of the cables. Trenches shall have concrete strip
footings and reinforced concrete walls. Cable trench covers shall weigh no more than 40kg each, must be
removable by hand, and must support a load of 200kg at the centre without being damaged. Where a cable route
crosses a roadway, either the covers must be able to support the full axle load of transformer delivery vehicles,
or cable ducts under the road capable of supporting this load must be installed.
The top of the trenches must be ±150mm above the finished terrace level.
Cable racking are not required for control cables in cable trenches.
200mm sleeves must be installed for each individual MV cable at substation road crossings and shall be grouped
in trefoil formation with 600mm separation distance ensuring adequate bending radius of the cable at all times.
2.4.2.11 Access Roads

Substation access roads, gate locations and internal roadways must be designed for heavy loads to withstand all
conditions. This is to allow for delivery of equipment (especially transformers), access for maintenance vehicles
(especially crane trucks or bucket lifts), and access for light delivery vehicles or passenger vehicles. All
roadways should be well-compacted and level, providing easy access for maintenance vehicles and staff. There
should not be erosion, humps, large stones, or loose gravel in roadways. The minimum requirement is 5 m wide
single lane road with 500 mm shoulder, minimum inside radius 21 m, and gates positioned to accommodate 5 m
off-tracking. The access road to the substation should be replenished and graded immediately prior to delivery
of any heavy equipment such as transformers or reactors. The access road will also be seamlessly jointed with
the existing tarred and new concrete platform roads.
The design of roadways depends on the type of soil. For well-graded sand and gravel, substation roads need a
200 mm thick base G7 material compacted to 98% MOD AASHTO. For high-clay-content soils and loose sand,
substation roads need a 200 mm thick sub-base course of G7 material compacted to 98% MOD AASHTO, and
a 200 mm thick base course of imported well-graded soil compacted to 93% MOD AASHTO.
2.4.2.12 Internal Roads

A suitable reinforced concrete road must be constructed through the yard for transformer delivery. The road
must be 4m wide with a 500mm shoulder and cast in blocks not exceeding 4m in length. 25mPa concrete must
be used and the road must be capable to accept low-bed trucks carrying 60 ton loads without being damaged.
A minimum inside turning radius of 21m shall be provided with 5m off-tracking allowance for heavy vehicles.
Head- and toe-channel for drainage, with drains under base-course at suitable intervals shall be provided.
Internal roads shall not form part of the storm water drainage system. Internal roads shall be adequately elevated
above the substation platform level to prevent any unnecessary flooding over internal roads.
2.4.2.13 Yard Cover

The entire substation yard must be covered with a 100mm layer of clean crushed granite of 27 – 35mm nominal
size. The stone cover will extend 1m beyond the fence and will be contained by concrete kerbing installed 1m
outside the fence. The yard stone shall be lightly compacted to set levels.
2.4.2.14 Hot dipped galvanizing

All exposed steel structures shall be hot dipped galvanized in accordance with the latest edition of ISO 1461
The galvanizing required must be of the highest standard and therefore the supplier is requested submit the
following:
 a certificate of compliance in accordance with ISO 10474
 certification that the work has been carried out by a galvanizer registered to an appropriate quality
assurance standard, preferably ISO 9001
The processes that are followed must be at minimum the following:
 De-greasing or caustic solution cleaning to remove organic contaminants such as dirt, oil, and grease
 Rinsing with clean water
 Pickling with acid solution which removes oxides and mill scale
 Fluxing. The steel is dipped in the flux. The purpose of the flux is to clean the steel of all oxidation
developed since the pickling of the steel and to create a protective coating
 Hot air drying
 Zink bath
 Quench and passivate is typically water with synthetic resins to provide additional protection.
2.4.2.15 Steel Support Structures

Lattice structures are preferred throughout. Structures to be installed shall be in accordance with international
standards and specifications.
Before any mass production and galvanizing of steel structures is undertaken, one structure of each type must
be assembled and the following verified:
 That all the paired holes in the assembles state align properly and without there being mechanical
interference of any part of the rest of the parts
 That all the members are manufactured according to the approved designs therefore. If there is a
dimensional problem the design must be changed
 Any welded seams or minor protruding imperfections that will hamper the structure members to align
and be flush must be identified and corrected
 Any sharp edges, cutting and or welding residues removed
Steel support structures shall be similar to the structures used elsewhere in the ZESCO network, manufactured
from hot rolled steel sections and bolted together. The basic design will be similar to the standard equipment
which is in use throughout Southern Africa and must be designed for the specific equipment to be installed on
it.
Structures shall be erected and aligned correctly in the horizontal and vertical planes before the final torque of
the bolts are done. Foundation bolts shall be tightened once the structure has been levelled and an epoxy based
grout must then be used to seal under the base.
All the steelwork shall be checked for plumbness, tightness of bolts and nuts and secureness to the foundation.
All structures will be provided with a nut between the footing and the foundation for final adjustment of the
equipment. Adaptor plates and shims will not be used to straighten equipment. After installation of all equipment
the space between the footing and foundation will be filled in with non-shrinking grout.
All structure steel fixing holes shall be pre-manufactured and galvanized to align with foundations bolts and
equipment holes. No cutting of any support steel will be allowed on site.
All structures, bolts, nuts and washers shall be hot dipped galvanized to ISO 1461. Any items not conforming
thereto will be rejected.
There is no galvanizing plant in Zambia to do corrective actions. Any items that require modifications after the
initial galvanizing will not be accepted.
Badly manufactured and galvanized steelwork will be rejected immediately.
2.4.2.16 Earth Grid and Connections

The contractor must do a soil resistivity and earthing grid study with an IEEE-80 - 2000 compliant simulation
program for the earth grid design. The grid must extend 1m beyond the security fence and cover the operating
positions of all switchgear. Earth mat shall be designed to have a resistance not exceeding 1Ω. The design
parameters in Table 9 shall be used for the earthing grid design.
Table 9 Earthmat Design Parameters
Description Detail
Design Parameters
Design Standard IEEE 80 -2000
Yard stone layer resistivity (100mm) 3,000 ohm.m
Body Weight 50kg
Max. fault clear time 0.5s
Max. System Voltage 132kV
Earth Fault Current 50% of Maximum Earth Fault
Depth of earth grid 1 meter below terrace ground level
Earth material – Equipment Bare Annealed Cu
70 mm² round Cu
Earthing material size: Earthing Grid 3x50mm Cu strap
Connections If required:
Earthing Electrodes 4 electrodes in total, 20m deep, one at each corner of the
substation.
Wenner method.
Soil resistivity measurements
5 Readings at electrode spacing of 1, 2, 4, 8 and 16 meter
Soil Model Typical 2 layer
Safety Parameters
Earth Grid Resistance < 1 ohm
Touch Potential limit 703V
Step Potential Limit 2,349V
Ground Potential Rise Limit 5,000V
Round annealed copper rod with a 10mm diameter, is to be used for the main earth grid. All earth tails between
the main earth grid and equipment must be 50 x 3mm flat copper, bolted to the structures. Each piece of
equipment shall be connected to the earth grid, in at least two positions.
All terminal towers shall be connected to the substation earth grid by means of two 50 x 3mm flat copper.
All connections shall be cleaned from any dirt or paint to ensure proper electrical connection from structures to
the earthing grid.
The trench bottom shall be free of rocks and stones and shall be compacted before placing the copper conductor
in the trench. The copper conductor shall be placed on this bed of compacted soil.
Excavate 1m deep and install the earth grid with connections to the steel support structures. All crosses and
joints must be brazed or welded together by exothermic welding, Copperweld or Silbraloy. Contractor must
provide everything necessary to make joints.
No joint in earth conductorsshall be made above the ground level.
The main earth grid trenches shall be back-filled and compacted with the excavated soil, in layers not exceeding
the civil engineer’s recommendations. The re-compacted areas will match that of the undisturbed and must be
proven by means of a DCP test.
Flat straps must be curled halfway around the round bar to ensure sufficient surface connection. The straps shall
exit the ground directly next to the foundation and must be bent and profiled to suit the equipment shape as close
as possible. Where necessary and on runs on concrete of more than 600mm, the strap must be fixed to the
concrete.
All reinforcing must be bonded to the main earth grid by means of a 50 x 3mm flat copper.
The palisade fence must be bonded to the main earth grid at intervals not exceeding 10m. Both sides of all gates
shall be bonded to the earthmat. Gates shall be bonded to gate poles at two different points by means of flexible
insulated earths.
Two 1.8m Cu earth electrodes in series will be installed at each of the two connections to main earth of each
lightning mast.
The continuity of the earth path from the equipment to the earth grid shall be measured after the equipment has
been installed. The earth resistance of all new equipment shall be measured after installation and bonding before
the connections to the terminal towers are done. The measurements shall be carried out and logged by the
contractor in the presence of the Engineer.
Sacrificial anodes will be a 60kg piece of railway track installed and connected to the main earthmat using
“Silbraloy” brazing.
Provision shall be made for four drilled holes, one at each corner of the substation which will be used as earth
electrodes. The holes shall be at least 100mm in diameter and 20 meters deep. The earth conductor shall be
inserted into the drilled hole to the bottom of the hole and backfilled with a conductive concrete.
For the buildings, a 50 x 3mm flat Cu earth strap will be installed in the entire length of the new power and
control cable trench against the trench wall by appropriate means. This conductor must then be extended and
jointed to the existing earth ring conductor at two places on opposite sides of the building by means of oxy-
acetylene brazing using Silbralloy brazing rods. All the metal cubicles, switchgear, auxiliary transformers, cable
racking etc. will be bonded thereto by means of a 50mm² BCEW by means of a fit for purpose termination taking
the connection of dissimilar metals into consideration.
2.4.2.17 Concrete Foundations

All equipment shall be mounted on support structures, secured on concrete bases by means of 24mm galvanized
anchor bolts. The length of the bolt shall suit the application. Anchor bolts must protrude at least 80mm above
the finished level of the concrete and shall be provided with two nuts and two washers to allow for levelling of
the structures.
The gaps under the structure footings must be filled with an approved grout mix after the structures have been
levelled out.
Concrete bases shall be designed for a soil bearing pressure of 150kPa or higher as catered for in the costing;
this however is dependent on in-situ testing for each excavation. Support foundations must be redesigned and
adapted for soil condition with a bearing pressure lower than 150kPa. Pad and chimney foundations shall be
used for substation equipment support structures in soil, and alternative designs may be proposed for hard rock.
The Contractor will be required to carry out a geotechnical investigation, with special attention to the positions
of the gantries, transformers and the building.
Concrete bases shall be finished smoothly above the platform compacted level and shall protrude 150mm above
the finished ground level. This will allow the foundations to protrude ± 50mm above the 100mm yard stone
cover. All foundations shall have 45º chamfer along the entire edge.
Earth connections on all foundations shall be made to a dedicated position on the structure. The foundation
anchor bolts may not be used as a connection point.
The contractor will design plinths for the 30MVA transformers which will carry the total load of the transformers
including all accessories and oil. The plinths must be flat without any provision for wheels. The plinth must be
covered with a Malthoid or similar membrane to prevent any moisture from the concrete to the transformer base.
Minimum cover for concrete sections will be maintained with pre-cast concrete spacers tied to the steel with
galvanized binding wire. Under no circumstances will off-cut rebar be used.
2.4.2.18 Fencing and Gates

The station fence shall be precision welded galvanized rectangular mesh fence 2.1m high and topped with a
600mm galvanized razor mesh. The razor mesh topping shall be bend outwards at an angle of 45°. It will be
fixed to the fence-top by means of a 50x50mm angle bracket. The panels shall be mounted between shaped steel
profile posts of 2.1m height above ground supported by single concrete foundations of typically 0.4m x 0.4m
and 600mm deep. This will have to be confirmed on site according to the prevailing soil conditions.
The posts must be hot dipped galvanized and shaped as such to complement the angled sections of the vertical
sides of the mesh. All posts must be provided with cap to keep water out. The posts will be embedded into the
foundations which must be designed by civil engineer. The intermediate fence posts shall be positioned at not
more than 3.5m and each third post shall be additionally braced where required to keep the alignment. At the
corners, each panel will have its own strain posts. The two posts shall be connected and will be supported by a
reinforced concrete foundation that will typically bigger than the intermediate post foundation. Concrete quality
grade minimum 25MPa.
The panels must be precision welded rectangular mesh. The mesh must be made from 4mm high tensile wire
with aperture size of 76.2mm horizontal and 12.7mm vertical. Each panel must have a typical coverage of
3,300mm wide x 2,100mm high. Each panel must be strengthened with 4 x 50mm deep 'v' formation horizontal
recessed bands spaced in such a manner to provide optimum rigidity for the size of the panel offered. Each panel
will also have flanges along sides that is typically 75mm deep at a 70º angle. This flange will be used to bolt the
panels onto formed posts from the inside. The panel is bolted to the post on both sides of each the ‘V’ bands. All
fixtures must be designed to be vandal proof allowing for a completely flush installation of the post and panels.
Each panel will also have a 30º flange on the top and bottom.
The clamps used must have recessed areas to allow the clamp to settle into the mesh like a comb when tightened.
The screws used must be high grade stainless steel and must be fastened with a tool not readily available off the
shelf. All clamps and accessories must be galvanized.
Every other profile post shall be connected to station earthing grid by 16mm diameter stranded copper wire.
A concrete dig barrier shall be installed 15cm above and 60cm below ground level underneath the fence. The
dig barrier must be equipped with suitable holes for drainage.
The station gate(s) shall be of a double winged rigid steel-frame structure with precision welded mesh fill-in
panel, 5m wide and of the same height as the fence. The supporting posts and its reinforced concrete foundations
shall be able to carry the full opening gate wings (min. 100° opening) as a cantilevering structure. A locking
gear shall be at the centre of the gate and gate wings shall be fitted with a central lock. All steel parts as well as
the precision welded mesh panel shall be hot-dip galvanised as the fence itself.
The new fence must provide an un-obstructed clear view of all the equipment inside.
The fence on the eastern side of the platform must be provided heavy duty concrete bollards minimum 1.2 m
high of which 900mm must be above ground and at 3m outside the main fence no further than 2m apart for the
entire length of the new platform. The bollards must be steel reinforced and must be installed with a concrete
footing. This must be catered for under the unit rate for the fence.
Access to site during construction will be by means of diamond mesh sliding gates. This must be allowed for in
the site establishment costs.
2.4.2.19 Equipment and Fence Labels

Labels shall conform to international standards. All equipment in the substation will be supplied with new labels.
The following guidelines shall be followed.
Each piece of electrical equipment shall be provided with a designation label 280mm x 220mm. The labels will
be manufactured from 1.5mm aluminium plate, shall be white with black letters. The letter will be higher than
the rest of the plate. Uniformity of the labels will be a priority. Labels will be fixed to structures by means of
galvanized bolts and nuts.
Warning signs and First Aid information labels shall be fitted on the fence, gates and doors with room
designation labels mounted above each door.
Warning signs shall be fixed to the outside of the building as is required by law.
The following signs shall typically be installed:
 Room name
 Unauthorised entry and interfering prohibited.
 Warning of electrical shock.
 Warning of dangers of condensed aerosol generators (CAG)
 Emergency procedures.
 Procedure in case of fire.
 First aid treatment of electrical accidents.
 Emergency numbers.
The switching station nameplate will be mounted against the street side fence.
Each building must be provided with a first aid kit contained in a wall mounted metal box close to the switchroom
main door.
Table 10 Guideline for the installation of Substation Labels
Label material Chromadek or enamel paint (not vinyl stickers)
Equipment designation system: ZESCO standard
Colours, fonts, etc. ZESCO standard

Both sides of isolators, at line entries, at all transformer
Application of phasing discs
bushings
Safety labels ZESCO standard
All panels shall be provided with an identification label.
2.4.2.20 Trench earthing

A 50 x 3mm flat Cu earth strap will be installed in the entire length of the new power and control cable trench
against the trench wall or overhead cable rack by appropriate means. This conductor must then be extended and
jointed to the existing earth ring conductor at two places on opposite sides of the building by means of exo-
welding. Oxy-acetylene brazing using Silbralloy brazing rods can be used only by approval from ZESCO and
only in places where exo-welding is not possible. All the metal cubicles, switchgear, auxiliary transformers,
cable racking etc. will be bonded thereto by means of a 50mm² BCEW by means of a fit for purpose termination
taking the connection of dissimilar metals into consideration.
2.4.3 HIGH GLOSS SYNTHETIC EPOXY RESIN FLOORING

2.4.3.1 Specifications
For systems exceeding 2 mm in

Depth of wear shall not exceed 0.1 mm
thickness
- (Class AR1)
- BCA Abrasion Tester to EN 13892-4
Loss of volume shall not exceed 1.0
1 Abrasion or
cm3 - (Class RWA1)
resistance - Rolling Wheel tester to EN 13892-5
Loss in weight shall not exceed 100
For systems less than 2 mm in
mg (1000 cycles/CS10 wheels/1000g
thickness
load)
- Taber Abrasion Tester to DIN 53 754
Pull off strength EN 1542, using reference concrete to
2 > 1.5 MPa: nature of failure to be
to EN
reported.
the substrate 1766 (type MC 0.40) as substrate
EN ISO 6272, when bonded to a
impact resistance > 4Nm
3 Impact resistance reference
with no cracking or de-bonding
concrete of EN 1766, (type MC)
EN 13687-3 but with test conditions as In either case, the bond of the flooring
Thermal
+20°C dry to +80°C wet, for interior to a reference concrete substrate of EN
4 compatibility to
floorings EN 13687-2, for exterior 1766 shall not fail by cracking or
concrete
floorings. detachment
Permeability to EN 12086 The permeability shall be expressed as
5
water vapour g/m2/24 hours.
Class I (3 days) or Class II (28 days):
6 Chemical the nature of the chemicals to be tested
resistance EN 13529
to be agreed between the manufacturer
and the potential user.
Electrical
7 IEC 61340-5-1 or EN 1081 To meet customer's specification
resistivity
The flexural modulus class shall be
Modulus of declared by the manufacturer and shall
8 elasticity ISO 178 be indicated by E, followed by the
(flexural) modulus of elasticity in kN/mm2, e.g.
E15.
9 Resistance to Pendulum Slip resistance tester to BS > 40, when tested wet (see section 8.2
slipping (wet) 8204-2 for detailed requirement)
2.4.3.2 General
It is imperative that this document be read in conjunction with the product manufacturer’s instructions.
Before any work is done the full specification sheet of the intended product must be submitted for approval.
The substrate must be designed independently of the flooring to withstand all structural, thermal and mechanical
stresses and loads that will occur during service. It should remain stable whilst protected by the flooring and be
provided with all necessary expansion, contraction and crack inducement joints to enable it to do so. The failure
of the substrate will reflect in the finish.
The surface strength of the concrete base or screed needs to be sufficient to restrain any stresses that occur during
the setting and hardening of the synthetic resin flooring.
The surface tensile strength of the concrete base or screed should be determined by the method given in EN1542
and should normally exceed 1.5 MPa. Where the mean surface tensile strength is less than 1.5 MPa the designer
should specify a suitable corrective measure like for example reinforcement of the surface with penetrating resin
sealers or more extensive preparation and making good. Alternatively, the surface strength of the base or screed
may be assessed using a rebound hammer (Schmidt) in accordance with BS 1881-202. For all classes of flooring
the rebound hammer readings should generally be above 25, but a lower reading may be acceptable if the surface
tensile strength of the base concrete or fine concrete screed exceeds 1.5 MPa.
Assessment of the hardness or strength of a concrete base surface with a rebound hammer should be done strictly
according to the supplier’s requirements.
The substrate needs to be finished with a strong even surface and laid to such falls as necessary.
Synthetic resin floorings should not be used to alter levels as a corrective measure for poor installation of
substrates. Where any adjustments to the existing level must be made, rather use a polymer-modified
cementitious levelling screed that is compatible with the final layer.
2.4.3.3 Damp proof membranes

A damp-proof membrane must be incorporated into the design of the concrete base, when ground supported.
The membrane must preferably be installed directly below the base.
2.4.3.4 Tolerances
Synthetic resin floorings will generally follow the profile of the underlying substrate, due to the method of
application. The agreed standards for flatness and regularity should therefore be produced in the base concrete
or levelling screed as far as possible.
2.4.3.5 Surface regularity

The modular construction of as well as moving part contained in the switchgear panels requires a high surface
regularity. To determine this, the 3 metre straightedge method given in BS 8204-1 is generally satisfactory for
the majority of floor uses to determine the degree of surface irregularity. The outcome of this will determine if
remedial actions are required before the final epoxy layer is applied.
2.4.3.6 New concrete bases and screeds

Great care should be taken to finish the floor to the accuracy required to negate the requirement for remedial
actions. The concrete should not contain a water repellent admixture where water-based synthetic resin floorings
are to be applied. All services should be confined within the base concrete or screed and not allowed to penetrate
the flooring.
To achieve sufficient tensile strength in the surface of the base concrete, it should preferably be designed to have
a minimum characteristic compressive strength of 25 MPa and adequate workability to allow full compaction.
If the tensile strength of the concrete is too low to accommodate synthetic resin floorings, it can be corrected by
a polymer-modified concrete screed to the approval of the epoxy flooring supplier.
Care should be taken that during the hardening and curing of the base slab or screed it does not suffer mechanical
damage or become contaminated with grease, oil etc. If such problems do arise the slab or screed should be
treated as for an old concrete base.
The concrete used should achieve the surface strengths specified or as is required before the flooring is laid.
Unless otherwise specified by the flooring manufacturer, the base should be at least 28 days old, with the relative
humidity at the surface no more than 75%.
For those synthetic resin floorings that are moisture sensitive during application, it is necessary to ensure that
sufficient of the water used in the construction of the base is eliminated. The use of curing membranes will
effectively prevent drying out until removed. After the curing of the concrete it is essential that the excess water
be allowed to evaporate. The time for this to happen should be considered at the planning stage.
Surface preparation is a most vital aspect of all flooring application. The quality and condition of the interface
between the substrate and the flooring determine its ability to withstand static and dynamic loads imposed in
use. Failure to transfer loads adequately results in loss of adhesion and hollowness.
The laitance on in-situ bases and any surface sealer or non-bonded curing compound should be entirely removed
by suitable mechanised equipment, e.g. shot-blasting, planing, grinding, to expose the coarse aggregate cleanly.
Care should be taken to ensure that high intensity mechanical treatment does not cause micro-cracking to weaken
the underlying substrate. For the thinner floorings, light contained shot-blasting or diamond grinding is preferred
so that the profile does not reflect in the finish.
The use of contained abrasive blasting equipment is more suitable than mechanical scrabbling which could
damage the surface.
After surface preparation all loose debris and dirt should be removed by vacuum equipment. Very fine dust may
need to be removed by detergent washing. The preparation operations should be delayed until shortly before
the flooring is to be laid to avoid the risk of fresh contamination or further accumulation of dirt.
2.4.3.7 Work on site

 It is imperative that the manufacturer’s instructions are studied in advance of the work starting,
since recommendations or restrictions may influence the overall programme. These instructions
should be incorporated in the flooring contractor's method statement. All materials must be new.
 Storage should be arranged so that consignments can be used in the order of their batch numbers.
It is therefore important that labels do not become damaged or detached from their containers.
 Absolutely no additives, be it colour, thinning or thickening agents, will be added unless

specifically allowed by the manufacturer.
2.4.3.8 Powder components and aggregates (including any pigments)

Bags of fillers, aggregates or other powdered components should be kept dry and stored in a weatherproof
building. If the floor is concrete, the bags should be stacked on a timber pallet away from walls. Fillers and
aggregates should be kept preferably at 15º - 20ºC to ensure that the resultant flooring mix does not set too
quickly or too slowly.
2.4.3.9 Liquid components

The containers of resins and hardeners should be stored in a weatherproof building maintained preferably at 15º-
20°C or as per the supplier’s specific requirements, unless the product manufacturer has stipulated other storage
conditions for the stated shelf life.
2.4.3.10 Batching
All materials should be accurately proportioned and mixed in the correct sequence in accordance with the
manufacturer's recommendations. It is usual to mix the liquid components together thoroughly before blending
in the fillers and aggregates.
The usable life of the mixed materials depends upon the temperature of the mixed materials. Manufacturers'
literature should give an indication of the working life of the properly mixed product at one or more temperatures.
As a rough guide, a 10°C rise in temperature may halve the working life and a 10°C fall may double the working
life. However, it is not advisable to mix and lay these products outside of the range 10-25°C unless the system
has been specially designed to be used for a different temperature range.
Resin systems are generally exothermic and so an important factor governing the temperature of the mixed
materials, is the volume being mixed. Larger volumes will heat up more so shortening the available working
life.
If the mixing area is not adjacent to the laying area an appropriate allowance for the time to transfer the mixed
material should be made to ensure sufficient time for the product to be installed within the working life.
2.4.3.11 Mixing Primers

The primer is usually a two-pack formulation supplied in pre-weighed quantities ready for site mixing. The two
components should be thoroughly mixed together mechanically to form a homogenous mix. The two
components should be mixed preferably using a slow speed (200-500 rpm) drill fitted with a mixing paddle,
taking care not to entrain excessive air in the mix.
It is important to ensure that any material adhering to the sides and bottom of the mixing vessel is always
thoroughly mixed in. It is good practice to transfer the mixed material into a clean container and stir well before
application. This procedure prevents the use of partially mixed material.
2.4.3.12 Flooring mix (including trowel-applied mixes, self-smoothing mixes and coatings)
All mixes should be mixed mechanically. Resin coatings shall be mixed using a heavy duty slow speed drill
(200-500 rpm) drill fitted with a mixing paddle. Forced action mixers of the rotating pan, paddle or trough type
shall be used for all flow applied and trowel applied screeds. Free fall mixers are not recommended because
there is insufficient shear action to disperse all the dry materials.
The reactive components are first thoroughly mixed together and then the fillers and/or aggregates are added
gradually whilst continually stirring. After all the fillers and/or aggregates have been added, sufficient mixing
time (typically 3-4 minutes) must be given to ensure thorough 'wetting' out of the fillers and/or aggregates by
the binder. Excessively vigorous mixing shall be avoided as this can lead to undesirable air entrainment. Care
should be taken to ensure that any material adhering to the sides, bottom and corners of the mixer is thoroughly
blended in.
2.4.3.13 Types of synthetic flooring

Table 11 Types of synthetic flooring
Type Name Typical thickness Description
Floor seal Dry film thickness up to 150 µm applied in 2 or more coats: generally
1
solvent or water borne.
applied in 2 or more coats: generally
2 Floor coating final thickness of 150-300 µm solvent-free but may be solvent- or water-
borne.
High build floor applied in 2 or more coats: generally
3 final thickness of 300-2000 µm
coating solvent-free.
multiple layers of floor coatings or flow-
4 Multi-layer flooring 1 mm + applied floorings with aggregate dressing:
often described as 'sandwich' systems.
Often referred to as 'self-smoothing' or
Flow applied flooring 2 to 3 mm 'self-levelling' flooring, and having a
5
smooth surface: or may be given a surface
dressing.
heavily filled, trowel-finished systems,
6 Screed flooring 4 mm + generally incorporating a surface seal coat
to minimize porosity.
Heavy duty flowable aggregate-filled system, having a smooth
7 4 to 6 mm
flooring surface: or may be given a surface dressing.
Heavy duty screed trowel-finished, aggregate-filled, system

8 6 mm + which is effectively impervious throughout
flooring
its thickness
2.4.3.14 Priming the substrate

The primer should be chosen to be compatible with the conditions of the substrate. Ideally the primer should be
a solvent-free, low viscosity composition to reduce the risk of solvent entrapment in the concrete and to
maximise penetration of the primer into the surface.
After mixing the components of the primer together, it should be applied as soon as possible after mixing (and
well within its working life) to the prepared substrate. The primer should be applied evenly to the substrate with
a stiff brush or roller or by tight trowelling. The substrate should be completely wetted by the primer to achieve
maximum penetration into the substrate and ensure good adhesion and to prevent pin-holing. Full saturation of
the surface is desirable but pooling of the primer should be avoided by using a clean roller to remove any excess.
When applying the screeded synthetic flooring of Types 6 and 8, a useful technique is to apply a scatter of fine,
clean and dry aggregate over the liquid primer, but avoiding localised saturation, to provide a key for adhesion
of the flooring and to reduce slippage under the trowel. As a guide an aggregate addition rate of 0.5 to 1.0 kg
per m² should be suitable. This also helps to reduce the risk of limited bond if the primer has cured too far.
With flow applied systems, two coats of primer, or an excess of primer in one coat, may be necessary to prevent
pin hole defects in the finish, and it is a wise precaution to provide for this in terms of material consumption and
timing.
The area of substrate which can be coated with the primer prior to the laying of the flooring will depend on the
working life of the primer, as specified by the manufacturer. Unless otherwise specified, the primer should be
partially cured to a tacky stage before the resin flooring is applied, to ensure a good bond between the primer
and the applied resin finish. However, for certain systems, particularly flow applied resin systems, it is essential
that the primer should have become tack free. The manufacturer’s instructions must therefore always be
followed.
2.4.3.15 Resin Coatings (Types 1-3)

These coatings are usually applied by spray, brush or roller in 2 or more coats, applied at right angles to each
other. Typically, the first coat must cure before the second coat is applied. The manufacturer’s instructions on
timing must be followed to ensure full bond between the coats.
2.4.3.16 Multi-layer flooring (Type 4)

These products are normally made using combinations of floor coatings (Types 2-3) or flow-applied flooring
(Type 5) with intermediate aggregate scatter. They should be applied strictly in accordance with the
manufacturer's instructions.
2.4.3.17 Flow applied systems (Types 5 & 7)

These compositions are designed to flow out readily to provide a smooth substantially level surface. They are
applied by spreading evenly over the surface, using a serrated trowel, pin rake or squeegee. This should be
followed by rolling with a spiked roller to release any entrapped air and assist in smoothing out. The use of the
spiked roller on areas which are starting to thicken or are partially set should be avoided.
The quality of surface finish achieved with flow applied systems is particularly temperature sensitive and the
manufacturer's recommendations in terms of minimum air and slab temperatures should be strictly adhered to.
Forced heating of the atmosphere over a cold slab is undesirable since it can promote blistering of the surface.
2.4.3.18 Trowel-Applied Resin Flooring (Types 6 & 8)

The material should be spread out over the primed substrate between screeding laths or bars or using a screed
box (sledge) to ensure a uniform thickness and level surface throughout. The screed should be well consolidated
to obtain the optimum properties from the end-product. A final smooth finish should be obtained using a suitable
steel trowel. Carbon steel trowels can lead to unsightly marking of the flooring surface. The trowel should be
kept clean always by using a minimum amount of cleaning solvent or water as advised by the manufacturer.
Over-trowelling should be avoided as this can cause patchiness and blistering in the finished floor.
Trowel-applied resin flooring provides a durable slip resistant floor surface for most applications. However, if a
more hygienic surface is required, it may be necessary to seal the surface using a one or two coat application of
a compatible resin sealer, much of which is absorbed into the trowel applied flooring. This may be either a
solvent-free or solvent-containing system applied by brush, squeegee or roller. It is usually applied after the
screed has cured, but taking care to ensure that the surface has not been contaminated during the curing period.
2.4.3.19 Reinforcement
Reinforcement, such as fibre glass cloth, may be included in the flooring system to minimise problems from
cracks or bay joints in the substrate. After applying the primer, a thin layer of the resin flooring is applied and
the fibreglass is rolled into it, overlapping the fabric at joins by at least 50 mm. Entrapped air should be avoided.
The final layer of resin flooring is then applied. If necessary, any outstanding reinforcement should first be
ground off.
2.4.3.20 Curing
The final floor system should be allowed to cure exactly according to the manufacturers' instructions. These
generally require 1-3 days at 15º-20°C before trafficking and 3-7 days before washing, before contact with
chemicals, or before any ponding tests. At site temperatures below 10°C these times will be substantially
increased.
The climate above the uncured resin floor should be maintained at least 3°C above the dew point or below 75 %
relative humidity to reduce the risk of condensation or 'blooming' on the floor finish. Condensation occurs when
the substrate temperature is lower than the dew point temperature, which is a function of the relative humidity
and the ambient air temperature. Table 12 shows the approximate relationship between these variables.
Table 12 Dew point temperatures
Ambient dry Dew point temperatures (°C) for ambient relative humidity between 40 and 100% RH
temperature
°C 40% 50% 60% 70% 80% 90% 100%
35 19 23 26 29 31 33 35
30 15 19 22 24 26 28 30
25 11 14 17 19 21 23 25
20 6 9 12 15 17 18 20
15 2 4 7 10 12 13 15
10 -3 0 3 5 7 9 10
5 -7 -5 -2 0 2 4 5
2.4.3.21 Osmotic blistering

Blistering which occurs soon after laying is generally caused by vapour pressure from moisture in the substrate.
Osmotic blisters are generally confined to synthetic resin floorings, resin coatings and flow applied systems, up
to about 6 mm in thickness.
Osmotic blistering can occur on suspended floors, as well as on ground supported slabs, if sufficient moisture is
retained in the concrete.
2.4.3.22 Prevention of osmotic blistering

It is considered good practice to take the following steps to minimise the risk.
 in new construction ensure the base concrete has low soluble salts by avoiding poorly washed
aggregates and by curing the concrete well immediately after laying to prevent premature surface
drying out;
 allow the concrete to dry out thoroughly after curing, preferably for a minimum of 21 days;
 using mechanical rather than chemical means of preparing the concrete surface by avoiding the
use of acid etching;
 by avoiding washing the concrete surface with detergent solutions as part of the preparation
procedure;
 by the complete removal of all contamination from existing floors: this may prove very difficult
where the concrete has been saturated for long periods with water soluble materials;
 levelling screeds should preferably be polymer-modified to minimise permeability and salt

migration;
 avoiding the use of water-dispersed primers;
 using primers which are free of water soluble constituents which might promote osmosis, for
example, benzyl alcohol;
 avoiding the use of solvents, especially in the primer;
 by ensuring that the synthetic resin flooring is precisely proportioned, either by weight or volume
as specified by the product manufacturer;
 by applying a scratch coat underneath.
2.4.3.23 Repair of osmotic blistering

Where osmosis has occurred, techniques which have proved successful in preventing the problem re- -appearing,
after cutting out the affected area and mechanically cleaning the exposed concrete, include:
 double application of a penetrating primer to the base to ensure complete coverage and maximum
adhesion of the replaced flooring;
 replacing with a trowel applied flooring;
 Hot compressed air blasting of the exposed concrete coupled with the application of a penetrating
primer whilst the concrete is still warm.
2.4.4 PRIMARY PLANT

The detailed Scope of Work is given in the Scope of Work section of this document. All the designs, equipment,
material and construction works shall comply with the details as described in the following sections of this
document.
2.4.4.1 Insulation levels

The insulation levels shown in Table 13 will be applied to equipment installed for this project. Note: The
creepage distance for Industrial substation is higher than the creepage distance specified on all the other projects
due to the high pollution in the area.
Special insulation levels for 11kV switchgear is specified in Table 13.
Table 13: Standard Insulation Levels and Creepage Distances
Insulation Levels Creepage distance

System Nominal System Highest over external
Voltage (kV) Voltage (kV) 60 sec power Hz insulation
BIL
withstand
(kV) (kV) (mm/kV)
11 17.51 38 95 25
33 36 70 200 25
Note 1: Bidders are required to provide 11kV indoor switchgear with a BIL of 95kV which relates to a Rated voltage of 17.5kV in
accordance with IEC 62271-1 2011 Table 1a.
2.4.4.2 Clearances
The clearances specified in Table 14 shall be used in the design of the substation layout.
Table 14 Electrical Clearances
Minimum Electrical Clearance in Minimum Working Clearance in

Voltages
mm mm
To the nearest
part, not at
To Nearest
System Nominal System Highest earth potential,
Phase-to-Earth Phase-to-Phase Unscreened live
Voltage Voltage of an insulator
(mm) (mm) conductor in air
( kV) ( kV) supporting a
(mm) live conductor
(mm)
11 12 200 270 2,600 2,450
33 36 430 580 3,000 2,450
2.4.4.3 Design fault levels

The applicable design fault levels for three-phase and single-phase to earth fault levels is summarised in Table
15.
Table 15: Design fault levels
Substation class Units 3Ph design level 1Ph design level
11kV Switchboard kA 31.5 16
33kV Busbar kA 31.5 16

2.4.4.4 Busbar, Conductor, Clamps and Cables

The 33kV busbars will be connected by means of aluminium conductors and aluminium tubes mounted on post
type insulators in a low-level configuration.
All stringing shall be done in accordance with the general arrangement and sections layout drawings as described
in the following sections. Jumpers shall be installed with an adequate loop to allow for shrinking and expansion.
Tubular Aluminium busbars shall be equipped with a suitable piece of aluminium conductor, typically Centipede
AAC for 60% of the busbar length in the inside and fixed on the one end of the tubular busbar for vibration
damping purposes. A 10mm drainage hole must be drilled in each tubular busbar at midpoint to facilitate the
drain of any moisture present.
Only one end of each section of tubular busbar supports shall be equipped with a fixed clamp. Provision shall
be made for a sliding clamp on the other end of every section of tubular busbar.
2.4.4.4.1 33kV Switchyard

The 33kV switchyard shall comply with the ratings and technology specified in Table 16.
Table 16 33kV Switchyard Busbar and Conductor Ratings
Design Limit Proposed Rating

Description
MVA Amp Conductor/Cable MVA Amp
33kV Busbar 90 1,600 80x4mm Aluminium alloy tube 106 1,860
33kV Transformer
90 1,600 Flexible Twin Centipede AAC 95 1,660
Incomer Bays
33kV Bus Coupler

90 1,600 Flexible Twin Centipede AAC 95 1,660
Bay
33kV Line Bay 30 800 Flexible Single Centipede AAC 50 830
2.4.4.4.2 11kV Switchgear

The 11kV switchgear shall comply with all the requirements of section 2.4.5 and the ratings in Table 17.
Table 17 11kV Switchgear Busbar and Conductor Ratings
Parameter Requirement
Technology Indoor, withdrawable, metal-clad switchgear.
Busbar material OEM standard
Interconnecting conductors OEM standard
Busbar rating 60MVA (3,150A)

30MVA incomers (1,600A), bus-couplers (2,500A)
Bay ratings
15MVA cable feeders (800A)
2.4.4.4.3 Clamps
Moulded aluminium clamps suitable rated will be used to make the connections to and from busbars and
equipment. Bolted clamps are preferred to crimped clamps for maintenance purposes.
The clamp assemblies shall be installed and torqued in accordance with the manufacturer’s specifications.
All conductors shall be cleaned to a shiny finish with a steel brush at the point where the conductor clamps are
to be applied.
An anti-oxidation compound shall be applied on all conductor and earthing connections, before clamps are
installed. This must be included for in the unit rates.
Clamps sizes shall be correctly specified for all connections. No modification to clamps, conductors or filling
of gaps will be allowed. All clamps will come pre-drilled.
For any current carrying Aluminium clamps the installation will be as follows:
 All clamps must have pre-drilled holes and must be packaged in heavy duty plastic bags to keep any
moisture out. Clamps must only be removed prior to its installation.
 Aluminium oxide must be removed from all current carrying sections of Aluminium clamps, stranded
conductors and tubular busbars prior to the connection being made.
 Use a steel wire brush or an 80-180 aluminium-oxide emery cloth and clean the areas until shiny in
appearance.
 Immediately apply a 0.25-0.5mm layer of high melting point non-oxidant grease, install the clamps
and fasten as per the manufacturers recommendations.
 If the applied greased gets contaminated with foreign matter, use a relevant solvent to remove the
grease and re-apply the grease. The solvent must be approved for aluminium and not do more damage
than good.
 Any tubular clamps or supports making use of a split body clamp must be so tightened that the gaps
on both sides of the clamp is the same thereby ensuring a properly seated clamp as indicated in Figure
16.
 The correct tightening sequence for multiple bolted clamps must be followed to ensure the internal and
external stresses on the clamp and busbar is balanced out as indicated in Figure 16.
Figure 16 Clamp fastening detail
2.4.4.4.4 Cable Ratings

XLPE Single core copper cables shown in Table 18 are to be installed between transformers and 33kV outdoor
yard and 11kV switchgear. The cables are to be routed in different trenches through separate entrances to the
substation yard and building.
The 33kV feeders of the existing Woodlands 33/11kV substation need to be connected from the overhead line
terminations to the new 33kV outdoor yard with cables as shown in Table 18.
Table 18 Cable Ratings
Design Limit Rating

Description Proposed Cable Amp
MVA kV Amp MVA In
Ground
33/11kV Transformer
30 11 1,575 3 x 630mm² 11kV XLPE 1C Cu / Ph 31 1,610
to 11kV switchboard
Bauleni 33kV Feeder
30 33 800 1 x 240mm² 33kV XLPE 3C Cu 26 460
No 1
Bauleni 33kV Feeder
30 33 800 1 x 240mm² 33kV XLPE 3C Cu 26 460
No 2
Chalala 33 kV OHL
30 33 800 1 x 240mm² 33kV XLPE 3C Cu 26 460
Feeder
Waterworks 33 kV
30 33 800 1 x 240mm² 33kV XLPE 3C Cu 26 460
OHL Feeder No 1
Waterworks 33 kV
30 33 800 1 x 240mm² 33kV XLPE 3C Cu 26 460
OHL Feeder No 2
UTH 33 kV OHL
30 33 800 1 x 240mm² 33kV XLPE 3C Cu 26 460
Feeder 2
2.4.4.5 Specific requirements for the 33kV switchyard bays

2.4.4.5.1 Feeder bays
The following is required in all feeder bays:
 Surge arresters must be installed on the line-side of line isolators.
 Voltage transformers must be installed on the line side of isolators.
 Line earth switches must be installed on line isolators with electrical interlocking to voltage
transformers.
 No circuit-breaker side earth switches are allowed on isolators. Make provision for portable earths and
associated portable earth connections throughout.
 The operating controls of feeder circuit breakers must be placed so that the operator is facing the
outgoing line bay when switching.
2.4.4.5.2 Transformer bays
In addition to busbar selection isolators, transformer isolators (on the transformer-side of circuit breakers) are
required for outdoor connections. For cable connections to indoor switchgear, the racked-out circuit breaker
truck is adequate isolation.
No circuit breaker side earth switches are allowed on isolators. Use portable earths with associated earth
connections throughout.
Provision should be made for a concrete runway and removable panels for offloading of the transformers.
LV cables must be installed on racking above level of bund wall, dropping into cable trench (still on racking).
No cables or piping shall be taken through the bund wall.
33/11kV Transformers shall have 33kV and 11kV cable connection on the same side, away from the substation
road.
The operating controls of transformer circuit breakers must be placed so that the operator is facing the
transformer when switching.
2.4.4.5.3 Bus couplers and sections
Current transformers and isolators must be provided on both sides of circuit breaker.
A voltage transformer must be provided on each section of the busbar.
No circuit breaker side earth switches are allowed on isolators. Use portable earths with associated earth
connections throughout.
Busbars are to be fully-supported by post insulators. HV equipment (and isolators in particular) must not be
used as busbar supports.
2.4.4.5.4 Neutral earthing
Neutral earthing affects prospective earth fault currents and surge arrester selection. For the classes of substation
required in this project, the standard neutral earthing policies in Table 19 will be applied.
Table 19: Neutral earthing
Substation class Neutral earthing policy

Transformer neutrals resistively earthed
33kV substations
500A (typically 39.0 Ω) per transformer
Transformer neutrals resistively earthed
11kV switchboards
500A (typically 12.7 Ω) per transformer
400V boards Transformer neutrals solidly earthed
2.4.4.6 Power Transformers

Transformers shall comply with the requirements of IEC 60076.
The vector groups and rating of transformers within the network must be coordinated to ensure operation
flexibility. The vector groups and ratings that are to be used are shown in Table 20.
Table 20: Transformer Rating and Vector Groups
Voltage ratio Rating Vector group Impedance
33/11kV 30MVA Dyn1 ±10%
Power transformers will be fitted with an oil immersed automatic on-load tap changer with a +5 -15% regulation
(referenced to the HV side) according to IEC 60214 and be designed to be maintenance free for 300 000
operations. (The power rating of the transformer shall be 100% throughout entire tapping range) The tap changer
must be from an approved supplier, and be able to withstand the same steady-state load and fault conditions as
the transformer.
Transformer testing shall comply with IEC60076 Part 3, 4 and 5. Transformer testing shall be done and submitted
according to Table 21. All routine tests shall be done in the presence of the client or client’s representative. Test
certificates of an identical unit shall be submitted for all special and type tests as required in Table 21. If these
test certificates are not available for identical units, these tests will be conducted in the presence of ZESCO or
Employer’s representative. The costs for all tests will be included in the pricing schedule. Although short circuit
withstand tests will not be required, all design information will be provided for an independent verification of
the transformer short circuit withstand capability.
Factory Inspection Tests will be conducted with the transformer fully assembled.
Table 21 Schedule of Transformer Tests Required
Type of Testing Provide

No Description
test Required Certificate
1 Measurement of winding resistance Routine Yes

2 Measurement of voltage ratio and check of phase displacement Routine Yes

No Description
3 Measurement of short-circuit impedance and load loss Routine Yes

4 Measurement of no-load loss and current Routine Yes
5 Dielectric tests Routine Yes
6 Tests on on-load tap-changers Routine Yes
Leak testing with pressure for liquid-immersed transformers
7 Routine Yes
(tightness test)
8 Check of the ratio and polarity of built-in current transformers. Routine Yes
Check of core and frame insulation for liquid immersed
9 Routine Yes
transformers with core or frame insulation
Determination of capacitances windings-to-earth and between
10 Routine Yes
windings.
Measurement of DC insulation resistance between each winding
11 Routine Yes
to earth and between windings.
Measurement of dissipation factor (tan δ) of the insulation system
12 Routine Yes
capacitances.
Measurement of dissolved gasses in dielectric liquid from each
13 Routine Yes
separate oil compartment except diverter switch compartment.
Measurement of no-load loss and current at 90 % and 110 % of
14 Routine Yes
rated voltage
15 Temperature-rise type test Type Yes
16 Dielectric type tests Type Yes
17 Determination of sound level Type Yes
Measurement of the power taken by the fan and liquid pump
18 Type Yes
motors.
19 Dielectric Special tests Special No No
20 Winding hot-spot temperature-rise measurements. Special No No
Determination of capacitances windings-to-earth, and between
21 Special No No
windings.
22 Determination of transient voltage transfer characteristics Special No No
23 Measurement of zero-sequence impedance Special Yes
24 Short-circuit withstand test Special Yes
Measurement of d.c. insulation resistance each winding to earth
25 Special No No
and between windings.
26 Vacuum deflection test on liquid immersed transformers Special Yes
27 Pressure deflection test on liquid immersed transformers Special Yes
28 Vacuum tightness test on site on liquid immersed transformers Special Yes
Yes, in
Measurement of frequency response (Frequency Response
factory
29 Analysis or FRA). The test procedure shall be agreed between Special
and on
manufacturer and purchaser.
site
30 Check of external coating Special Yes
31 Measurement of dissolved gasses in dielectric liquid. Special Yes

No Description
Mechanical test or assessment of tank for suitability for

32 Special Yes
transport (to customer specification).
Determination of weight with transformer arranged for transport.
For transformers up to 1,6 MVA by measurement. For larger
33 Special No No
transformers by measurement or calculation as agreed between
manufacturer and purchaser.
Note: Testing is compulsory where test certificates of an identical transformer unit cannot be provided by
the bidder
Bidders need to submit a Short Circuit Type Test Certificate in accordance with IEC 60076-5 (as indicated in
Table 21 item 24) of a similar transformer from an ISO/IEC 17025 accredited, high voltage testing facility. A
transformer is considered similar to another transformer taken as a reference if it has the following characteristics
in common with the latter:
 Similar voltage ratings

 Same type of operation, for example generator step-up unit, distribution, interconnection transformer;
 Same conceptual design, for example dry type, oil-immersed type, core type with concentric windings,
sandwich type, shell type, circular coils, non-circular coils;
 Same arrangement and geometrical sequence (vector group) of the main windings;
 Same type of winding conductors, for example aluminium, aluminium alloy, annealed or work-
hardened copper, metal foil, wire, flat conductor, continuously transposed conductors and epoxy
bonding, if used;
 Same type of main windings, for example helical-, disc-, layer-type, pancake coils;
 Absorbed power at short circuit (rated power/per unit short-circuit impedance) between 30% and 130%
of that relating to the reference transformer;
 Axial forces and winding stresses occurring at short circuit not exceeding 120% of those relating to the
reference transformer;
 Same manufacturing processes;
 Same clamping and winding support arrangement.
Over loading capability of the transformer shall be in accordance to IEC 60076-7.

Bushings shall be provided for HV, MV and Neutral connections.
Transformer cooling shall be of 75% ONAN 100% ONAF and separate conservator tanks shall be provided for
the main tank and tap changer.
Power cables will be mounted against the cable termination structure by means of a UV resistant cable clamp
that will be installed every 1m. These clamps must be included in the unit rate for a cable termination structure.
Transformer protection and control cables will be installed in the protection and control cable trench. These are
to be kept separate from the power cables at all times.
The contractor must make provision for all transport for the transformers up to and including the delivery to site.
Transformers must be supplied complete will all accessories and bushings including the HV and MV surge
arrestors as well as digital surge counters. Costing should include all manufacturing, shipping, transportation,
off-loading, assembling, testing, commissioning and associated costs to get the transformer fully operational.
The transformers shall be adequately protected during transit.
The requirement for any lifting equipment is for the contractor’s account and must be included for in the
applicable unit rates.
The contractor is responsible for the erection and “Cold Commissioning” of the new transformer after erection
on the plinth.
A 3-axis accelerometer recorder will be installed on the transformer at the factory prior to it being loaded for
transport to site. The recorder will only be removed once the transformer has been moved into its final position.
The results of the recording will be made available to the engineer within one day of offloading. Should the
results be higher than is allowed, the contractor will bear the costs for subsequent additional testing as well as
corrective measures required. The accelerometer must take measurements based on a setpoint as per the tender
document in the change in acceleration either positive or negative. If the measurements are taken on a time
interval basis, it must be done every 15 seconds. The raw data must be downloadable from the device with
timestamps and acceleration for each of the three (XYZ) planes.
The contractor will be responsible for all the connections of the jumpers, cables, the installation of the surge
arresters and the energizing of the transformers after successful commissioning.
Testing and commissioning of the transformer shall be done in the presence of ZESCO’s representatives.
The contractor must install Malthoid between the transformer base and the plinth.
The transformers shall have overloading capabilities in accordance with IEC 60076-7 Table 4.
Surge arrestor brackets, jacking pads and lifting lugs must be provided.
Dielectric strength of oil shall be determined in accordance with the method prescribed in IEC 60156.
Only virgin oil is to be supplied by the contractor as per specified IEC 60296.
The terminal markings on the diagram plate shall be as specified in Appendix D of BS 171.
The rated through current of the tap-changer, as defined in 4.17 of IEC 60214, shall not be less than that the
maximum current through the tapping winding.
The transformer shall be equipped with a bagged main conservator.
The rating and diagram plates shall be of stainless-steel not less than 2 mm in thickness. The required information
shall be engraved on the plate and the engravings filled with a UV stable glossy black. The rating and diagram
plate shall be in accordance with the requirements of IEC 60076.
Oil tests of all transformers need to be submitted by an approved laboratory before any transformer is
commissioned. Oil tests older than one month will not be accepted and will have to be redone.
2.4.4.7 Neutral Earthing Resistor
Transformer primary neutrals will be earthed through earthing resistors as shown in Table 19. Transformer MV
winding shall be earthed by means of a 10A continuous rating, (500A for 10 seconds) NER, limiting the earth
fault magnitude to 500A per transformer.
The NER shall be fitted with the required Current transformers.
The unit shall be oil insulated and will be filled at the factory with virgin mineral oil according to IEC60296.
The unit shall be outdoor type. Air insulated NERs will NOT be accepted.
The unit shall be provided with the following:
 Oil filling and breather pipe.
 Oil conservator with direct reading oil level indicator. The oil conservator shall be mounted
perpendicular to MV bushings.
 Drain plug and drain valve.
 Earthing terminal.
 Flat underbase suitable for mounting on an elevated structure.
 Lifting lugs.
Rating and diagram–plate for the NER made of stainless-steel and the data engraved as specified in IEC 60289.
The current transformer details shall also appear on the plate. Current limiting resistor data shall also be
inscribed.
The current limiting resistor will be suitably insulated and securely mounted in the tank in such a way that any
possible gas production from overheating resistors will not compromise the insulation levels of any of its
components.
2.4.4.8 Outdoor HV Circuit Breakers

Circuit Breakers shall be of the three pole, single mechanism type, with spring operating mechanism. Spring
charging shall be done by means of an 110V DC electric motor.
The circuit breakers shall be in accordance with the requirements of the latest revision of IEC 62271-100 edition
2, with SF6 gas insulation to IEC 40680. Testing of the circuit breakers shall be done in accordance with the
latest revision of IEC 60060-1 edition 3.
Two tripping circuits and one closing circuit shall be provided and shall not share any common wiring. External
protection trip signal shall not be routed through the circuit breaker local/remote selector switch while provision
shall be made for local open and close control through the selector switch on the circuit breaker mechanism,
without interrupting the protection signals.
The mechanism box for all circuit breakers shall be installed at a level that allows easy operation from ground
level. Operating mechanisms and handles shall be stored in an easily accessible place within the circuit breaker
mechanism box.
The operating control cubicle must be placed in such a way that when the operator looks at the controls he must
also face the equipment being switched e.g. the transformer in a transformer bay and the line equipment if it is
a line bay.
2.4.4.9 Isolating Switches

The isolating switches shall be of the centre rotate double break motorised operating type mechanisms.
All shaft movements shall be facilitated by means of roller or ball bearings. The centre insulator shall rotate with
the contact arm. Contacts shall be silver plated and spring loaded. Contacts shall be designed in such a way that
current will not pass through any springs used in the contact.
Insulators used for isolators, shall be tested in accordance with IEC 60383.
Mechanical and electrical interlock systems will be incorporated. Earthing switches shall not close when
isolators are still closed or line voltage transformers are still alive.
All isolating operating handles shall be equipped with suitable flexible earths connected to the steel support
structure (and to the main earth grid).
2.4.4.10 Current Transformers

33kV Outdoor current transformers shall be of standard ratings to be suitable for multiple uses for the various
applications and shall be in accordance with IEC 60044-1.
Bushings shall be porcelain and shall be tested in accordance with IEC 60383 or IEC 60168.
Multiple cores shall be provided for the different protection requirements as well as for metering. The Contractor
will be responsible for the calculation of current transformer ratios to suit the application for each current
transformer, whether it be an incomer feeder, transformer bay or line protection.
2.4.4.11 Voltage Transformers

Voltage transformers shall comply with the requirements as laid down in IEC 60044-2 and shall have two LV
windings. All voltage transformers shall have a secondary voltage of 110V.
Voltage transformers shall be of the inductive type. The position of the voltage transformers will be as discussed
in Section 2.4.4.5 and shown on the Single Line Diagram.
2.4.4.12 Surge Arresters

Surge arresters shall be of the metal oxide type, outdoor, station class suitable for structure mounting.
The insulating housing shall be silicon rubber or porcelain and hermetically sealed and shall be tested in
accordance with IEC 60168 and IEC 62217.
The arrester shall be capable of absorbing lightning and switching surges without damage to the equipment.
Testing shall be done in accordance with IEC 60060.
2.4.4.13 Earth Ball Joint and Portable Earths

Two portable-earth connection pegs per phase per isolator structure shall be installed.
Twelve potable earths must be provided (two per phase on both side of the earthed section) and will each consist
of the following:
 A 4m 95mm² stranded conductor with a UV stable PVC covering.
 Line end peg clamp.
 Earth end peg clamp.
2.4.4.14 Safety and Health Equipment

A pin/notice board manufactured from soft board and covered with felt inside an aluminium frame, 1,500mm x
1,000mm must be installed in the substation.
A white board shall be mounted against the wall of the substation. The size of the white board will be 1,200mm
x 1,000mm.
An approved First Aid kit shall be provided for the substation.
Signs, danger notices and labels shall be installed in accordance with international standards and requirements.
Each piece of Primary equipment shall be labelled in accordance with the Single Line Diagram and to the
satisfaction of ZESCO. All labels shall be in English.
A key box must be provided in the relay room for all keys to padlocks and doors in the substation.
Durable frame for mounting the emergency contact details must be provided in all buildings.
2.4.4.15 General Substation Equipment

A substation desk / drawing cabinet shall be provided in the substation and each switching station. The desk
shall have shelving underneath and a hinged top cover. Space shall be provided for the storing of documents
and drawings.
A bench shall be provided at the desk. Both bench and desk shall be secured to the floor in an approved manner.
One set of Operating and Maintenance manuals as well as equipment brochures must be provided in the Sub-
station.
An “As built” single line diagram in A1 format of the complete substation, mounted in a frame must be provided.
A wall-mounted, console desk with hinged lid must be provided in the relay room for the substation logbook.
Where trolleys are provided to extract switchgear, two trolleys of each type required must be provided with the
switchboard.
2.4.5 11KV SWITCHGEAR

IEC 62271-100 High voltage alternating current circuit breakers.
High-voltage switchgear and control gear : AC metal-enclosed switchgear and control gear for
IEC 62271-200
rated voltages above 1 kV and up to and including 52 kV
IEC 62271-102 AC disconnectors and earthing switches
IEC 60694 Common clauses for high voltage switchgear and control gear standards
AC metal-enclosed switchgear & control gear for rated voltages above 1 kV and up to and
IEC 60298
including 72.5kV.
IEC 61128 Alternating current disconnectors bus-transfer current switching by disconnectors.
IEC 61129 Alternating current earthing switches - Induced current switching.
IEC 60265 High voltage switches.
IEC 60137 Bushings for alternating voltages above 1000V.
Characteristics of indoor and outdoor post Insulators for systems with nominal voltages greater
IEC 60273
than 1000V.
IEC 60815 Guide for the selection of insulators in respect of polluted conditions
IEC 60233 Tests for hollow insulators for use in electrical equipment.
IEC 60099-4. Metal - oxide surge arresters without gaps for AC systems
IEC 6099-5. Surge arresters: Selection and application recommendation
IEC 60044-1 Instrument transformers, Part-1: Current transformers.
IEC 60044-2 Instrument transformers, Part-2: Voltage transformers.
IEC 60044-6 Instrument transformers, Part-6: Current transformers.
IEC 60186 Voltage transformers.
IEC 60282 High voltage fuses.
IEC 60269 Low voltage fuses.
IEC 61233 High voltage alternating current circuit breakers – Inductive load switching
IEC 60059 IEC standard current rating.
IEC 60529 Degree of protection of enclosures.
IEC 60270 Partial discharge measurements.
IEC 60060 High voltage test techniques
IEC 60071 Insulation coordination
IEC 60255 Electric relays

IEC 61238 Compression and mechanical connectors
IEC 62305 (ALL

Protection against lightning
PARTS)
SP-ESG-007 ZESCO - 33 & 11kV metalclad indoor switchgear
SP-GGE-001 General technical requirements
111233-40-SPE-
LTDRP protection detail design specification
EE-0005
111233-40-SPE-
LTDRP SCADA detail design specification
EE-0003
111233-40-SPE-
LTDRP telecommunications detail design specification
EE-0004
2.4.5.2 General
 Switchboards shall consist out of metal clad panels, circuit breakers and fused contactors and shall be
designed, constructed and tested in accordance with this specification.
 The switchgear will consist of an air insulated board with a single busbar.
 LV compartment cubicles must be sized to accommodate all the various protection schemes and
equipment as specified in “LTDRP Protection Detail Design Specification - 111233-40-SPE-EE-0005
“. Proposed LV compartment door layouts must be submitted with the tender.
 All designs shall be done by a competent, suitably qualified engineer. All designs will be internally
reviewed and approved by a professionally registered engineer before designs are submitted for review.
 The contractor shall integrate his designs seamlessly with all subcontractors and take full responsibility
to provide a complete and fully functional end product to the satisfaction of ZESCO. The contractor
shall design the switchgear for compatibility with the intended use as a whole, taking full cognisance
of the proposed integrated protection and control, SCADA and metering schemes / systems.
 It is further an explicit condition of this specification that the design responsibility lies with the
contractor and that no approvals of designs will relieve the contractor from his responsibility to submit
a fully functional design to internationally acceptable standards.
 The switchgear will be designed, type tested and rated for service in a 3 phase, 3 wire, 50Hz, low
resistance or solid earthed, medium voltage 11kV distribution system in accordance with the
recommendations of IEC 62271-100, IEC 62271-200 and IEC 62271- 102.
 Switchgear must be internal arc classified based on IEC 62271-200 as specified in the data sheets. The
switchgear supplier will take cognisance of the switchgear room and the environment where the
switchgear will be installed. A qualifying statement must be submitted with his tender on the suitability
of the equipment offered. A specific requirement will be the safe dissipation of gases during internal
ARC fault as well as any additional trunking, if required, to achieve this.
 Two copies of all type and routine test certificates shall be supplied in accordance with the relevant IEC
62271 parts for all equipment in the panels as applicable.
 All material for the complete installation of the switchgear shall be supplied.
 One set of special tools and appliances required for normal operation and maintenance shall be supplied
per each substation.
 The panel assembly must be done by the supplier or his approved subcontractor and must be included
for in the unit rates thereof.
2.4.5.3 Construction of panels

2.4.5.3.1 General requirements
 The switchgear panels shall be of arc proof, metal clad, air insulated, free standing, extendable type,
containing power buses, and earthing bus and draw out type switching devices. The panels shall be
supplied complete with all necessary terminal plates, cable glands for cable entry, wiring trunking for
LV wiring and multi core cables.
 Each switchgear panel shall be a self-contained unit with a minimum degree of protection of IP4X for
indoor installations based on IEC 60529.
 The pollution level shall be taken as "medium" (creepage distance of 20mm/kV) for all equipment
installed indoors or inside enclosures.
 Access to equipment installed inside panels (e.g. current transformers, cable terminations etc.) shall be
such that removal and replacement thereof can be conveniently carried out with the panels in situ, by
removal of barriers or covers fixed with bolts and nuts. Nuts shall be welded in position or secured by
means of a mechanical fixing device. (no self-tapping screws shall be used).
 Panels for indoor installation shall be constructed from mild steel frames and mild steel sheeting (at
least 2mm), powder coated with a minimum thickness of 50µm to the colour as specified in the detail
specification.
 A floor frame will be supplied with the switchgear to cater for installation on uneven substation floor
surfaces.
 All bolts, nuts, washers fixing equipment etc. shall be stainless-steel.
 The panels shall be bolted together to form a continuous, self-supporting and self-contained board of
uniform appearance capable of extension at both ends with similar panels.
 An earthing busbar shall be provided for the entire length of the board and shall make provision for
connection points at each panel section. The cross-sectional area of the earthing busbar shall be
minimum 150mm².
 The typical board layout will be as per 111233-DRG-EE-003
 All cable feeders must have surge arrestors in the panels.
 The maximum allowable width for the panels with are as follows:
WIDTH
o Incomers 1000mm
o Bus sections 1000mm
o Bus riser 1000mm
o Feeder 800mm
2.4.5.3.2 Busbars
 The busbars shall be air insulated and contained in an isolated compartment.
 The 50Hz electrical ratings of the busbar shall be in accordance (or better) with the data listed in the
data sheet.
 Busbars shall be made from electrical grade high conductivity hard drawn copper, capable of carrying
the continuous rated current as specified in the detail specification, without exceeding the maximum
temperature rise specified in the relevant standard.
 The busbars shall be mechanical braced for the asymmetrical ampere rating and duration of the circuit
breaker having the highest making-current rating. There shall be no barriers down the busbar runs
except on either side of the busbar section switch. Barriers shall not be used to provide mechanical
support for busbars or connections. Entry through barriers between cubicles shall be via purpose-
designed bushings.
 All joints and tees in busbars shall be made with high tensile stainless-steel bolts, nuts and washers,
securely tightened with a torque wrench to the manufacturers specified torque settings. These settings
shall aim to minimize contact resistance and avoid distortion and / or hardening of the copper due to
overstressing.
 Insulated bushings shall comply with IEC 60137.
2.4.5.3.3 Cable termination compartments
 Cables shall terminate in air-insulated compartments.
 Provision will be made to be able to terminate the following cables:
o Substation main board incomers: up to 4 x 630mm² 1C steel wire armoured cables per phase
o Substation main board feeders: up to 2 x 185mm² 3C wire armoured cables per panel
o Substation local feeders: up to 1 x 185mm² 3C wire armoured cable per panel
o Auxiliary transformer feeders: up to 1 x 120mm² 3C wire armoured cables per panel
 Insulated gland plates with substantial copper earthing strips connected to the earth terminal shall be
provided for termination of cables.
 Control cables will terminate via top entry from a suspended cable tray and will be by means of an
appropriate mechanical compression gland with a shroud.
 Power cables will terminate from below and by means of the heat shrink kind.
 Wooden or HDPE cable support structures for power cables must be included.
 Gland plate for control cables must be included.
2.4.5.3.4 Labels
 Permanent labels shall be provided to identify each protection relay, meter, instrument, switch and
indication light. These labels will also be provided on the back side of the LV compartment door where
applicable.
 Each panel shall have a door mounted label identifying the circuit breaker number and the circuit name.
An identical label shall be mounted on the back of the panel for easy identification.
 Labels shall be engraved multi-layer laminated plastic, with black characters on a white background as
follows
o Relays and instruments - 6mm

o Panels - 30mm
o Boards - 50mm
 All labelling shall be in English.
 Labelling shall be fixed to the panels with pop rivets.
2.4.5.3.5 LV control wiring
 For any LV control wiring requirements refer to the “LTDRP Protection Detail Design Specification –
111233-40-SPE-EE-0005”.
2.4.5.3.6 Circuit breakers
 The circuit breaker shall be of the vertical or horizontal isolating, withdrawable type with on-board
protection. Where trolleys are required to remove circuit breakers, voltage transformers or contactors
from the panel, at least two trolleys of each size / type will be provided as standard operating equipment
to facilitate swopping of similar equipment.
 Circuit breakers shall be of the vacuum type unless otherwise specified.
 The 50Hz electrical ratings of the circuit breaker shall be in accordance (or better) with the data listed
in the data sheet.
 Rated insulation level for circuit breakers shall be in accordance with IEC 60071 and will be listed in
the data sheet.
 The control mechanism of the circuit breaker shall of the spring assisted trip free type with anti-
pumping circuitry. The circuit breaker shall be equipped with mechanical tripping and closing in
addition to electrical trip and close.
 A busbar earth switch will be provided for each section of the MV board. Sufficient interlocking will
be provided to prevent inadvertent closing of an earth switch onto a live busbar, or the energization of
an earthed busbar.
 Interlocking shall be provided to prevent connecting the circuit breaker to, or disconnecting it from, the
bus stubs unless the circuit breaker is open.
 A feeder cable earth switch will be incorporated into the feeder circuit breaker.
 Barrier shutters shall be provided which effectively close the bus stub connection openings when the
circuit breaker is withdrawn. These shutters will be pad lockable and clearly marked to indicate the
primary circuit, i.e. busbar, cable, left busbar or right busbar. Facilities shall be provided for
independently padlocking each shutter in the closed position.
 All compartment doors giving direct access to high voltage equipment shall be mechanically
interlocked so that the door cannot be opened whilst the equipment is live.
 Suitable indication shall be provided to mechanically indicate the position of the switching device, i.e.
racked-in, racked-out (isolated), earthed, on/off. The indication shall be readily visible from the front
of each panel.
2.4.5.3.7 Earth switches
 Earth switches shall be according to IEC 62271-102.
 Cable feeders shall be provided with fault-make rated earthing switch. Each busbar section shall be
provided with its own earthing switch.
 Earth switches shall be rated for the same fault ratings as the circuit breaker and busbars.
 The busbar earthing shall be interlocked to prevent earthing of an energized busbar.

 The integral earthing shall be capable of being padlocked in the earthed position.
 Earth switches shall be equipped with mechanical and electrical interlocking to prevent:
o Closing a cable earth switch unless the circuit breaker is open and disconnected from the bus
stubs.
o Reconnection of the circuit breaker to the bus stubs if the earth switch is closed.
o Closing the circuit breaker if the earth switch is inadvertently left closed due to failure of the
mechanical interlock.
2.4.5.3.8 Switch disconnectors
 Disconnectors shall be according to IEC 62271-102.
 Integral type circuit test facilities shall be provided.
 Clear indication must be provided to confirm the status of the disconnector.
 Mechanical interlock shall be provided on the door to prevent opening of the door with the disconnector
in the closed position.
 It shall not be possible to gain access to the busbar side of the disconnector, even in the open position,
while the busbar is live.
 Disconnectors shall normally only be used in conjunction with a circuit breaker or fused unit to connect
a filter bank or load control system to the busbar.
2.4.5.3.9 Switch-fuse
 Fuse switches shall be according to IEC 62271-107.
 Integral three-pole earthing facilities to earth the cable side of the switching device shall be provided,
unless otherwise approved.
 The use of a switch disconnector between the fused unit and the busbar is paramount.
 Fuses shall be of the air-insulated, HRC cartridge striker pin type, which shall trip all phases in the
event of one fuse blowing.
 Integral type circuit test facilities must be provided.
2.4.5.3.10 Current transformer

For current transformer requirements refer to the “LTDRP Protection Detail Design Specification– 111233-40-
SPE-EE-0005”
2.4.5.3.11 Voltage transformer

For voltage transformer requirements refer to the “LTDRP Protection Detail Design Specification– 111233-40-
SPE-EE-0005”
2.4.5.3.12 Voltage sensors

 A capacitive integrated voltage indicator for permanent monitoring of all three line voltages for “cable
live”, and “busbar live” indication shall be provided on each panel.
 The voltage indicators shall comply with IEC 61243-5, consisting of flashing LED diodes deriving its
power directly from the primary system via capacitive coupling electrodes.
 The indicators will be of a type that allows for secondary phasing and rotation checks
2.4.5.3.13 Auxiliary supplies

 For any AC or DC requirements refer to the “LTDRP Protection Detail Design Specification-111233-
40-SPE-EE-0005”.
 The cost of all external wiring cabling will be included for in the secondary plant BOQ of the relevant
batch and lot.
 The cost of all internal wiring and assembly must be included for in the unit rates for the switchgear.
2.4.5.4 Control, protection and alarm circuitry
 The cost of all protection and control schemes as well as the external cabling therefore will be included
for in the secondary plant BOQ of the relevant batch and lot.
 All internal wiring and assembly must be included for in the unit rates for the switchgear.
 Control, protection and alarm systems and circuitry shall be as required by the system or as specified
in the main specification but shall be approved by ZESCO.
2.4.5.4.1 Control
 With the bay selector switch set to local, control will be done from in front of the panel by means of a
0-30s time delayed operation.
 With the bay selector switch set to remote, control will be done from the main SCADA control.
2.4.5.4.2 Protection Schemes
 For any protection scheme requirements refer to the “LTDRP Protection Detail Design Specification–
111233-40-SPE-EE-0005”
batch and lot.
2.4.5.4.3 SCADA
 For any SCADA requirements refer to “LTDRP SCADA Detail Design Specification– 111233-40-
SPE-EE-0003”.
batch and lot.
2.4.5.4.4 Ammeters and Voltmeters

 All indicating instruments shall have an accuracy of at least 3%.
 Ammeters shall be of incorporate thermal maximum demand indication where required.
 Voltage as well as ammeter selector switches shall be provided if called for in the detail specification.
2.4.5.4.5 Indication Requirements
 All panels will be equipped with cluster LED type lights on the panel door indicating:
o Circuit Breaker Open: Green.

o Circuit Breaker Closed: Red.
 All earth switch position statuses will be clearly indicated with LED type semaphores or on the
protection relay LCD graphical display.
 All alarms and trip conditions will be clearly indicated via either programmed LEDs on the protection
relay or an alarm annunciator.
2.4.5.4.6 Test Terminal Blocks

 For any test block requirements refer to the “LTDRP Protection Detail Design Specification– 111233-
40-SPE-EE-0005”
2.4.5.4.7 Space Heaters

 Anti-condensation heaters (230V AC) shall be provided to ensure that no condensation can occur in
any of the compartments. A switch shall be provided to control the heaters.
 A thermostatically controlled switch, adjustable between 10°C and 20°C shall be provided in the supply
circuit to the heaters with an overriding switch for the thermostat.
 The wiring from the heater elements to connection terminals shall be high temperature insulation
covered, with a suitable compression-type gland.
batch and lot.
2.4.5.4.8 Interlocking
To be read in conjunction with “LTDRP Protection Detail Design Specification– 111233-40-SPE-EE-0005”
Under all circumstances interlocking conditions will be clearly displayed. The following interlocking will be
catered for:
 Busbar earth switch:
The busbar earth switch will be interlocked to close only under the following conditions:
o No busbar voltage present derived from the busbar voltage transformer and supervised to
detect voltage transformer racking and voltage transformer MCB statuses.
o Bus section circuit breaker must be open and racked out.
o All Incomer and feeder circuit breakers connected to the specific busbar must be open and
racked out.
 Incomer, and bus section circuit breakers:
o It will not be possible to close any circuit breaker in the service position if the relevant busbar
earth switch is not open.
o Each transformer feeder circuit breaker will send a hardwired inter-trip (52b contact) to the
lower voltage incoming circuit breaker.
o It will not be possible to close the transformer LV circuit breaker if the transformer HV circuit
breaker is open.
2.4.5.4.9 Deliveries
2.4.5.4.9.1 General
 Drawing numbers and plant equipment item numbers shall be allocated by ZESCO. All drawings shall
be prepared by using either Autocad or Microstation CAD packages and supplied in *.dxf, *.dwg or
*.dgn formats.
 Typical drawings are not acceptable unless they are revised to show only the equipment being
furnished.
 Graphic symbols for wiring diagrams shall comply with IEC 60617.
2.4.5.4.9.2 Structural Drawings
 Structural drawings shall be completely dimensioned, showing:
o Arrangement.
o Plan, front view, and other elevation views if pertinent.
o Required clearances for opening doors and for removing circuit breakers.
o Conduit or cable entrance locations for bottom entrance.
o Busbar locations and configurations.
o Incoming and outgoing cable termination positions.
o Anchor bolt locations.
o Earthing connections.
o Mass of equipment. Individual mass of stationary units and circuit breakers, if shipped
separately.
o Foundation holding down bolting details showing mounting rails and run-out rails for draw-
out circuit breakers.
2.4.5.4.9.3 Single Line Diagrams
 Single line diagrams shall show:
o Instrument transformers.
o Relays with their ANSI device numbers.
o Meters and meter switches.
o Other pertinent devices.
2.4.5.4.9.4 Schematic Diagrams

 Schematic wiring diagrams shall be furnished for each different electrically operated circuit breaker
control scheme and show the following:
o All control devices and device contacts, each of which shall be labelled with its correct ANSI
device function number, or reference.
o Device terminal numbers, terminal block numbers and terminal numbers.
o All internal interconnections, bus wiring, inter panel wiring and connections to external
equipment.
o Relay internal logic configuration.
o Protection relay setting sheet.
2.4.5.4.9.5 As-Built Drawings

 On completion of installation and commissioning of the relevant equipment, the originals of the above
drawings shall be updated by the equipment supplier to reflect the as-built status.
 The supplier shall then also provide engineer/employer with one copy of all relevant CAD data for
drawing records and drawing reproduction.
2.4.5.4.9.6 Materials List

 A materials list shall be furnished listing the quantity, rating, type, and manufacturer's catalogue number
of all equipment in each unit.
2.4.5.4.9.7 Documentation
The following documentation requirements will form part of the scope of work and deliverables:
 Functional design specification
 Detail design specification
 Approved for constructions drawings
 Protection relay configuration files before FAT commence
 Pre-FAT report and results
 FAT file containing all FAT reports, marked up drawings, punch lists before equipment can be shipped
 Bill of lading for the transport to site
 As commissioned drawings
 Operating and maintenance manuals. Installation, operating, and maintenance instructions shall cover
all the equipment furnished including all protective relays, fuses, auxiliary relays and other equipment
and shall include characteristic curves for all protective relays and fuses.
 Handing over of as-built documentation
2.4.5.4.9.8 Operating and maintenance equipment

Provide a set of operational and maintenance equipment per board which will include but not be limited to:
 One trolley of each size required (where applicable).
 Operating handles.
 Any other special tools that is necessary to safely operate and maintain the board.
2.4.5.4.9.9 Spare Parts Lists
 Complete spare parts list, including parts location diagrams or drawing and prices, which the
manufacturer recommends for the first two years' operation, shall be submitted with the tender. The
following is mandatory for each board but the contractor must list and include additional requirements
under the unit rate therefore:
o 1 x Spring charge motor

o 1 x Closing coil
o 1 x Tripping coil
o 1 x Circuit breaker control switch
2.4.5.5 Factory acceptance tests
Each board will go through a proper FAT process. ZESCO or their nominated representative will witness the
FAT procedure and approve all FAT documentation before approval will be given to transport equipment to site.
Although the protection and control schemes are measured and specified elsewhere, the FAT will encompass
the complete board. Notwithstanding the test requirements of IEC 62271-101 and IEC 62271-105 the following
FAT procedure will be applicable:
2.4.5.5.1 Responsibilities
FAT will be conducted within the following framework:
 The switchgear supplier will be primarily responsible for conducting the FAT and to compile all FAT
documentation.
 ZESCO or his representatives will only witness FAT as a quality control function and does not take
responsibility for the correctness of the equipment supplied.
 The switchgear supplier will remain responsible for the rectification of any defects found during FAT
or SAT.
2.4.5.5.2 Pre-FAT checks

The switchgear supplier will complete all pre-FAT checks and notify ZESCO at least 2 weeks in advance before
checks will commence and when the pre-FAT documents will be completed and ready for inspection. ZESCO
might request to witness specific tests. Once these tests are completed, ZESCO will verify the test results and
request to witness specific items.
Pre-FAT checks will include, but not be limited to the following:
 Ring out of all wiring,
 Insulation tests on all wiring circuits,
 Equipment nameplate verification based on a comprehensive equipment list,
 Marked up schematic diagrams and equipment lists,
 Circuit breaker test results, including pressure test, vacuum bottle test, speed tests, trip and close coil
tests, mechanical checks,
 Mechanical operation and alignment checks,
 Apply DC and check operational functionality,
 Current transformer magnetization curves, ratio and polarity checks with the current transformer
installed and wired into the panel,
 Voltage transformer polarity and ratio checks with the voltage transformer installed and wired into the
panel,
 Upload protection relays with approved logics, protection settings and configuration settings,
2.4.5.5.3 FAT tests:

On completion and approval of all pre-FAT documentation, the switchgear supplier will commence with the
functional testing of protection schemes. ZESCO will be notified at least 2 weeks in advance before FAT
commences to allow ZESCO or their representative to witness these tests. Once these tests are completed,
ZESCO will verify the test results and request to witness specific items.
FAT tests will include but not be limited to:
 Extensive functional testing of each panel protection and control scheme to prove relay configuration,
wiring, logics, protection and control philosophies,
 Secondary injection to prove relay configuration and correct application of protection settings,
 Overall scheme tests, i.e. busbar arc protection, busbar blocking, interlocking etc.
 Where required, scheme testing will be done with primary injection.

2.4.5.6 Site acceptance testing
Although the switchgear supplier will not be responsible for SAT, the rectification of any defects found (and the
associated cost) during SAT will remain the responsibility of the switchgear supplier.
The contractor shall provide unit rates to provide assistance during the hot commissioning phase.
Commissioning assistance will be provided by either one of the following:
 The design engineer primarily responsible for the design to date, or
 Competent suitable qualified commissioning technician that will be approved by ZESCO.
 No sub-contractors will be allowed to provide commissioning assistance.
2.4.5.7 Training
The contractor will be required to provide equipment specific and commissioning training on equipment as
called for below.
i. Various training requirements as specified in this specification might be required to be

combined to provide a proper overview off all equipment supplied.
ii. ZESCO will provide a training venue and the supplier shall provide for all training equipment
required.
iii. ZESCO will provide at least 3 weeks’ notice prior to commencement of training courses.
iv. The contractor shall provide each trainee with a certificate indicating that the trainee has been
introduced and can operate, maintain, setup and test the relevant equipment trained for.
The contractor shall provide the following:

 Demonstrate and train personnel on mechanical functions such as racking, interlocking, earthing and
any other requirements of the panels.
 Explain all relay indications and interlocking functions.

Installed panels will be used for training purposes.
2.4.5.8 Packing
 The equipment shall be packed to international best practices and in such a manner that it will be
comprehensively protected against any environmental conditions expected during handling and
transport for delivery.
 Spare parts and tools must be packed separately and marked as such.
2.4.5.9 Auxiliary power supplies

2.4.5.10 System design
The substation auxiliary supplies shall be fed from two auxiliary transformers with a generator supply as back-
up. Refer to the “LTDRP Protection Detail Design Specification– 111233-40-SPE-EE-0005”.
2.4.5.10.1 Outdoor installation

The typical system configuration is shown in Figure 17. Two main incomers from auxiliary transformers, to an
outdoor main switchboard with slow changeover. Generator incomer, with automatic mains fail starting, and
non-critical load dropping. Paralleling of incomers and the standby generator is dangerous, and shall be
prevented by electrical controls and/or interlocks. Power supplies to outdoor equipment will be fed directly from
the outdoor main switchboard. Cables for critical and non-critical indoor loads to an indoor ac board.
Outdoor loads include:

 Yard lighting to be operated by a day / night switch.
 Three-phase supply at every second transformer (two transformers per supply), with earth leakage
protection at the supply point.
 Single-phase supplies at every third bay, with earth leakage protection at the supply point.
2.4.5.10.2 Indoor installation
Indoor boards for critical and non-critical loads. Critical loads are separated into those that can tolerate a short
interruption while the generator starts (fed by AC), and those that cannot be interrupted (fed by substation
batteries).
Critical, but interruptible, loads include:
 Battery chargers,
 Lights in relay room and switchgear room, and
 Certain identified socket outlets.
Uninterruptible loads include:

 Network switches,
 Telecommunication terminal equipment, and
 Inverters for operator workstations (not ac UPS units).
2.4.5.10.3 Auxiliary transformers

Auxiliary transformers will be fed from 11kV switchboard via a fused-switch.
The auxiliary transformers shall have cable terminating boxes on the 11kV and 400V windings. An open bushing
transformer with a hood to cover open bushings is not acceptable.
Capacity to be calculated based on AC and DC load lists, with a typical 10% reserve capacity.
Figure 17 Typical AC/DC distribution
Auxiliary transformers will be a low loss transformer designed and constructed in accordance with IEC 60076.
The core and winding assembly will be located at the tank bottom, will be braced in the two horizontal directions
and fixed at the level of the upper yoke clamps.
None of the core and winding assemblies will be suspended from the tank cover.
The oil cooling shall be ONAN.

The windings shall be connected as Dyn11 as per IEC 60076.
The percentage impedances shall be as per IEC 60076.
Auxiliary transformers will be provided with an offload lockable tap switch the range of which will be +- 2 taps
in steps of 2.5% to correspond to 95 and 105% of the rated primary voltage. The tapping range shall be stated
on the rating plate.
The LV terminals shall be extended into a weather proof enclosure having a vertically hinged full side panel
door where the circuit breaker and removable neutral link shall be mounted.
The auxiliary transformer shall be controlled by moulded-case air circuit breaker suitable sized for the load and
prospective fault level. The circuit breaker shall be equipped with trip alarm contacts.
The unit shall be provided with the following:
 Drain plug and drain valve.
 Earthing terminal.
 Flat underbase suitable for mounting on an elevated structure.

 Lifting lugs.
 Thermometer pocket.
2.4.5.10.4 Generator
A generator shall be installed as backup supply in the event that the substation auxiliary AC supply is lost. The
generator set installation shall automatically take over the load in the event of a mains failure or abnormal voltage
condition of any one or more phases after this condition has persisted for a pre-set (but adjustable) period.
A control system shall be provided which shall monitor the mains continuously. In the event of any abnormality
(parameters pre-set but generally adjustable) the control system shall initiate the disconnection of the load from
the mains supply and start the generator automatically. The generator shall supply critical load only.
The engine shall be diesel fuelled with compression ignition, direct injection and amply rated for the site
electrical output, load characteristics and power factor as specified in the applicable Technical Schedule.
The engine shall be capable of delivering an output of 110% of the specified electrical load at the same speed
for one (1) hour in any period of 12 hours consecutive running.
The engine and installation shall be of neat appearance and all water, lubricating and diesel oil lines, filters and
stop cocks shall be leak free.
All service connections to the engine shall be flexible to allow the free movement of the set and to prevent the
transmission of vibration to the building or other structural elements.
All engine flexible or rigid piping not heat resistant shall be adequately protected against damage by radiant
heat.
Engine wiring shall be of the heat-resisting type.
All moving parts shall be adequately mechanically protected against accidental contact.
Tenderers shall state in the applicable Technical Schedule the specified fuel consumption of the complete set
with auxiliary equipment in litre per hour at 100%, 75%, 50% and 25% load to an accuracy of 10%. These
figures shall be guaranteed and proved during site tests.
An automatic low oil pressure cut-out system which will de-energise the stop solenoid on the engine and give
the alarm as indicated shall be fitted.
An oil pressure gauge shall be fitted in the main lubrication oil circuit after the oil filter(s). An oil temperature
gauge shall be fitted in the case of air cooled engines.
A concrete plinth shall be provided for the generator. The base frame shall be placed directly on a concrete floor
and may be bolted to the floor. The frame must be high enough off the floor to facilitate easy installation and
removal of the drip tray specified and for the draining of engine oil. The frame shall be of rigid construction
enabling the complete set to be transported without dismantling.
An engine-mounted fuel pump shall be fitted. The fuel tank shall preferably be mounted in such a position that
fuel is gravity fed to the engine. The tank shall be fitted with a full height transparent gauge glass. The fuel tank
shall contain enough diesel for four hours operation at 100% load.
Should the engine require a particular grade of fuel, this shall be clearly stated in the tender.
The generator shall be equipped with a baffle or absorption type silencer, designed and constructed that sound
level measurements taken at 3 meters of the exhaust opening shall not exceed 70dB.
The generator shall be electrically started from a battery set (integral to the generator) and will be controlled by
the panel mounted starter control circuitry. A 230V battery charger with auto trickle facility shall be provided.
The overload capacity of the alternator shall be such as to allow overloads of 10% for one hour or 50% for two
minutes.
The voltage regulation shall be better than ±1% of the nominal voltage specified at all loads with a power factor
between unity and 0,8 and within the engine speed variations of 4,5% between 0% and 100% of full load. The
output wave form shall be sinusoidal and the deviation from a true sine wave shall not exceed 5%. The line-to-
line harmonic content or distortion (Distortion Factor) when measured between any of the phases at any linear
load capacity of the alternator shall not exceed 4%.
This installation shall comply in all aspects with the applicable Acts and Regulations.
2.4.5.10.5 Auxiliary cable ratings

Cable ratings for auxiliary supplies will be according to cables specified in Table 22. It is the contractor’s
responsibility to confirm compliance to all load, fault level and volt drop requirements.
Table 22 Auxiliary Cable Ratings
Design Limit Rating

Fault Proposed Fault Amp Fault
Description
kVA V Amp Level Conductor/Cable Level In Level
(kA) (MVA) Ground (kA)
From 11kV
Switchgear to 1x 11kV 120mm² 3C XLPE
200 11,000 11 15.7 218 314 16.2
Auxiliary Cu
Transformers
From Auxiliary
1x 1000V 120mm² 4C PVC
Transformers to 200 400 288 2.9 0.17 285 9.8
Cu
AC Board
From Auxiliary
1x 1000V 95mm ² 4C PVC
Generator to AC 50 400 75 2.9 0.17 245 9.8
Cu
Board
2.4.5.11 Factory Acceptance Tests and training on Primary Equipment

FAT is mandatory on Transformers, Circuit Breakers, Isolators, Current Transformers and Voltage
Transformers. The contractor will make the necessary arrangements for FAT which shall include bookings at
the testing facility, transportation, per diem, accommodation and meals for his staff to attend and facilitate each
FAT. The contractor shall provide costing in the bill of quantities for the following duration of FAT inspections:
Table 23 Summary of FAT and Training requirements
FAT Training - Overse as Training-Local
Pe r die m Per die m

Description
(per (per
No of No of No of
engine e r Duration e ngine er Duration Duration
Enginee rs Engine ers Engine e rs
per day per day
USD) USD)
Primary Plant
4 days per
5 $365.00 NA 4 1 week
Transformer transformer
11kV Switchgear (engineers) 5 $365.00 2 weeks NA 4 1 week
11kV Switchgear (operations) NA NA NA 3 $120.00 3 days NA NA
HV Breakers and Isolators
5 $365.00 1 week NA 4 1 week
CTs and VTs
MV Cables 3 $365.00 5 NA 4 1 week
EHV Cables 5 $365.00 4 days NA 4 1 week
Se condary Plant
Telecomms 3 $120.00 3
Transmission Protection 2 $120.00 2
Distribution Protection 2 $120.00 2
5 $365.00 1 week 2 weeks 2 weeks
Transmission SCADA 2 $120.00 2
Distribution SCADA 2 $120.00 2
Metering 1 $120.00 1
Note: 1 All duration periods exclude any travelling time. Duration periods shown are the actual time spent on
training and FAT.
2.4.5.12 Protection, Control, and Telecommunication Equipment

Please refer to:
 LTDRP Protection Detail Design Specification – Document no. 111233-40-SPE-EE-0005
 LTDRP SCADA Detail Design Specification – Document no. 111233-40-SPE-EE-0003
 LTDRP Telecommunications Detail Design Specification – Document no. 111233-40-SPE-EE-0004
 ZESCO Technical Specifications for Telecommunications Optical Line Terminal Access Equipment.
 ZESCO Technical Specifications for Optical Fibre Cable.
 Decommission specification - Document no.11233-40-SPE-EE-0018

2.4.6 MV CABLE INSTALLATION
Power cables with extruded insulation and their accessories for rated voltages
from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) –
IEC 60502-2
Part 2: Cables for rated voltages from 6 kV (Um = 7,2 kV) up to
30 kV (Um = 36 kV)
IEC 60183 Guide to the selection of high-voltage cables
IEC 60228 Conductors of insulated cables
IEC 60793 Optical fibres
IEC 60794 Optical fibre cables
Optical fibres — Polarization mode dispersion measurement techniques for single-mode optical
IEC 61941
fibres
IEC 61282-3 Fibre-optic communication system design guides. Calculation of polarization mode dispersion
SP-ECA-001 Cables & accessories
SP-ECA-002 Cable joints
SP-ECA-004 Power cable installation

Figure 18 MV cable construction
1. Conductor - Copper.
2. Conductor screen – Extruded semi-conductive layer.
3. Insulation – XLPE.
4. Core screen - Extruded free strippable semi-conductive layer.
5. Semi-conductive numbered tape - 1, 2 and 3 Printed on alternative cores.
6. Metallic screen - Copper tape.
7. Filler material – Pre-formed plastic.
8. Binder tape.
9. Inner sheath.
10. Armouring – Galvanized steel wire for three-core cables and Aluminium wire for single core cables.
For radial water blocking install water swellable tapes below and above armouring.
11. Outer sheath – Polyethylene.
2.4.6.2 Excavations
Existing services will be pointed out to the contractor as far and as accurate as possible with the information that
is available, however the responsibility will remain with the contractor to find and safely expose all existing
services by hand. The contractor must survey the proposed route to determine the optimal placement of the
cable with regards to obstacles, road crossings and existing services, as follows:
 Cross cuts must be done at 50m intervals by hand to determine the position and depth of all existing
services to plan the trench route before excavation commences.
 The contractor must also make use of a non-invasive cable detection system first to survey the route
and determine the least congested area. Survey implies as many runs in as many directions as is
required to cover the whole pavement.
 Due to the amount of existing services the unit rates must make provision for the most efficient way of
exposing these services without damages. The use of compressed air excavation tools like an “Air
Knife” or similar must be provided for in the unit rates for excavations.
Tarred road surfaces are not to be damaged. All road crossings must be drilled.
Classification of soil will be done as follows:
Hard/dense soil
 Generally, any soil which requires the close application of picks, jumpers or scarifiers to loosen; for
example stiff clay, gravel and cobble stone.
 Note: Cobble stone is rock fragments usually rounded or semi-rounded having maximum diameter in
any direction between 80mm and 300mm.
Soft disintegrated rock (not required blasting)
 This shall include rock or boulders, which can be excavated by barring, wedging and splitting manually
or using pneumatic tools. It shall also include embedded boulders measuring not more than one metre
in any one direction.
 Note: The mere fact that the contractor resorts to blasting to loosen the material shall not mean that it
will be classified as hard rock.
Hard rock (requiring blasting)

This shall include all rock occurring in large masses which cannot be removed except by blasting. Hard varieties
of rock such as granite with or without veins and secondary minerals which in the opinion of the engineer
requires blasting shall be considered as hard rock. Boulders of hard rock larger than one metre in any one
direction lying in the overburden and requiring blasting for easy and efficient removal shall also be classified as
hard rock. All blasting shall be of the non-explosive, chemical expanding type. Conventional blasting will only
be allowed under instruction from the engineer. Only an authorized and duly registered person/company
registered at the Mines Safety Department, Ministry of Mines will be allowed to conduct any explosive
operations. The contractor must provide proof of registration before he will be instructed to proceed. The
allowance for blasting will be for more smaller explosions rather than fewer larger explosions. Every possible
precaution must be taken to prevent injury to people and damage to the surroundings. These must include, but
not be limited to heavy conveyor belting and old tyres used.
Claims for excavations will be processed according to the trench dimensions provided. Over excavation will not
be considered.
Generally, the centre line of trenches will be 1m from the stand boundary. Obstructions encountered should be
brought under the attention of the engineer.
A minimum distance of 300mm shall be maintained between the cable and other services.
No trees shall be cut during the execution of the contract unless specifically arranged with the engineer. Should
any trees have to be removed, the contractor shall arrange for the complete uprooting and trimming of tree trunks,
as well as the stacking of all trunks and branches. Holes caused by the uprooting shall be filled and consolidated.
Rubble shall be removed to leave the site neat and tidy. The contractor shall be held responsible for any damage
that may occur during the felling of trees.
The trench shall be cleaned of all stones and sharp objects to a neat square finish.
Provision shall be made at road crossing to keep the roads open during the cable installation period by installing
heavy-duty steel plates across the open trenches. The contractor shall include this in the tender price.
All railway lines plus all tarred roads are to be crossed with sleeves by boring (drilling) underneath to a depth of
at least 1.5m into which the cable is to be laid. Sleeves are to be strong enough not to buckle under the load of
the ground above, and correctly sized for the cable. In addition to these sleeves at crossings, cable manholes
will be constructed on either side of each crossing. This will be done by means of brick and mortar and at the
same depth as the accompanying cable trench. The design of the manhole must make provision to keep out any
ground water but the use of a subsoil drain can be considered. The top of the manhole must be a minimum of
300mm above NGL. All power cables, spare sleeves, as well as the fibre-optic cable on the same route, will
enter the manhole. All subsoil entries into the manhole will be sealed watertight. The manholes must be
positioned to act as a transition point where a change in direction can be done. Lockable watertight lids must
also be provided, the size of which must be able to cater for both power and fibre optic during installation.
Where the cable is installed along a tarred road and crosses a dirt road that might become a tarred road, sleeves
must be installed for each cable plus one spare. The unit rate for sleeves will make provision for joint couplings
as well as end-caps where require.
It is preferred that trenches not be left open overnight. If it is unavoidable, however, the contractor must, as a
minimum, install orange trench barrier netting. The netting must be a bright orange colour, a minimum of 1.2m
high and supported every 2m by a wooden or iron pole of 1.5m to prevent injury to passers-by. In areas where
the open excavation is not very well lit, the contractor may, in addition to the netting, make use of red strobe
lights positioned in intervals of 5m. The contractor remains responsible for safety in and around the open
excavation until it is backfilled.
2.4.6.3 Bedding and blanket layers

If the trench is rocky, the bottom of the trench shall be filled across the full width with a 75mm layer of suitable
soil sifted through a 6mm mesh and levelled off.
Only sandy clay or loam soil with a satisfactory thermal resistivity (not exceeding 1.2C m/W) may be used for
this purpose. Sea or river sand, ash, chalk, peat clinkers or clayey soil shall not be used.
Where no suitable soil is available on site, the contractor shall import fill from a commercial source.
The bedding under joints shall be fully consolidated to prevent subsequent settling.
After the cable has been installed, a further blanket layer of bedding material shall be provided to extend to
75mm above the cables. This layer must be levelled and lightly compacted by hand.
2.4.6.4 Backfilling
Backfilling of trenches shall not commence without inspection.
Backfilling shall be done with soil suitable to ensure settling without voids. No large stones or rocks shall be
present in the backfill material for the first section above the blanket layer as per the design. Thereafter all soil
used for backfilling shall pass through an 80mm mesh to ensure that the maximum allowable diameter of stones
present in the backfill material is 75mm.
The material to be utilised for compacted backfill shall be deposited in horizontal layers having a thickness of
not more than 300mm before being compacted. In backfilling, the bedding on top of the cable shall be covered
first with a 200mm layer of well graded material containing no pieces larger than 20mm, before any coarse
material is deposited.
The distribution of materials shall be such that the compacted material will be homogeneous to secure the best
practicable degree of compaction, impermeability and stability.
Prior to and during compaction operations, the backfill materials shall have the optimum moisture content
required for the purpose of compaction, and the moisture content shall be uniform throughout the layers.
The material shall be compacted by compaction machines to a minimum of 95% MOD AASHTO. Compaction
certificates will be required.
Surplus material shall be removed from site and suitably disposed of.
On completion, the surface shall be prepared to match the surrounding area. In the case of roadways or paved
areas the excavations shall be consolidated to the original stability and the surface finish reinstated.
2.4.6.5 Cable Markers and labelling

Brass or aluminium plates shall be cast into the top of the cable marker blocks in such a manner that they cannot
be pried loose. The wording "ELECTRICAL CABLE" shall be stamped on the plates as well as direction arrows
and the cable voltage rating.
Cable markers shall be installed on the surface along all the underground routes and shall project 35mm above
normal ground level unless the projected markers could be a hazard to pedestrian or other traffic in which case
they shall be installed flush with the surface.
Type B route markers will be installed on the outskirts of town and in areas where a high possibility exists that
cables will be damaged by development.
Cable markers shall be installed at the beginning and ending of a cable run (e.g. where a cable enters a substation
or building), at changes of direction, above all joints, above cable pipe/sleeve entries and exits at road crossings.
On long cable runs it must be installed every 50m.
All cables must be marked at all joints and at each cable end by means of stainless-steel tape which is clamped
around the cable. The following information shall be punched onto the stainless-steel tape for the cable under
consideration:
1. Voltage
2. Cable size
3. Year of installation
4. Connected from
5. Connected to
2.4.6.6 Cable Installation
Applicable ZESCO standards:
 SP-ECA-004 – Power cable installation.
Danger tape shall be installed above both the 11kV cables, only at the depth as indicated, along the entire trench
length. The tape must be 450mm wide and must be a minimum of 200 micron thick. It must be bright orange
or yellow with red skull and crossbones and the words "ELECTRIC CABLE" printed on not more than 1m
intervals.
Concrete slabs (900x300x65mm) will also be installed where any other services are crossed, either 300mm above
or 300mm below so that the new cable is comprehensively protected. In areas where a high risk of damage
exists, the entire trench will be packed with concrete slabs.
Pulling eyes shall be provided on both ends of a cable drum length. The pulling eye shall be securely connected
to both the cable conductor and the sheath to avoid elongation of the sheath during installation.
Cable rollers shall be used to run out cables. Rollers shall be spaced so that the length of cable in the trench will
be totally suspended during the laying operation and sufficiently close to prevent undue sagging and the cable
from touching the ground. Rollers shall also be placed in the trench in such a manner that they will not readily
capsize.
During the installation of the cable, the drum shall be mounted on a suitable sized cable trolley. Under no
circumstances will the drum be laid flat, the cable uncoiled and the coils rolled along the trenches.
Cables shall have heat shrink end caps fitted and will stay on until the joints and terminations are made.
Cable rollers shall have no sharp projecting parts liable to damage the cables.
Where cables have to be drawn around corners, well-lubricated skid plates shall be used. The skid plates shall
be securely fixed between rollers and shall constantly be examined during cable laying operations.
Where cables have to be drawn through sleeves or ducts, a suitable cable sock shall be used and particular care
shall be exercised to avoid abrasion, elongation or distortion of any kind.
The maximum allowable tension when pulling a cable with a cable stocking is as follows:
 For steel wire armoured cables F = 0.94d4x10-6kN.
 For steel tape armoured or un-armoured cables F = 0.39d4x10-6kN.
 For control and communication cables F = 0.26d4x10-6kN.
The maximum allowable tension when pulling a cable with a pulling eye connected to the conductors is as
follows:
 Copper cables F = core size x number of cores x 4.9x10-2kN/mm.
 Aluminium cables F = core size x number of cores x 2.94x10-2kN/mm.
Where d is the outside diameter of the cable in mm and F is the force in N.
The contractor remains responsible to confirm the limitations of the cable from his supplier. If the values
provided by the supplier differ from those provided above, the contractor must change his adapt his installation
methods to accommodate it. It will be assumed that the price or rates contained in the tender includes for the
installation of cables in pipes and ducts or below existing or newly installed services. The Engineer shall be
informed timeously of the intention to carry out all cable laying operations to allow an inspection of the works
if so required.
The cable shall be installed using a winch and care shall be taken not to exceed the maximum permissible pulling
force specified by the manufacturer.
Where conditions are particularly difficult, the continuous bond pulling method shall be used.
The maximum permissible bending radius of a cable is typically fifteen times the cable diameter. This must be
confirmed in the technical schedules according to a specific supplier’s requirements. Any damage resulting from
ignoring this value will be rectified by the contractor at his own expense to the satisfaction of the engineer.
2.4.6.7 Joints and terminations

 SP-ECA-001 – Cables and accessories
 SP-ECA-002 – Cable joints
2.4.6.7.1 General
The joints and terminations shall be type tested, with the cable in order to prove compatibility as follows:
 IEC 60502 for 11kV cables
The Cu conductors shall be jointed together using an approved conductor jointing process.
Joints and terminations shall be supplied with all necessary material required for making the joints or
terminations in their entirety. The equipment for each joint and termination shall be packed in a separate case
with step by step instructions and drawings included.
All joints and terminations will only be performed by certified tradesmen, the credentials of whom must be
available on site.
Remove water blocking material from within the conductors with care before inserting into lugs and connectors
for crimping.
Where a visual representation of the phase rotation colours is required for MV cables it shall be:
 L1 – R(red)
 L2 – Y(yellow)
 L1 – B(blue)
2.4.6.7.2 Terminations
Heat shrinkable termination kits shall be used for terminations.
The conductors of the cable shall be connected directly to the switchgear bus-bars in the cable terminal boxes
with cable lugs. The conductors shall be soldered properly to the cable lugs.
When cutting away insulation from cable conductors to fit into lugs, care shall be taken that no strands are left
exposed. Under no circumstances may any of the conductor strands be cut away to fit into lugs.
Suitable lugs shall be used and preferably be solidly seated to cable conductor ends. Lugs may be crimped using
mechanical, hydraulic or pneumatic tools specifically designed for this purpose. Under no circumstances may
a lug be crimped by means of a hammer and/or punch.
Lugs crimped to Cu shall be subjected to thorough inspection with relation to material and quality of crimping
by the engineer.
Contact surfaces shall be thoroughly cleaned and smoothed and fixing bolts shall match the hole size of the lug
and shall be manufactured of cadmium plated tensile steel.
The complete kit shall be packed in a container that is marked for the type of cable insulation and construction
as well as the voltage range for which the materials are suitable.
An illustrated set of instructions for the installation of the materials shall accompany the kit.
The terminations shall make minimal, if any, use of insulating or stress relieving tapes. The use of electrical
stress control and insulating tubing, heat-shrunk onto the terminations is preferred above the other methods.
The kits shall include suitable boots for the covering of the terminal studs on the equipment. The ends shall be
terminated strictly in accordance with the termination manufacturer's specification and shall withstand the same
test voltage as the rest of the cable.
The heat-shrinkable and other materials used for the terminations shall be of high quality and shall retain their
electrical and mechanical properties without deterioration.
Terminations shall be made of a material that gives lasting protection against ultraviolet radiation.
The cores of all cables terminated shall be completely covered with a shrunk-on protective layer against surface
tracking, ultra-violet radiation and weathering.
Cables shall be terminated in accordance with the recommendations laid down by the manufacturers of the cables
and the terminations employed.
2.4.6.7.3 Cable Joints

During outdoor jointing operations, the joint bays shall be adequately covered by tents of waterproof material
suitably supported. When necessary, a trench shall be excavated around the bay to prevent the ingress of
moisture. The sides of the hole shall be draped with small tarpaulin or plastic sheeting to prevent loose earth
from falling in during jointing operations.
Joints shall be to the cable manufacturer’s and joint manufacturer’s specifications and fully water- and airtight
and shall be free of voids and air pockets.
The joint shall not impair the anti-electrolysis characteristics of the cable.
The crossing of cores in joints will not be permitted under any circumstances.
The electrical continuity of all the conductors and screens shall not be impaired by the joints and the earth
continuity shall be accomplished within the joints, i.e. no external earth continuity conductor that will be subject
to corrosion, is acceptable. The joints shall be completely covered by a watertight sheath to prevent corrosion.
In the case of joints in cables with an outer PVC anti-electrolysis sheath, the joints shall be subject to the same
electrical insulation test as the outer sheath of the cable.
High voltage cable joints shall be of the heat shrinkable type.
Cable joints for heat shrinkable materials shall be packed as a complete joint kit in a container that is marked for
the type of cable insulation and construction as well as the voltage range for which materials are suitable.
An illustrated set of instructions for the insulation of the materials shall accompany every kit.
The joints shall make minimal, if any, use of insulating or stress relieving tapes. The use of electrical stress
control and insulating tubing that is heat-shrunk onto the joint is preferred above other methods.
Sheath voltage limiters and link boxes will not be required unless the contractor proves otherwise in the
submission of his design.
The contractor shall leave slack in the form of two coils 2 m on either side of the joint. The coils must comply
with the bending radius requirements of the cable supplier.
All cables must be marked at all joints and at each cable end by means of stainless-steel tape which is clamped
around the cable. The following information shall be punched on to the stainless-steel tape for the cable under
consideration:
a) Cable destination
b) Voltage of the cable
c) Type of cable
d) Conductor material of the cable

e) Size of the cable.
2.4.6.8 Cable Tests
The cable insulation and outer sheath shall be tested in accordance with the manufacturer’s recommendations
and IEC60060-1.
The insulation test shall be by means of an applied AC voltage (not DC).
Outer sheath tests shall routinely be performed immediately after the installation and backfilling of a length of
cable, so that repairs, if required, can be done at that stage.
The cost of testing shall be included in the tender price.
Cables shall be pressure-tested and the exact leakage current shall be tabulated and certified.
Low frequency tests are preferred to DC test sets.
All tests will be witnessed by ZESCO and the engineer.
Test results must be indicated on a test certificate and must be handed in as part of the maintenance manual.
2.4.6.9 Coordination of services

Any 11kV cabling that will be installed outside of the existing stand, will be installed on the same route as other
existing services such as water, sewerage, electric cables, stormwater and fibre optics. The contractor must
coordinate the installation of the new cables and fibre optics with all existing services by gathering information
from all service providers involved as to positioning of the said services as well as trench cross cuts on the
planned routes.
2.4.7 OPTICAL FIBRE CABLE

Any existing optical fibre cable that is connected to the existing substation, will be exposed by hand, re-routed,
jointed if required and terminated onto the communication’s cabinet of the new substation and will comply with
the following:
2.4.7.1 General
Full particulars of the cable proposed need be submitted to the engineer for approval.
The contractor must survey the route in order to find the best position for a joint pit / draw box taking into
account the max permissible tension in the cable during installation as well as the drum length.
Lubricants are to be avoided during installation.
Draw boxes shall be provided at all acute changes of direction and at splicing positions and will be installed to
the manufacturers’ requirements “out of line” from the trench.
The box must have inside dimensions large enough, minimum 600 x 600mm or bigger as required by the DUCT
fibre supplier, to be able to coil the cable inside.
It must be purposefully made and can be either be sectional concrete, fibre cement or Polyethylene with a
lockable lid bearing the ZESCO logo thereon.
It must also be water and dust tight after installation.
2.4.7.2 Duct requirements

Duct must be jointed with purposefully designed compression couplings that is water and dust tight.
Duct must be cut with pipe shears and the inside reamed to remove rough edges.
The duct must be manufactured with virgin polymers and must have a life expectancy of 50 years.
The inside/outside diameter must typically be 50/42mm.

Drum lengths must be optimized to minimize joints.
The duct must have an inner wall of silicon material to reduce friction during installation.
The duct must be ordered with a heavy duty pulling tape to facilitate the installation. The tape must not damage
the inner wall of the duct during installation.
Any additional requirements for the installation of the fibre must be included for in the unit rates for installation.
Care must be taken during the installation and jointing of the duct to avoid the ingress of dirt which might
damage the fibre optic cable during installation.
2.4.7.3 Optic fibres

Optical fibre cables shall be of the compact duct type, 24-core, dual window, single mode, non-dispersion
shifted type.
Joints in the optical fibre cable will only be allowed as a last resort. Drum lengths to be optimised.
Each optical fibre shall have a core diameter of 10µm.
The optical fibres shall be of the single mode graded index type to CCITT Recommendation G652 for operation
at nominal wavelengths of 1300nm and 1550nm. All characteristics and tolerances shall apply over the
temperature range of – 10°C to + 60°C.
Terminate each fibre at both ends onto the patch panels provided
The contractor must do the comprehensive fibre point to point testing, in both directions, according to IEC
60793-1-40 and make the test sheets available to the engineer.
The contractor shall at every draw box and termination coil the fibre-optic cable within the limits as prescribed
by the supplier to make a minimum of 10m slack available at each point. This slack will be tied together in four
places to keep it from uncoiling.
2.4.7.4 Communications cabinet
Supply and install an expandable 19” communications cabinet with optical distribution frames suitable for
industrial use for each of the existing supplies.
Each patch module must have a minimum of 48 ports with further capacity to increase the number of ports to
96.
Each patch panel shall be provided with a complete set of FC ceramic mid-couplers and FC pigtails (non-
ruggedized) to terminate the entire cable, irrespective of the number of cores used. The cost of these must be
included for in the unit rate for the patch panel.
Each patch panel shall be comprehensively labelled, clearly showing the source of the connected fibre cable.
The cost of this must be included for in the unit rate for the patch panel.
The installation of optical distribution frames is to splice the fibres thereto and do the point-to-point testing. For
secondary equipment and integration requirements refer to Item 7.5 hereunder.
2.4.7.5 Protection, control, and telecommunication equipment

Please refer to:
 LTDRP Telecommunications Detail Design Specification – Document no. 111233-40-SPE-EE-0004
 ZESCO Technical Specifications for Telecommunications Optical Line Terminal Access Equipment.
2.5 DEMOLISHING OF EXISTING INFRASTRUCTURE

The existing Woodlands Substation will only be demolished once the new Substation has been energised and all
the existing load transferred thereto.
The existing switchgear and control buildings will not be demolished. These buildings must be stripped of all
the equipment which must be delivered to the Zesco farm.
Where the building has been contaminated as a result of typically oil and/or acid spills, it must be thoroughly
cleaned to make it safe to be used as offices. No structural or functionality modification will be done.
There is an existing radio mast. This mast will not be demolished as it will be reconnected to the new
communications equipment.
Any demolishing must strictly be done in accordance with 111233-40-SPE-EE-0018 - Dismantling of Overhead
Line and Substation Equipment Specifications.
3. DRAWINGS
3.1 LOT 1 - CONSTRUCT NEW WOODLANDS 33/11 KV SUBSTATION
3.1.1 Primary plant
DRAWING NUMBERS DESCRIPTION

111233-2001-DRG-ELE-0001 SINGLE LINE DIAGRAM
111233-2001-DRG-ELE-0002 SITE PLAN
111233-2001-DRG-ELE-0003 GENERAL ARRANGEMENT
111233-2001-DRG-ELE-0005 EARTH GRID LAYOUT
111233-2001-DRG-ELE-0007 SECTIONS AND CLAMPS
111233-2001-DRG-ELE-0008 LIGHTNING LAYOUT
111233-2001-DRG-ELE-0009 LIGHTING LAYOUT
111233-2001-DRG-ELE-0010 BUILDING LAYOUT
111233-1900-DRG-ELE-0002 GUARD HOUSE
111233-1900-DRG-ELE-0003 TRANSFORMER PLINTH
111233-1900-DRG-ELE-0004 OIL HOLDING DAM
111233-1900-DRG-ELE-0005 FIRE WALL
111233-1900-DRG-ELE-0006 WATER TANK
W6 SEPTIC TANK AND SOAKAWAY STANDARD DRAWING
33 kV DOUBLE EARTHED STRUCTURE
G11392
TERMINAL STRUCTURE
POLE CABLE TERMINATION
MAZ-ALB-DM-08-G-12190
FOR 11kV CABLE
POLE MOUNTED CABLE TERMINATION
ZAM-GEN-41-G-12827
33 kV UNDERGROUND CABLE
GH9709 CABLE TERMINAL POLE DUEAL CONSTRUCTION
3.1.2 Protection, control and telecommunication equipment

3.1.2.1 Typical panel layouts

111233-DRG-EE-002 33 KV PROTECTION PANEL LAYOUT
111233-DRG-EE-004 33 KV METERING PANEL LAYOUT
3.1.2.2 Protection philosophy block diagrams

111233-EE-BD-001 33/11 KV TRANSFORMER PROTECTION
111233-EE-BD-002 33 KV INCOMER PROTECTION
111233-EE-BD-003 33 KV FEEDER PROTECTION
111233-EE-BD-004 33 KV BUS SECTION PROTECTION
111233-EE-BD-005 33 KV BUSZONE PROTECTION

111233-EE-BD-006 11 KV INCOMER PROTECTION
111233-EE-BD-008 11 KV BUS SECTION PROTECTION
111233-EE-BD-009 11 KV ARC PROTECTION
111233-EE-BD-010 AC/DC DISTRIBUTION PHILOSOPHY
3.1.2.3 SCADA philosophy block diagrams

111233-EE-BD-020 33 KV SCADA PHILOSOPHY
3.1.2.4 Telecommunications philosophy block diagrams

111233-EE-BD-021 33 KV TELECOMMUNICATION PHILOSOPHY
4. SUPPLEMENTARY INFORMATION
Attached specifications:
 Technical Specifications for Telecoms Optical Line Terminal / Access Equipment
 Technical Specifications for Optical Fibre Cables: Optical Ground Wire (OPGW), All Dielectric Self
Supporting (ADSS), Direct Buried Underground (DUCT)
 Environmental and Social Management Plan for The Lusaka Transmission and Distribution Rehabilitation
Project
 Health and Safety Management Plan for The Lusaka Transmission and Distribution Rehabilitation Project
 111233 REP011 - Dismantling of Overhead Line and Substation Equipment Specifications
 Waste Management Procedure
 111233-40-SPE-EE-0003 - LTDRP SCADA Detail Design Specification
 111233-40-SPE-EE-0004 - LTDRP Telecommunications Detail Design Specification
 111233-40-SPE-EE-0005 - LTDRP Protection Detail Design Specification
 111233-50-STD-NM-GE-0001 Method statement for bush clearing
 111233-80-GDL-EE-0001 – Bid Document Outline.2.
General ZESCO Technical Specifications are available in electronic format on request.

All Supplementary Information is included in Volume 2 after the Drawings.
5. SCHEDULE OF TECHNICAL REQUIREMENTS

Tenders must complete this schedule in detail as insufficient data may invalidate a tender.
Tenderers shall only offer equipment as called for in the specifications as part of their main offer. Alternatives
shall be listed separately from these Tender documents.
Where such alternative equipment is offered subject to final approval, the Tenderer shall submit detailed
information to enable the Engineer to evaluate the equipment with the tender. If the information submitted is
not adequate to satisfy the Engineer that the equipment is acceptable such an alternative offer will not be
considered.
Section VII. Employer's Requirements Part 2-105
Technical Schedules
Lot 1 – WOODLANDS 33/11kV SUBSTATION and SWITCHING

STATIONS

Name of Bidder
Lot 1 Rev 5
Part 2-106 Section VII. Employer's Requirements
____________________________________________________________________________________________________________________________________________
Modification of any part of the Technical Schedules might result in the misplacement of information which is crucial for successful Bid evaluation. Bidders
should follow and adhere to the following rules and guidelines in completing the Technical Schedules:
1 Make sure it is the latest Revision of the Technical Schedules which might have been submitted as an Addendum.
2 Bidders need to keep the format of the Technical Schedules exactly the same as the original:
found in the different sections of this Technical Schedules
6 Do not copy and paste values, please make sure information provided is accurate according to the specified equipment
This Technical Schedules must be submitted in Excel format with the Bidding Documents. The Schedules must be submitted on flash disk in a clearly
marked envelope indicating the following information: Tender number, LOT number, Description and Bidder's name. The envelope must be attached to
the cover page of Volume 1.
Before the Technical Schedules are submitted make sure of the following:
11 The Bidder's Name is provided in the space provided on the front page
Lot 1 Rev 5
_______________________________________________________________________________________________________
WOODLANDS SUBSTATION
TECHNICAL SCHEDULES
Table of Contents
Sequence
Item No Description
No
1 1 Power Transformer 33/11kV 30 MVA
115 2 33kV Circuit Breakers - Incomers and Bus-Sections
157 3 33kV Circuit Breakers - Feeders
199 4 33 kV Isolators
224 5 33kV Current Transformer - Post
245 6 33kV Current Transformer - Ring
259 7 33kV Voltage Transformers
310 9 11kV Earthing Resistor
337 10 200kVA Auxiliary Transformer
392 11 50kVA Generator
459 12 33kV Surge Arrestors
497 14 33kV Post Insulators
511 15 Substation 11kV Switchgear
559 16 630mm² 6.35/11kV 1C Cu XLPE AWA
584 17 240mm² 19/33kV 3C Cu XLPE SWA
609 18 240mm² 6.35/11kV 3C Cu XLPE SWA
635 19 120mm² 6.35/11kV Cu 1C XLPE AWA
660 20 120mm² 6.35/11kV Cu 3C XLPE SWA
685 21 120mm² 1kV 4C Cu PVC SWA
708 22 Outside Termination - 630mm² 6.35/11kV AWA XLPE 1-Core Cu Cable
729 23 Inside Termination - 630mm² 6.35/11kV AWA XLPE 1-Core Cu Cable
750 24 Outside Termination - 240mm² 19.05/33kV SWA XLPE 3-Core Cu Cable
771 25 Outside Termination - 240mm² 6.35/11kV SWA XLPE 3-Core Cu Cable
792 26 Inside Termination - 240mm² 6.35/11kV SWA XLPE 3-Core Cu Cable
813 27 Inside Termination - 120mm² 6.35/11kV SWA XLPE 3-Core Cu Cable
834 28 Inside Termination - 120mm² 6.35/11kV AWA XLPE 1-Core Cu Cable
855 29 Cable Joint - 630mm² 6.35/11kV AWA XLPE 1-Core Cu Cable
874 30 Cable Joint - 240mm² 19/33kV SWA XLPE 3-Core Cu Cable
893 31 Cable Joint - 240mm² 6.35/11kV SWA XLPE 3-Core Cu Cable
912 32 Cable Joint - 120mm² 6.35/11kV SWA XLPE 3-Core Cu Cable
931 33 Free-standing Panel and Junction Box
970 34 Relay Technical Specification
1029 35 Transformer Protection
1094 36 33kV Busbar Protection
1116 37 33kV Bus Section Protection
1131 38 33kV Feeder Protection
1161 39 33kV Incomer Protection
1187 40 11kV Transformer Incomer Protection
1215 41 11kV Arc Protection
1226 42 11kV Bus Section Protection
1236 43 11kV Local Feeder Protection
1262 44 AC/DC Distribution Boards
1315 45 110V Batteries
1356 46 110V Battery Charger
1408 47 48V Batteries
1455 48 48V Battery Charger
1507 49 Metering
1536 50 Substation SCADA Specification
1609 51 Substation Telecommunication specification
Lot 1 Rev 5
_______________________________________________________________________________________________________
WOODLANDS SUBSTATION
SCHEDULE OF TECHNICAL REQUIREMENTS
Tenderers shall only offer equipment as called for in the specifications as part of their main offer. Alternatives shall be listed
separately from these Tender documents.
Where such alternative equipment is offered subject to final approval, the Tenderer shall submit detailed information to enable
the Engineer to evaluate the equipment with the tender. If the information submitted is not adequate to satisfy the Engineer that
the equipment is acceptable such an alternative offer will not be considered. Where Bidders choose to submit more than one
supplier for the same equipment, the Employer has the right to choose which equipment the Bidder should supply.
The provided typical 33kV and 11kV combined control, protection and telecommunication panels shall be strictly used as the
The technical schedule below should be completed in conjunction with the following:
- LTDRP SCADA Detail Design Specification - Document No. 111233-40-SPE-0003
- LTDRP Telecommunication Detail Design Specification - Document No. 111233-40-SPE-0004
- LTDRP Protection Detail Design Specification - Document No. 111233-40-SPE-0005
- ZESCO Technical Specifications for Telecommunications Optical Line Terminal Access Equipment
SEQ REQUIRED OFFERED

ITEM DESCRIPTION UNIT
No SCHEDULE A SCHEDULE B
1 1 Power Transformer 33/11kV 30 MVA -----
2 1 General information -----
3 1.1 Manufacturer Specify
4 1.2 Model number Specify
5 1.3 Country of Origin Specify
6 1.4 Specifications IEC 60076
7 1.5 Transformer construction Three winding
8 1.6 Phases Three
9 1.7 System Phases Three
10 1.8 Frequency 50 Hz
11 Virgin mineral oil.
1.9 Insulating medium
12 Non corrosive
13 1.10 Indoor/Outdoor Outdoor
14 1.11 Cooling Specify
15 1.12 Continuous Rated power at all Taps: ONAN/ONAF MVA 65/90
Continuous rated power of Tertiary winding to be determined
16 1.13 MVA Specify
by manufacturer
17 1.14 Rated Primary voltage kV 33
18 1.15 Rated Secondary voltage kV 11
19 1.16 Rated Tertiary voltage kV 11
20 1.17 Tapped winding kV 33
21 1.18 Number of taps 17
22 1.19 Tapping range +5/-15%
23 1.20 Tap steps % 1.25%
Maschinenfabrik
24 1.21 Tap Changer Make Reinhausen
Germany
25 1.22 Tap Changer Model Specify
26 1.23 On/off load On load
27 1.24 Number of maintenance free operations 300,000
28 1.25 Highest HV voltage(Um) kV 36
29 1.26 Highest MV voltage(Um) kV 12
30 1.27 Primary surge protection (33kV) SA per Phase
31 1.28 Primary neutral earthing (33kV) N/A
32 1.29 Primary SA brackets (33kV) Yes
33 1.30 Secondary surge protection (11kV) SA per Phase
34 1.31 Secondary neutral earthing (11kV) NER
35 1.32 Secondary SA brackets (11kV) Yes
36 1.33 Tertiary earthing (33kV) N/A
37 1.34 External insulation: -----
38 1.34.1 Primary Lightning impulse withstand level (33kV) kV 200
39 1.34.2 Primary neutral impulse withstand level kV Specify
40 1.34.3 Secondary Lightning Impulse withstand level (11kV) kV 95
41 1.34.4 Secondary neutral Impulse withstand level kV Specify
42 1.34.5 Primary Short Time AC withstand (33kV) kV 70
43 1.34.6 Primary neutral Short Time AC withstand (33kV) kV Specify
44 1.34.7 Secondary Short Time AC withstand (11kV) kV 28
Lot 1 Rev 5
_______________________________________________________________________________________________________

45 1.34.8 Secondary neutral Short Time AC withstand (11kV) kV Specify
46 1.35 Internal insulation: -----
47 1.35.1 Primary Lightning impulse withstand level (33V) kV 170
48 1.35.2 Primary neutral impulse withstand level kV Specify
49 1.35.3 Secondary Lightning Impulse withstand level kV 95
50 1.35.4 Secondary neutral Impulse withstand level kV Specify
51 1.35.5 Primary Short Time AC withstand (33kV) kV 70
52 1.35.6 Primary neutral Short Time AC withstand (33kV) kV Specify
53 1.35.7 Secondary Short Time AC withstand (33kV) kV 28
54 1.35.8 Secondary neutral Short Time AC withstand (33kV) kV Specify
55 1.36 Vector group Dyn1
56 1.37 Accelerometer Yes, 3 axis
57 1.38 Auxiliary supply voltage (3ph) V AC 400
58 1.39 Protection & control VT secondary voltage V AC 110
59 1.40 DC control voltage V DC 110
60 1.41 Conservator With Oil Gauge Yes
61 1.42 Dehydrating Breather Yes
62 1.43 Buchholz Relay (Main Tank & Tap Changer) Yes
63 1.44 Pocket For Oil Top Temperature Thermometer Yes
64 1.45 Dial Type Oil Temperature Indicator with Alarm and Trip Yes
Dial Type Winding Temperature Indicator with Alarm and
65 1.46 Yes
Trip Contacts
66 1.47 Cooler Fan Control Circuit Yes
67 1.48 Drain Valve Yes
68 1.49 Oil Filtration Connections Yes
69 1.50 Oil Sampling Facilities Yes
70 1.51 Pressure Relief Device Yes
Earthing Terminals at two opposite locations (To be suitable
71 1.52 Yes
for 50mm x 3mm flat copper)
72 1.53 Lifting Lugs Yes
73 1.54 Jacking Pads Yes
74 2 Cooling Radiators: -----
75 2.1 Quantity No Specify
76 2.2 Size (each) m2 Specify
77 2.3 Surge arrestor brackets HV and MV
78 2.4 Conservator bag Yes
79 2.5 33kV Terminals arrangement Air bushings
80 3 Special Information -----
81 3.1 Impedance at nominal tap (33kV) % 10
82 3.2 Maximum tap % Specify
83 3.3 Minimum tap % Specify
Short Circuit Current Withstand (kA for 2s) with infinite
84 3.4 kA Specify
source
Short Circuit Type Test Certificate from an ISO/IEC 17025
85 3.5 Yes
accredited, high voltage testing facility
86 3.6 Noise Level (dB) dB <77
87 4 Transformer Losses -----
88 4.1 No Load Losses (kW) kW Specify
89 4.2 Load Losses @ 75˚C (kW) and rated current at: -----
90 4.2.1 At maximum tap kW Specify
91 4.2.2 At nominal tap kW Specify
92 4.2.3 At minimum tap kW Specify
93 5 Efficiency on nominal tap and unity PF at: -----
94 5.1 100% load % 99.723
95 5.2 50% load % Specify
96 5.3 Power Required for Cooling equipment kW Specify
97 5.4 Altitude m 1,400
98 6 Temperature rise at altitude: -----
99 6.1 Top oil °C 50
100 6.2 Windings °C 55
101 6.3 Hotspot of winding °C <68
102 6.4 Seismic Hazard ( ground acceleration) Attached m/s² 0.2-0.4
103 Cloud Grey
6.5 Transformer color
104 NCS-2305-R99B
105 Cloud white
6.6 Conservator color
106 NCS-0704-G38Y
Lot 1 Rev 5
_______________________________________________________________________________________________________

107 7 Site Information -----
Woodlands Substation at
Coordinates:
108 7.1 Transformer delivered for Task 1 to: -----
15°26'42.97"S
28°20'43.12"E
109 7.2 Off-load and final placement Yes
110 7.3 Distance from off-loading position m 10
111 7.4 Rise or fall to off-loading position mm 100
112 7.5 Place 3 ply Malthoid transformer and plinth Yes
113 7.6 Transport and offloading Method Low-bed truck &
114
115 2 33kV Circuit Breakers - Incomers and Bus-Sections -----
118 1.2 Circuit breaker Model number Specify
120 1.4 Rated System Voltage kV 33
121 1.5 Maximum System Voltage kV 36
122 1.6 Rated Continuous Current A 1,600
123 1.7 Minimum Rated Fault Breaking Capacity kA 31.5
124 1.8 Rated duration of Fault Breaking Capacity s 3
125 1.9 Minimum Rated Power Frequency Withstand Voltage kV 70
126 1.10 Minimum Rated Power Frequency Withstand Voltage across kV 80
127 1.11 Rated Lightning Impulse Withstand Voltage kV 170
128 1.12 Rated Lightning Impulse Withstand Voltage across gap kV 195
129 1.13 Number Of Series Breaks Per Phase 1
130 1.14 Insulation Medium SF6
131 1.15 Minimum Height Of Pole Base Above Ground Level mm 2,400
132 1.16 Minimum Phase spacing mm 650
133 1.17 Creepage Distance Top Pole mm/kV 25
134 1.18 Creepage Distance Bottom Pole mm/kV 25
135 1.19 Minimum Height Of Lowest Live Part mm 2,900
136 1.20 Min Ambient Operating Temperature °C -30
137 1.21 Max Ambient Operating Temperature °C 50
138 2 Electrical Tripping -----
139 2.1 Nominal Voltage V DC 110
140 2.2 Maximum Power Rating Per System At Nominal Voltage W 2
141 2.3 Back-Up Tripping As Above Yes
142 2.4 Min. Tripping Voltage % 70
143 2.5 Min. Closing Voltage % 70
144 2.6 Max Breaking Time ms 50
145 2.7 No. Of Trip Coils 2
146 2.8 No. Of Close Coils 1
147 3 Mechanism Box -----
148 3.1 Manual Reset Yes
149 3.2 Motor Reset Yes
150 3.3 Motor Voltage V DC 110
151 3.4 Type Of Closing Device Spring
Stored energy to permit operating sequence 0 – 0.3s – CO –
152 3.5 Yes
3min - CO
153 3.6 Local / Remote switch Yes
154 3.7 Number Of Mechanisms Per Breaker. 1
155 3.8 Mechanically operated indicator Yes
156
157 3 33kV Circuit Breakers - Feeders -----
164 1.6 Rated Continuous Current A 800
168 1.10 Minimum Rated Power Frequency Withstand Voltage across kV 80
170 1.12 Rated Lightning Impulse Withstand Voltage across gap kV 195
Lot 1 Rev 5
_______________________________________________________________________________________________________

174 1.16 Minimum Phase spacing mm 650
194 3.5 Yes
3min - CO
198
199 4 33 kV Isolators -----
202 1.2 Isolator Model number Specify
204 1.4 Centre Rotating Double Break Yes
205 1.5 Normal operating voltage kV 33
206 1.6 Maximum system voltage kV 36
207 1.7 Minimum Distance Between Contact Poles mm 800
Angle Of Operating Mechanism handle (Fully Closed To Fully
208 1.8 Deg 90
Open)
209 1.9 Rated Load Current A 1,600
210 1.10 Minimum Phase Spacing mm 1,200
211 1.11 Minimum Creepage Distance mm/kV 25
212 1.12 Impulse Level (BIL) kV 170
213 1.13 Power Frequency Withstand kV 70
214 1.14 Fault Rating kA 31.5
215 1.15 Minimum Short Time Fault Rating s 3
216 1.16 Number Of Normally Open/Normally Closed Auxiliary 6/6
217 1.17 Number Of Sweeping Auxiliary Contacts 2
218 1.18 Interlocking Facilities On Mechanism Yes, Mechanical and
219 1.19 Operation Plane Horizontal
220 1.20 Interlocked With Circuit Breakers Fleeting Contacts
221 1.21 Earthing Switch Mechanism interlocked with Isolator Manual on Line Bays
222 1.22 Insulated Flexible Earthing on operation handle Yes
223
224 5 33kV Current Transformer - Post -----
227 1.2 Current transformer Model number Specify
229 1.4 Stem Diameter mm 38
230 1.5 Stem Minimum Length mm 100
231 1.6 Bushing Material Porcelain / Composite
232 1.7 Bushing Strength kN 4
233 1.8 Type Of Internal Insulation Oil
234 1.9 Fault Current rating kA 31.5
238 1.13 Power Frequency Withstand Voltage kV 70
239 1.14 Height of lowest “Live” part above ground mm 2,400
Lot 1 Rev 5
_______________________________________________________________________________________________________

CT core details to be provided by the Contractor as part of the
240 1.15 Note
Secondary Plant Design
241 1.16 Type Post
800A
242 1.17 Feeder Ratio
Multi ratio
1,600A
243 1.18 Bus Section Ratio
Multi ratio
244
245 6 33kV Current Transformer - Ring -----
250 1.4 Type Of Insulation mm Cast Resin
251 1.5 Minimum Fault Current rating kA 31.5
256 1.10 -----
257 1.11 Type Ring
258
259 7 33kV Voltage Transformers -----
262 1.2 Voltage transformer Model number Specify
266 1.6 Bushing Material Porcelain
269 2 33kV VT Electrical Details -----
270 2.1 Nominal Ratio kV/V 33/110
271 2.2 Accuracy Class 3P/0.2
272 2.3 Primary Voltage (Line To Earth) kV 33/√3
273 2.4 Secondary Voltage (Line To Earth) V 2 x 110/√3
274 2.5 Volt Ampere Burden VA 100 & 50
275 2.6 Number Of Windings 2
276 2.7 Type Of VT Inductive
277 2.8 Creepage Distance mm/kV 25
278 2.9 Rated lighting impulse withstand voltage kV 170
280 2.11 Voltage Factor 1.9
281
High Rupturing Current
287 1.4 Primary fuses
(HRC) limiting type
Primary and secondary fuse replacement possible with VT in
288 1.5 Yes
withdrawn position
289 1.6 Insulation Class Class E or Better
290 1.7 Withdrawable rail mounted with handle, situated on top of unit Yes
Plug in and withdrawable with automatic operating of spout
291 1.8 Yes
shutters
292 1.9 Latch to hold VT in service position Yes
293 1.10 Latch release required before VT can be isolated. Yes
Busbar VTs in a separate
panel
294 1.11 Location
Incomer VTs on incomer
panels
296 2.1 Number of phases 3
297 2.2 Number of limbs 5
299 2.4 Nominal Ratio kV/V 11/110V
Lot 1 Rev 5
_______________________________________________________________________________________________________

300 2.5 Voltage Class kV 12
301 2.6 Vector Group YnYn
306 2.11 Type of VT Inductive
307 2.12 Rated lightning impulse withstand voltage kV 95
309
310 9 11kV Earthing Resistor -----
311 1 Manufacturer Specify
312 2 NER Model number Specify
313 3 Country of Origin Specify
314 4 Nominal system voltage kV 11
315 5 Maximum system voltage kV 12
316 6 Nominal frequency Hz 50
317 7 Impulse Withstand Voltage kV 95
318 8 Minimum creepage mm/kV 25
319 9 Nominal short-time (for 10s) current (r.m.s.) A 500
320 10 Maximum continuous current (r.m.s.) A 25
321 11 Zero sequence resistance Rr at 100°C ohm 12.7
322 12 Nominal voltage (Un/√3) kV 6,35
323 13 Temperature coefficient at 100°C Specify
324 14 Specific heat capacity Specify
325 15 Temperature range in which (d) and (e) apply Specify
326 16 Insulation type Oil
327 17 Air Insulation optional No
328 18 Tank color Grey
329 19 Conservator color White
330 20 HV and LV Connection Cable Termination Box
331 21 Stem diameter M12 (Thread)
332 22 Current Transformer according to protection design Yes
333 23 Buchholz relay Manufacturer Specify
334 24 Minimum size mm 50
335 25 NER Total Mass kg Specify
336
337 10 200kVA Auxiliary Transformer -----
340 1.2 Auxiliary transformer Model number Specify
342 1.4 Nominal rating kVA 200
343 1.5 Vector symbol, if other than as specified Dyn11
344 1.6 Primary voltage kV 11
345 1.7 Secondary voltage V 400
346 1.8 Impedance voltage, if other than as specified % 4.0 – 5.0
347 1.9 Number of phases Three-phase
348 2 Insulation level -----
349 2.1 Lightning impulse withstand MV kV 95
350 2.2 Lightning impulse withstand LV kV 30
351 2.3 Power frequency withstand voltage MV kV 28
352 2.4 Power frequency withstand voltage LV kV 2.5
353 3 Losses, if other than as specified -----
354 3.1 No-load losses W 520
355 3.2 Load losses W 2,700
356 4 Dimensions -----
357 4.1 Overall height mm ±1,600
358 4.2 Overall length mm ±1,400
359 4.3 Overall width mm ±1,100
360 5 Constructional details and fittings -----
361 5.1 Off-circuit tapping switch YES
362 5.2 Flat underbase YES
363 5.3 Tank type Sealed
364 5.4 Expansion space % 15
365 5.5 Tank cover of sealed transformer to be bolted, if so agreed NO
366 5.6 Pressure-relief device NO
367 5.7 Conservator NO
368 5.8 Total mass kg < 1,250
369 5.9 Terminations Cable termination box
Lot 1 Rev 5
_______________________________________________________________________________________________________

370 5.10 Ground-mounted transformers YES
371 5.11 Corrosive environment Medium
372 5.12 Colors of finishing coats, if different from standard Grey
373 5.13 Insulating material, if other than as specified Oil
374 5.14 Cooling method ONAN
375 5.15 Enclosure Outdoor
376 5.16 Maximum noise dB 48
377 5.17 Wheels Yes
378 5.18 Lifting lugs Yes
379 6 Medium-voltage bushings -----
380 6.1 Material Porcelain
381 6.2 Creepage distance mm/kV 25
382 6.3 BIL kV 95
1x120mm² 3C XLPE Cu
383 6.4 MV Supply conductor
Cable
384 7 Low-voltage bushings -----
385 7.1 Material Porcelain
386 7.2 Creepage distance mm/kV 25
387 7.3 BIL kV 25
1x120mm² 4C PVC Cu
388 7.4 LV Supply conductor
Cable
389 7.5 Number of conductors per terminal 1
390 7.6 Position of bushings Side
391
392 11 50kVA Generator -----
395 1.2 Generator Model number Specify
397 1.4 Duty Standby
398 1.5 Drive Direct
Sound Attenuated
399 1.6 Outdoor Enclosure
Canopy type
400 1.7 Sound level at one meter from enclosure dB(A) <70
401 1.8 IP rating 65
402 1.9 Compliance to IEC 60034-1 Yes
403 1.10 Compliance to IEC 60034-22 Yes
404 1.11 Base Skid
405 1.12 Dimensions (L x W x H) m Specify
406 2 Engine -----
408 2.2 Type Specify
410 2.4 Cooling Radiator - Water
411 2.5 Rated Speed Specify
412 2.6 Electric Start Yes
413 2.7 Battery voltage V 12 or 24
414 2.8 Alternator A/V Specify
415 2.9 220 Volt battery charger (with auto trickle charge) Yes
416 3 Generator set ratings at specified sea level -----
420 3.4 Frequency Hz 50
421 3.5 Frequency variance % ± 2.5
422 3.6 Rated Prime Power @ 0.8 pf kW 40
423 3.7 Rated Prime Power kVA 50
424 3.8 Volts 3ph/1ph V 400/230
425 3.9 Automatic Voltage regulation % ± 5.0
426 3.10 Total Harmonic Content % < 5.0
427 4 Controller -----
431 4.4 Synchronizing with mains No
432 4.5 Automatic starting with mains fail No
433 5 Instrumentation and Control -----
434 5.1 Service hour meter Yes
435 5.2 Emergency stop Yes
436 5.3 Water temperature Yes
Lot 1 Rev 5
_______________________________________________________________________________________________________

437 5.4 Oil Pressure Yes
438 5.5 Speed Indicator Yes
439 5.6 Off / Manual / Auto switch Yes
440 5.7 High Engine Temperature protection cut out Yes
441 5.8 Low oil pressure protection cut out Yes
442 5.9 Over speed protection cut out Yes
443 5.10 Short circuit protection Yes
444 5.11 Earth fault protection Yes
445 5.12 Single phase socket outlet Yes
446 5.13 Three phase socket outlet Yes
447 5.14 Earth leakage protection Yes
448 5.15 Fuel level indication Yes
449 5.16 Battery charger volt meter Yes
450 6 Fuel -----
451 6.1 Fuel Type Diesel
452 6.2 Fuel grade compatibility ppm 50 to 500
453 6.3 Fuel tank Liter 200 to 250
454 6.4 Fuel efficiency at 100% duty Liter/Hou < 11.5
455 6.5 Fuel pump Engine mounted
456 6.6 Base mounted fuel tank Yes
457 6.7 Duration of continuous running at full load without refueling Hours 10
458
459 12 33kV Surge Arrestors -----
462 1.2 Surge arrestor Model number Specify
464 1.4 Operating Duty Class kA 10
465 1.5 Class Station
466 1.6 Maximum Operating Voltage (L-L) kV 36
467 1.7 System Normal Rated Voltage (L-L) kV 33
468 1.8 Maximum Continuous Operating Voltage MCOV (L-G) Uc kV 20
469 1.9 Minimum Rated Voltage L-G kV 26
470 1.10 Nominal Lightning Discharge Current (4/10µs) kA 100
471 1.11 Peak Residual Voltage For 10kA 8/20µs Current Impulse kV 62
472 1.12 BIL (Housing) kV 170
475 1.15 Rated Energy Absorption Capability kJ/kV 3.6
476 1.16 Type kJ/kV ZnO
477
485 1.6 System Maximum Operating Voltage (L-L) kV 12
487 1.8 Maximum Continuous Operating Voltage MCOV (L-G) Uc kV 9.6
492 1.13 Discharge Current Withstand (4/10µs - 2 Shots) kA 65
496
497 14 33kV Post Insulators -----
499 2 Insulator Model number Specify
501 4 Material Porcelain
502 5 Minimum Failing Load kN 4
503 6 Number of Sheds Specify
504 7 Length min mm 475
505 8 Dry Arcing Distance Specify
506 9 BIL (Housing) kV 170
Lot 1 Rev 5
_______________________________________________________________________________________________________

507 10 Power Frequency Withstand kV 70
508 11 Creepage Distance mm/kV 25
509 12 Mass per Insulator kg Specify
510
511 15 Substation 11kV Switchgear -----
512 1 General requirements -----
514 1.2 Switchgear Model number Specify
516 1.4 Application Indoor / freestanding
517 1.5 Type Withdrawable /
518 1.6 Interrupting medium Vacuum
519 1.7 Insulating medium Air
520 1.8 Arc vent ducts Specify
521 1.9 Painting color RAL 7035
522 1.10 Panel heaters V AC 230
523 1.11 LV compartment lighting Yes
524 1.12 Incomer / bus-section / bus-riser dimensions mm 1000
525 1.13 Main / local feeder dimensions mm 800
526 2 Board ratings -----
527 2.1 Rated voltage kV 11
528 2.2 Maximum voltage kV 12
529 2.3 Rated power frequency withstand voltage kV 28
530 2.4 Rated lightning impulse withstand voltage kV 95
531 2.5 Rated frequency Hz 50
532 2.6 Main busbar rating A 3150
533 2.7 Incomer breaker rating A 2500
534 2.8 Local feeder breaker current rating A 630
535 2.9 Bus section breaker rating A 2500
536 2.10 Minimum rated short time withstand current kA/3s 31.5
537 2.11 Internal ARC classification (AFLR) current withstand kA 31.5
538 2.12 Internal ARC classification (AFLR) time s 1
539 2.13 Specific creepage distance mm/kV 25
540 3 Operating details -----
541 3.1 Operating sequence O-0.3s-CO-3min-CO
542 4 Control details -----
543 4.1 Tripping and closing voltage V DC 110
544 4.2 Spring rewind motor V DC 110
545 5 Substation board cable connections -----
546 5.1 Power cabling entry Bottom back
547 5.2 Control cabling entry Top
548 6 Panel earthing requirements -----
549 6.1 Main earth bar mm² 150
550 6.2 Cable earth switch Yes
551 6.3 Busbar earth switch Yes
552 7 Control equipment on panel -----
553 7.1 Trip/close/neutral switch Yes
554 7.2 Local/remote switch (lockable) Yes
555 7.3 Cable live LEDs Yes
556 7.4 Circuit breaker status LEDs Yes
557 7.5 Type test certificates provided Yes
558
559 16 630mm² 6.35/11kV 1C Cu XLPE AWA -----
562 3 Specification IEC 60502
563 4 Voltage kV 6.35/11
564 5 Maximum permissible Voltage kV 12
565 6 Number of cores 1
566 7 Symmetrical fault level withstand kA/1s 88
567 8 Cross section mm² 630
568 9 Conductor material Cu
569 10 Insulation XLPE
570 11 Armouring AWA
571 12 Sheath Polyethylene
572 13 Cable type Screened
573 14 Length per drum m 300
574 15 Radial water blocking Water swellable tapes
575 16 Weight per drum kg Specify
576 17 Cable bending radius mm 750
Lot 1 Rev 5
_______________________________________________________________________________________________________

577 ZESCO
578 Year of manufacture
579 18 Cable marking at 1m intervals IEC 60502
580 Voltage
581 Cable size
582 19 Type test certificates provided Yes
583
584 17 240mm² 19/33kV 3C Cu XLPE SWA -----
588 4 Voltage kV 19/33
595 11 Armouring Galvanized SWA
602 ZESCO
605 Voltage
606 Cable size
608
609 18 240mm² 6.35/11kV 3C Cu XLPE SWA -----
613 4 Voltage kV 6.35/11
Lot 1 Rev 5
_______________________________________________________________________________________________________

627 ZESCO
630 Voltage
631 Cable size
633
634
635 19 120mm² 6.35/11kV Cu 1C XLPE AWA -----
639 4 Voltage kV 6.35/11
653 ZESCO
656 Voltage
657 Cable size
659
660 20 120mm² 6.35/11kV Cu 3C XLPE SWA -----
664 4 Voltage kV 6.35/11
678 ZESCO
681 Voltage
682 Cable size
684
685 21 120mm² 1kV 4C Cu PVC SWA -----
689 4 Voltage kV 1
692 7 Symmetrical fault level withstand kA/1s 13.8
695 10 Insulation PVC
Lot 1 Rev 5
_______________________________________________________________________________________________________

697 12 Length per drum Specify
698 13 Weight per drum Specify
699 14 Radial water blocking Polyethylene sheath
700 15 Cable bending radius mm Specify
701 ZESCO
704 Voltage
705 Cable size
706 17 Cable phase colors RYB-Bl
707
708 22 Outside Termination - 630mm² 6.35/11kV AWA XLPE 1-Core Cu Cable -----
712 4 Voltage kV 6.35/11
714 6 Cable size mm² 630
716 8 Type of lugs Crimped
717 9 Earth kit Yes
718 10 Complete kit from one supplier Yes
719 11 Shelf life of termination kit months 24
720 12 Termination type Heat shrink
721 13 Cable type XLPE
722 14 Manufacturers reference number Specify
723 15 Special tools required Yes/no
724 16 Specify tools if yes Specify
725 17 Phase rotation RYB
727 19 Indoor / Outdoor Outside
728
729 23 Inside Termination - 630mm² 6.35/11kV AWA XLPE 1-Core Cu Cable -----
733 4 Voltage kV 6.35/11
738 9 Earth kit Yes
748 19 Indoor / Outdoor Inside
749
750 24 Outside Termination - 240mm² 19/33kV SWA XLPE 3-Core Cu Cable -----
759 9 Earth kit Yes
Lot 1 Rev 5
_______________________________________________________________________________________________________

770
771 25 Outside Termination - 240mm² 6.35/11kV SWA XLPE 3-Core Cu Cable -----
775 4 Voltage kV 6.35/11
780 9 Earth kit Yes
791
792 26 Inside Termination - 240mm² 6.35/11kV SWA XLPE 3-Core Cu Cable -----
796 4 Voltage kV 6.35/11
801 9 Earth kit Yes
811 19 Indoor / Outdoor Inside
812
813 27 Inside Termination - 120mm² 6.35/11kV SWA XLPE 3-Core Cu Cable -----
817 4 Voltage kV 6.35/11
822 9 Earth kit Yes
832 19 Indoor / Outdoor Indoor
833
834 28 Inside Termination - 120mm² 6.35/11kV AWA XLPE 1-Core Cu Cable -----
Lot 1 Rev 5
_______________________________________________________________________________________________________

838 4 Voltage kV 6.35/11
843 9 Earth kit Yes
853 19 Indoor / Outdoor Indoor
854
855 29 Cable Joint - 630mm² 6.35/11kV AWA XLPE 1-Core Cu Cable -----
859 4 Voltage kV 6.35/11
864 9 Earth kit Yes
873
874 30 Cable Joint - 240mm² 19/33kV SWA XLPE 3-Core Cu Cable -----
883 9 Earth kit Yes
892
893 31 Cable Joint - 240mm² 6.35/11kV SWA XLPE 3-Core Cu Cable -----
897 4 Voltage kV 6.35/11
902 9 Earth kit Yes
Lot 1 Rev 5
_______________________________________________________________________________________________________

911
912 32 Cable Joint - 120mm² 6.35/11kV SWA XLPE 3-Core Cu Cable -----
916 4 Voltage kV 6.35/11
921 9 Earth kit Yes
930
Lot 1 Rev 5
_______________________________________________________________________________________________________

931 33 Free-standing Panel and Junction Box -----
932 1 Metallic free-standing panels for control and protection: -----
936 1.4 Panel type 19 Inch Swing frame
937 1.5 Equipment mounting Flush Mounting
938 1.6 Dimensions (width x depth x height): 600 x 800 x 2,200 mm
939 1.7 Mild steel body 2mm minimum thickness, door 2.5mm Yes
Modular standard (IEC297), Pad lockable doors, Door
940 1.8 Yes
switched lamps, Thermostat/hygrostat controlled heaters
941 1.9 Power outlets fed from earth leakage protection Yes
942 1.10 Tiled Mimic Yes
Zinc coated top plates with EMV cable glands for all control
943 1.11 Yes
and LV power cables, Anchoring bolts
944 1.12 Test block for current PK2 type or similar
945 1.13 Test blocks for voltage PK2 type or similar
946 1.14 Test switches for DC circuits Slide links
Entrelec M series or
947 1.15 Terminal blocks
equivalent
948 1.16 Cut-out windows for bus wiring – covered with rectangular 3 per sidewall
949 1.17 Lifting eyebolts on each top corner M12
950 1.18 Panel color RAL7035
Indoor in substation
951 1.19 Installation
control building
952 1.20 Degree of Protection IP54
Typicals to be enclosed
953 1.21 Outline and layout drawing No.
with bid
954 1.22 Quality assurance Specify
Marshalling Kiosk Or Yard Junction Box (complete one
955 2 -----
per kiosk type)
959 2.4 Material 3CR12 Stainless
960 2.5 Access Doors Front and Back
961 2.6 Welding plugs: 3 phase 400V (Trfr MK only) 1 per Kiosk
962 2.7 Three pin plugs 1 phase 240V 15 Amp 1 per Kiosk
VTJB, CTJB,
963 2.8 Application
Transformer MK, Yard
equivalent
965 2.10 Doors Lockable
with bid
969
970 34 Relay Technical Specification -----
All Bay Control Units (BCUs) are to meet the following
971 1 -----
specifications as a minimum
974 1.3 Country of origin Specify
975 2 Minimum Functionality -----
976 2.1 Graphical Man-Machine Interface Yes
977 2.2 Fuse Fail Supervision Yes
978 2.3 Main Trip Circuit Supervision (Dual State) Yes
979 2.4 Backup Trip Circuit Supervision (Dual State) Yes
980 2.5 Circuit Breaker Fail Protection Yes
981 2.6 Voltage and Current Measuring Functions Yes
982 2.7 3 Phase Power Measuring Functions Yes
983 2.8 Circuit Breaker Wear Monitor Yes
984 2.9 3 Pole Tripping Multi shot(selectable) auto-reclose relay (79) Yes
Yes - SCADA & Local
985 2.10 Electrically operated devices’ control selection via relay
pushbuttons / switch
Yes - SCADA & Local
986 2.11 Local / Remote Control Selection
selection via relay
Lot 1 Rev 5
_______________________________________________________________________________________________________

Yes - SCADA & Local
987 2.12 Auto-reclose relay (79) On/Off Control selection
selection via relay
Yes - SCADA & Local
988 2.13 Auto-reclose relay (79) Local/Remote control selection selection via relay
Attach Data Sheet, Technical Specifications and Type Test
989 2.14 Yes
certificates
All supplied Master Trip / Lock-out Relays are to meet the
990 3 -----
following specifications at a minimum
992 3.2 Type or designation Specify
994 4 Technical Details -----
995 4.1 Mechanically Latched Yes
996 4.2 Flagged Indication Yes
997 4.3 Reset Electrical or Manual
998 4.4 Maximum Operation time ms 25
999 4.5 Rated Supply Voltage Vdc 110-220
1000 4.6 Rated Supply Voltage Operation Range % 80 - 120
1001 4.7 Output Contact Rated Voltage V 400
1002 4.8 V AC/DC Yes
certificates
All Protection Relays are to meet the following technical
1003 5
specifications at a minimum -----
1004 5.1 Rated Voltage (Un) V AC 110
1005 5.2 Rated Current (In) A 1
1006 5.3 Continuous Voltage Withstand V 2 x Un
1007 5.4 Rated Frequency (fn) Hz 50
1008 5.5 Thermal Current Withstand: Continuous A 4 x In
1009 5.6 Thermal Current Withstand: 10s A 25 x In
1011 5.8 Input Impedance: (In = 1A) mW < 100
1012 5.9 Output Contact Rated Voltage V AC/DC 250
1013 5.10 Power/ Signal Contact Thermal Withstand capability: A 5
1014 5.11 Power/ Signal Contact Thermal Withstand capability: 3s A 8-15
1015 5.12 Power/ Signal Contact Thermal Withstand capability: 0.5s A 10-30
1016 5.13 Binary Input Voltage Range V dc 90-220
1017 5.14 Rated Auxiliary Supply Voltage V dc 110-220
1018 5.15 Rated Auxiliary Supply Voltage Operation Range % 80 - 120
Internal Alarm variable
1021 5.18 Internal hardware and Software Supervision programmable to a fail-
safe Output Contact
Data Communication port to Substation LAN – IEC61850
1022 5.19 Yes
(including send /receive GOOSE)
1023 5.20 Full Local and Remote Control and Interlocking Yes
1024 5.21 Local Data Communication port Yes (front)
Fibre - Ethernet
1025 5.22 Type of Communication Ports Copper - Engineering
access
Minimum sampling rate
1026 5.23 Disturbance Recorder Oscillographs kHz
of 1kHZ
1027 5.24 Yes
certificates
1028
1029 35 Transformer Protection -----
1030 1 Differential Protection Relay (Main 1 Protection) -----
1034 2 Differential Protection Relay (Main 2 Protection) -----
1036 2.2 Model Specify
1039 3.1 Main transformer differential protection (87T) Yes
1040 3.2 Low impedance 2 Winding Restricted Earth fault Protection Yes
1041 3.3 Transformer primary overcurrent protection (50/51, 50/51 N) Yes
1042 3.4 Transformer HV and MV overcurrent protection (50/51, 50/51 Yes
1043 3.5 Two circuit breaker failure protection (48 BF) Yes
Lot 1 Rev 5
_______________________________________________________________________________________________________

1044 3.6 Synchro check (25) No
1045 3.7 3 Stage 3 Phase Over-current Protection (50/51) Yes
1046 3.8 3 Stage Earth Fault Protection (50/51 N) Yes
1047 3.9 Sustained Earth Fault Protection (HV & MV) Yes
1048 3.10 Directional Over-current Protection Yes
1049 3.11 Directional Earth Fault Protection Yes
1050 3.12 Second Harmonic Restraint for Transformer Inrush Yes
1051 3.13 Fifth Harmonic Restraint with adjustable deactivation level Yes
1052 3.14 Over Flux Protection (over flux selectable to alarm, trip or Yes
1053 3.15 Under / Over Voltage Protection Yes
1054 3.16 Internal CT ratio correction and Vector Group matching Yes
Phase Current and Angle display to confirm Vector Group
1055 3.17 Yes
matching
1056 3.18 Differential and restraint current display Yes
1057 3.19 Trip Circuit Supervision (Dual State) No
1058 3.20 Number of Heavy Duty Output Relays Specify - Match Solution
1059 3.21 Number of Programmable Signal Output Relays Specify - Match Solution
1060 3.22 Number of Programmable Binary Inputs Specify - Match Solution
1061 3.23 Number of Programmable LEDs Specify
1062 3.24 Sequence of event recorders ms 1ms resolution
1063 3.25 Yes
certificates
1064 3.26 Number of Voltage Inputs 4
1065 3.27 Maximum Power Consumption Specify
1066 4 Bay Control Unit -----
1067 4.1 As per spec Yes
1068 5 Automatic Voltage Regulating Relay -----
Tap-changer Protection (Over and Under-voltage and over-
1073 6.1 Yes
current blocking)
1074 6.2 Line Voltage Drop Compensation Yes
1075 6.3 Tap Position Indication (Digital) Yes
1076 6.4 VT Fuse-fail blocking Yes
1077 6.5 Tap Change Alarms Yes
1078 6.6 Tap Change in progress Indication Yes
Master Follower &
1079 6.7 Transformer paralleling control Limiting of Circulating
Current (selectable)
1080 6.8 Local Tap Change Control Yes
Yes - Local selection via
1081 6.9 Local / Remote control selection
relay pushbuttons /
Yes - SCADA & Local
1082 6.10 Manual / Auto control selection selection via relay
pushbuttons
Yes - SCADA & Local
1083 6.11 Manual Raise / Lower control selection via relay
pushbuttons
1084 6.12 Definite and Inverse time Voltage control characteristic Yes
1085 6.13 External Blocking Input Yes
1086 6.14 “Tap Position”-Interface to Transformer BCD
1087 6.15 Transformer Parallel Operation Yes
1088 6.16 Yes
(including send/receive GOOSE)
1089 6.17 Local Data Communication Port Yes
1091 7 Master Trip / Lock-out Relays -----
1093
1094 36 33kV Busbar Protection -----
1095 1 33kV Busbar Protection -----
1099 1.4 Minimum Functionality -----
1100 1.5 Main bus bars protection (87 B) based on breaker and half No
1101 1.6 Operating principle Current differential
1102 1.7 Centralised / Decentralised scheme Centralised
Lot 1 Rev 5
_______________________________________________________________________________________________________

Integrated (describe
1103 1.8 Check-zone functionality
method)
1104 1.9 High/ Low Impedance Low
1105 1.10 Minimum number of Zones 2 (extendable)
1106 1.11 Breaker fail and bay isolation functionality via switches Yes
1107 1.12 Minimum number of bays including spare bays 6
1108 1.13 Current Transformer Supervision Yes
1109 1.14 Internal CT ratio correction Yes
1110 1.15 Phase Current and Angle, Differential and restraint current Yes
1112 1.17 Number of Voltage Inputs Optional
1113 1.18 Yes
certificates
1114 1.19 Master Trip Relays Required if not
1115
1116 37 33kV Bus Section Protection -----
1124 2.3 Directional overcurrent and earth fault protection (67/67N) Yes
1127 2.6 Yes
certificates
1130
1131 38 33kV Feeder Protection -----
1136 2 11kV Normal Feeder Protection -----
1140 2.4 Onboard Indoor Protection Yes
Yes - 5A primary for
1146 3.5 Directional Sensitive Earth Fault Protection
overhead lines
1147 3.6 Under / Over Voltage Protection No
1149 3.8 Main Trip Circuit Supervision (Dual State) No
1150 3.9 Backup Trip Circuit Supervision (Dual State) No
1157 3.16 Yes
certificates
1160
Lot 1 Rev 5
_______________________________________________________________________________________________________

1161 39 33kV Incomer Protection -----
1162 1 33kV Incomer Protection -----
1170 2.4 Under Frequency Protection Yes
1172 2.6 Directional Sensitive Earth Fault Protection Yes
1183 2.17 Attach Data Sheet, Technical Specifications and Type Test Yes
1186
1187 40 11kV Transformer Incomer Protection -----
1197 2.4 Under Frequency Protection Yes
1199 2.6 Directional Sensitive Earth Fault Protection Yes
1210 2.17 Attach Data Sheet, Technical Specifications and Type Test Yes
1214
1215 41 11kV Arc Protection -----
1222 2.1 Zone Selectivity Yes
1223 2.2 Cable compartment zone selectivity Yes
1224 2.3 Intertripping relays Yes
1225
Lot 1 Rev 5
_______________________________________________________________________________________________________

1233 2.1 As per BCU spec Yes
1234 2.2 Yes
certificates
1235
1236 43 11kV Local Feeder Protection -----
overhead lines
1258 2.16 Yes
certificates
1261
1262 44 AC/DC Distribution Boards -----
1263 1 Automatic change over panel -----
Three way Automatic
1267 1.4 Type
Change Over
1268 1.5 Installation In Separate Panel -
Typical to be enclosed
1269 1.6 Outline and layout drawing
with bid
Double and Three pole -
1270 1.7 MCB types Earth leakage on all
single phase supplies
1271 2 AC Wall mounted -----
with bid
1276 2.5 Panel covers and warning labels Yes
1277 2.6 Protection of incoming circuits MCBs
1279 3 AC Distribution Panel -----
with bid
From one phase and
1286 3.7 AC Method of connection
Neutral busbar
Lot 1 Rev 5
_______________________________________________________________________________________________________

1288 3.9 Signaling LEDs (Common alarm for MCB tripped, etc) Yes
1289 3.10 Nameplates Yes
1290 3.11 Identification labels Trafolite
1291 3.12 Single phase plugs 2
1292 3.13 Analogue AC Voltage meter with selector switch Yes
1293 3.14 Test switches for current and voltage Yes
1294 3.15 Enclosure type Free-standing
1295 3.16 Dimensions (length x width x depth) 600 x 800 x 2,200 mm
1296 4 DC Distribution Panel -----
1302 4.6 DC Method of connection From pos and neg
1303 4.7 Signaling LEDs (Common alarm for MCB tripped, etc) Yes
1304 4.8 Nameplates Yes
1305 4.9 Identification labels Trafolite
1306 4.10 Analogue DC Voltage meter Yes
1307 4.11 Test switches for current and voltage Yes
1308 4.12 Test switches for DC circuits Yes
Entrelec M series
terminals - Spring loaded
with bid
1312 4.16 Enclosure type Free-standing
1313 4.17 Dimensions (length x width x depth) 600 x 800 x 2,200 mm
1314
1315 45 110V Batteries -----
1316 1 General -----
1317 1.1 Manufacturer - Specify
1318 1.2 Type - Specify
1319 1.3 Country of origin - Specify
1320 2 Nominal Characteristics -----
1321 2.1 Cell type - NiCAD
1322 2.2 Number of cells by battery - Specify
1323 2.3 Rated battery voltage V DC 110
1324 2.4 Floating cell voltage per cell V 1.27
1325 2.5 Floating charge current A Specify
1326 2.6 Equalizing cell voltage V 1.6 to 1.65
1327 2.7 Rated A-h cell capacity at 25°C (for 10 h discharge time) A-h Specify
1328 2.8 Cell end voltage at 25°C (for A-h capacity) V DC Specify
1329 2.9 Number of positive plates A Specify
1330 2.10 Discharge current during 1 minute at rated end voltage A Specify
1331 2.11 Short circuit current A Specify
1332 2.12 Life expectancy years > = 20
1333 3 Cabinet -----
1334 3.1 Container type - Specify
1335 3.2 Container material - Specify
1336 3.3 Container dimensions (H x L x D) mm Specify
1337 3.4 Electrolyte Specify
1338 4 Accessories -----
1339 4.1 Battery support - Yes
1340 4.2 Floor mounted cabinet - Yes
1341 4.3 Thermometer - Yes
1342 4.4 Electrolyte densimeter - Yes
1343 4.5 Battery voltmeter with loading resistance - Yes
1344 4.6 Anticorrosive grease - Yes
1345 4.7 Jumper for cells connections set Yes
1346 4.8 Isolated tools set Yes
1347 4.9 Characteristic data or curves charts to be supplied Yes
1348 4.10 Voltage vs time at rated A-h - Specify
1349 4.11 Current vs time at rated A-h - Specify
1350 4.12 Temperature derating factor for battery capacity - Specify
1351 5 Standards -----
IEC 60623
1352 5.1 Manufacturing -
ANSI/IEEE 450
1353 5.2 Quality assurance - ISO 9001
1354 6 Installation - Indoor inside control
Lot 1 Rev 5
_______________________________________________________________________________________________________

1355
1356 46 110V Battery Charger -----
1357 1 110VDC Batteries - -----
1360 1.3 Catalogue no - Specify
Dual Parallel
1363 2.1 Configuration
w/automatic switchover
1364 2.2 AC Supply V AC 400/240, 4W
1365 2.3 Frequency of AC supply Hz 50
1366 2.4 AC input current A Specify
1367 2.5 DC output voltage V DC 110
DC. output voltage regulation with 0 to 100 % load, ± 10 %
1368 2.6 % ±1
input voltage variation and ± 5 % frequency variation
1369 2.7 DC output current A Specify
1370 2.8 Maximum ripple without battery % 5 max
1371 2.9 Floating range V DC 99-150
1372 2.10 Equalizing range V DC 99-150
1373 2.11 Equalizing time delay setting range hours 6 – 48
1374 2.12 Max. recharge time (80 %) of battery hours 12
1375 2.13 Equalizing/floating switching - manual and automatic
1376 2.14 Current limiting adjustment % 50 – 100
1377 2.15 Main to backup charger transfer - Manual and automatic
1378 2.16 Rectifier type - thyristor
1379 3 Transformer (if applicable) -----
1380 3.1 Type - Dry
1381 3.2 Power kVA Specify
1382 3.3 Two separate primary/secondary windings - Yes
1383 3.4 Primary/secondary voltage V AC Specify
1384 3.5 Efficiency % Specify
1385 3.6 Short-circuit current proof - Current limited
1386 3.7 Surge suppression AC & DC - Yes
1387 3.8 Reverse battery protection - Yes
1388 3.9 Meantime between failures MTBF h > 10 000
1389 4 Mean repair time MTR h <1
1390 4 Instruments and indication -----
1391 4.1 Digital ammeter - Yes
1392 4.2 Digital voltmeter - Yes
1393 4.3 Ground fault alarm lamp and contact - Yes
1394 4.4 AC failure alarm lamp and contact - Yes
1395 4.5 Charger failure alarm lamp and contact - Yes
1396 4.6 Max./min. voltage alarm lamp and contact - Yes
1397 4.7 Equalizing/floating signalling lamps and contact - Yes
1398 4.8 AC "ON" signalling lamp and contact - Yes
1399 4.9 Low battery voltage lamp and contact - Yes
1400 4.10 Manual operation selector contact - Yes
1401 4.11 Common alarm for all of above - Yes
1402 4.12 Enclosure type free-standing, IP 50
IEC 60947
ANSI/NEMA PE 5
Indoor inside control
1406 6 Installation -
building
1407
1408 47 48V Batteries -----
1409 1 General - - -----
1415 2.1 Cell type - NiCAD
1416 2.2 Number of cells by battery - Specify
1417 2.3 Rated battery voltage V DC 48
1418 2.4 Floating cell voltage per cell V 1.27
1419 2.5 Floating charge current A Specify
1420 2.6 Equalizing cell voltage V 1.6 to 1.65
Lot 1 Rev 5
_______________________________________________________________________________________________________

1421 2.7 Rated A-h cell capacity at 25°C (for 10 h discharge time) A-h Specify
1422 2.8 Cell end voltage at 25°C (for A-h capacity) V DC Specify
1423 2.9 Number of positive plates A Specify
1424 2.10 Discharge current during 1 minute at rated end voltage A Specify
Entrelec M series
1427 2.13 Terminal type -
terminals or equivalent
1428 2.14 Number of charge/discharge cycles - Specify
1429 2.15 Internal cell resistance W Specify
1432 3 Cabinet -----
1433 3.1 Container type - Specify
1434 3.2 Container material - Specify
1435 3.3 Container dimensions (H x L x D) mm Specify
1436 3.4 Electrolyte Specify
1438 4.1 Battery support - Yes
1439 4.2 Floor mounted cabinet - Yes
1440 4.3 Thermometer - Yes
1441 4.4 Electrolyte densimeter - Yes
1442 4.5 Battery voltmeter with loading resistance - Yes
1443 4.6 Anticorrosive grease - Yes
1444 4.7 Jumper for cells connections set Yes
1445 4.8 Isolated tools set Yes
1446 4.9 Characteristic data or curves charts to be supplied Yes
1447 4.10 Voltage vs time at rated A-h - Specify
1448 4.11 Current vs time at rated A-h - Specify
1449 4.12 Temperature derating factor for battery capacity - Specify
IEC 60623
ANSI/IEEE 450
building
1454
1455 48 48V Battery Charger -----
1456 1 48VDC Batteries - - -----
1462 2.1 Configuration Single mode
1463 2.2 AC Supply V AC 400/240, 4W
1464 2.3 Frequency of AC supply Hz 50
1465 2.4 AC input current A Specify
1466 2.5 DC output voltage V DC 48
DC. output voltage regulation with 0 to 100 % load, ± 10 %
1467 2.6 % ±1
input voltage variation and ± 5 % frequency variation
1468 2.7 DC output current A Specify
1469 2.8 Maximum ripple without battery % 5 max
1470 2.9 Floating range V DC 40 – 60
1471 2.10 Equalizing range V DC 40 – 60
1472 2.11 Equalizing time delay setting range hours 6 – 48
1473 2.12 Max. recharge time (80 %) of battery hours 12
1474 2.13 Equalizing/floating switching - manual and automatic
1475 2.14 Current limiting adjustment % 50 – 100
1476 2.15 Main to backup charger transfer - Manual and automatic
1477 2.16 Rectifier type - thyristor
1478 3 Transformer (if applicable) -----
1479 3.1 Type - Dry
1480 3.2 Power kVA Specify
1481 3.3 Two separate primary/secondary windings - Yes
1482 3.4 Primary/secondary voltage V AC Specify
1483 3.5 Efficiency % Specify
1484 3.6 Short-circuit current proof - Current limited
1485 3.7 Surge suppression AC & DC - Yes
1486 3.8 Reverse battery protection - Yes
Lot 1 Rev 5
_______________________________________________________________________________________________________

1487 3.9 Meantime between failures MTBF h > 10 000
1488 3.10 Mean repair time MTR h <1
1489 4 Instruments and indication -----
1490 4.1 Digital ammeter - Yes
1491 4.2 Digital voltmeter - Yes
1492 4.3 Ground fault alarm lamp and contact - Yes
1493 4.4 AC failure alarm lamp and contact - Yes
1494 4.5 Charger failure alarm lamp and contact - Yes
1495 4.6 Max./min. voltage alarm lamp and contact - Yes
1496 4.7 Equalizing/floating signalling lamps and contact - Yes
1497 4.8 AC "ON" signalling lamp and contact - Yes
1498 4.9 Low battery voltage lamp and contact - Yes
1499 4.10 Manual operation selector contact - Yes
1500 4.11 Common alarm for all of above - Yes
1501 4.12 Enclosure type free-standing, IP 50
IEC 60947
ANSI/NEMA PE 5
building
1506
1507 49 Metering -----
1508 1 33kV Metering -----
1509 1.1 Energy meter Specify
In separate panel
1513 1.5 Installation (see metering panel
layout)
1514 2 11kV Metering -----
11kV Incomers & 11kV
1519 2.5 Installation feeders on-board
protection panel
Stats Metering - 0.5
1521 3.1 Active energy meter class
Tariff Metering – 0.2
1522 3.2 Reactive energy meter class
1523 3.3 Digital MM interface RS 232 or USB
1524 3.4 Compatibility Windows, Vista or NT
1525 3.5 Energy management software Included
1526 3.6 Integration in Substation Automation System Yes
IEC 61850/IEC 62056-
1527 3.7 Serial Interface with adequate Communication Protocol
21/Ethernet
1528 4 Direct-read metering instruments -----
1529 4.1 AC bus voltmeter Digital display
Mini-moulded circuit breaker with auxiliary contact with
1531 5.1 Yes
auxiliary contact
1532 5.2 Test switches (voltage, current) Yes
1533 5.3 Terminal blocks and rail
equivalent
1534 6 Yes
certificates
1535
1536 50 Substation SCADA Specification -----
1551 1 Remote Terminal Unit -----
1553 1.2 Model Number Specify
1555 2 Technical Specifications -----
1556 2.1 Analogue Inputs (voltage range and number of)
1557 2.2 Digital Inputs (voltage range and number of) As per SCADA
1558 2.3 Digital Outputs (voltage range and number of) specification section 5.1
1559 2.4 Fibre ports (number of)
Lot 1 Rev 5
_______________________________________________________________________________________________________

1560 2.5 Upstream Communication Ports (number of) Specify
IEC 60870-5-101
Upstream Communication Ports (communication protocol
1561 2.6 RP 570/571
support)
IEC 60870-5-104
As per SCADA
1562 2.7 Downstream Communication Ports (number of)
specification section 5.1
1563 IEC 61850
1564 Downstream Communication Ports (communication protocol DNP 3.0
2.8
1565 support) SPA-Bus
1566 Modbus
1570 3 Substation Local Area Network -----
Communication cabling and equipment required to interface As per SCADA
1571 3.1
Workstation equipment to Substation LAN specification section 5.2
Communication cabling and equipment required to interface
1572 3.2 Fibre
Substation LAN to IEDs
Communication cabling and equipment required to establish
1573 3.3 Fibre
Substation LAN Backbone
As per SCADA
1574 3.4 Substation LAN Backbone redundancy
As per SCADA
1575 3.5 Substation LAN to IED interface redundancy
1576 3.6 RTU to IED and inter-IED communication protocol IEC 61850
1577 3.7 GPS Time Server Manufacturer and Model Number Specify
1578 3.8 GPS Time Server Country of Origin Specify
1579 3.9 GPS Time Server Protocol SNTP
1580 3.10 GPS Time Server Protocol Accuracy ms 10
1581 4 Ethernet Switches -----
As per SCADA
1585 4.4 Ethernet Switches (number of)
1586 4.5 Rated Auxiliary Supply Voltage V DC 110
1587 4.6 Rated Auxiliary Supply Voltage Operation Range 80% - 120%
1589 IEC 61850
1590 GOOSE
1591 MMS
4.8 Protocol Support
1592 IEEE 802.1q
1593 IEEE 802.1d
1594 SNTP
1606 5 Spares -----
1607 5.1 Mandatory Spares As per Schedule 5
1608
1609 51 Substation Telecommunication specification -----
1610 1 Woodlands Substation PCM/PDH/SDH Multiplexer -----
Multiplexer Backbone Technical Specifications (although the
functionalities listed here might not initially be required, the
1614 1.4 STM-64
multiplexer must be able to support this functionality at a later
stage by the addition of the required cards)
Lot 1 Rev 5
_______________________________________________________________________________________________________

1628 ELine and ELAN
MPLSTP based VPWS
1629
1.5 Services and VPLS
1630 TDM PWE3
1631 ETH PWE3
Synchronous Ethernet
1632 1.6 Clock Synchronization
IEEE 1588v2
1633 2 Woodlands Substation Optical Distribution Frames -----
1637 2.4 DDF Capacity (number of ports) 21
1638 2.5 ODF Capacity (number of ports) Specify
1639 3 Substation Phones -----
1643 3.4 Phones (number of) 2
1644 4 Spares -----
1645 4.1 Mandatory Spares As per Schedule 5
Lot 1 Rev 5

Contractor
LOT 2 - Coventry – Kafue 33kV Overhead Line Upgrade


A. PROJECT BACKGROUND
amongst other, increasing the power intake and distribution capacity and reliability of the 132kV ring
surrounding Lusaka. The ring currently connects Lusaka West - Roma - Leopards Hill - Waterworks -
Coventry - Lusaka West substations. During the execution of the LTDRP packages, the integrity of the ring
must be protected by avoiding the isolation of more than one section at any point in time.
1 OBJECTIVE
2 OVERVIEW
 Lot 1: Woodlands 33/11kV Substation Upgrade (Separate document)
 Lot 2: Coventry – Kafue 33kV Overhead Line Upgrade (This document)
 Lot 3: Industrial – Matero 33kV Corridor Upgrade (Separate document)
3 NETWORK DIAGRAM
The existing 33kV networks are shown in Figure 1 and the proposed alterations to these networks are shown
in Figure 2.
Figure 1: Existing Coventry Kafue 33kV network
Figure 2: Proposed changes to Coventry and Kafue 33kV network
4 DEPENDENCIES
There are no inter-lot and inter-project dependencies as the 33kV links between Coventry and Kafue are
merely being up-rated.
5 SCHEDULE
The typical schedule of the Package 8 Lot 2 is shown in Figure 3
MONTHS
1 2 3 4 5 6 7 8 9 10 11 12
Package 8 Lot 2
Lead Time
Task 1
Task 2
Task 3
6 ABBREVIATIONS
Item Description
°C Degree Celsius
A Ampere
BS British standard
cm Centimetre
Cu Copper
DC Direct Current
DPC Damp proof coarse
EN European norms
HF High frequency
Item Description
HV High Voltage
Hz Hertz
kA Kilo Amperes
kg Kilogram
kl Kilo litre
kPa Kilo Pascal
kV Kilo Volts
m/s Meter per second
mPa Mega Pascal
MV Medium Voltage
MVA Mega Volt Ampere
OLTC Online tap changer
Pa Pascal
TRFR Transformer
Item Description
UV Ultra violet
ZESCO Zambia Electricity Supply Commission
7 SCOPE OF WORK
The scope of work summary for Package 8 Lot 2 is divided into the following tasks:
 Task 1: 33kV OHL and cable feeders from Coventry Substation to Kafue Substation
 Task 2: 33kV feeder bays at Coventry Substation and Kafue Substation
The substation works are typically divided into three disciplines, namely
 Civil works.
The overhead line works are typically divided into three disciplines, namely
 Phase conductor and OPGW,
 Conductor hardware and assemblies, and
 Civil works and structures.

The work in each discipline must be planned according to the implementation methodology for the whole
project, taking careful note that disciplines are inter-dependent, with the possibility that certain personnel,
equipment, and sub-contractors will be mobilised and demobilised as required.
document. It does not necessarily describe all the work in detail. The scope of work described in this report
is a preliminary design and, accordingly, all estimates and projections contained herein are based on limited
data availability. Therefore, while the work, results, estimates and projections herein may be generally
indicative of the nature and quality of the project, they are not definitive.
The prospective bidders must study the documents and drawings and ensure that he allows for all the material
required to provide a complete fully functional installation. Bidders need to outline any significant material
omissions in their Bids. It is important to note that the scope of work is design, supply, installation and
commissioning, up to final handover of the fully functional substation, properly integrated into the Lusaka
Transmission and Distribution network.
specify these items, supported by the necessaries calculations, in line with the standards provided, for
approval of the Engineer
8 LOT 2 TASK 1 : 33kV OHL and cable feeders from Coventry

Substation to Kafue Substation
8.1 General
The aim of this task is to improve the load sharing and interconnectivity between the Coventry and Kafue
Road Substations. The current layout as well as the proposed layout can be seen in Figure 4 and Figure 5.
The affected 33kV networks connecting the Coventry and Kafue Road Substations are indicated in and are
connected as follows:
 There are two 2km 33kV 150mm² ACSR single circuit wooden pole lines between Coventry and
Kafue Road substations as indicated in yellow in Figure 5.
 On the Coventry side, each line is supplied from Coventry by means of a 200m 185mm² 33kV
XLPE, 3C AL cable as indicated in blue in Figure 5.
 On the Kafue Road side, where the servitude crosses the T2 Kafue Road, one line is supplied with
a 800m 185mm² 33kV XLPE, 3C Cu cable as indicated in red in Figure 5 and the other line is
supplied with a 3 x 800m x 240mm² 33kV XLPE, 1C Cu cable as indicated in green in Figure 5.
With reference to Figure 4 and Figure 5 the following:
 Demolish per “111233-40-SPE-EE-018 Dismantling of Overhead line and Substation Equipment

Specification”, the 2km north-eastern 33kV line.
 Construct in its place from Coventry Substation a 2km 33kV (2 x 36MVA) double circuit line with
self-supporting steel monopole structures and OPGW to the T2 Kafue Road . This line must have
double cable termination wooden structures at each end onto which a slack-span will be made from
the monopole onto each circuit separately.
 Demolish per “111233-40-SPE-EE-018 Dismantling of Overhead line and Substation Equipment
Specification”, the 2km south-western 33kV line.
 On the Coventry side, expose the 200m x 185mm² 33kV XLPE, 3C AL cable and on the Kafue
Road side the 3 x 800m x 240mm² 33kV XLPE, 1C Cu cable, reclaim and deliver to the ZESCO
farm.
 Install at the Coventry Substation and on both circuits 200m 19/33kV 500mm² 1C AWA Cu XLPE
cable per phase from the cable termination structure onto the new switchgear.
 Install at the Kafue Road substation and on both circuits 800m 19/33kV 500mm² 1C AWA Cu
XLPE cable per phase from the cable termination structure one onto the existing switchgear and
one onto the new switchgear.
8.2 PROTECTION, CONTROL AND TELECOMMUNICATION EQUIPMENT

8.2.1 Protection
 The protection settings be redone and recommissioned. .

Figure 4 Coventry and Kafue 33kV network changes
Figure 5 Geographical layout of Coventry and Kafue Road existing 33kV networks
9 LOT 2 TASK 2 : 33kV feeder bays at Coventry Substation and

Kafue Substation
9.1 General
The aim of this task is to improve the load sharing and interconnectivity between the Coventry and Kafue
Road Substations. The current line bays are underrated and must be replaced
. SUBSTATION CIVIL WORKS
With reference to Figure 6 & Figure 7 the following civil works is required:
 Remove and set aside for later use the yard stone in the affected areas.
 Design, supply and install foundations for all new equipment.
 Design, supply and install steelwork for all new equipment.
 Design, supply, install and connect all new equipment to the existing busbar with Centipede.
 Connect all new equipment to the existing substation earth grid.
9.2 PRIMARY PLANT

For both Coventry and Kafue Substations supply and construct complete with foundations, steelwork and
equipment, the following:
 Three complete new 33kV feeder bays each consisting of
o One cable termination structure with surge arrestors.
o One double side break line isolator with an earth switch
o Three current transformers.
o One circuit breaker.
o One double side break busbar isolator.
o All clamps with twin Centipede jumpers
 All new power and control cables.
 Install equipment labels for the new bay and new safety and information signs for the entire
substation as per the specification.
Following the successful commissioning, supply as-built drawings, maintenance manuals, cable schedules
and other necessary drawings, as applicable, including software copies in AutoCad format (three sets of each).

 LTDRP SCADA Detail Design Specification
 LTDRP Telecommunication Detail Design Specification
 LTDRP Protection Detail Design Specification
 LTDRP Decommissioning Specification
9.3.1 Protection
 The existing protection panels at Coventry and Kafue Substations must be re-used.
Protection settings must be redone to see if there is still adequate coordination between the two
substations
 Integration of new equipment and existing protection panels into the existing protection system is
part of the scope.
 All primary and secondary cable work is included.
 All affected protection to be re-commissioned.

 The complete new feeder bays shall be integrated into the existing SCADA and
telecommunications systems at both Substations. It is the responsibility of the contractor to
determine, supply, install and commission all necessary equipment to facilitate the full
functionality of the SCADA and telecommunications systems.
 Recommissioning of the necessary SCADA and telecommunications systems form part of this
contract.
 The Contractor will be responsible for the integration of these schemes to a fully functional status
and to the current level of functionality and performance.
9.3.3 Other
 Supply 33kV statistical meter panels with the required meters at both ends (Coventry and Kafue).
Please supply the meters and ethernet switches as per supplementary information
Meter Model: DTSD178 3Phase 3/4 Wires AMI meter IEC62053-22 IEC62053-23 with
Ethernet communication model with Ethernet communication module
Ethernet Switch Model: ZTE 2928E, 24 Ethernet 10/100M RJ45 electrical ports, 2 GE
Combo ports and 2 GE SFP optical ports, fixed - AC/DC power supply.
 Supply the new 33kV feeder protection and control panels from the existing AC/DC distribution
panels.
 Supply and install all necessary current transformer and voltage transformer junction boxes with
terminals as well as all necessary multicore control and small power cables including terminations.
 Factory acceptance tests (FATs), witnessed by three engineers of each discipline (protection,
SCADA and telecommunications) as the representatives of ZESCO shall be conducted according
to the specifications. Sufficient time should be set aside for a thorough FAT. As far as practically
possible, the protection and control scheme FAT will be conducted together with the SCADA
system FAT.
 Site Acceptance Tests (SATs) and local and overseas training to be provided for by the contractor
as detailed in the specifications. These tests and training will be applicable to all the equipment
supplied under this contract.
schedules and other necessary drawings, as applicable, including software copies in AutoCad
format (three sets of each).
Figure 6 Coventry Substation 33kV yard
Figure 7 Kafue Substation 33kV yard

B. SPECIFICATION
The Specification for this Lot corresponds to the tasks in the Scope of Work. It contains standard details on
any possible ZESCO related equipment and works. Functional requirements for design and construction are
described below, which must be read in conjunction with the ZESCO Standard Specifications (Section VII
Works Requirements – Supplementary Information) and Technical Schedules (Section X Contract Forms).
10 Reference standards
The design shall be in accordance to the latest version of the local ZESCO codes & standards, British
Standards (BS) or relevant IEC standards listed in the table below:
NB: In the absence Local codes and standards, British Standards (BS) or relevant IEC standards shall take
precedence. Where there is any conflict between the requirements of the Specification and the Specification
of Equipment, then the Specification shall take precedence. Where there is any conflict between the
requirements of this Specification and International Standards, then this Specification shall take precedence,
unless otherwise agreed to, in writing, by the Engineer.
10.1 ZESCO SPECIFICATIONS
VOLUME 1
SP - CSS - 000 CIVIL WORKS

1 SP - CSS - 001 Civil Works Substation General
2 SP - ECA - 001 Cables and Accessories
3 SP - ECA - 002 Cable Joints
4 SP - ECA - 003 Installation of small wiring & Trunking
5 SP - ECA - 004 Power Cable Installation
6 SP - ECO - 001 Overhead line & Earth Conductor
7 SP - ECO - 002 Aerial Bundled Conductors
SP - EIN - 000 INSTRUMENTS ( IN )
8 SP - EIN - 001 Metering Equipment
9 SP - EIN - 002 Credit Dispensing Units
10 SP - EGE - 001 Small Power Distribution Unit (Ready Board)
SP - ESC - 000 SYSTEM CONTROL
11 SP - ESC - 001 SCADA System for Regional Control Centre
SP - ESG - 000 SWITCHGEAR ( SG )
12 SP - ESG - 001 Unit Substation Switchgear
13 SP - ESG - 002 Surge Arresters
14 SP - ESG - 003 Pole Mounted Equipment
15 SP - ESG - 004 Auto Recloser (Pole Mounted)
16 SP - ESG - 005 Distribution Pillars, Fuses and Fuselinks
17 SP - ESG - 006 33 kV Outdoor Switchgear

18 SP - ESG - 007 33kV & 11kV Metal Enclosed Indoor Switchgear
19 SP - ESG - 008 Control Relays & Ancillary Equipment
VOLUME 2
SP - ESS - 000 SUBSTATION GENERAL ( SS )

1 SP - ESS - 001 Substation Auxiliary’s
2 SP - ESS - 002 Unit Substations
3 SP - ESS - 003 Substation Earthing - Lightning Protection & NER
4 SP - ESS - 004 11kV & 0.4kV Reticulation System Earthing
SP - ESU - 000 SUPPORTS ( SU )
5 SP - ESU - 001 Supports and Foundations
6 SP - ESU - 002 Wood Pole Supports
7 SP - ESU - 003 Tubular Steel Poles and Ancillary Equipment
8 SP - ESU - 004 Overhead line Insulators
9 SP - ESU - 005 Stays
10 SP - ESU - 006 Installation of 0.4-33kV OHL & ABC System
SP - ETR - 000 TRANSFORMER ( TR )
11 SP - ETR - 001 Distribution Transformers
12 SP - ETR - 002 Power Transformers
13 SP - ETR - 003 Current & Voltage Transformers
14 SP - GGE - 001 General Technical requirements
15 SP - GGE - 002 Works & Site Tests for S/S Equipment
16 SP - GGE - 003 Unit Substation Installation
17 SP - GGE - 004 Drawings/Operations & Maintenance Instructions
19 SP - GTE - 001 Test Equipment
20 SP - GTO - 001 Tools and Equipment
21 SP - GVE - 001 Vehicles Trucks Tractors & Portable Equipment
22 SP - GVE - 002 Cable Test and Fault Location Vehicle
23 SP - GVE - 003 Mobile Insulating Oil Treatment Plant
10.2 IEC STANDARDS
No Title Reference

1.5 IEC 60156
power frequency
1.9
1.18 IEC 60289
Coil
1.20 IEC 60422
1.22 Electrical Equipment for the Analysis of Free and Dissolved IEC 60567
Gases

2.2 IEC 62271-100:2011
No Title Reference

High-voltage switchgear and control gear – Part 103: Switches
3.2 IEC 62271-103:2011
for rated voltages above 1kV up to and including 52kV
3.3 IEC 62271-104:2015
current switches for rated voltages higher than 52kV
Tests on indoor and outdoor post insulators of ceramic material
3.4 IEC 60168:1994
or glass for systems with nominal voltages greater than 1000V

4.3 IEC 60168:1994

Instrument transformers – Part 4: Capacitive voltage
5.3 IEC 61869-5:2011
transformers

Surge arresters – Part 4: Metal-oxide surge arresters without
6.2 IEC 60099-4:2014
gaps for AC systems
6.3 IEC 60168:1994
6.4 voltage >1 000V – General definitions, test methods and IEC 62217:2012
acceptance criteria
10.3 BRITISH STANDARDS
No Title Reference
1. GENERAL
10.4 EUROPEAN STANDARDS

No Title Reference
1. GENERAL
1.1 EN 413-1
conformity criteria
11 Personnel requirements
requirements:

No. Position Experience - minimum Experience
minimum (years) (years)
must be professionally registered as a project manager at an international recognised institution. Certified
copies of this registration need to be submitted with this Bid.
Monthly Progress Meetings will be held on site and must be attended by at least the Contractor’s
Representative and the Site Manager. The Contractor’s Representative will be duly authorised to make
decisions on behalf of the Contractor.
It is a specific requirement that the Contractor’s Representative, Site Manager and Safety Official must be
fluent in English and the language of the Contractor's personnel. The above shall be in accordance with the
General Conditions.
12 Required documentation submission

The successful Bidder will be required to submit the following information during the execution of the
contract for approval as a minimum requirement:
No. Position
Detailed project schedule showing all planned activities including starting and completion dates for:
b. Data Collection
c. Design
d. Design Approvals
e. Procurement,
1
i. Construction
k. Handover.
Detailed designs and drawings for substations, switching stations and associated plant including the
following:

2 b. Site Layouts
e. Clamp schedule
f. Structural steel layouts
No. Position
g. Earthing Designs
h. Sections
i. Lighting Layouts
j. Lightning layouts.
k. Fire protection designs
l. Control Building layout
m. Cable trenches
n. All relevant protection and metering designs
o. All relevant SCADA, Telecommunication and Substation automation designs

3 d. Foundations designs
e. Earthing designs
h. Protection settings
Submission and approval of Technical details for all equipment listed in the Technical Schedules prior
4
to ordering.
5 Geotechnical studies and soil analysis of substation site area.
13 33kV Single circuit wooden pole structures

13.1 GENERAL
 All 33kV distribution networks are to be constructed per the Lusaka distribution rehabilitation
specifications provided. It shall remain the responsibility of the contractor to verify such drawings
to his satisfaction. The Employer accepts no responsibility for the completeness, correctness or
adequacy of any tower drawings provided.
 Changes in structure configurations shall be reviewed and accepted by the Employer prior to
installation.
 The contractor shall be fully responsible for his designs and their satisfactory performance in
service.
 Acceptance by the Employer does not relieve the contractor of responsibility for the adequacy of
the design, dimensions and details.
13.2 WOODEN POLE STRUCTURES

 Wooden poles shall typically be 14m with a 195-225mm pole top diameter and must have a fibre
strength of 55MPa for pine poles and 63MPa for eucalyptus poles and shall be planted 2.2m deep.
 The bottom shall be cut square to the longitudinal axis of the pole and the top shall have a slight
slant.
 The poles shall be pressure impregnated and shall not be cut to a shorter length or smaller diameter
after impregnation. The moisture content at the time of impregnation shall be less than 170g/kg.
 Retention and penetration requirement.
 Poles shall be fitted with gang nail or 4 turns of 2.5mm galvanized steel wire on each end.
 Poles shall not deviate as specified in BS 1990:1984.
 Poles shall be marked in accordance with Zesco specification SP-ESU-006.
 All drilled holes shall be treated on site with creosote prior to installation of hardware.
 Holes will not be drilled within 150mm from the end for Pine poles and 100mm for Eucalyptus
poles.
13.2.1 Wooden pole earthing requirements

 The 33kV lines will be constructed with shield wires. On the intermediate structures the earth wire
is supported by the pole through a reel insulator and galvanized bolt assembly. The shield wires
must be earthed at both poles of each H-pole structure by bonding the shield wire to a down wire
with an appropriate clamp. The down wire is then fixed against the wooden pole every 500mm
with a galvanized U-nail. Because steel cross arms are proposed it is not required to bond all metal
parts. The down wires must just be bonded to the steel cross arm.
 For wooden cross arms, bind all metal parts of the intermediate structure together with galvanised
steel wire and bonding clips and bond to the down wires. Extend the galvanized steel wire up to
the bottom of the pole fixed thereto every 500mm by means of galvanized steel u-nails.
 Where the 33kV cable terminates onto the 33kV overhead line as indicated in Figure 9, the sheath
of the cable is to be bonded to earth plus a distribution class surge arrestor is to be connected from
each phase to earth. The surge arrestor installation will be accompanied by an outdoor cable
termination and support system consisting of typically two or more sets of horizontally mounted
steel cross-arms. For wooden cross arms the surge arrestors will be interconnected by means of a
25mm² BCEW. Regarding Figure 10 the earthing of the surge arresters will be by means of a
25mm² PVC insulated copper conductor terminating onto a 4 x 1,2m copper cladded counterpoise
earth rod installed a minimum of 500mm below ground level. The counterpoise legs must be 5m
each of 25mm² BCEW to achieve an earth of 30Ω or less.
 Because of the stays present on all wood pole strain structures, BIL down wires are only required
from the top of the pole to the cross arm. The stay would serve as a down wire. If steel cross arm
is used, bond the shield wires to the cross arms. If wooden cross arms are used, bind all metal parts
of the structure together with galvanised steel wire and bonding clips. All stays must be provided
with stay insulators with a BIL of 300kV. This is typically fibre glass rod type.
 All earthing terminations to be made with compression lugs or bolted clamps. Copper conductor
with a minimum cross-sectional area of 16mm² to be used for earthing leads and bonding
conductor. Earth rods to be 16mm Cu plated.
 Care must be taken when connecting dissimilar metals together.
13.2.2 Terminal structures

Regarding Figure 8 a typical terminal structure.
 Terminal structures will be horizontally configured inline stayed H-pole structures with double
4.7m steel angle cross arms.
 The top of the pole where the shield wires attach is braced with a 3.1m steel angle cross arm and
galvanized bolt assemblies.
 Strain insulators to be clevis and tongue and the supporting insulators, where applicable, to be a
line post insulator with galvanized steel spindles if required.
 Any hardware must have a minimum of 120kN tensile strength.
 All exposed steel hardware must be galvanized as per ISO 1461.
 Where a visual representation of the phase rotation is required, this can be done with Red-Yellow-
Blue.
Figure 8 : Typical Terminal Structure
13.2.3 Cable termination structures

Regarding Figure 9 a typical cable termination structure.
 Figure 9 indicates a cable termination on a vertical structure. The cable termination structures under
this project will be from horizontal configured H-pole structure as indicated in Figure 8.
 Where the jumper conductors might go under clearance it must be fixed to the structure by means
of a post insulator support assembly which will include the post insulator, spindle and conductor
ties.
 The jumpers onto the surge arrestor will be the same as the phase conductor.
 The earthing of the surge arrestor installation will be done as indicated in Figure 10.
Figure 9 : Typical Cable Termination Structure
Figure 10 : Surge Arrestor Earthing Installation
13.2.4 Stays and anchors

Regarding Figure 11 a typical stay assembly.
 Stays to have a 114kN ultimate load.
 Holes for conventional stays may be dug by hand, augured by machine or dug with a back-actor.
 No stays shall be planted without the relevant stay plates fitted onto the stay rod.
 Steel stay wire shall be in accordance with IEC 60888:1987: Zinc-coated steel for stranded
conductors.
 A rectangular stepped hole shall be dug so that the length of the hole is in line to the projected line
of the stay wire.
 The hole shall be large enough for the stay plate to fit in, with minimum dimensions of 2m long,
1m wide and 1,950mm deep.
 Once the hole is dug, the front face of the lower step shall be undercut to accommodate the stay
plate. An 80mm wide slot shall be cut in the steps at 45° to allow for the stay rod.
 The stay plate shall be placed up against undisturbed soil on the pole side of the hole. The hole
shall be backfilled and compacted/rammed in maximum 150 mm layers. In poor soil areas, a 1:10
cement/sand mixture to be used for backfilling.
 Stay rod to protrude 150mm above ground level.
 Stay rod diameter to be M20 with a minimum length of 2,500mm.
 Stay plate to be 440mm x 440mm and 10mm thick.
 Stay wire to be 19/2.65 galvanised steel wire.
 The amount and layout of stays installed for strain structures shall be as per the contractor’s design.
 If hanging free, the stay insulator must not be closer than 4m to natural ground level.
Figure 11 : Typical stay assembly
13.2.5 Hardware assemblies for attachment of phase conductor assemblies
 All hardware used must be a minimum of 120kN for the 33kV line.
 See standard Zesco drawings for more details.
a) Suspension assemblies
Figure 12Figure 12 shows a typical suspension assembly for wooden H-pole structures. Please take note that
the glass discs will be replaced by a composite insulator.
Figure 12 : Typical suspension assembly for wooden H-poles
b) Strain assemblies
Figure 13 shows a typical strain assembly for wooden H-pole structures. Please take note that the glass
discs will be replaced by a composite insulator.
Figure 13 : Typical strain assembly for wooden H-poles

14 33kV Double circuit self-supporting steel monopole structures
14.1 GENERAL
The following structure types are included in this specification:
 Double circuit self-supporting intermediate structures (flanged);
 Double circuit self-supporting terminal structures (flanged);
 Double circuit self-supporting angle strain structure (flanged);
14.2 DEFINITIONS
The expression span lengths shall be taken to mean the horizontal distance between the centre lines of adjacent
structures.
The ground clearance is the minimum distance between the conductor and ground level in a span with the
conductor at its maximum design temperature.
The equivalent span is the calculated span length for tensioning a multiple span section such that the tension
of the equivalent span may be used for tensioning the whole section.
The upward vertical load imposed by the conductor at a support resulting from the gradients to the adjacent
spans is called the conductor uplift (minimum weight span).
The electrical clearance as specified is the separation distance between conductors based on the minimum
distance allowing for mid-span swing.
The maximum span is the maximum permitted length of any span for the conductor spacing adopted.
The sag is the maximum vertical distance between a conductor’s lowest centenary curves that spans between
supports and a straight line joining the conductor’s points of support.
The weight span is the horizontal distance between the lowest points of a conductor on either side of the
support. The lowest points of the catenary curves of both adjacent spans can be on the same side of the
support at steeply sloping terrain.
The horizontal load imposed by wind pressure acting at right angles to any element of the overhead line is
called the wind loading.
The wind span is the sum of half the wind loading on each of the two adjacent spans i.e. the horizontal distance
between the points at mid-span on each side of a support.
14.3 AMBIENT CONDITIONS

The following ambient and environmental conditions are applicable for all designs.

Ambient Temperature
Absolute Max. 45ºC
Absolute Min. 2ºC
Lightning conditions High with an average lightning ground flash density
of 10 -15 flashes per km² per annum
Relative Humidity
Maximum 86%
Minimum 39%
Extreme Wind Speed 28m/s
Hail Occasional
14.4 TEMPLATING
The contractor shall optimise each line in terms of span lengths and structure heights.
The templating of the line on the provided route and acquired ground profile (as described in the Specification
for Construction Activities) will be done prior to any ordering of material or construction commences. The
line templating is part of the design work and shall be provided together with all other design drawings for
approval to the Engineer.
Standard Engineering design procedures shall be used to determine the sag and tension profile for the specific
transmission line. The following is applicable to the conductors under the conditions stated.
Sag shall be calculated under the following conditions:
Table 2 : Sag reference temperature
Sag reference temperature Sag reference data

Maximum design sag temperature: As per ambient conditions
Minimum operating temperature: As per ambient conditions
The maximum tension in the conductor shall not exceed 40% of the breaking tension at the minimum
temperature as defined in the environmental conditions and maximum wind load, and simultaneously shall
not exceed 20% of breaking load at average daily temperature of 15°C without wind except for sections with
extra-long spans where compliance with the specified maximum working tensions under the assumed
maximum loading conditions may necessitate a lower figure for the 15°C still air tensions.
All specified safety clearances to ground and other structures should strictly be adhered to.
When a conductor breaks, the adjacent suspension insulators will swing away from the broken conductor
span. The insulator string becomes part of the catenary of the span adjacent to the broken span and results in
that span’s sag increasing. The sag should adhere to all the required safety clearances.
Every structure supporting a crossing span shall be designed in such a manner that it will be able to withstand
the loads that may be imposed upon it should a breakage of any phase conductor or earth conductor occurs.
As far as is reasonably practicable, every structure supporting a crossing span shall be located so that it will
not touch the crossed service if it falls over but also shall be located as close to the point of crossing as is
reasonably practicable.
14.5 PROFILE DRAWINGS

The contractor shall supply two hard copies and an electronic copy (in DXF format) of the line templating
drawings. The hard copies shall be plotted on a suitable scale on A0 paper and overlap such to ease continuity
between sheets. The electronic copy’s scale shall by 1:1 in the specified survey coordinate system.
The following information shall be indicated on the strip plans:
 All relevant features such as fences, cadastre information, tracks, rivers, watercourses, pipelines,
telecommunication circuits, power lines, railways, dwellings and any other obstructions.
 All features mentioned shall be accurately shown over a strip 30m wide centred on the centre line,
and generally outside this strip up to such as a power line or any other high object or structure.
 The angle of crossing, with the width of the feature to be crossed, shall be shown in the case of
railways, power lines, roads and telephone circuits.
 The strip plan shall be continuous even where the route traverses long featureless sections.
 Vegetation types shall be identified as far as possible by referring to the density of vegetation, i.e.
scattered, light, medium, dense bush, or cultivated land.
 Any areas of soft sand, marsh, or flooded ground shall be shown as these may be unsuitable for
placing structures.
 Angles of deviation shall be shown, and each angle point shall be the start of a new section for
representation and section chainage purposes.
 Positions of structures indicating their type and coordinates.
 Stringing chart at various ambient and stringing temperatures for ease of use on site indicating
initial sagging information per span.
 Conductor installation chart indicating proposed positions of conductor mid span joints.
On the strip plan the centre line of the overhead line shall be represented by a thick line at the bottom of the
profile sheet running continuously between consecutive angle points or terminal points.
The profile shall be drawn above the plan and is to correlate to the features on the strip plan. An arbitrary
datum may be used. Information on the profile shall include:
 The ground profile shall show the elevation above the chosen datum and shall include two
horizontal lines associated with the datum, the first uppermost giving the section chainage
increasing along the route of the line between bend points. The second and lower line shall contain
the total chainage between the start and finish of the line.
 Elevations shall be recorded above the chainage.
 The minimum required safety clearances over all obstacles.
 The expected initial sagging at both the minimum and maximum temperatures.
 The expected final sagging at minimum and maximum operating temperatures.
 Where the treasury ground slope exceeds 1 in 10, levels are to be shown on the profile at 10 metres
from the centre line, as dotted lines either side of the centre line, indicated left and right on the
elevation in the forward direction of the profile.
Where existing services (roads, telephone lines, railways, power lines etc.) are crossed a cross-section
drawing of the proposed crossing shall be provided on the strip plan at the relevant crossing.
14.6 LOADING TREES

Loading trees will be in accordance with SANS 10280-1:2013 Section 3.2 Simplified method using the design
wind speed as specified in 1 Site ambient conditions.
14.7 STEEL MONOPOLE STRUCTURES

All monopoles must be self-supporting. The strength of the poles must be calculated per the following inputs
and must reflect in the schedule of rates:
 Wind span : 250m
 Weight span : 450m
14.7.1 Double circuit structure

The proposed double circuit steel monopole structure will be as indicated in Figure 14.
Figure 14 : Typical double circuit steel monopole
14.7.2 DIMENSIONS
The overall lengths of the poles shall be determined by the contractor from the profile drawings. The actual
pole length shall not differ from the stated overall length by more than 50mm.
The base and tip diameters of the actual structure shall not differ from the designed diameter by:
 5mm for diameters up to 350mm
 1,5% for diameters over 350mm
Diameters at slip joints shall not differ such that the minimum required slip length is not obtained.
14.7.3 JOINTS
Flanged and slip joints should be aligned such that there is minimum pole deflection around the joint
14.7.4 SLIP JOINTS

The overlap section of a slip joint shall be at least 1.5 times the top diameter of the male section. In the case
of a non-uniform cross section pole, the overlap section of the slip joint shall be at least 1,5 times the largest
top diameter of the male section. Female slip joints shall have rapping plates on seams to avoid splitting.
The slip length shall not differ more than 50mm from the designed slip length.
14.7.5 FLANGED JOINTS

Flanged joints shall be manufactured with a jig set up in the manufacturer’s workshop to ensure squareness
of the flange onto the pole. Mating faces of cross-arm flanges shall be square to ensure surface contact on
assembly. One set of 10 off x 0.5mm thick finger packs shall be supplied with each batch of 10 poles for
slight pole adjustments. These packs shall be of such a nature that they can be installed without unbolting
flanges.
14.7.6 WELDS
Coded welding personnel shall perform all welding. Finished welds shall be smooth with no sharp edges.
Welds shall be of a strength that does not change the designed proof load, ultimate load or crippling load.
The ends of longitudinal welds shall be strengthened at slip joints on female sections to prevent splitting.
Butt welds shall have 100% penetration.
Seam welds shall have a minimum penetration of 60% except in slip joints where 100% penetration is
required. The inside weld at the slip joint shall be ground back to ensure no obstruction when obtaining the
desired slip lengths.
All shaft circumferential welds and their associated sections of longitudinal welds and all longitudinal welds
for the female parts of a slip joint shall be full-penetration welds to achieve full base material strength.
The shaft shall be centrally welded onto the base plate. All shaft structural welds shall be performed with
submerged arc technology.
Cross-arm tubular sections shall be centrally welded onto the connecting flanges.
All fitting-related welding shall be performed with inert gas technology.
14.7.7 OPENINGS
If specified, openings (e.g. bolt-holes, slots etc) shall be made in the poles during the manufacture of the
poles. These openings may be required for the attachment of cross-arms and other equipment. All openings
shall be made before galvanizing or treating.
Bolt hole tolerances are as follows:
 6mm for foundation bolts.
 2mm for all other bolts.

Plates for insulator attachments shall be manufactured with keyholes and dimensions in accordance with the
supplied insulator details.
14.7.8 GALVANISING AND POLE TREATMENT

These structures will be used in all environments. All poles shall be hot dip galvanised to ISO 1461 and shall
have a minimum coating thickness as indicated in Table 3 therein.
All structures shall be suitably straightened after galvanizing without causing damage to the galvanizing
surface or to the structure itself. No curved, bent or twisted structures will be accepted.
Poles to be planted shall be bitumen treated from 200mm above the ground line to 500mm below ground line.
following:

 Hot air drying
 Zink bath
 Quench and passivate is typically water with synthetic resins to provide additional protection..
There is no galvanizing plant in Zambia to do corrective actions. Any items that require modifications after
the initial galvanizing will not be accepted.
14.7.9 DRAWINGS
The structure layout drawings are a guideline of what is required with regard to layout, attachment heights,
stay levels, wind and weight spans etc. The manufacturer shall ensure that designs and manufacturing are
suited to the structure required.
A set of manufacturing drawings is required for checking and approval purposes before manufacturing
commences.
A complete and correct set of as-built drawings are required for record on completion of the job.
14.7.10 TESTS
All tests are to be in accordance with IEC 60652: Loading tests for overhead line structures. One structure
for each structure type will be type tested, the length chosen for the structure will be the length with the largest
loads in the structure.
14.7.11 FINISH
The finished product shall have a smooth external surface free from steel splinters and welding splatter. All
surfaces shall be clean and shall present a neat appearance. All corners shall be rounded with no sharp edges.
14.7.12 LADDERS/CLIMBING SYSTEM

Brackets for removable climbing steps, if applicable, shall be vertically spaced at 300mm and configured
such that the climber has a comfortable climbing path. The brackets shall permit easy installation of
removable steps without becoming trapped or wedged into the brackets.
Brackets welded onto the structures for propriety system, if applicable, shall suit the spacing of the ladder
brackets. The ladder supplier shall be consulted for attachment details. If this system is used on a structure,
the brackets on the structure shall start at approximately 9m above ground level. This lower portion shall be
accessed by means of a standard ladder and will prevent unauthorised persons climbing the structures.
Should a permanent ladder be required on the structure, the ladder shall be supplied loose and bolted onto the
structure on site. This will ensure that no damage is caused to the ladder during transportation.
14.7.13 STRAIGHTNESS TEST

Straightness shall be taken as the maximum distance measured between the centre-line of the faces of the
pole being measured, at any point along the length of the pole, to a line drawn from the centre of the tip of
the pole to the centre of the butt of the pole. The measurements shall be done on at least two faces of the pole
which are at 90° to each other. Measure, to the nearest 5mm, the deviation from straight.
14.7.14 STEEL REQUIREMENTS

The minimum thickness of the steel used for manufacture of poles shall be 4.5mm or larger unless specified
in the data schedules. The steel used shall be grade S355JR in accordance with EN 10025. If different grades
of steel are used for manufacture these must be approved by the employer before manufacturing commences.
The manufacturer shall ensure that mill certificates are available and traceable to structures manufactured.
All bolts used shall be grade 8.8 bolts. No electroplated bolts will be permitted.
14.7.15 ULTIMATE LOAD TEST

The ultimate load test shall be completed on all structures being tested and shall be executed once the working
load tests are done. The ultimate loads indicate the loads the structure will carry including factors of safety
as specified. Tests shall be carried out on strong and weak planes of asymmetrical poles. The tests need only
be completed in one direction on symmetrical poles.
The load shall be applied to the structure in increments of 10% up to 90% of the ultimate load, thereafter in
increments of 5% of the ultimate load until failure. This 100% load shall be held for 60 seconds before being
released. Deflection readings shall be taken whilst the load is being applied and once the load has been
released.
The structure shall withstand the applied loads for 60 seconds without failure of any component. Deflections
more than those depicted in the deflection requirements shall constitute the failure of the structure.
14.7.16 DEFLECTION REQUIREMENTS

The horizontal deflection for a structure loaded with safe working loads shall be no greater than 2.2% of the
total pole height. The permanent horizontal set allowed after application and removal of working loads shall
be no greater than 1% of the total pole height.
The horizontal deflection for a structure loaded with ultimate loads shall be no greater than 5.5% of the total
pole height. The permanent horizontal set allowed after application and removal of ultimate loads shall be
no greater than 3% of the total pole height.
14.7.17 MARKING AND PACKAGING

a) Marking
All structures and components to be uniquely identified with permanent marking which will enable the details
of the structure to be established at any time after assembly. All identification marks and structure-related
information are to be easily readable after the structure has been assembled. The following information shall
be clearly and indelibly marked with characters at least 20mm high and indented 1mm. This information
shall be 15m above the ground line on finished poles:
 the manufacturers name, trade name or trade mark;
 the overall length of the pole in meters e.g. “23m”;
 the ultimate load design e.g. “ UL = 23kN”;
 the crippling load (if applicable) e.g. “CL = 100kN”
The following information shall be marked on the pole and be in included in an erection procedure to be
issued with every batch of pole dispatch to site:
 the minimum and maximum slip joint penetration limits

 holding-down bolt torque requirements
 maximum axial slip-joint assembly load
 orientation of sections with respect to one another to be clearly and permanently marked
 pole/baseplate orientation with respect to the line to be identified
b) Packaging
All structures shall be suitably stacked to avoid damage during transport. Dunnage shall be used
between steel members to avoid these touching and damaging each other. No buckled, bent or twisted
structures and associated bracketry will be accepted on site. The manufacturer shall deliver to site, with the
structures, adequate quantities of Zinc-fix squish packs to patch small areas of damaged galvanizing due to
transport. Large areas of damaged galvanizing will not be accepted.
14.7.18 ACCEPTANCE CRITERIA FOR TESTS

The mast shall resist all working loads without showing signs of buckling or crippling. Any signs of member
buckling, signs of buckling onset, connection failure or deflections more than those of the deflection
requirements of this document shall constitute the failure of the structure
14.7.19 METHOD OF ERECTION

Ensure that a safe working area around the pole and the hole is maintained.
With the truck-mounted crane, position the bottom, middle and top sections of the pole as close to the
foundation hole as possible.
Align the bottom, middle and top sections of the pole to slide into one another.
Ensure that the sections are as horizontally level in relation with one another as possible before start of
assembly.
These methods are only typical and must be adjusted to conditions on site.
Bottom section slinging:
 Using the slipknot/choke-hold method sling with 2 x 3m long nylon slings.
 Ensure lowest wrapping end is closest to pole section base.
 Ensure highest ends are below earth attachment-brackets.
 Attach 2 x D-shackles one at each end of the slings.
Figure 15: Strain monopole-horizontal assembly bottom section slinging
Middle section slinging:

 Using the slipknot/choke-hold method, sling with 2 x 3m long nylon slings.
 Ensure highest wrapping end is closest to pole section top.

 Attach 2 x D-shackles, one at each end of the slings.
Figure 16: Strain monopole-horizontal assembly middle section slinging
Attach a coffin hoist to each set of slings on opposite sides of the pole, ensuring that the coffin hoists are
primarily attached in-line, middle section to bottom section.
Figure 17: Strain monopole-horizontal assembly joining middle to bottom section
Measure the length of the pole and see how far the two sections must be pulled together to give the correct
length of the pole as indicated on engineers drawing.
Mark required slip distance of top pole with insulation tape.
With the coffin hoists, tension both sides equally until the two sections have slid together up to insulation
tape mark.
Manually manoeuvre the top section to assist with the sliding together of the sections.
Remove insulation tape after correct slip level has been achieved.
Follow the same procedure as above when joining the middle and top sections of the pole.
No structure shall be erected prior to a final inspection on the pole excavations and approval thereof by the
site supervisor.
Mono-pole structure erection will be subjected to the following criteria:
 All structures shall be erected vertically within 2mm in 1.0m in both transversal and longitudinal
directions. For the correct structure orientations in relation to the line direction refer to detail
drawings;
 During the structure erection, the tension in all stays shall be 10% (±2%) of the minimum breaking
strength of the stay wire, after all rigging equipment has been removed.
 All structures shall be properly cleaned prior to the erection thereof. Sand, mud and other dirt must
be thoroughly cleaned with nylon brushes.
 Structures should only be lifted into place at the identified lifting points as detailed by the design
and the manufacturer of the structures.
14.7.20 EARTHING
The following standards are applicable:
 IEC 60071 Insulation co-ordination — Part 1 to 3
 IEC 60815 Guide for the selection of insulators in respect of pollution conditions.
The total earthing resistance of the line shall be less than 3.5Ω with 60% of the poles having earth resistances
smaller than 20Ω. The earthing resistance of the poles for the first kilometre from substation shall be less
than 10Ω.
The shield wire shall be earthed to the substation earth.
The underground earthing for the towers shall only be finalised once the footing resistance tests have been
carried out. The required earthing electrode shall be determined from the footing resistance tests.
The terminal structures will be bonded to the substation’s main earth grid.
At all electrified railway crossing & metal pipelines, the line’s earth conductor will be isolated from the
structure for ±800m on both sides of the crossing.
The earthing of each structure must be done as indicated on drawing AUR-OHL-EAR-MP-001 as follows:
 Each structure shall have its own earth.
 The earth shall be concealed, i.e. earth connection to the pole is beneath ground level and no part
of the earthing system may be visible from ground.
 All terminal structures of the OHL shall be bonded to the respective earth mats of the substations
using a 30x3mm Cu bonding strap.
 Earth rods shall be 1,5m copper plated steel.
 Stranding of bare copper conductor shall be 7/1.67mm for 16mm² or 19/1.34mm for 25mm².
 The contractor shall measure the resistance of every pole installation and submit the test certificates
containing the test results to the Engineer. A copy of the calibration certificate for the measuring
instrument must accompany the test certificate and should not be older than 6 months.
 All joints and connections will be done by means of exothermic welding and covered with
bituminous tape.
 Precautions shall be taken to prevent electrochemical reaction between dissimilar metals.
 The trenches shall be backfilled completely and immediately after the installation of the earth
rods/straps.
Should the earthing of the structures not be as is required, additional earthing can be installed in the form of
a counterpoise as follows
 A combination of horizontal radial and vertical earth electrodes shall be used and connected to the
structures.
 The design made provision for 6m crow’s foot for 70% of the structures.
 Crow’s foot earthing electrodes shall be as per AUR-OHL-EAR-MP-001.
The counterpoise can be further enhanced if required as follows:
 The first 150mm thick backfill layer in the earth trenches to consist of 1 part of agricultural gypsum
properly mixed with 3 parts of clean imported topsoil.
 The backfilling to be slightly watered and thoroughly compacted in layers not exceeding 150mm
in thickness.
 The final backfill layers to consist of clean excavated material from the earth trenches. The
backfilled material to be slightly watered and thoroughly compacted in layers not exceeding
250mm in thickness.
For earth trenches in rocky-terrain where the required earth trench depths can’t be reached:
 The backfilling of earth strap trenches in rocky areas where no proper trenching can be done, a
conductive mixture of carbonaceous aggregate (e.g. graphite, bentonite or any other approved
conductive mixture shall be used.
 A 3:1 sand/conductive cement mixture shall be used.
After the complete installation of a standard structure earthing system at all structures, the footing resistances
shall be measured by the Contractor and in situations where the measured structure footing resistance doesn’t
comply with the required 20Ω requirement, additional earthing systems shall be installed until the required
footing resistance are met or otherwise instructed by the Engineer.
After the complete installation of the additional earthing systems the relevant structure footing resistances
shall be re-measured by the Contractor in the presence of the Engineer and results shall be recorded at each
measuring attempt. Structure footing resistance records shall be submitted to the Engineer for evaluation and
acceptance.
14.8 AEOLIAN VIBRATION DAMPING

The position and mechanical parameters of vibration dampers installed on the phase conductors and shield-
wires shall be based on a vibration damping study, which shall take into consideration the possible range of
wind speeds, the characteristics of the terrain where the line will be installed, and the long-term mechanical
performance and strength of the conductors and shield wires. It is required that vibration amplitudes and
frequencies are limited to the extent that the conductors and shield-wires have an expected lifetime of at least
30 years.
14.9 SPECIFICATION FOR CONDUCTORS

Conductors will comply with IEC 61089:1997: Round wire concentric lay overhead electrical stranded
conductors with the amendments to include conductors made of combinations of zinc-coated and aluminium-
clad steel wires.
The aluminium shall be of the highest purity commercially obtainable and the contractor shall submit
certificates of analyses giving the percentage and nature of any impurities in the metal of which the wires are
made, and precautions taken during the manufacture of steel-cored aluminium conductors to prevent the
possibility of contamination by copper particles or other materials which may adversely affect the aluminium.
14.9.1 Stranding
The stranding of each layer of the conductor shall be as close and even as possible. The outermost layer shall
be right-handed. The wire shall be so stranded that the conductor is essentially free from the tendency to
untwist or spring apart when cut. Steel cores shall be stranded on tubular or planetary stranders.
The completed conductor shall be uniformly cylindrical and shall be capable of withstanding normal handling
during manufacturing, transportation, and installation without being deformed from its cylindrical form in
such a way as to increase corona losses and radio interference
14.9.2 Grease
If specified, the core and the inner layers of aluminium shall be greased with an approved grease complying
with IEC 61394. Grease shall be uniformly applied in accordance with Case 4 of Annex C of IEC 61089.
Only one type of grease shall be used on the steel core and all the aluminium layers on all conductors in an
order. All aspects of manufacture and delivery of greased conductors shall be completed in such a manner
that grease is not displaced toward the outer surface of the conductors.
14.9.3 Lay ratio

Lay ratios shall be in accordance with IEC 61089.
14.9.4 Drum length

The length of conductor on a drum shall not vary by more than +2% and 0% from the nominal length.
The variation in length between conductors forming a matched set shall not exceed 20m. Only one continuous
length of conductor per drum shall be permitted. The accuracy of measurement shall be 0.5%.
14.9.5 Tests
The supplier shall carry out sample production tests, and the results shall be made available within 14 days
of completion.
A complete set of conductor type tests certificates, in accordance with IEC 61089, must be submitted for at
least one conductor per design (e.g. 6/1), at tender stage. This set of type tests will qualify the design range
at tender stage.
The tenderer will give a good estimate of the creep each conductor can expect over a 20-year lifespan. The
estimate must be given with full details of the calculation thereof.
14.9.6 Packaging and marking

The line conductors shall be supplied on returnable steel drums or non-returnable wooden drums, constructed
to enable the conductors to be run out smoothly, and in lengths as long as can be conveniently handled and
erected. Drums shall be marked with the length of conductor on the drum and with an arrow to show the
correct direction of rolling.
14.10 SPECIFICATION FOR SHIELD-WIRES

Shield wires shall be OPGW equal to galvanized steel strand the type 19/2.65 (UTS of 113kN) complying
with BS 183 Grade 700. Steel conductors and their associated fittings shall be tested in the manner specified
for conductors, and the breaking load shall not be less than 95% of the steel conductors breaking load.
Steel conductors shall be in accordance with IEC 60888: 1987: Zinc-coated steel for stranded conductors
supported by SANS 182-5: 1979: Conductors for overhead transmission lines. Zinc-coated steel wires for
conductors and stays.
In terms of the stranding, the application of grease, the lay ration, drum length, tests and packaging
requirements the shield wires shall conform to the same specification as the conductors.
14.11 SPECIFICATION FOR HARDWARE

14.11.1 Hardware design
Clamps and fittings shall be of a design approved for the conductor in accordance with the relevant
paragraphs.
All hardware shall at least provide the same ultimate strength as the chosen insulator. All strain equipment
to be designed for 120kN or higher if required.
The connecting attachments, including bolts, nuts and washers, shall be included in the insulator assemblies.
Only hump back split pins will be used where split pins are required.
All materials shall be free from folds, cracks and other exterior and interior defects which can affect its
strength, ductility, durability of ability to function.
All materials shall be inspected and tested in full to prove compliance with the requirements of the
specifications and to the satisfaction of the engineer. The testing shall be carried out according to the relevant
standards approved by the engineer.
14.11.2 Galvanizing
Galvanizing will be done to specification ISO 1461 2009: Hot dip galvanized coatings on fabricated iron and
steel articles — Specifications and test methods.
Except where specified to the contrary, all iron and steel used in the construction of the contract works shall
be galvanized in accordance with IEC standards after all sawing, shearing, drilling, punching, filling, bending
and machining are completed.
Galvanising shall be applied by the hot process (except the electro-galvanising shall be permissible for steel
wires), and for all parts other than steel wires shall consist of a suitable thickness of zinc coating as indicated
in Table 3 of ISO 1461. The zinc shall be smooth, clean, of uniform thickness and free from defects.
Tests shall be carried out as specified in the specifications.
14.11.3 Full tension clamps

Only compression type full tension clamps to be used on all conductors. The full tension clamps shall be as
light as possible. The part that will be in contact with the conductor shall be of aluminium.
The compression type full tension end clamp (dead end) shall consist of three parts, one aluminium
compression body for the aluminium part of the conductor, together with an integral lug, one crimp joint
terminal for connection of the jumper and one compression eye of galvanised steel for the steel core. The
inline full tension clamp (mid span joint) shall also consist of two parts, one aluminium compression body
for the aluminium part of the conductor, and one compression galvanised steel inner for the steel core. The
material shall comply with BS 1490 (aluminium).
The current carrying capacity shall be equal to or better than that of the conductor. The compression type
full tension clamp shall be filled with grease prior to compression to protect the conductor against corrosion.
When installed, the full tension clamp shall develop a holding force of at least 95% of the ultimate strength
of the conductor without causing slipping off, or damage to the conductor or any part thereof.
14.11.4 Vibration dampers

Stockbridge vibration dampers are to be used on all ACSR conductors. Dampers to comply with
IEC 61897:1998: Requirements and tests for Stockbridge type Aeolian vibration damper and
IEEE STD 664:1993: The material shall comply with BS1004A.
The damper shall be designed for a working life of at least 30 years and the design shall take full account of
environmental factors, including conductor temperature variations between -10 °C and 80 °C, ultraviolet
radiation, ozone and atmospheric pollutants.
The dampers for phase conductors shall be free from visible corona at the test voltage. This means that corona
should not be seen by either a camera or naked eye (in a dark room) during test.
Spiral vibration dampers will be used on the steel conductors. Make and type of spiral vibration dampers to
be specified in the detailed technical specifications and approved by the engineer for use before installation.
14.11.5 Repair sleeves

The repair sleeves used shall only be of the compression type. The compression repair sleeve shall preferably
be two-piece type of aluminium alloy.
When properly applied such repair-sleeves shall achieve 95% of the ultimate strength of the conductor, when
less than one fourth of the aluminium wires of the outer layer is damaged, in accordance with BS 3288 part
2.
The resistance of the repair sleeves shall not be more than 50% of the resistance of the conductor itself on the
same length as the repair sleeve.
The repair sleeves shall be filled with grease prior to compression to protect the conductor against corrosion.
14.11.6 Stay assemblies

Stay wires and their associated fittings, where applicable, shall be tested in the manner specified for
conductors, and the breaking load shall not be less than 95% of the stay wire breaking load.
The number of stay wires per structure on strain towers may vary. It is the contractor’s responsibility to
verify quantities and supply accordingly.
14.11.7 Stay wire

Stay wires shall be galvanized steel strand of the type 19/2.65 (UTS of 114kN) complying with BS 183 Grade
700, unless the designer requires a higher UTS. Stay wires and their associated fittings shall be tested in the
manner specified for conductors, and the breaking load shall not be less than 95% of the stay wire breaking
load.
Steel stay wire shall be in accordance with IEC 60888:1987: Zinc-coated steel for stranded conductors.
14.11.8 Stay rods and base plates

Base plate dimensions shall be altered from specified sizes to suit the soil loading conditions and shall be
provided with locking facilities to prevent turning of the stay rods. The minimum requirement for the base
plates shall be galvanized mild steel plate, galvanized as specified or epoxy tar coated, 450mm x 450mm x
6mm.
A minimum 24mm diameter stay rods shall be used.
If the above required stay plate and stay dimensions are not size adequately to withstand the full load the stay
wire then an alternative larger specification can be proposed for approval.
14.11.9 Guy grips & fittings

Guy grips shall be of the preformed galvanised steel wire type.
Thimbles shall be used with guy grips to support wires through the eye or bow of the stay rod. The stay wire
will be connected to the pole using a specific stay connecting point with a non-rigid fitting combination.
14.11.10 Armour rod

Armour rods shall be used to protect ACSR conductor at all clamping points on the suspension stand-off
insulators. The size of the armour rods shall be suitable for the conductor used.
No armour rods are required where stand-off insulators are used to suspend jumpers at strain poles. Take
note that the correct clamp must be used to secure the jumper to the suspension insulator as the sizes will be
different than the size used to clamp the conductor and armour rod at normal suspension poles.
14.12 SPECIFICATION FOR SILICON RUBBER INSULATOR

The materials shall be free from folds, cracks and other exterior and interior defects which can affect its
strength, ductility, durability or ability to function.
All material shall be inspected and tested in full to prove compliance with the requirements of these
standards approved by the engineer. The approval by the engineer shall not relieve the tenderer of this
responsibility.
All metal fittings should be made of hot-dip galvanised steel.
Free surface of insulating parts shall be cleaned from cement and other impurities.
Care should be taken during installation as not to damage the insulators in any way.
Assembly shall be performed in such a way that the electrical and mechanical properties cannot be affected
and to ensure that the insulating part is not subject to any abnormal mechanical stresses.
The cap of the strain insulator shall be of malleable cast or forged iron, spheroidal graphite cast iron, or heat
treated. The graphite in malleable cast iron shall only appear in the form of temper carbon, and the graphite
in spheroidal graphite cast iron shall only be present in spheroidal form. The socket coupling shall be in
accordance with IEC 60120 and have an internal height in accordance with IEC 60372. Cap and pin shall be
hot-dip galvanised. The pin shall be protected by a zinc-collar sleeve.
Split-pins shall be of copper alloy or stainless steel and be in accordance with IEC 60372. W-clips are not
accepted.
Each insulator unit shall be marked with the name or trade mark of the manufacturer and the year of
manufacture in accordance with IEC 60383 and means to ensure the system of traceability for each of the
component parts. In addition, each insulator unit shall be marked with the specified electro-mechanical or
mechanical failing load in conformity with IEC 383, or the first part of the designation in accordance with
IEC 60305.
14.13 HARDWARE ASSEMBLIES

14.13.1 Phase conductor assembly for intermediate structures
Figure 18: Phase conductor intermediate assembly
14.13.2 Phase conductor jumper support on strain structure
Figure 19: Phase conductor jumper support assembly

14.13.3 Strain assembly
Figure 20: Phase conductor strain assembly
14.13.4 Shield wire intermediate assembly
Figure 21: Earthed shield wire intermediate assembly

1.1.2 Shield wire strain assembly
14.14 SPECIFICATIONS FOR FOUNDATIONS

14.14.1 Excavation definitions
Soft Ground shall mean ground that can be removed by hand tools and shall include loose ground, clay, made-
up ground, loose or soft shale, loose shale and any boulders less than 75mm in diameter.
Pickable ground shall mean rock that can be loosened by hand pick or crowbar and include hard shale,
compact shale, stone of similar hardness and boulders exceeding 75mm in diameter but not exceeding 0.3m3
in volume.
Hard rock shall mean granite, quarzitic sandstone, solid shale, slate and rock of similar or greater hardness
and boulders exceeding 0.3m3 in volume and can only be excavated by mechanical means or the use of light
charges subject to the consent of the Engineer.
Very soft ground shall mean ground which is of such a nature that causes the foundation excavation to
continuously cave in or fill up and where access to and from the excavations are difficult. This includes sand,
lime and clay including excavations in waterlogged areas.
14.14.2 Soil types
 Type 1 – Bearing pressure 150 – 300kPa

14.14.3 Foundation design loads

The ultimate simultaneous tower design loads shall be used for foundation design purposes. The foundation
loads thus calculated shall be further factored upwards for foundation design purposes by a load factor as
specified in the Table 3.
Table 3 : Structure type
Structure type Load factor

Self-supporting lattice / monopole 1.2
Guyed lattice / monopole 1.1
Guy anchor 1.3
The foundations shall in addition be designed for the most critical cases that would result from the occurrence
of the maximum permissible tolerance situations as listed above.
14.14.4 Directly buried poles

The elongated side of the hole shall be in line with the conductors to limit the effect of wind loading on the
foundation. The foundation sizes shall be designed by the contractor’s civil engineer.
Manhole rings may be used for the installation of the poles. Poles may either be planted directly in the hole
dug and then soil compacted around the pole, or else manhole rings may be used to form the foundation for
the pole and compaction shall then be done around the manhole ring.
The pole shall be stayed temporarily with 4 stays until the foundation have cured enough to take the full
loading of the pole. The pole may only be strung-on 14 days after the foundation is completed.
All structures shall be vertical within a tolerance at the structure top of 0.3% of the overall structure height,
before erection of the conductors.
Poles shall not exhibit either twisting or bowing greater than the approved tolerances. After erection of the
conductors the vertical tolerance of the structures shall not exceed 0.5% of the height and the standoff
insulator transverse alignment shall be square with the line to within half the width measured at the cross-
arm end.
Suitable ladders shall be used whenever necessary during erection of the structures. All ladders shall be
removed when erection work is not in progress.
14.14.5 Flanged poles/Pad and chimney foundations

The foundations shall be designed to withstand, with less than 20mm of differential settlement or
displacement, the maximum foundation reactions resulting from the withstand loadings stated in 14.14.3,
with the dead weight of the tower included at unity factor of safety.
The foundations shall be designed for the maximum combinations of compression, uplift and horizontal shear
forces. In addition, a 650mm maximum projection of the pier and stub above ground level shall be
incorporated in the design. The stub only is to be encased in concrete; the tower steel above the diagonal
members is not to be encased.
All concrete subjected to tension, where the permissible tensile stress is exceeded, shall be adequately
reinforced with deformed reinforcing steel bars. The maximum permissible tensile stress in the concrete shall
be 1.75MPa. Piers shall be reinforced for their full length with the reinforcing properly anchored in the pad.
The minimum number of longitudinal bars provided in a pier shall be four 12mm diameter bars with a
minimum yield stress of 450MPa. The links shall be 8mm diameter mild steel bars at a maximum spacing
equal to the smallest lateral dimension of the section, less 100mm.
Pads designed with a full 45° core may be utilised. All faces of such a core where the permissible tensile
stress in the concrete is exceeded are to be adequately reinforced to prevent the development of tension cracks.
After completion of the pad and chimney foundation, the foundation shall be left to cure for at least 14 days
before being subjected to and loads.
Flanged poles shall be lifted in place and bolted down on the bottom flange to the recommended torque in
accordance to SANS 10162.
14.15 SPECIFICATIONS FOR CONSTRUCTION ACTIVITIES

14.15.1 General
Way leaves and right of access facilities, subject to the requirements of landowners and tenants will be
provided by the employer, but the contractor will be responsible for the provision of access routes or tracks
along the line routes to enable him to carry out the erection of the transmission line.
When the contractor is about to commence work on any property he shall be responsible to ascertain from
the engineer whether the servitudes are in order and give the occupier of such property adequate notice of the
commencement of the work.
If the contractor wishes to make a store on any property, he shall first obtain written permission to do so from
the occupier of such property.
All staff shall be provided with the necessary identifications indicating their employment by the contractor
and adequate supervision shall be employed to protect the interests of the occupier of the property.
When the contractor is about to carry out erection of the conductors or installation of earth electrodes or
counterpoise along or across public roads, telegraph or telephone lines, railways or across power lines he
shall be responsible for giving the requisite notice to the appropriate authorities of the date and time at which
he proposes to perform the work.
Where the local authorities and other public undertakings affected deem it necessary for the protection of the
public and the assistance of traffic, to provide flagmen or watchmen or installation of warning lights etc. The
cost of such provision shall be borne by the contractor.
The employer will pay for unavoidable damage to crops but the contractor shall at his own expense make
good to the reasonable satisfaction of the authorities, owners, and tenants concerned, all land, property, rods,
field drains, fences, walls, hedges, gates and the like which are damaged or disturbed during the execution of
the Works and shall remove all surplus material after erection.
During the progress of the work the contractor shall be entirely responsible for the proper fencing, watching
and lighting of excavations, dumps of material, ladders and the like and for the prevention and straying of
and damage to livestock until backfilling of excavations and permanent reinstatement of fences, walls,
hedges, gates and the like be completed. The contractor shall be held responsible for any injury to the public
and damage to livestock due, in the opinion of the engineer, to failure to comply with the above requirements.
In the event of any dispute or questions of damage or for the adequacy of provisions made for permanent or
temporary replacement or repair, the contractor shall at once inform the employer.
14.15.2 Route
The contractor will be provided with a set of plans showing the routes of the transmission lines and any setting
out details which may be available. The contractor must gather information about conditions on site during
the tendering phase and price accordingly. The contractor will responsible to gather all information regarding
the ground profile along the route by either with the use of aerial surveying or ground surveying and
observations. The ground profile should be accurate enough to enable the contractor to design the line as
required by this specification.
The contractor will, subject to approval with the employer and an appointed surveyor, peg out all turn
positions for the contractor. The contractor will be responsible to verify and re-peg the turn points if required.
The terminal points at ends of each line will be indicated by the employer.
14.15.3 Servitude Preparation and bush clearing

Although most of the servitudes are existing the contractor will be responsible for the preparing the entire
route for construction. This might include pruning or complete removal of trees where necessary along the
routes of overhead lines.
The contractor shall allow for the required bush clearing based on on-site evaluation prior to the closure. The
pruning and cutting of branches are to be included in the stringing rate and not included under the bush
clearing rate.
Where trees are to be removed, the contractor shall completely uproot the relevant trees and stack them in
position approved by the employer or engineer. All holes caused by such uprooting shall be filled in by him
to leave the site clean and tidy, all to the satisfaction of the engineer.
Utmost care shall be taken when uprooting trees, as the contractor will be responsible for all the claims due
to any damage and/or injury caused by such uprooting of trees. Where the branches of trees are to be pruned,
such pruning shall be neatly carried out in an effective and workmanlike fashion to the satisfaction of the
engineer.
Unless specifically indicated otherwise herein or on the accompanying drawing, tenderers shall allow in their
tenders for:
 The removal of trees, except shrubs, with trunks within a vertical plane parallel to and 5m from the
nearest conductor along the routes of all lines;
 The pruning of all trees branches, along the routes of all lines, in such a way that no branch will
project through a vertical plane parallel to and 3m from the nearest conductor, on the understanding
that such branches of which the highest points are below 4m above ground level need not be pruned
unless it is within 3m from any pole.
14.15.4 Environmental
The contractor will be responsible to comply with all the local occupational health, safety and environmental
laws and legislations.
This includes all required documentation and must be financially catered for, with sufficient time and
planning allocated to environmental compliance measures.
14.15.5 Pegging of structure positions

The contractor shall set out the route of the line determining the alignment of all structures as per the approved
design. The work shall be undertaken by competent surveyors who are familiar with the requirements and
working conditions. The contractor shall be responsible to ascertain the correctness of structure positions on
site according to the drawings and shall, where so required, re-measure and determine positions in conjunction
with the engineer.
The contractor shall notify the engineer to inspect the pegged route at least seven days before excavations
begin.
The contractor will also be responsible to set out all stays whether bisector or inline stays are required.
On completion of the contract, the contractor shall provide the engineer with as-build drawings as specified
elsewhere in this specification.
14.15.6 Civil & foundations

a) General
All civil and foundation work will be done in accordance with:
 SP-CSS-001 Civil Works
 SP-ESU-001 Supports and Foundations
 IEC 61773:1996Overhead lines – Testing of foundations for structures

Foundations shall extend 1m above ground level at all structures running close to the mining areas due to the
high corrosive environment.
b) Foundations
Sample holes to be made and soil nomination and foundation designs to be done by the contractor’s certified
civil engineer. The contractor in conjunction with the engineer will approve the foundation type to be used
for each structure. The approval by the engineer of foundation installations shall not relieve the contractor
of this responsibility. Each foundation shall have a completed foundation record signed by the contractor’s
civil engineer, indicating that the soil was nominated and that responsibility is taken for the foundation
construction.
Limited soil analysis will be performed during pegging of structures. The results of which will be made
available to the contractor.
It shall be the responsibility of the contractor to ensure that a foundation record is filled out for each
foundation installed.
c) Excavation
The contractor shall make sure that no existing services are damaged during excavation.
At each structure position the contractor shall excavate, install the appropriate foundation and backfill the
excavation as required.
The contractor shall be responsible for ensuring that the subsoil at each foundation location is suitable to
withstand the design loading which will be imposed upon it by the foundation and shall be responsible for
any subsidence or failure of foundations due to insufficient care having been taken in the examination of the
soil or in the installation of the foundations.
Excavations shall be made to the full dimensions required and shall be finished to the prescribed lines and
levels. The bottom or sides of excavations upon or against which concrete is to be placed shall be undisturbed.
If, at any point in excavation, the natural material is disturbed or loosened it shall be filled with 10MPa
concrete. All excess excavation and over-excavation performed by the contractor for any purpose or reason
shall be at the expense of the contractor.
When the material at foundation depth is found to be partly a soil or material that is compressible, all
compressible material shall be removed for an additional depth of 200mm and filled with 20MPa concrete.
The excavations shall be protected to maintain a clean subgrade until the foundation is placed. Any sand,
mud, silt or other objectionable material which may accumulate in the excavation shall be removed at the
contractor's expense prior to concrete placement.
Where holes, deeper than 1.5m, are dug by hand special care shall be taken to ensure that there is shoring
available for the hole to prevent the hole collapsing. When no construction is taking place, or it is unavoidable
to leave the excavations open overnight, the affected holes must be effectively barricaded to ensure public
and animal safety. This is typically done by means of 1.5m steel or wooden droppers installed 2m apart and
1m from the edge of the excavation together with bright orange HDPE safety netting 1.2m high. Where there
is high traffic volume and pedestrians, small strobe light must be installed as part of the barricading.
d) Approval of excavations
It shall be the responsibility of the contractor to notify the engineer upon completion of the excavation for
foundations. No shuttering, reinforcing steel or concrete shall be placed until the excavation has been
inspected and approved by the engineer.
e) Backfilling
After completion of foundation installation, the contractor shall backfill each excavation with suitable
material.
The material to be utilised for compacted backfill shall be deposited in horizontal layers having a thickness
of not more than 300mm before being compacted. In backfilling, the pad of the foundation shall be covered
The material to be compacted shall contain no stones more than 150mm in diameter, and be free from organic
material such as trees, brush, scraps, etc.
The distribution of materials shall be such that the compacted material will be homogeneous to secure the
best practicable degree of compaction, impermeability and stability.
required for compaction, and the moisture content shall be uniform throughout the layers.
The material shall be compacted by mechanical compaction machines to a minimum of 90% of the density
of the undisturbed material. If required by the engineer, the contractor will test compaction to proof 90% has
been achieved.
The surface of the backfill around the foundation shall be carried to an elevation such that water will not
accumulate.
Material removed from the excavation, which is not suitable for, or is not required for backfill shall be spread
evenly over or adjacent to the site.
Where the excavated material is not suitable for backfill, the contractor shall stabilise the backfill material
with one part cement per ten parts of soil or as an alternative import select backfill material to the site,
provided the cost of select backfill does not exceed the cost of cement-stabilising the excavated material.
Where excavated material primarily consists of broken rock, shale, the contractor shall import select backfill
material.
f) Concrete works
All cement will conform to the EN 413-1 specification and all the sub-clauses contained therein.
It is preferred that any mass pour concrete (large single volumes) be from a commercial ready-mix supplier
against the specifications requested as it can be poured in one go and will provide consistency throughout the
volume as part of a foundation cannot be rejected, it has to be the entire foundation.
Smaller batches for small foundations can be mixed on site on condition that the design of the mix of each
specific volume be made available for scrutiny and records are kept and signed off regarding material
proportions used, the intended foundation it is for and that cubes are prepared for that batch.
Under no circumstances will any concrete be mixed by hand.
The concrete shall be mechanically vibrated once poured to ensure there will be no honeycombs in the
concrete and that proper compaction of the concrete is attained. Over-vibration of concrete will cause
segregation of the concrete and weaken it.
Concrete shall not be poured directly into a hole deeper than 1.5m without a chute to prevent segregation of
the concrete.
The concrete that has started to set without being finally placed must be discarded. Adding water to make it
workable will not be allowed.
All concrete shall be thoroughly mixed by machine with only sufficient water to ensure a workable
mix. Consistency tests shall be made when required by the Project Manager. The slump test shall be done
for each new batch of concrete in the presence of the engineer. The slump in a truncated cone 300 mm high
and of standard dimensions shall be between 25 and 50 mm, corresponding to a stiff plastic consistency. This
must be done for each new batch delivered to site and the results written down.
The sand used shall be evenly graded concrete sand free from all debris and growth. The maximum size
stone to be used for all concrete works shall be 26.5mm. The maximum water to cement ratio shall be less
than 0.7.
the concrete. The concrete shall be mechanically vibrated once poured to ensure there will be no honeycombs
in the concrete and that proper compaction of the concrete is attained. Over-vibration of concrete will cause
segregation of the concrete and weaken it. The concrete shall not stand for periods of time and then have
water added to it to make it workable as it weakens the concrete.
If the outside air temperature is less than 5°C, concrete shall not be mixed or poured as the cold will cause
the water to freeze.
g) Aggregates
All aggregates shall be new, clean and free of weeds and roots. The aggregate grading shall be suitable for
concrete and within the aggregate curve of the mix design.
Class

nominal sizes:
5,000µm
92 – 100
4,750µm
90 – 100
150µm
5 - 25
percentage
2
percentage
Organic impurities darker than the colour of the -
this requirement shall not be
Class
impurities.
Presence of sugar -
the specimens made with the
Soluble deleterious impurities been washed, except that this -
Requirement
Property
Grading1), mass
percentage of
material that passes 75.0 53.0 37.5 26.5 19.0 13.2 9.5 6.7
sieves2) of nominal
aperture size, mm
75.0 100 100 100
53.0 0-50 85- 98-100
50.0 0-43 100 85-100 100
37.5 0-25 70- 15-55 90-100
28.0 0-7 85 0-50 85-100
26.5 0-5 0-50 0-28 15-55 100
20.0 0-28 0-25 0-50 90-100
19.0 0-25 0-7 0-28 85-100 100
14.0 0-7 0-5 0-25 15-55 90-100
13.2 0-5 0-7 0-30 85-100 100
10.0 0-5 0-28 15-55 90-
9.5 0-25 0-55 100 100
7.1 0-9 0-30 85- 90-100
Requirement
Property
6.7 0-5 0-25 100 85-100
5.0 0-7 25- 25-58
4.75 0-5 58 0-55
2.36 0-55 0-28
2.0 0-28 0-25
1.18 0-25 0-5
1.0 0-5 0-4
0-4
Dust content for
material passing
through a 75 µm 2
sieve mass
percentage
Aggregate crushing
value (ACV)3), of
less than 13,2 mm
and more than 9,5 29
mm fraction (dry),
mass percentage,
max.
10 % FACT value, of
less than 13,2 mm
and more than 9,5
mm fraction (dry),
kN, min.
h) Concrete test cubes

All testing of concrete shall be carried out in accordance with the requirements of BS CP 114, clause 601 and
BS 1881. During mixing of concrete for each section of the work and at such other times as directed by the
Project Manager.
Consistency and bleeding tests and such other preliminary tests as the Project Manager may direct, shall be
taken as often as directed by the Project Manager. No concrete of any type or class shall be used in the works
before the preliminary tests have shown specified compressive strength and workability.
Concrete cubes must be prepared for every new batch of concrete in the following manner:
 Prepare 3 specimens for each test age. Moulds should be made of a non-absorbent
material150x150x150mm. The mould construction must be such that the specimen can be easily
removed. Three cubes shall be tested after 7 days, another three at 14 days and the remaining 3
cubes after 28 days.
 Put in each mould +- 50mm well mixed concrete, compact with a tampering rod and ensure the
layer is uniform. Do not over compact as it might cause laitance and segregation.
 Repeat for layers 2 and 3 taking care that the already compacted layer beneath is not disturbed.
 After the third layer take a steel trowel and smoothen the exposed surface.
 Cover all the specimens with an impervious sheet, followed by wet matting, sacks, or similar
material, and then store them in a place that is free from vibration, excessive draughts, direct
sunlight and low temperatures for 20 h to 24 h.
 Demould the specimens and immerse them in portable water that is preferably maintained at 22 °C
to 25 °C, until they are transferred to the test facility.
 During curing the cubes must be well protected against damage and/or vibration.
i) Water
Water should be clean, free from chlorides, sulphates, other salts and organic matter. Potable water will
generally be suitable.
j) Reinforcing
Where reinforcing is required in the design, it shall be free of loose rust, grease and dirt. The reinforcing
shall be fixed with wire ties that are tightly bound to prevent any movement during the pouring of concrete.
Foundation bolts are to be the hooked kind and must be fastened properly before the concrete is poured.
k) Curing
Where concrete is exposed to the air, curing is required. The concrete shall be covered with a 50mm layer of
river sand and this shall be kept constantly moist for a period of seven days, or a plastic membrane shall be
placed over the exposed concrete and sealed. Curing compounds may also be used for curing permitted that
it is non-corrosive. These shall be approved by the engineer.
14.15.7 Construction / Temporary stays

The temporary stays will be the exact same specification as for the permanent kind
The contractor shall make provision for the sufficient quantity of temporary stays at all in-line and angle
strain structures, to ensure the stability and plumpness of the structures, as well as the safety of the contractor’s
workmen.
All temporary stays will remain intact and tensioned until completion of the stringing, regulating and
clamping activities of the phase conductors and shield wires.
The contractor can install temporary stays on the conventional method or alternatively pre-cast stay anchor
blocks per phase can be used.
For both situations, all temporary installed stays and stay anchor blocks must be completely removed from
site after completion of the stringing activities.
All excavations left from the removed conventional installed stay assemblies must be properly backfilled,
compacted and sites re-instated.
A maximum 45° with the horizontal or flatter stay installation angle is required for temporary stays, under all
circumstances.
14.15.8 Hardware installation

14.15.8.1 Compression hardware
Only hexagonal compressions, of the “ALCAN” range, will be accepted. Only compression equipment
specified by tension clamp supplier shall be used. Compression equipment and operating personnel shall be
approved by the supplier to ensure the correct installation of the tension clamps. Proof thereof shall be
available on site at all times. The hydraulic tool, dies and fittings shall be designed for a minimum output
force of 890kN. All press equipment to be approved before use.
The conductor in use determines the specific size of the press and full tension clamp to be used. Compressions
to be made for the full area provided on both the aluminium and galvanised steel parts.
14.15.8.2 Vibration dampers

All calculations for the correct placement of the vibration dampers shall be provided to the engineer. The
IEEE Guide for laboratory measurement of the power dissipation characteristics of aeolian vibration dampers
for single conductors will be used for calculations.
14.15.8.3 Repair sleeves

In the case of local damage to isolated strands of a conductor during erection the use of repair sleeves of
approved type may be permitted under extreme circumstances at the discretion and specific approval of the
engineer. If approved the cost of the repair sleeve including transport and labour will be carried by the
contractor.
14.15.8.4 Stay assemblies

No permanent stays required as all structures will be self-supporting.
The stay type or size is not determined by the voltage of the line but by the size of the conductor used as well
as the load requirements. The number of required stays per structure should be determined by the maximum
load experienced by the structure.
Steel stay wire shall be in accordance with IEC 60888: 1987: Zinc-coated steel for stranded conductors
supported by BS183
Holes for conventional stays can be dug by hand, augured by machine or dug with a backactor. A rectangular
stepped hole shall be dug so that the length of the hole is in line to the projected line of the stay wire. The
hole shall be large enough for the stay plate to fit in.
Once the hole is dug, the front face of the lower step shall be undercut to accommodate the stay plate. An
80mm wide slot shall be cut in the steps at 45° to allow for the stay rod. This is essential as without this the
stay rod will cut into the ground during tensioning or after a good rain and cause the pole to lean or possibly
break.
The stay plate shall be placed up against undisturbed soil on the pole side of the hole and the hole shall be
backfilled and compacted as specified.
No stays shall be planted without the relevant stay plates onto the fitted end of the stay rod.
Stay rod assemblies shall be planted to ensure stays are at an angle of 45° and are more than 2m apart to
ensure adequate volume of loading soil on the base plate. Under no circumstances may stay rods be bent.
No damaged steel wires will be used. The direct tension with the specified safety factor will determine the
size of the steel wire as well as the number of stays used per structure.
All stay excavations and compactions shall be done as specified elsewhere in this specification.
The positioning of both the temporary as well the permanent stays on the ground shall be determined by the
contractor’s civil engineer and presented to the engineer for approval.
14.15.8.5 Armour rod

No armour rods are required where stand-off insulators are used to suspend jumpers at strain poles.
Helically formed armour rods to be used on all suspension clamp attachments, included in the trunnion clamp
assembly.
The size of the armour rods to be used at all suspension insulator assemblies shall be suitable for the conductor
used.
14.15.8.6 Jumpers
Jumpers, although not a specific item, are included in the contract.
The jumper conductor will be the same size as the phase conductor used on the line.
14.15.9 Road, railway and telecommunication crossings

Where an overhead line crosses a proclaimed road, railway or tramway or a communication line, the
contractor shall comply with the clearance to the requirements as prescribed and shall further ensure:
 The deviation from a right-angle crossing shall be not greater than 30°.
 The supporting structures at the crossing point shall be labelled as required.
 That no mid span joints shall be permitted in the crossing span.
If, in addition, any special guarding of alternative construction is required, this and any material incidental
thereto shall be provided at prices to be approved. Unless otherwise approved, inline or angle strain structures
shall be installed on both sides of railway crossings.
At overhead line or telephone crossings where the line being surveyed crosses between two poles or
structures, the conductor heights of both lines shall be determined using appropriate calculation methods or
computer programs to ensure the safe crossing of these lines. The bottom line shall be templated at minimum
operating temperature and the top line at maximum operating temperature.
At railway crossings, the distance from the crossing point to the nearest railway identification mark shall be
recorded. This may be either a numbered railway telegraph pole or a ground distance marker, or other
identifiable feature.
All crossings shall be co-ordinated with the departments concerned.
14.15.10 Stringing of conductors

The conductors and earth wires shall be pulled-up and tensioned according to "Code of Practice for Overhead
Power Lines for Conditions Prevailing in South Africa" as specified in the NRS 041.
Twin conductors or double circuit lines, where required, shall be strung simultaneously to ensure matched
sags.
Conductors and earth wires shall be strung to the design template approved by the employer. The contractor
shall provide suitable dynamometers, sighting rods or other approved apparatus necessary for the proper
checking of the work. Dynamometers shall be tested and if necessary re-calibrated if so required by the
engineer. Unless otherwise approved, after final erection and adjustment the sag in any span shall be to the
satisfaction of the engineer.
The equipment and methods used for stringing the conductors (including earth conductors) shall be such that
the conductors will not be damaged. All equipment shall be in excellent condition. Care shall be taken
always to ensure that the conductors do not become kinked, twisted or abraded in any manner.
The contractor shall make suitable arrangements for temporary staying of structures, and anchoring of
conductors when necessary. Conductors may not be anchored to any portion of any structure, except strain
structures and then only at the points designed for conductor attachment. Temporary anchoring to footings
and guy anchors will not be permitted. Where temporary anchoring is required, suitable temporary anchors
shall be provided. Installation and removal of temporary anchors will be the contractor's responsibility.
Running boards shall pass through blocks smoothly without hanging, catching or causing wide variations in
pulling tensions, damage to the blocks or over stressing of structures. The pulling line shall be a non-rotating
type, which will not impart twist or torque to the running board or conductors. Swivels shall be used to attach
the pulling line and conductors to the running board.
Tensions, while pulling, must be sufficient to clear all obstacles safely without damage to the conductor. At
no circumstances, shall the pulling tension exceed the tension shown on the sag charts. Pulling of more than
one drum length of conductor shall be subject to the engineer's approval.
Adequate protection shall be provided where there may be danger of a conductor being crossed over by
vehicles, or damaged by other equipment and objects. Conductors shall not be left in contact with the ground,
vegetable matter or any conducting or semi-conducting material. Wood lagging, or similar material shall be
used to protect the conductor when working at ground level.
The placement of tensioning and pulling equipment shall be such that the vertical angle of pull on a cross arm
or standoff insulator during stringing operations shall not be more than 20°. Conductors shall not be pulled
around angles which exceed 20°. With tandem-mounted blocks, the pulling angle shall not exceed 40°.
The sheaves shall conform to the conductor manufacturer's recommendation as to the diameter, and to the
size and shape of the groove for the size of conductor used. Sheaves shall have a minimum diameter of fifteen
times the conductor diameter at the base of the groove. Block surfaces which will be in contact with the
conductor, shall be coated with neoprene or rubber. This covering shall be kept clean and free of materials
which might damage the conductor surface.
The conductors, joints and clamps shall be erected using approved tools and shall be erected in such a manner
that no bird caging, over-tensioning of individual wires or layers, or other deformation or damage to the
conductor shall occur. Auxiliary erection clamps or haling devices shall be of approved design and shall,
under erection conditions, allow no relative movement of strands or layers of the conductors. Cutting of
layers of conductors shall be carried out with tools designed not to damage underlying strands.
Cropping or shearing of complete conductors shall not be permitted.
Unless otherwise approved, conductors shall be run under partial tension and erected by means of snatch
blocks and running blocks of approved materials and dimensions, at every intermediate structure and by other
approved means to reduce to a minimum contact between the conductor and the ground or other obstruction
during erection.
Under no circumstances shall any conductor be dragged along the ground.
The contractor shall also make any necessary special arrangements for running out and sagging the conductors
where the route crosses buildings, gardens or other grounds over which erection cannot be carried out in the
normal manner.
The contractor shall also make such special arrangements as the engineer may approve where power lines are
to be crossed.
No additional payments will be made for the erection of the line conductors over roads, railways and
communication circuits, or over or under existing power lines which have been dead for the time being.
The contractor shall include in his price for stringing, the pruning and cutting branches.
14.16 SPECIFICATIONS FOR LINE TESTS

The following tests are required:
 Such tests as may be required by the engineer to prove the load bearing capacity of foundations and
stay anchors;
 Continuity and resistance of the earth conductor;
 Structure footing resistance tests;
 Phase rotation;
 Continuity of OPGW and communications.
14.17 LABELS
Regarding Figure 23 the numbering of the structures will typically be as follows:
 All material will be UV resistant.

 Substrate will be a 1mm thick galvanized steel plate typically 1,260 x 120mm with three sets of
slots for mounting purposes.
 Background will be bright yellow powder coating.
 The lettering will be 75 x 75mm and will be heat resistant paint.
 After painting the letter and graphics, the whole plate will be sealed with a clear powder coating.
 Each pole number will be strapped to the pole with three stainless steel straps, underneath each
circuit, and shall not obscure the number in any way.
Regarding Figure 24 the phase identification plate will typically be as follows:

 Substrate will be a 1mm thick galvanized steel plate typically 230mm in diameter with one set of
 Background will be bright red, yellow and blue powder coating.
 The lettering will be 150mm high and 100mm wide and made from 3M Scotchcal.
 After applying the letter the whole plate will be sealed with a clear powder coating.
 The phase identification discs will be strapped to the pole with one stainless steel strap typically at
the first pole from the substation, and shall not obscure the number in any way.
Figure 23: Typical pole number
Figure 24: Typical phase identification plates

15 Conventry and Kafue substation expansion


Ambient Temperature
Absolute Max. 45ºC
Absolute Min. 2ºC
Relative Humidity
Maximum 86%
Minimum 39%
Hail Occasional
15.2 PRIMARY PLANT

The detailed Scope of Work is given in the Scope of Work section of this document. All the designs,
equipment, material and construction works shall comply with the details as described in the following
sections of this document.
15.2.1 Insulation levels

The insulation levels shown in Table 7 will be applied to equipment installed for this project.
Impulse Creepage distance over external

System System 60 sec power Hz
withstand insulation
nominal highest withstand voltage
voltage
voltage ( kV) voltage ( kV) (kV) (mm/kV)
(kV)
33 36 170 70 25
15.2.2 Clearances
Minimum Electrical
Voltages Minimum Working Clearance in mm
Clearance in mm
To the nearest part, not
To Nearest
System Nominal System Highest Phase-to- Phase-to- at earth potential, of an
Unscreened live
Voltage Voltage Earth Phase insulator supporting a
conductor in air
( kV) ( kV) (mm) (mm) live conductor
(mm)
(mm)
33 36 320 320 2,750 2,450
15.2.3 Design fault levels

9.
15.2.4 Busbar, Conductor, Clamps and Cables

The existing 33kV busbar is a low-level configuration and consists of 80 x 6mm aluminium tubes installed
post insulator supports. The same will be used for the busbar extension. The busbar support clamps for the
entire north-eastern busbar will be replaced to make provision for expansion and contracting. Only one end
of each section of tubular busbar supports shall be equipped with a fixed clamp. Provision shall be made for
a sliding clamp on the other end of every section of tubular busbar. Tubular busbars shall be equipped with
Centipede conductor on the inside for 60% of the length of the tube and fixed on the one end of the with the
correct clamps and end caps for vibration damping purposes.
All stringing shall be done in accordance with the general arrangement and sections layout drawings as
described in the following sections. Jumpers shall be installed with an adequate loop to allow for shrinking
and expansion.
15.2.5 33kV Switchyard


Description
33 kV Line Bay 30 524 Flexible Single Centipede AAC 50 830
15.2.6 Clamps
All conductors shall be cleaned to a shiny finish with a steel brush at the point where the conductor clamps
are to be applied.
of gaps will be allowed. It is the contractor’s responsibility to ensure that clamps fit correctly on existing
equipment.
15.2.7 Cable Ratings

XLPE Single core copper cables shown in Table 11 are to be installed between cable termination structures
from the substation and the new 33kV lines.
Design Limit Rating

Proposed
Description Amp
MVA kV Amp Conductor/Cable MVA
In Ground
Between substation
1 x 33kV XLPE AWA Cu 1C
and line 33kV cable 36 33 629 35.5 620
500mm² per phase
termination structures
15.2.8 Specific requirements for 33kV switchyard bays

15.2.9 Feeder bays
transformers.
 No circuit-breaker side earth switches are allowed on isolators. Make provision for portable earths
and associated portable earth connections throughout.
15.2.10 Outdoor HV Circuit Breakers

charging shall be done by means of an 110VDC electric motor.
The circuit breakers shall be in accordance with the requirements of the latest revision of IEC 62271-100
edition 2, with SF6 gas insulation to IEC 40680. Testing of the circuit breakers shall be done in accordance
with the latest revision of IEC 60060-1 Edition 3.
Two tripping circuits and one closing circuit shall be provided and shall not share any common wiring.
External protection trip signal shall not be routed through the circuit breaker local/remote selector switch
while provision shall be made for local open and close control through the selector switch on the circuit
breaker mechanism, without interrupting the protection signals.
level. Operating mechanisms and handles shall be stored in an easily accessible place within the circuit
breaker mechanism box.
15.2.11 Isolating Switches

The line isolator shall be of the centre rotate double break motorised operating type mechanisms.
All shaft movements shall be facilitated by means of roller or ball bearings. The centre insulator shall rotate
with the contact arm. Contacts shall be silver plated and spring loaded. Contacts shall be designed in such a
way that current will not pass through any springs used in the contact.
15.2.12 Current Transformers

Multiple cores shall be provided for the different protection requirements as well as for metering. The
Contractor will be responsible for the calculation of current transformer ratios to suit the application for each
current transformer, whether it be an incomer feeder, transformer bay or line protection.
15.2.13 Voltage Transformers

Voltage transformers shall comply with the requirements as laid down in IEC 60044-2 and shall have two
LV windings. All voltage transformers shall have a secondary voltage of 110V.
Voltage transformers shall be of the inductive type. The position of the voltage transformers will be as
discussed in Section 15.2.8 and shown on the Single Line Diagram.
15.2.14 Surge Arresters

15.2.15 Earth Ball Joint and Portable Earths

Twelve potable earths must be provided (two per phase on both side of the earthed section) and will each
consist of the following:
15.2.16 Medium Voltage Cables

The medium voltage cable installation shall comply with the requirements in Section 17 and the applicable
Technical Schedules.
Cables must be installed in R-Y-B trefoil formation with a separation distance of 600mm between cable
groups where applicable.
15.2.17 Safety and Health Equipment

 A pin/notice board manufactured from soft board and covered with felt inside an aluminium frame,
1,500mm x 1,000mm must be installed in the substation.
 A white board shall be mounted against the wall of the substation. The size of the white board will
be 1,200mm x 1,000mm.
 An approved First Aid kit shall be provided for the substation.

Signs, danger notices and labels shall be installed in accordance with international standards and
requirements.
15.3 AUXILIARY POWER SUPPLIES

The substation auxiliary supplies are existing. The contractor must verify its suitability according to the
following specifications:
 For AC distribution refer to the “LTDRP Protection Detail Design Specification– 111233-40-SPE-
EE-0005”.
 For DC distribution refer to the “LTDRP Protection Detail Design Specification– 111233-40-SPE-
EE-0005”.
15.4 PROTECTION, CONTROL, AND TELECOMMUNICATION EQUIPMENT

Please refer to:
 LTDRP Telecommunications Detail Design Specification – Document no. 111233-40-SPE-EE-

0004
 ZESCO Technical Specifications for Telecommunications Optical Line Terminal Access

Equipment.
15.5 CIVIL WORK

Contractors should familiarise themselves with site conditions and price accordingly. The contractor must
appoint a registered civil engineer to do a soil profile. All new foundations must be designed according to
15.5.1 Terrace and Drainage

Embankments and fills shall be compacted in layers not exceeding a compacted thickness of 150 mm,
provided that the minimum relative density specified is achieved throughout the layer when compacted. The
contractor shall obtain the Project Manager’s approval of the previous layer before the next layer is spread. If
the Contractor wishes to continue placing fill before density test results are available, he may do so entirely
at his own risk and, should tests fail, then the Contractor must remove both the layer being tested and those
placed above it, all at his own expense. Unless otherwise specified, embankments and fills shall be compacted
to a minimum relative dry density of 91% Mod AASHTO.
Embankments shall be constructed as far as is reasonable in layers parallel to the formation and to the full
width corresponding to the height at which the work is being carried out from time to time. In no circum-
stances may a narrow portion of the embankment be constructed first and material "side-tipped" to make up
the specified width.
Density tests must be taken on every layer at a frequency of one for every 1000 m² of area. The specified
density is a minimum, so the Contractor must aim to achieve a higher density than the minimum specified.
The substation platform is existing. All new work should be done taking into consideration any above or sub-
soil services.
The yard must be cleaned from any vegetation after completion.
Any excavations on the existing platform must be re-compacted in layers not exceeding 150mm to the original
density value which is typically 95% MODAASHTO.
If fill material is required, it must be G5 to G7 material with a neutral Ph. value and a low electrical resistivity
≤100Ωm. The use of dump rock from mining activities will not be accepted.
15.5.2 Geo-technical and Environmental

It will be the responsibility of the Contractor to perform the necessary geotechnical tests on the terrace to
determine the bearing pressure for the design of all the foundations. The results of this study must be
The Contractor shall base his designs on these results and all calculations must be submitted for acceptance.
The contractor shall allow for rock drilling and blasting if necessary. Blasting will be of the chemical
expanding type.
Any material to be imported must be from a commercial source. The material must be of G5 – G7 quality
with a neutral PH value and a low electrical resistivity.
15.5.3 Buildings
15.5.3.1 Main substation building
Protection panels are existing at both Coventry and Kafue. No alterations to the building required.
15.5.3.2 Cable access - buildings

Any new cables that must enter the building, must do so in ducts provided therefore.
15.5.3.3 Electrical installations

No alterations to the electrical installation of the existing building required. If any changes are made to the
electrical installation, the EPC Contractor shall obtain a new certificate of compliance for the electrical
installation from the applicable inspection authority.
15.5.3.4 Indoor lighting

Indoor lighting is existing. No changes required.

Outdoor lighting is existing. No changes required.
15.5.4 Lightning protection

Lightning masts are present. No alterations required.
15.5.5 Indoor fire protection

The Matero Substation building already has an automatic gas flooding system installed.
15.5.6 Cable Trenches

Within switchyards, control cables are in covered cable trenches. The trenches are existing and must be re-
used.
15.5.7 Yard Stone

Yard cover is existing. The yard stone in the affected area must be removed and set aside for later re-
incorporation into the affected area. After completion of the scope of work the yard must be cleaned and free
of weeds.
15.5.8 Steel Support Structures

standards and specifications. All structures shall be hot dipped galvanized in accordance with ISO 1461
edition 3.
which is in use throughout Southern Africa and must be designed for the specific equipment to be installed
on it.
Structures shall be erected and aligned correctly in the horizontal and vertical planes before the final torque
of the bolts are done. Foundation bolts shall be tightened once the structure has been levelled and an epoxy
based grout must then be used to seal under the base.
equipment. Adaptor plates and shims will not be used to straighten equipment. After installation of all
equipment the space between the footing and foundation will be filled in with non-shrinking grout.
equipment holes. No modifications after galvanizing.
15.5.9 Galvanising and pole treatment

following:

 Hot air drying
 Zink bath
15.5.10 Earth Grid and Connections

There is an existing earth grid. The contractor must install an additional earth grid to make provision for the
new equipment typically in 1m blocks from the edge of the existing earth grid as is required and measure the
earth mat resistance and measure to determine if it is compliant with IEEE-80 – 2000. The grid must cover
the operating positions of all switchgear. Earth mat shall have a resistance not exceeding 1Ω. Should this
not be the case mitigating measures must be discussed with the engineer. The design parameters in Table 12
shall be used for the earthing grid design.
Round annealed copper rod with a 10mm diameter, is to be used for the main earth grid. All earth tails
between the main earth grid and equipment must be 50 x 3mm flat copper, bolted to the structures. Each
piece of equipment shall be connected to the earth grid, in at least two positions. The new lightning mast will
have 4 bonding leads with 4 x 1,5m Cu plated earth rods.
All connections shall be cleaned from any dirt or paint to ensure proper electrical connection from structures
to the earthing grid.
The trench bottom shall be free of rocks and stones and shall be compacted before placing the copper
conductor in the trench. The copper conductor shall be placed on this bed of compacted soil.
No joint in earth tails shall be made above the ground level.
The main earth grid trenches shall be back-filled and compacted with the excavated soil, in layers not
exceeding the civil engineer’s recommendations. The re-compacted areas will match that of the undisturbed
and must be proven by means of a DCP test.
Flat straps must be curled halfway around the round bar to ensure sufficient surface connection. The straps
shall exit the ground directly next to the foundation and must be bent and profiled to suit the equipment shape
as close as possible. Where necessary and on runs on concrete of more than 600mm, the strap must be fixed
to the concrete.
The continuity of the earth path from the equipment to the earth grid shall be measured after the equipment
has been installed. The earth resistance of all new equipment shall be measured after installation and bonding
before the connections to the terminal towers are done. The measurements shall be carried out and logged
by the contractor in the presence of the Engineer.
Description Detail
Design Parameters
Body Weight 50kg
Earthing material size:
Earthing Grid 10mm round Cu
Connections 50x3mm Cu strap
Wenner method.
Soil resistivity measurements 5 Readings at electrode spacing of 1, 2, 4, 8 and 16
meter
Safety Parameters
15.5.11 Concrete Foundations

This section must be read in conjunction with Section 14.15.6
The slump test shall be done for each new batch of concrete in the presence of the engineer. The slump for
this application should typically be 50 – 100mm.
All equipment shall be mounted on support structures, secured on concrete bases by means of 24mm
galvanized anchor bolts. The length of the bolt shall suit the application. Anchor bolts must protrude at least
80mm above the finished level of the concrete and shall be provided with two nuts and two washers to allow
for levelling of the structures.
The gaps under the structures must be filled with an approved grout mix after the structures have been levelled
out.
used for substation equipment support structures in soil, and alternative designs may be proposed for hard
rock.
The Contractor will be required to carry out a geotechnical investigation, with special attention to the
positions of the gantries, transformers and the building.
Concrete bases shall be finished smoothly above the platform compacted level and shall protrude 150mm
above the finished ground level. This will allow the foundations to protrude ± 50mm above the 100mm yard
stone cover.
All new foundations will be provided with a 45º chamfer.
15.5.12 Equipment Labels

The substation currently has very little equipment labels and signs. The contractor shall replace all safety
signs and install labels on all the structures new and existing. The proposed label set must be submitted to the
engineer for approval before the order is placed.
Labels shall conform to international standards. All equipment in the substation will be supplied with new
labels. The following guidelines shall be followed.
Each piece of electrical equipment shall be provided with a designation label 280mm x 220mm. The labels
will be manufactured from 1.5mm aluminium plate, shall be white with black letters. The letter will be higher
than the rest of the plate. Uniformity of the labels will be a priority. Labels will be fixed to structures by
means of galvanized bolts and nuts.
Label material
Application of phasing discs Both sides of isolators, at line entries
All new panels shall be provided with identification label.

 Room designation labels mounted above each door.
 Warning of dangers of condensed aerosol generators (CAG).
16 Demolishing of existing infrastructure

Any demolishing of the two existing 33kV overhead lines must be strictly done in accordance with “111233-
40-SPE-EE-0018 - Dismantling of Overhead Line and Substation Equipment Specifications”. All materials
recovered must be taken to the Zesco farm that is typically 18km from site and is indicated in Figure 25.
Figure 25: Zesco Farm location

17 33kv cable installation
17.1 SPECIFICATIONS
from 1 kV (Um = 1,2kV) up to 30kV (Um = 36kV) –
IEC 60502-2
Part 2: Cables for rated voltages from 6kV (Um = 7,2kV) up to
30kV (Um = 36kV)
IEC 61941
fibres
Figure 26: MV cable construction

8. Binder tape.
9. Inner sheath.
17.2 EXCAVATIONS
Existing services will be pointed out to the contractor as far and as accurate as possible with the information
that is available, however the responsibility will remain with the contractor to find and safely expose all
existing services by hand. The contractor must survey the proposed route to determine the optimal placement
of the cable with regards to obstacles, road crossings and existing services, as follows:
 Due to the amount of existing services the unit rates must make provision for the most efficient way
of exposing these services without damages. The use of compressed air excavation tools like an
“Air Knife” or similar must be provided for in the unit rates for excavations.
Hard/dense soil
 Generally any soil which requires the close application of picks, jumpers or scarifiers to loosen; for
 Note: Cobble stone is rock fragments usually rounded or semi-rounded having maximum diameter
in any direction between 80mm and 300mm.

 This shall include rock or boulders, which can be excavated by barring, wedging and splitting
manually or using pneumatic tools. It shall also include embedded boulders measuring not more than
one metre in any one direction.
 Note: The mere fact that the contractor resorts to blasting to loosen the material shall not mean that
it will be classified as hard rock.

 This shall include all rock occurring in large masses which cannot be removed except by blasting.
Hard varieties of rock such as granite with or without veins and secondary minerals which in the
opinion of the engineer requires blasting shall be considered as hard rock. Boulders of hard rock
larger than one metre in any one direction lying in the overburden and requiring blasting for easy
and efficient removal shall also be classified as hard rock. All blasting shall be of the non-explosive,
chemical expanding type.
Claims for excavations will be processed according to the trench dimensions provided. Over excavation will
not be considered.
Generally, the centre line of trenches will be 1m from the stand boundary. Obstructions encountered should
be brought under the attention of the engineer.
No trees shall be cut during the execution of the contract unless specifically arranged with the engineer.
Should any trees have to be removed, the contractor shall arrange for the complete uprooting and trimming
of tree trunks, as well as the stacking of all trunks and branches. Holes caused by the uprooting shall be filled
and consolidated. Rubble shall be removed to leave the site neat and tidy. The contractor shall be held
responsible for any damage that may occur during the felling of trees.
Provision shall be made at road crossing to keep the roads open during the cable installation period by
installing heavy-duty steel plates across the open trenches. The contractor shall include this in the tender
price.
All railway lines plus all tarred roads are to be crossed with sleeves by boring (drilling) underneath to a depth
of at least 1.5m into which the cable is to be laid. Sleeves are to be strong enough not to buckle under the
load of the ground above, and correctly sized for the cable. In addition to these sleeves at crossings, cable
manholes will be constructed on either side of each crossing. This will be done by means of brick and mortar
and at the same depth as the accompanying cable trench. The design of the manhole must make provision to
keep out any ground water but the use of a subsoil drain can be considered. The top of the manhole must be
a minimum of 300mm above NGL. All power cables, spare sleeves, as well as the fibre-optic cable on the
same route, will enter the manhole. All subsoil entries into the manhole will be sealed watertight. The
manholes must be positioned to act as a transition point where a change in direction can be done. Lockable
watertight lids must also be provided, the size of which must be able to cater for both power and fibre optic
during installation.
Where the cable is installed along a tarred road and crosses a dirt road that might become a tarred road sleeves
must be installed for each cable plus one spare. The unit rate for sleeves will make provision for joint
couplings as well as end-caps where require.
It is preferred that trenches not be left open overnight. If it is unavoidable, however, the contractor must, as
a minimum, install orange trench barrier netting. The netting must be a bright orange colour, a minimum of
1.2m high and supported every 2m by a wooden or iron pole of 1.5m to prevent injury to passers-by. In areas
where the open excavation is not very well lit, the contractor may, in addition to the netting, make use of red
strobe lights positioned in intervals of 5m. The contractor remains responsible for safety in and around the
open excavation until it is backfilled.
200mm x 6m Sleeves must be installed for each individual MV cable at each of the substations where the
cable enters substation underneath the fence and onto the platform.
17.3 BEDDING AND BLANKET LAYERS

If the trench is rocky, the bottom of the trench shall be filled across the full width with a 75mm layer of
suitable soil sifted through a 6mm mesh and levelled off.
Only sandy clay or loam soil with a satisfactory thermal resistivity (not exceeding 1.2C m/W) may be used
for this purpose. Sea or river sand, ash, chalk, peat clinkers or clayey soil shall not be used.
17.4 BACKFILLING
present in the backfill material for the first section above the blanket layer as per the design. Thereafter all
soil used for backfilling shall pass through an 80mm mesh to ensure that the maximum allowable diameter
of stones present in the backfill material is 75mm.
of not more than 300mm before being compacted. In backfilling, the bedding on top of the cable shall be
covered first with a 200mm layer of well graded material containing no pieces larger than 20mm, before any
coarse material is deposited.
The material shall be compacted by compaction machines to a minimum of 95% MOD AASHTO.
Compaction certificates will be required.
17.5 CABLE MARKERS AND LABELLING

Brass or aluminium plates shall be cast into the top of the cable marker blocks in such a manner that they
cannot be pried loose. The wording "ELECTRICAL CABLE" shall be stamped on the plates as well as
direction arrows and the cable voltage rating.
normal ground level unless the projected markers could be a hazard to pedestrian or other traffic in which
case they shall be installed flush with the surface.
Type B route markers will be installed on the outskirts of town and in areas where a high possibility exists
that cables will be damaged by development.
Cable markers shall be installed at the beginning and ending of a cable run (e.g. where a cable enters a
substation or building), at changes of direction, above all joints, above cable pipe/sleeve entries and exits at
road crossings. On long cable runs it must be installed every 50m.
All cables must be marked at all joints and at each cable end by means of stainless steel tape which is clamped
consideration:
1. Voltage
2. Cable size
4. Connected from
5. Connected to
17.6 CABLE INSTALLATION

Danger tape shall be installed above both the 11kV cables, only at the depth as indicated, along the entire
trench length. The tape must be 450mm wide and must be a minimum of 200 microns thick. It must be bright
orange or yellow with red skull and crossbones and the words "ELECTRIC CABLE" printed on not more
than 1m intervals.
Concrete slabs (900x300x65mm) will also be installed where any other services are crossed, either 300mm
above or 300mm below so that the new cable is comprehensively protected. In areas where a high risk of
damage exists, the entire trench will be packed with concrete slabs.
Pulling eyes shall be provided on both ends of a cable drum length. The pulling eye shall be securely
connected to both the cable conductor and the sheath to avoid elongation of the sheath during installation.
Cable rollers shall be used to run out cables. Rollers shall be spaced so that the length of cable in the trench
will be totally suspended during the laying operation and sufficiently close to prevent undue sagging and the
cable from touching the ground. Rollers shall also be placed in the trench in such a manner that they will not
readily capsize.
Where cables must be drawn around corners, well-lubricated skid plates shall be used. The skid plates shall
be securely fixed between rollers and shall constantly be examined during cable laying operations.
Where cables must be drawn through sleeves or ducts, HDPE sleeves must be used. A suitable cable sock
shall be used and care shall be exercised to avoid abrasion, elongation or distortion of any kind.
The maximum allowable tension when pulling a cable is 70N/mm2 of conductor area. The contractor remains
responsible to confirm the limitations of the cable from his supplier. It will be assumed that the price or rates
contained in the tender includes for the installation of cables in pipes and ducts or below existing or newly
installed services. The Engineer shall be informed timeously of the intention to carry out all cable laying
operations to allow an inspection of the works if so required.
The cable shall be installed using a winch and care shall be taken not to exceed the maximum permissible
pulling force specified by the manufacturer.
The maximum permissible bending radius of a cable is typically fifteen times the cable diameter. This must
be confirmed in the technical schedules per a specific supplier’s requirements. Any damage resulting from
ignoring this value will be rectified by the contractor at his own expense to the satisfaction of the engineer.
17.7 JOINTS AND TERMINATIONS

17.7.1 General
available on site.
Remove water blocking material from within the conductors with care before inserting into lugs and
connectors for crimping.
Where a visual representation of the phase rotation colours are required for MV cables it shall be:
 L1 – R(red)
 L1 – B(blue)
17.7.2 Terminations
When cutting away insulation from cable conductors to fit into lugs, care shall be taken that no strands are
left exposed. Under no circumstances may any of the conductor strands be cut away to fit into lugs.
Suitable lugs shall be used and preferably be solidly seated to cable conductor ends. Lugs may be crimped
using mechanical, hydraulic or pneumatic tools specifically designed for this purpose. Under no
circumstances may a lug be crimped by means of a hammer and/or punch.
by the engineer.
Contact surfaces shall be thoroughly cleaned and smoothed and fixing bolts shall match the hole size of the
lug and shall be manufactured of cadmium plated tensile steel.
The kits shall include suitable boots for the covering of the terminal studs on the equipment. The ends shall
be terminated strictly in accordance with the termination manufacturer's specification and shall withstand the
same test voltage as the rest of the cable.
The cores of all cables terminated shall be completely covered with a shrunk-on protective layer against
surface tracking, ultra-violet radiation and weathering.
Cables shall be terminated in accordance with the recommendations laid down by the manufacturers of the
cables and the terminations employed.
17.7.3 Cable Joints

continuity shall be accomplished within the joints, i.e. no external earth continuity conductor that will be
subject to corrosion, is acceptable. The joints shall be completely covered by a watertight sheath to prevent
corrosion.
In the case of joints in cables with an outer PVC anti-electrolysis sheath, the joints shall be subject to the
same electrical insulation test as the outer sheath of the cable.
Cable joints for heat shrinkable materials shall be packed as a complete joint kit in a container that is marked
for the type of cable insulation and construction as well as the voltage range for which materials are suitable.
The contractor shall leave slack in the form of two coils 2m on either side of the joint. The coils must comply
around the cable. The following information shall be punched on to the stainless-steel tape for the cable
under consideration:
c) Type of cable
17.8 CABLE TESTS

and IEC60060-1.
Outer sheath tests shall routinely be performed immediately after the installation and backfilling of a length
of cable, so that repairs, if required, can be done at that stage.

17.9 COORDINATION OF SERVICES

All new infrastructure lines and cables will be installed on the same route as other existing services such as
water, sewerage, electric cables, stormwater and fibre optics. The contractor must coordinate the installation
of the new cables and fibre optics with all existing services by gathering information from all service
providers involved as to positioning of the said services as well as trench cross cuts on the planned routes.
C. DRAWINGS
STEEL MONOPOLE
111233-0000-DRG-CE-DE-0001 33kV HARDWARE
STRAIN ASSEMBLY DRAWING
STEEL MONOPOLE
INTERMEDIATE ASSEMBLY DRAWING
STEEL MONOPOLE
JUMPER SUPPORT ASSEMBLY DRAWING
STEEL MONOPOLE
111233-0000-DRG-CE-DE-0004 SHIELD WIRE HARDWARE
STEEL MONOPOLE
KAFUE ROAD SUBSTATION
111233-60-DRG-EE-SE-0028 33KV LINE BAY
GENERAL ARRANGEMENT
COVENTRY SUBSTATION
111233-60-DRG-EE-SE-0029 33KV LINE BAY
GENERAL ARRANGEMENT
COVENTRY TO KAFUE ROAD
111233-COV/KAF-PP-1 SHT 1-3
33 kV DISTRIBUTION LINE
AURECON STANDARD DRAWINGS
AUR-OHL-EAR-MP-001 TYPICAL EARTHING ARRANGEMENT FOR PAD AND CHIMNEY
STRUCTURE
TERMINAL POLE EARTHED
GH9727
33kV STRUCTURE FOR 200mm² & 300mm² ACSR
SECTION ANGLE POLE CONSTRUCTION
GH9728
33kV EARTHED STRUCTURE FOR 200mm² & 300mm² ACSR
INTERMEDIATE POLE EARTHED
GH9729
ZAM-GEN-41-G-12827
33kV UNDERGROUND CABLE
ZAM-GEN-DE-G-12831 33kV STAYS
33kV OVERHEAD LINE
ZAM-GEN-DM-08-G-12260
DISK INSULATOR SUSPENSION ASSEMBLY
33kV OVERHEAD LINE
DISC STRAIN ASSEMBLY

SUPPLEMENTARY
INFORMATION
1. LTDRP SCADA Detail Design Specification – 111233-40-SPE-EE-0003.
2. LTDRP Telecommunications Detail Design Specification – 111233-40-SPE-EE-0004.

3. LTDRP Protection Detail Design Specification – 111233-40-SPE-EE-0005.
4. ZESCO Technical Specifications for Telecommunications Optical Line Terminal Access Equipment.
5. ZESCO LTDRP - Environmental and Social Management Plan_ 1st Draft.
6. ZESCO LTDRP HSMP.
7. ZESCO Waste Management Procedure Version 1 Signed.

8. 111233 REP011 Dismantling of OHL and Substation Equipment - Rev 2.
9. Metering Requirements

Section___________________________________________________________________________________________________________________________________________________
VII. Employer's Requirements Part 2-213
LTDRPP4

LOT 2: Coventry – Kafue 33kV Overhead Line Upgrade
Task 1: 33kV OHL and cable feeders from Coventry Substation to Kafue Substation
Task 2: 33kV feeder bays at Coventry Substation and Kafue Substation
Name of Bidder
Lot 2 Rev 5
____________________________________________________________________________________________________________________________________________
Lot 1 Rev 5
_______________________________________________________________________________________________________
LOT 2 - COVENTRY - KAFUE SUBSTATION 33kV UPGRADE
TECHNICAL SCHEDULES
Table of Contents
Sequence No Item No Description

1 1 33kV Circuit Breakers - Incomers, Bus-Sections and Bus Couplers
197 9 500mm² 19.05/33kV 1C Cu XLPE AWA
222 10 Inside Termination -500mm² 19.05/33kV AWA XLPE 1-Core Cu Cable
262 12 Marshalling Kiosk Or Yard Junction Box (complete one per kiosk type)
278 13 Insulators
314 14 Tension clamps
338 15 Conductors
373 16 Armour rods
389 17 Repair sleeves
397 18 Vibration dampers
411 19 Steel monopole
Lot 2 Rev 5
_______________________________________________________________________________________________________
LOT 2 - COVENTRY - KAFUE SUBSTATION 33kV UPGRADE
The provided typical 132kV, 33kV and 11kV combined control, protection and telecommunication panels shall be strictly used

1 1 33kV Circuit Breakers - Incomers, Bus-Sections and Bus Couplers -----
16 1.14 Min Distance Between Poles mm 750
36 3.5 Yes
3min - CO
40
Lot 2 Rev 5
_______________________________________________________________________________________________________

76 3.5 Yes
3min - CO
80
90 1.8 Deg 90
Open)
105
Lot 2 Rev 5
_______________________________________________________________________________________________________

122 1.15 Note
123 1.16 Type Post
800A
Multi ratio
1,600A
Multi ratio
126
138 1.10
139 1.11 Type Ring
140
163
Lot 2 Rev 5
_______________________________________________________________________________________________________

182
196
197 9 500mm² 19.05/33kV 1C Cu XLPE AWA -----
201 4 Voltage kV 19.05/33
215 ZESCO
218 Voltage
219 Cable size
221
222 10 Inside Termination -500mm² 19.05/33kV AWA XLPE 1-Core Cu Cable -----
226 4 Voltage kV 19.05/33
231 9 Earth kit Yes
241 19 Indoor / Outdoor Indoor/Outdoor
242
247 4 Voltage kV 19.05/33
Lot 2 Rev 5
_______________________________________________________________________________________________________

252 9 Earth kit Yes
261
262 12 Marshalling Kiosk Or Yard Junction Box (complete one per kiosk type) -----
264 2 Model number Specify
265 3 Degree of Protection IP54
266 4 Material 3CR12 Stainless
267 5 Access Doors Front and Back
268 6 Welding plugs: 3 phase 400V (Trfr MK only) 1 per Kiosk
269 7 Three pin plugs 1 phase 240V 15 Amp 1 per Kiosk
VTJB, CTJB,
270 8 Application
271 9 Terminal blocks
equivalent
272 10 Doors Lockable
273 11 Degree of Protection IP54
274 12 Outline and layout drawing No.
with bid
275 13 Quality assurance Specify
276
277
278 13 Insulators -----
279 1 Post Insulator -----
280 1.1 Name of Manufacturer/Supplier Specify
282 1.3 Type of Insulators Silicon Rubber
283 1.4 Mechanical Strength including fittings -----
284 1.5 Failing Load kN 13.25
285 1.6 Cantilever Strength (40% of failing) kN 5.3
286 1.7 Nominal Voltage kV 33
287 1.8 Maximum Operating Voltage kV 36
289 1.10 Basic Insulation Level (BIL) kV 170
290 1.11 Number of Sheds Specify
291 1.12 Length mm Specify
292 1.13 Dry Arcing Distance Specify
293 1.14 Creepage Distance 900
294 1.15 Medium - High Pollution mm/kV 25
295 1.16 Mass per Insulator kg Specify
296 2 Strain/Suspension Insulator -----
299 2.3 Does equipment comply with the specification Specify
300 2.4 Type of Insulators Silicon rubber
301 3 Mechanical Strength including fittings -----
302 3.1 Failing Load kN 120
309 3.8 Dry Arcing Distance mm specify
310 3.9 Creepage Distance mm 900
313
314 14 Tension clamps -----
315 1 Tension End Clamp (Bear) -----
Lot 2 Rev 5
_______________________________________________________________________________________________________

319 1.4 Aluminium Outer (Inside Diameter) mm 23.45
320 1.5 Galvanized Forged Steel Inner (Inside Diameter) mm 10.05
321 1.6 Overall Length mm Specify
Hexagon ‘ALCAN’
322 1.7 Compression Type
Range
323 1.8 Breaking Force kN 112
324 1.9 Current Transfer Through Jumper Terminal Lug Min A 650
325 1.10 Jumper Attachment 2×M12 bolted
326 2 Inline Full tension joint (Bear) -----
Hexagon ‘ALCAN’
Range
336 2.10 Current Transfer Min A 650
337
338 15 Conductors -----
339 1 Phase Conductor -----
342 1.3 Type Bear
343 1.4 Current Rating A 650
344 1.5 Overall Diameter mm 23.45
345 1.6 Strand And Wire Diameter mm 30/7/3.35
346 1.7 Aluminium Area mm² 264.42
347 1.8 Ultimate tensile strength kN 112
348 1.9 Final modules elasticity MPa 83,400
349 1.10 Coefficient of linear expansion (1/°C) 18.43 x 10E-6
350 1.11 Standard drum length (min) m 2,000
351 2 Optical Ground Wire -----
352 2.1 Grease Conductor Yes
353 2.2 Type of Fibre Carrier Specify
354 2.3 Number of Fibres 24
355 2.4 1 S Burn-Off Current kA 21.5
356 2.5 Strand and Wire Diameter mm Specify
357 2.6 Breaking Strength kN Specify
358 2.7 Diameter mm Specify
359 2.8 Mass N/m 8.1 max
360 2.9 Standard drum length m Specify
361 3 Optical Fibre -----
363 3.2 Type of Fibre Single Mode ITU-T G.652
364 3.3 Mass per Length of Cable kg/km < 200
365 3.4 Cable Diameter mm ≤ 15
366 3.5 Cabled Cut-Off Wavelength nm ≤ 1,260
367 3.6 Anti-Tracking Sheath Yes
368 3.7 Maximum Design Span Length m >400
369 3.8 Ultimate Tensile Strength kN ≥ 35
Maximum Working Load (Where Fibre Strain Does Not
370 3.9 kN Specify
Exceed 0.2 % in the Fibres)
371 3.10 Maximum Continuous Load (Fibre Under No Strain) kN Specify
372
373 16 Armour rods -----
377 1.3 Type Spiral
378 1.4 Size mm 19.80-21.08
379 1.5 Length mm 1,450
380 1.6 Wire Diameter mm 6.35
381 2 Shield Wire -----
384 2.3 Type Spiral
Lot 2 Rev 5
_______________________________________________________________________________________________________

385 2.4 Size mm 13.2
386 2.5 Length mm 1,000
388
389 17 Repair sleeves -----
Hexagon ‘ALCAN’
Range
395 1.5 Length mm 220
396
397 18 Vibration dampers -----
401 1.3 Type Stockbridge
402 1.4 Size mm 23.45
403 1.5 Length mm 520
404 2 EARTH WIRE -----
407 2.3 Type Spiral
408 2.4 Size mm Specify
409 2.5 Length mm 1346
410
411 19 Steel monopole -----
412 1 Intermediate double circuit -----
415 1.3 Steel structure Tubular monopole
416 1.4 Type Hot dipped galv,355JR
417 1.5 Minimum tube thickness mm 3
418 1.6 No of sections Specify
419 1.7 Foundation (planted/flanged) Flanged
420 1.8 Conductor configuration
421 1.9 Suspension 2 x Vertical circuits
422 1.10 Conductors per phase 1
423 1.11 No of earth conductors 1
Tip load intermediate 33kV steel monopole (based on wind
424 1.12 kN Specify
span 250m, weight span 450m)
425 1.13 Safety factor
426 1.14 On calculated strength 2.5
427 1.15 On type tested breaking strength 2.2
428 1.16 Minimum conductor attachment height (shortest pole) m 10
Post insulator / angled
429 1.17 Insulator
baseplate
430 2 Strain double circuit -----
438 2.8 Conductor configuration 2 x Vertical circuits
Tip load 0-30 degree angle (based on wind span 250m, weight
441 2.11 kN Specify
span 450m)
Tip load 30-60 degree angle (based on wind span 250m,
442 2.12 kN Specify
weight span 450m)
443 2.13 kN Specify
weight span 450m)
444 2.14 Safety factor on calculated strength 2.5
445 2.15 Safety factor on type tested breaking strength 2.2
447 2.17 Suspension Insulators (jumpers)
baseplate
Lot 2 Rev 5
_______________________________________________________________________________________________________

448 2.18 Terminal/strain insulators Plate bracket
449 3 Intermediate triple circuit -----
457 3.8 Conductor configuration 3 x Vertical
460 3.11 kN Specify
463 3.14 Minimum Conductor Attachment Height (Shortest Pole) m Specify
baseplate
465 4 Strain triple circuit -----
Tip Load 0-30 degree angle (based on wind span 250m, weight
476 4.11 kN Specify
span 450m)
Tip Load 30-60 degree angle (based on wind span 250m,
477 4.12 kN Specify
weight span 450m)
478 4.13 kN Specify
weight span 450m)
481 4.16 Minimum conductor attachment height (shortest pole) m Specify
491 1.8 Yes
494 1.11 Yes
equivalent
control building
with bid
506 2 -----
per kiosk type)
Lot 2 Rev 5
_______________________________________________________________________________________________________

VTJB, CTJB,
514 2.8 Application
equivalent
with bid
520
522 1 -----
Yes - SCADA & Local
Yes - SCADA & Local
selection via relay
Yes - SCADA & Local
selection via relay
Yes - SCADA & Local
540 2.14 Yes
certificates
541 3 -----
553 4.8 V AC/DC Yes
certificates
554 5
Lot 2 Rev 5
_______________________________________________________________________________________________________

safe Output Contact
573 5.19 Yes
Fibre - Ethernet
access
of 1kHZ
578 5.24 Yes
certificates
579
overhead lines
606 3.16 Yes
certificates
609
610 23 Metering -----
611 1 33kV Metering -----
In separate panel
616 1.5 Installation (see metering panel
layout)
617 2 11kV Metering -----
Lot 2 Rev 5
_______________________________________________________________________________________________________

11kV Incomers & 11kV
622 2.5 Installation feeders on-board
protection panel
624 3.1 Active energy meter class
625 3.2 Reactive energy meter class
626 3.3 Digital MM interface RS 232 or USB
627 3.4 Compatibility Windows, Vista or NT
628 3.5 Energy management software Included
629 3.6 Integration in Substation Automation System Yes
630 3.7 Serial Interface with adequate Communication Protocol IEC 61850/IEC 62056-
631 4 Direct-read metering instruments -----
632 4.1 AC bus voltmeter Digital display
Mini-moulded circuit breaker with auxiliary contact with
634 5.1 Yes
auxiliary contact
635 5.2 Test switches (voltage, current) Yes
636 5.3 Terminal blocks and rail
equivalent
637 6 Yes
certificates
Lot 2 Rev 5

Contractor
LOT 3 - Industrial – Matero 33kV Corridor Upgrade


A. PROJECT BACKGROUND
amongst other, increasing the power intake and distribution capacity and reliability of the 132kV ring
surrounding Lusaka. The ring currently connects Lusaka West - Roma - Leopards Hill - Waterworks -
Coventry - Lusaka West substations. During the execution of the LTDRP packages, the integrity of the ring
must be protected by avoiding the isolation of more than one section at any point in time.
1. OBJECTIVE
2. OVERVIEW
 Lot 1: Woodlands 33/11kV Substation Upgrade (Separate document)
 Lot 2: Coventry – Kafue 33kV Overhead Line Upgrade (Separate document)
 Lot 3: Industrial – Matero 33kV Corridor Upgrade (This document)
o Task 4 –33kV feeder bay Matero Substation
3. NETWORK DIAGRAM
The existing 33kV networks are shown in Figure 1 and the proposed alterations to these networks are shown
in Figure 2.
Figure 1 Existing Matero, Liverpool and Mungwi 33kV networks.
Figure 2 Proposed changes to the Matero 33kV network
4. DEPENDENCIES
Inter-lot and inter-project dependencies exist and are summarised as:
 The completion of the 132/33/11kV Industrial Substation for the completion of the Industrial to
Mungwi 33kV lines.
 The completion of the Matero Substation 33kV line bay for the completion of the Matero to
Liverpool 33kV lines.
5. SCHEDULE
The typical schedule of the Package 8 Lot 2 is shown in Figure 3.
MONTHS
1 2 3 4 5 6 7 8 9 10 11 12
Package 8 Lot 3
Lead Time
Task 1
Task 2
Task 3
6. ABBREVIATIONS
Item Description
°C Degree Celsius
A Ampere
BS British standard
cm Centimetre
Cu Copper
DC Direct Current
DPC Damp proof course
EN European norms
Item Description
HF High frequency
HV High Voltage
Hz Hertz
kA Kilo Amperes
kg Kilogram
kl Kilo litre
kPa Kilo Pascal
kV Kilo Volts
m/s Meter per second
mPa Mega Pascal
MV Medium Voltage
MVA Mega Volt Ampere
OLTC Online tap changer
Pa Pascal
Item Description
TRFR Transformer
UV Ultra violet
ZESCO Zambia Electricity Supply Commission
7. SCOPE OF WORK
The scope of work summary for Package 8 Lot 3 is divided into various tasks, which is described in the
following sections.
 Task 1 - OHL from Industrial Substation to Mungwi Substation
 Task 2 - OHL from Mungwi Substation to Liverpool Substation
 Task 3 - OHL from Liverpool Substation to Matero Substation
 Task 4 - 33kV feeder bay Matero Substation
The substation works are divided into three disciplines, namely:
 Civil works.
The overhead line works are typically divided into three disciplines, namely
 Phase conductor and OPGW,
 Conductor hardware and assemblies, and
 Civil works and structures.
The work in each discipline must be planned according to the implementation methodology for the whole
project, taking careful note that disciplines are inter-dependent, with the possibility that certain personnel,
equipment, and sub-contractors will be mobilised and demobilised as required.
document. It does not necessarily describe all the work in detail. The prospective bidders must study the
documents and drawings and ensure that he allows for all the material required to provide a complete fully
functional installation. Bidders need to outline any significant material omissions in their Bids. It is important
to note that the scope of work is design, supply, installation and commissioning, up to final handover of the
fully functional substation, properly integrated into the Lusaka Transmission and Distribution network.
specify these items, supported by the necessaries calculations, in line with the standards provided, for
approval of the Engineer.
8. LOT 3 TASK 1: OHL FROM INDUSTRIAL SUBSTATION TO

MUNGWI SUBSTATION
8.1 General
The aim of this task is to improve the load sharing and interconnectivity between the Lusaka West, Mungwi,
Roma and the new Industrial Substations. The current layout as well as the proposed layout can be seen in
and . In Figure 4, the blue, yellow and green lines are existing lines that will be modified to make provision
for and included on the new infrastructure.
The affected 33kV networks connected to the Lusaka West and Roma Substations indicated in are connected
as follows:
 There is a 33kV single circuit wooden pole line connected between Matero and Liverpool
substations.
 There is a 33kV single circuit wooden pole line connected between Liverpool and Lusaka West
substations.
 There is a 33kV single circuit wooden pole line connected between Liverpool and Mungwi
substations.
 At Mungwi Substation there are spare equipped bays available for the new Matero 33kV and
Industrial 33kV lines. The Liverpool feeder at Mungwi Substation will be re-used.
 At Liverpool Substation the Mungwi, Lusaka West as well as the Matero 33kV feeders will be re-
used.
 At Matero Substation the Liverpool feeder will be re-used. There is space for the new Mungwi
33kV feeder but it will have to be equipped.
 The two Mungwi 33kV line bays at Industrial Substation is available.
Figure 4 Lusaka West and Roma 33kV networks

With reference to Figure 5 implement the following:
 Demolish according to “111233-40-SPE-EE-018 Dismantling of Overhead line and Substation

Equipment Specification”, the 33kV single circuit line between Liverpool and Mungwi
Substations.
 Replace the demolished Liverpool/Mungwi 33kV line with a double circuit self-support steel
monopole line from Liverpool Substation to the Mungwi crossing.
 Construct in the same servitude from the other side of the crossing a triple circuit self-supporting
steel monopole structure form the Mungwi crossing up to the Mungwi Substation.
 String from Liverpool Substation a 33kV line partly on one side of the double circuit and partly on
the same side of the triple circuit up to Mungwi Substation and terminate. Install and terminate at
both Mungwi and Liverpool substations one 19/33kV 500mm² 1C AWA Cu XLPE cable per phase
from the cable termination structure onto the switchgear.
 Construct from Industrial Substation a 33kV (2 x 31MVA) double circuit line with self-supporting
steel monopole structures to where it intersects with the Liverpool / Mungwi servitude. From this
point string the two 33kV / 31MVA Industrial circuits onto the vacant circuits of the triple circuit
structure up to Mungwi Substation. Terminate at both substations by means of one 19/33kV
500mm² 1C AWA Cu XLPE cable per phase from the cable termination structure onto the
switchgear.
 Any termination of a cable to a steel monopole must typically go through an intermediary structure
which is at a safe level to mount the ancillary equipment like the surge arrestors on.
 The 33kV bay equipment, line protection panel with an ABB main relay and control cabling at
Mungwi Substation is existing.
 The 33kV indoor breaker with onboard Siemens protection at Liverpool Substation is existing.
Figure 5 Mungwi, Industrial Double Circuit 33kV network


8.2.1 Protection
• The protection settings be redone and recommissioned.
9. LOT 3 TASK 2: OHL FROM MUNGWI SUBSTATION TO

LIVERPOOL SUBSTATION
With reference to Figure 6 the following:
Equipment Specification” the Liverpool/Lusaka West 33kV single circuit line from Liverpool
Substation up to Mungwi Substation and install an inline strain structure to support the remainder
of the wooden pole line to Lusaka West.
 Construct a (2 x 31MVA) double circuit line with self-supporting steel monopole structures to from
Mungwi Substation up to the Mungwi crossing. From there jump with one circuit across the road
up to the Liverpool/Matero line.
 At Mungwi Substation connect the existing Lusaka West / Liverpool 33kV line onto one circuit of
the new double circuit line. From Mungwi Substation terminate the new Matero 31MVA feeder
onto the vacant circuit of the double circuit and string both 31MVA circuits up to the termination
tower at the cable termination tower of the Liverpool/Matero line at the Mungwi crossing. On both
ends of this double circuit line terminate onto the 33kV switchgear with one 19/33kV 500mm² 1C
AWA Cu XLPE cable per phase.
 The 33kV bay equipment, line protection panel with an ABB main relay and control cabling at
Mungwi Substation is existing.
 The indoor 33kV panels onboard Siemens protection for the Lusaka West feeder as well as a spare
panel for the new Mungwi feeder with onboard Siemens protection is available at Liverpool
Substation.
 Any termination of a cable to a steel monopole must typically go through an intermediary structure
which is at a safe level to mount the ancillary equipment like the surge arrestors on.
Figure 6 Mungwi, Lusaka West and Liverpool Substation 33kV networks


9.1.1 Protection
10. TASK 3: DOUBLE CIRCUIT OHL FROM LIVERPOOL

SUBSTATION TO MATERO SUBSTATION
With reference to Figure 7 the following:
Equipment Specification” the existing wooden pole line from Matero up to the cable termination
structure. Construct a 33kV (2 x 31MVA) double circuit self-support steel monopole line from
Matero Substation up to the cable termination structure. String both 31MVA circuits of the line
from Matero up to the termination structure. Re-terminate the cable from Liverpool Substation onto
the terminal pole and connect the two intended Mugwi points together. Install at Matero Substation
one 19/33kV 500mm² 1C AWA Cu XLPE cable per phase from the cable termination structure
onto the switchgear for both circuits.
 From the Mungwi intersection string the 31MVA Liverpool feeder circuit onto the vacant circuit
of the double circuit structure constructed earlier and terminate at Liverpool Substation with a
19/33kV 500mm² 1C AWA Cu XLPE cable per phase.
 Any termination of a cable to a steel monopole must go through an intermediary structure which is
at a safe level to mount the ancillary equipment like the surge arrestors on.
 Supply and install one 33kV line protection panel with top entry cabling at Matero Substation for
the new Mungwi 33kV line according to the existing specification and to work in harmony with
the Siemens systems that are present.
Figure 7 Mungwi, Liverpool and Matero Substation 33kV networks


10.1.1 Protection
11. TASK 4: 33KV FEEDER BAY MATERO SUBSTATION

11.1 General
Matero 33/11 kV substation is located 6km northwest of Lusaka city centre (co-ordinates 15°21'51.17"S
28°15'22.32"E). The substation can be accessed by a tarred road.
The existing Matero 33/11kV Substation has an installed transformation capacity of 60MVA. The 33kV yard
has sufficient space to add the additional Mungwi feeder bay as indicated in Figure 8.
The equipment that must be demolished is indicated in red.
Figure 8: Matero 33/11kV Substation existing general arrangement

With reference to Figure 8 and Figure 9, the substation consists of the following:
 2 x 30MVA Transformer bays.
 1 x 33kV Split busbar with a bus section isolator.

 3 x 33kV Feeder bays that is cabled from their respective cable termination structures to lines they
are connected to outside of the platform.
 The substation auxiliary supplies are 100kVA 33/0.4kV 3 phase distribution type transformers and
are fed from the 33kV busbar via drop-out fuses. There is one on both sides of the 33kV bus section
isolator.
 There is a control building which houses a two-sectioned 11kV switchgear panel, 33kV control
panels, a store room, a toilet as well as the battery room.
 There is also one lightning mast as well as a telecoms mast.
 The only yard lights present is currently mounted against the building one of which is missing.
 The Roma and Liverpool feeder bays are equipped with overhead line termination gantries which
are not used anymore as their respective supplies are cabled.
 The proposed feeder bay is indicated in red in Figure 9.
Figure 9: Single line diagram of Matero substation

11.2 Substation construction plan

The scope of the task is expected to be completed without compromising on worker safety and least number
of outages. To minimise the impact on the existing substation operation the construction is proposed to be
completed as indicated in Figure 10 as follows:
 De-energise the north-eastern section of the 33kV busbar by opening and locking out the Roma
feeder.
 Open and lock out the bus section isolator.
 Close the 11kV bus section to keep the Matero West, Matero East, New Lilanda and National Heros
No 2 feeders energised for the duration of the work.
 Do 33kV busbar modification.
 Install the new Mungwi 33kV feeder as indicated.
 Connect to overhead lines by means of cables.
Figure 10: Matero Substation construction plan

11.3 Scope of work
The scope of work described in this report is a preliminary design and, accordingly, all estimates and
projections contained herein are based on limited data availability. Therefore, while the work, results,
estimates and projections herein may be generally indicative of the nature and quality of the project, they are
not definitive.
The prospective bidder must study the documents and drawings and ensure sufficient allowance is made for
material and labour to complete the installation. It is important to note that the scope of work is design, supply,
installation and commissioning, up to final handover of the fully functional substation, properly integrated
into the Lusaka Transmission and Distribution network.
11.3.1 SUBSTATION CIVIL WORKS

With reference to Figure 10 the following civil works is required:
 Remove and set aside for later use the yard stone in the affected areas.
 Design, supply and install foundations for all new equipment.
 Design, supply and install steelwork for all new equipment.
 Design, supply, install and connect all new equipment to an earth grid and connect the newly
installed earth grid to the existing substation earth grid.
 Construct control cable trench to match existing, complete with covers from the new equipment to
existing trenches as indicated GA drawing 111233-0000-DRG-EE-GA-0002.
 Dismantle and remove the north-eastern section of the affected busbar.
 Remove the outermost busbar support on the north-eastern section completely and install
foundation and steelwork for new busbar support structure.
 Install new busbar for new feeder bay with the correct combination of fixed/sliding clamps.
 Design, supply and install one 14m lighting / lightning mast.
11.3.2 PRIMARY PLANT

Supply and construct complete with foundations, steelwork and equipment, the following:
 One complete new 33kV feeder bay consisting of
o One single side break busbar isolator to match existing.
o One combined circuit breaker and CT structure.
o One double side break line isolator.
o One combined cable termination, surge arrestor and VT structure.
 Install yard lights on new and existing lighting / lightning masts including all fittings and power
cables from AC distribution board.
 Install new light fitting against the building to match existing.
 Install equipment labels and new safety and information signs for the entire substation as per the
specification.
Following the successful commissioning, supply as-built drawings, maintenance manuals, cable schedules
and other necessary drawings, as applicable, including software copies in AutoCad format (three sets of each).
11.3.3 PROTECTION, CONTROL AND TELECOMMUNICATION EQUIPMENT

 LTDRP SCADA Detail Design Specification
 LTDRP Telecommunication Detail Design Specification
 LTDRP Protection Detail Design Specification
 LTDRP Decommissioning Specification
11.3.3.1 Protection
 One new 33kV feeder protection panel matching existing panel to be installed. All integration into
the existing protection system is part of the scope.
 All primary and secondary cable work is included.
 All affected protection to be re-commissioned.
11.3.3.2 SCADA and Telecommunications

 The complete new feeder bay shall be integrated into the existing SCADA and telecommunications
systems. It is the responsibility of the contractor to determine, supply, install and commission all
necessary equipment to facilitate the full functionality of the SCADA and telecommunications
systems.
 Recommissioning of the necessary SCADA and telecommunications systems form part of this
contract.
 The Contractor will be responsible for the integration of these schemes to a fully functional status
and to the current level of functionality and performance.
11.3.3.3 Other
 Supply 33kV Tariff Metering for the new feeder bay.
 Supply the new 33kV feeder protection panel control panels from the existing AC/DC distribution
panels.
 Supply and install all necessary current transformer and voltage transformer junction boxes with
terminals as well as all necessary multicore control and small power cables including terminations.
 Factory acceptance tests (FATs), witnessed by three engineers of each discipline (protection,
SCADA and telecommunications) as the representatives of ZESCO shall be conducted according
to the specifications. Sufficient time should be set aside for a thorough FAT. As far as practically
possible, the protection and control scheme FAT will be conducted together with the SCADA
system FAT.
 Site Acceptance Tests (SATs) and local and overseas training to be provided for by the contractor
as detailed in the specifications. These tests and training will be applicable to all the equipment
supplied under this contract.
schedules and other necessary drawings, as applicable, including software copies in AutoCad
format (three sets of each).
B. SPECIFICATION
The Specification for this Lot corresponds to the tasks in the Scope of Work. It contains standard details on
any possible ZESCO related equipment and works. Functional requirements for design and construction are
described below, which must be read in conjunction with the ZESCO Standard Specifications (Section VII
Works Requirements – Supplementary Information) and Technical Schedules (Section X Contract Forms).
12. REFERENCE STANDARDS
The design shall be in accordance to the latest version of the local ZESCO codes & standards, British
Standards (BS) or relevant IEC standards listed in the table below:
NB: In the absence Local codes and standards, British Standards (BS) or relevant IEC standards shall take
precedence. Where there is any conflict between the requirements of the Specification and the Specification
of Equipment, then the Specification shall take precedence. Where there is any conflict between the
requirements of this Specification and International Standards, then this Specification shall take precedence,
unless otherwise agreed to, in writing, by the Engineer.
12.1 ZESCO SPECIFICATIONS
VOLUME 1
SP - CSS - 000 CIVIL WORKS

1 SP - CSS - 001 Civil Works Substation General
2 SP - ECA - 001 Cables and Accessories
3 SP - ECA - 002 Cable Joints
4 SP - ECA - 003 Installation of small wiring & Trunking
5 SP - ECA - 004 Power Cable Installation
6 SP - ECO - 001 Overhead line & Earth Conductor
7 SP - ECO - 002 Aerial Bundled Conductors
SP - EIN - 000 INSTRUMENTS ( IN )
8 SP - EIN - 001 Metering Equipment
9 SP - EIN - 002 Credit Dispensing Units
10 SP - EGE - 001 Small Power Distribution Unit (Ready Board)
SP - ESC - 000 SYSTEM CONTROL
11 SP - ESC - 001 SCADA System for Regional Control Centre
SP - ESG - 000 SWITCHGEAR ( SG )
12 SP - ESG - 001 Unit Substation Switchgear
13 SP - ESG - 002 Surge Arresters
14 SP - ESG - 003 Pole Mounted Equipment
15 SP - ESG - 004 Auto Recloser (Pole Mounted)
16 SP - ESG - 005 Distribution Pillars, Fuses and Fuselinks
17 SP - ESG - 006 33 kV Outdoor Switchgear
18 SP - ESG - 007 33kV & 11kV Metal Enclosed Indoor Switchgear
19 SP - ESG - 008 Control Relays & Ancillary Equipment
VOLUME 2
SP - ESS - 000 SUBSTATION GENERAL ( SS )

1 SP - ESS - 001 Substation Auxiliary’s
2 SP - ESS - 002 Unit Substations
3 SP - ESS - 003 Substation Earthing - Lightning Protection & NER
4 SP - ESS - 004 11kV & 0.4kV Reticulation System Earthing
SP - ESU - 000 SUPPORTS ( SU )
5 SP - ESU - 001 Supports and Foundations
6 SP - ESU - 002 Wood Pole Supports
7 SP - ESU - 003 Tubular Steel Poles and Ancillary Equipment
8 SP - ESU - 004 Overhead line Insulators
9 SP - ESU - 005 Stays
10 SP - ESU - 006 Installation of 0.4-33kV OHL & ABC System
SP - ETR - 000 TRANSFORMER ( TR )
11 SP - ETR - 001 Distribution Transformers
12 SP - ETR - 002 Power Transformers
13 SP - ETR - 003 Current & Voltage Transformers
14 SP - GGE - 001 General Technical requirements
15 SP - GGE - 002 Works & Site Tests for S/S Equipment
16 SP - GGE - 003 Unit Substation Installation
17 SP - GGE - 004 Drawings/Operations & Maintenance Instructions
19 SP - GTE - 001 Test Equipment
20 SP - GTO - 001 Tools and Equipment
21 SP - GVE - 001 Vehicles Trucks Tractors & Portable Equipment
22 SP - GVE - 002 Cable Test and Fault Location Vehicle
23 SP - GVE - 003 Mobile Insulating Oil Treatment Plant
12.2 IEC STANDARDS
No Title Reference

1.5 IEC 60156
power frequency
1.9
1.18 IEC 60289
Coil
1.20 IEC 60422
1.22 Electrical Equipment for the Analysis of Free and Dissolved IEC 60567
Gases

2.2 IEC 62271-100:2011
No Title Reference

High-voltage switchgear and control gear – Part 103: Switches
3.2 IEC 62271-103:2011
for rated voltages above 1kV up to and including 52kV
3.3 IEC 62271-104:2015
current switches for rated voltages higher than 52kV
3.4 IEC 60168:1994

4.3 IEC 60168:1994

Instrument transformers – Part 4: Capacitive voltage
5.3 IEC 61869-5:2011
transformers

Surge arresters – Part 4: Metal-oxide surge arresters without
6.2 IEC 60099-4:2014
gaps for AC systems
6.3 IEC 60168:1994
6.4 voltage >1 000V – General definitions, test methods and IEC 62217:2012
acceptance criteria
12.3 BRITISH STANDARDS
No Title Reference
1. GENERAL
12.4 EUROPEAN STANDARDS

No Title Reference
1. GENERAL
1.1 EN 413-1
conformity criteria
13. PERSONNEL REQUIREMENTS

requirements:

No. Position Experience - minimum Experience
minimum (years) (years)
must be professionally registered as a project manager at an international recognised institution. Certified
copies of this registration need to be submitted with this Bid.
Monthly Progress Meetings will be held on site and must be attended by at least the Contractor’s
Representative and the Site Manager. The Contractor’s Representative will be duly authorised to make
decisions on behalf of the Contractor.
It is a specific requirement that the Contractor’s Representative, Site Manager and Safety Official must be
fluent in English and the language of the Contractor's personnel. The above shall be in accordance with the
General Conditions.
14. REQUIRED DOCUMENTATION SUBMISSION

The successful Bidder will be required to submit the following information during the execution of the
contract for approval as a minimum requirement:
No. Position
Detailed project schedule showing all planned activities including starting and completion dates for:
b. Data Collection
c. Design
d. Design Approvals
e. Procurement,
1
i. Construction
k. Handover.
Detailed designs and drawings for substations, switching stations and associated plant including the
following:

2 b. Site Layouts
e. Clamp schedule
f. Structural steel layouts
No. Position
g. Earthing Designs
h. Sections
i. Lighting Layouts
j. Lightning layouts.
k. Fire protection designs
l. Control Building layout
m. Cable trenches
n. All relevant protection and metering designs
o. All relevant SCADA, Telecommunication and Substation automation designs

3 d. Foundations designs
e. Earthing designs
h. Protection settings
Submission and approval of Technical details for all equipment listed in the Technical Schedules prior
4
to ordering.
5 Geotechnical studies and soil analysis of substation site area.
15. 33KV OVERHEAD LINES

30 years.

clad steel wires.
15.2.1 Stranding
15.2.2 Grease
15.2.3 Lay ratio

15.2.4 Drum length

15.2.5 Tests
of completion.
at tender stage.

erected. Drums shall be marked with the length of conductor on the drum and also with an arrow to show the

Steel conductors shall be galvanized steel strand of the type 19/2.64 (UTS of 113kN) complying with BS 183
Grade 700. Steel conductors and their associated fittings shall be tested in the manner specified for
conductors, and the breaking load shall not be less than 95% of the steel conductors breaking load.
15.4 SPECIFICATION FOR SILICON RUBBER INSULATORS

responsibility.
accepted.
IEC 60305.

paragraphs.
15.5.2 Galvanizing
The preparation for galvanising and the galvanising itself shall not adversely affect the mechanical properties
of the coated material.



When properly applied such repair sleeves shall achieve 95% of the ultimate strength of the conductor, when
2.

15.5.7 Stay wire

load.

6mm.

15.5.10Armour rod
No armour rods are required were stand-off insulators are used to suspend jumpers at strain poles. Take note
that the correct clamp must be used to secure the jumper to the suspension insulator as the sizes will be
different than the size used to clamp the conductor and armour rod at normal suspension poles.
16. 33KV SINGLE CIRCUIT WOODEN POLE STRUCTURES
16.1 GENERAL
 All 33kV distribution networks are to be constructed according to the Lusaka distribution
rehabilitation specifications provided. It shall remain the responsibility of the Contractor to verify
such drawings to his satisfaction. The Employer accepts no responsibility for the completeness,
correctness or adequacy of any tower drawings provided.
 Changes in structure configurations shall be reviewed and accepted by the Employer prior to
installation.
 The Contractor shall be fully responsible for his designs and their satisfactory performance in
service.
 Acceptance by the Employer does not relieve the Contractor of responsibility for the adequacy of
the design, dimensions and details.
16.2 WOODEN POLE STRUCTURES
 Wooden poles shall typically be 14m with a 195-225mm pole top diameter and must have a fibre
strength of 55MPa for pine poles and 63MPa for eucalyptus poles and shall be planted 2.2m deep.
 The top shall be cut square to the longitudinal axis of the pole.
 The poles shall be pressure impregnated and shall not be cut to a shorter length or smaller diameter
after impregnation. The moisture content at the time of impregnation shall be less than 170g/kg.
 Retention and penetration requirement.
 Poles shall be fitted with gang nail or 4 turns of 2.5mm galvanized steel wire on each end.
 Poles shall not deviate from straight to a greater extent than specified in BS 1990:1984.
 Poles shall be marked in accordance with Zesco specification SP-ESU-006.
 All drilled holes shall be treated on site with creosote prior to installation of hardware.
 Holes will not be drilled within 150mm from the end for Pine poles and 100mm for Eucalyptus
poles.
16.2.1 Wooden pole earthing requirements

 The 33kV lines will be constructed with shield wires. On the intermediate structures the earth wire
is supported by the pole through a reel insulator and galvanized bolt assembly. The shield wires
must be earthed at both poles of each H-pole structure by bonding the shield wire to a down wire
with an appropriate clamp. The down wire is then fixed against the wooden pole every 500mm
with a galvanized U-nail. Because steel cross arms are proposed it is not required to bond all metal
parts. The down wires must just be bonded to the steel cross arm.
 For wooden cross arms, bind all metal parts of the intermediate structure together with galvanised
steel wire and bonding clips and bond to the down wires. Extend the galvanized steel wire up to
the bottom of the pole fixed thereto every 500mm by means of galvanized steel u-nails.
 Where the 33kV cable terminates onto the 33kV overhead line as indicated in Figure 14, the sheath
of the cable is to be bonded to earth plus a distribution class surge arrestor is to be connected from
each phase to earth. The surge arrestor installation will be accompanied by an outdoor cable
termination and support system consisting of typically two or more sets of horizontally mounted
steel cross-arms. For wooden cross arms the surge arrestors will be interconnected by means of a
25mm² BCEW. With reference to Figure 15 the earthing of the surge arresters will be by means of
a 25mm² PVC insulated copper conductor terminating onto a 4 x 1,2m copper cladded counterpoise
earth rod installed a minimum of 500mm below ground level. The counterpoise legs must be 5m
each of 25mm² BCEW to achieve an earth of 30Ω or less.
 As a result of the stays present on all strain structures, BIL down wires are only required from the
top of the pole to the cross arm. The stay would serve as a down wire. If steel cross arm are used,
bond the shield wires to the cross arms. If wooden cross arms are used, bind all metal parts of the
structure together with galvanised steel wire and bonding clips. All stays must be provided with
stay insulators with a BIL of 300kV. This is typically fibre glass rod type.
 All earthing terminations to be made with compression lugs or bolted clamps. Copper conductor
with a minimum cross-sectional area of 16mm² to be used for earthing leads and bonding
conductor. Earth rods to be 16mm Cu plated.
 Care must be taken when connecting dissimilar metals together.
16.2.2 Intermediate structures

With reference to
Figure 11 a typical intermediate structure.
 The structure has a horizontal configuration by means of a single 4.1m steel angle cross arm fixed
to two 14m poles by means of bolt assemblies. The poles are planted 2m apart.
 Suspension insulators and associated hardware must be 120kN.
 All exposed steel hardware must be galvanized.
Figure 11 : Typical Intermediate Structure
16.2.3 Strain structures

With reference to Figure 12 a typical strain structure.
 Strain structures will be horizontally configured, bisector stayed H-pole structures with double
 For long sections of line, an in-line strain with stays shall be placed at distances not greater than
1.5km to prevent cascading of poles.
Blue.
Figure 12 : Typical Strain Structure
16.2.4 Terminal structures

With reference to Figure 13 a typical terminal structure.
 Terminal structures will be horizontally configured inline stayed H-pole structures with double

Blue.
Figure 13 : Typical Terminal Structure
16.2.5 Cable termination structures

With reference to Figure 14 a typical cable termination structure.
 Figure 14 indicates a cable termination on a vertical structure. The cable termination structures
under this project will be from horizontal configured H-pole structure as indicated in Figure 13.
 Where the jumper conductors might go under clearance it must be fixed to the structure by means
of a post insulator support assembly which will include the post insulator, spindle and conductor
ties.
 The jumpers onto the surge arrestor will be the same as the phase conductor.
 The earthing of the surge arrestor installation will be done as indicated in Figure 15.
Figure 14 : Typical Cable Termination Structure
Figure 15 : Surge Arrestor Earthing Installation
16.2.6 Stays and anchors

With reference to Figure 16 a typical stay assembly.
 Stays to have a 114kN ultimate load.
 Holes for conventional stays may be dug by hand, augured by machine or dug with a back-actor.
 No stays shall be planted without the relevant stay plates fitted onto the stay rod.
 Steel stay wire shall be in accordance with IEC 60888:1987: Zinc-coated steel for stranded
conductors.
 A rectangular stepped hole shall be dug so that the length of the hole is in line to the projected line
of the stay wire.
 The hole shall be large enough for the stay plate to fit in, with minimum dimensions of 2m long,
1m wide and 1,950mm deep.
 Once the hole is dug, the front face of the lower step shall be undercut to accommodate the stay
plate. An 80mm wide slot shall be cut in the steps at 45° to allow for the stay rod.
 The stay plate shall be placed up against undisturbed soil on the pole side of the hole. The hole
shall be backfilled and compacted/rammed in maximum 150 mm layers. In poor soil areas, a 1:10
cement/sand mixture to be used for backfilling.
 Stay rod to protrude 150mm above ground level.
 Stay rod diameter to be M20 with a minimum length of 2,500mm.
 Stay plate to be 440mm x 440mm and 10mm thick.
 Stay wire to be 19/2.64 galvanised steel wire.
 The amount and layout of stays installed for strain structures shall be as per the contractor’s design.
 If hanging free, the stay insulator must not be closer than 4m to natural ground level.
Figure 16 : Typical stay assembly
16.2.7 Hardware assemblies for attachment of phase conductor assemblies

 All hardware used must be a minimum of 120kN for the 33kV line.
 See standard Zesco drawings for more details.
a) Suspension assemblies
Figure 17Figure 17 Shows a typical suspension assembly for wooden H-pole structures. Please take note that
the glass discs will be replaced by a composite insulator.
Figure 17 : Typical suspension assembly for wooden H-poles
b) Strain assemblies
Figure 18 shows a typical strain assembly for wooden H-pole structures. Please take note that the glass discs
will be replaced by a composite insulator.
Figure 18 : Typical strain assembly for wooden H-poles

17. 33KV MULTI CIRCUIT SELF-SUPPORTING STEEL

MONOPOLE STRUCTURES
17.1 GENERAL
The following structure types are included in this specification:
 Double or triple circuit self-supporting intermediate structures (flanged);
 Double or triple circuit self-supporting terminal structures (flanged);
 Double or triple circuit self-supporting angle strain structure (flanged);
17.2 DEFINITIONS
The expression span lengths shall be taken to mean the horizontal distance between the centre lines of adjacent
structures.
The ground clearance is the minimum distance between the conductor and ground level in a span with the
conductor at its maximum design temperature.
The equivalent span is the calculated span length for tensioning a multiple span section such that the tension
of the equivalent span may be used for tensioning the whole section.
The upward vertical load imposed by the conductor at a support resulting from the gradients to the adjacent
spans is called the conductor uplift (minimum weight span).
The electrical clearance as specified is the separation distance between conductors based on the minimum
distance allowing for mid-span swing.
The maximum span is the maximum permitted length of any span for the conductor spacing adopted.
The sag is the maximum vertical distance between a conductor’s lowest centenary curves that spans between
supports and a straight line joining the conductor’s points of support.
The weight span is the horizontal distance between the lowest points of a conductor on either side of the
support. The lowest points of the catenary curves of both adjacent spans can be on the same side of the
support at steeply sloping terrain
The horizontal load imposed by wind pressure acting at right angles to any element of the overhead line is
called the wind loading.
The wind span is the sum of half the wind loading on each of the two adjacent spans i.e. the horizontal distance
between the points at mid-span on each side of a support.


Ambient Temperature
Absolute Max. 45ºC
Absolute Min. 2ºC
Relative Humidity
Maximum 86%
Minimum 39%
Hail Occasional
17.4 TEMPLATING
The contractor shall optimise each line in terms of span lengths and structure heights.
The templating of the line on the provided route and acquired ground profile (as described in the Specification
for Construction Activities) will be done prior to any ordering of material or construction commences. The
line templating is part of the design work and shall be provided together with all other design drawings for
approval to the Engineer.
Standard Engineering design procedures shall be used to determine the sag and tension profile for the specific
transmission line. The following is applicable to the conductors under the conditions stated.
Sag shall be calculated under the following conditions:
Table 2 : Sag reference temperature
Sag reference temperature Title

Maximum design sag temperature: As per service conditions
Minimum operating temperature: As per service conditions
The maximum tension in the conductor shall not exceed 40% of the breaking tension at the minimum
temperature as defined in the environmental conditions and maximum wind load, and simultaneously shall
not exceed 20% of breaking load at average daily temperature of 15°C without wind except for sections with
extra-long spans where compliance with the specified maximum working tensions under the assumed
maximum loading conditions may necessitate a lower figure for the 15°C still air tensions.
All specified safety clearances to ground and other structures should strictly be adhered to.
When a conductor breaks, the adjacent suspension insulators will swing away from the broken conductor
span. The insulator string becomes part of the catenary of the span adjacent to the broken span and results in
that span’s sag increasing. The sag should adhere to all the required safety clearances.
Every structure supporting a crossing span shall be designed in such a manner that it will be able to withstand
the loads that may be imposed upon it should a breakage of any phase conductor or earth conductor occurs.
As far as is reasonably practicable, every structure supporting a crossing span shall be located so that it will
not touch the crossed service if it falls over but also shall be located as close to the point of crossing as is
reasonably practicable.
17.5 PROFILE DRAWINGS

The contractor shall supply two hard copies and an electronic copy (in DXF format) of the line templating
drawings. The hard copies shall be plotted on a suitable scale on A0 paper and overlap such to ease continuity
between sheets. The electronic copy’s scale shall by 1:1 in the specified survey coordinate system.
The following information shall be indicated on the strip plans:
 All relevant features such as fences, cadastre information, tracks, rivers, watercourses, pipelines,
telecommunication circuits, power lines, railways, dwellings and any other obstructions.
 All features mentioned shall be accurately shown over a strip 30m wide centred on the centre line,
and generally outside this strip up to such as a power line or any other high object or structure.
 The angle of crossing, with the width of the feature to be crossed, shall be shown in the case of
railways, power lines, roads and telephone circuits.
 The strip plan shall be continuous even where the route traverses long featureless sections.
 Vegetation types shall be identified as far as possible by referring to the density of vegetation, i.e.
scattered, light, medium, dense bush, or cultivated land.
 Any areas of soft sand, marsh, or flooded ground shall be shown as these may be unsuitable for
placing structures.
 Angles of deviation shall be shown, and each angle point shall be the start of a new section for
representation and section chainage purposes.
 Positions of structures indicating their type and coordinates.
 Stringing chart at various ambient and stringing temperatures for ease of use on site indicating
initial sagging information per span.
 Conductor installation chart indicating proposed positions of conductor mid span joints.
On the strip plan the centre line of the overhead line shall be represented by a thick line at the bottom of the
profile sheet running continuously between consecutive angle points or terminal points.
The profile shall be drawn above the plan and is to correlate to the features on the strip plan. An arbitrary
datum may be used. Information on the profile shall include:
 The ground profile shall show the elevation above the chosen datum and shall include two
horizontal lines associated with the datum, the first uppermost giving the section chainage
increasing along the route of the line between bend points. The second and lower line shall contain
the total chainage between the start and finish of the line.
 Elevations shall be recorded above the chainage.
 The minimum required safety clearances over all obstacles.
 The expected initial sagging at both the minimum and maximum temperatures.
 The expected final sagging at minimum and maximum operating temperatures.
 Where the treasury ground slope exceeds 1 in 10, levels are to be shown on the profile at 10 metres
from the centre line, as dotted lines either side of the centre line, indicated left and right on the
elevation in the forward direction of the profile.
Where existing services (roads, telephone lines, railways, power lines etc.) are crossed a cross-section
drawing of the proposed crossing shall be provided on the strip plan at the relevant crossing.
17.6 LOADING TREES

Loading trees will be in accordance with SANS 10280-1:2013 paragraph 3.2 Simplified method using the
design wind speed as specified in section 17.3 Site ambient conditions.
17.7 STEEL MONOPOLE STRUCTURES

All monopoles must be self-supporting. The strength of the poles must be calculated according to the
following inputs and must reflect in the schedule of rates:
 Wind span : 250m
 Weight span : 450m
17.7.1 Triple circuit structure

The proposed triple circuit steel monopole structure will be as indicated in Figure 19.
Figure 19 : Typical triple circuit steel monopole

17.7.2 Double circuit structure

The proposed double circuit steel monopole structure will be as indicated in Figure 20.
Figure 20 : Typical double circuit steel monopole
17.8 JOINTS
Flanged and slip joints should be aligned such that there is minimum pole deflection around the joint
17.9 SLIP JOINTS

The overlap section of a slip joint shall be at least 1.5 times the top diameter of the male section. In the case
of a non-uniform cross section pole, the overlap section of the slip joint shall be at least 1,5 times the largest
top diameter of the male section. Female slip joints shall have rapping plates on seams to avoid splitting.
The slip length shall not differ more than 50mm from the designed slip length.
17.10 FLANGED JOINTS

Flanged joints shall be manufactured with a jig set up in the manufacturer’s workshop to ensure squareness
of the flange onto the pole. Mating faces of cross-arm flanges shall be square to ensure surface contact on
assembly. One set of 10 off x 0.5mm thick finger packs shall be supplied with each batch of 10 poles for
slight pole adjustments. These packs shall be of such a nature that they can be installed without unbolting
flanges.
17.11 WELDS
Coded welding personnel shall perform all welding. Finished welds shall be smooth with no sharp edges.
Welds shall be of a strength that does not change the designed proof load, ultimate load or crippling load.
The ends of longitudinal welds shall be strengthened at slip joints on female sections to prevent splitting.
Butt welds shall have 100% penetration.
Seam welds shall have a minimum penetration of 60% except in the area of slip joints where 100% penetration
is required. The inside weld at the slip joint shall be ground back to ensure no obstruction when obtaining
the desired slip lengths.
All shaft circumferential welds and their associated sections of longitudinal welds and all longitudinal welds
for the female parts of a slip joint shall be full-penetration welds in order to achieve full base material strength.
The shaft shall be centrally welded onto the base plate. All shaft structural welds shall be performed with
submerged arc technology.
Cross-arm tubular sections shall be centrally welded onto the connecting flanges.
All fitting-related welding shall be performed with inert gas technology.
17.12 OPENINGS
If specified, openings (e.g. bolt-holes, slots etc) shall be made in the poles during the manufacture of the
poles. These openings may be required for the attachment of cross-arms and other equipment. All openings
shall be made before galvanizing or treating.
Bolt hole tolerances are as follows:
 6mm for foundation bolts.
 2mm for all other bolts.

Plates for insulator attachments shall be manufactured with keyholes and dimensions in accordance with the
supplied insulator details.
17.13 GALVANISING AND POLE TREATMENT

These structures will be used in all environments, from coastal regions to inland areas. All poles shall be hot
dip galvanised to ISO 1461 and shall have a minimum coating thickness as indicated in Table 3 therein.
17.14 DRAWINGS
The structure layout drawings are a guideline of what is required with regard to layout, attachment heights,
stay levels, wind and weight spans etc. The manufacturer shall ensure that designs and manufacturing are
suited to the structure required.
A set of manufacturing drawings is required for checking and approval purposes before manufacturing
commences.
A complete and correct set of as-built drawings are required for record on completion of the job.
17.15 TESTS
All tests are to be in accordance with IEC 60652: Loading tests for overhead line structures. One structure
for each structure type will be type tested, the length chosen for the structure will be the length with the largest
loads in the structure.
17.16 FINISH
The finished product shall have a smooth external surface free from steel splinters and welding splatter. All
surfaces shall be clean and shall present a neat appearance. All corners shall be rounded with no sharp edges.
17.17 DIMENSIONS
The overall lengths of the poles shall be determined by the contractor from the profile drawings. The actual
pole length shall not differ from the stated overall length by more than 50mm.
The base and tip diameters of the actual structure shall not differ from the designed diameter by:
 5mm for diameters up to 350mm
 1,5% for diameters over 350mm
Diameters at slip joints shall not differ such that the minimum required slip length is not obtained.
17.18 LADDERS/CLIMBING SYSTEM

Brackets for removable climbing steps, if applicable, shall be vertically spaced at 300mm and configured
such that the climber has a comfortable climbing path. The brackets shall permit easy installation of
removable steps without becoming trapped or wedged into the brackets.
Brackets welded onto the structures for propriety system, if applicable, shall suit the spacing of the ladder
brackets. The ladder supplier shall be consulted for attachment details. If this system is used on a structure,
the brackets on the structure shall start at approximately 9m above ground level. This lower portion shall be
accessed by means of a standard ladder and will prevent unauthorised persons climbing the structures.
Should a permanent ladder be required on the structure, the ladder shall be supplied loose and bolted onto the
structure on site. This will ensure that no damage is caused to the ladder during transportation.
17.19 STRAIGHTNESS TEST

Straightness shall be taken as the maximum distance measured between the centre-line of the faces of the
pole being measured, at any point along the length of the pole, to a line drawn from the centre of the tip of
the pole to the centre of the butt of the pole. The measurements shall be done on at least two faces of the pole
which are at 90° to each other. Measure, to the nearest 5mm, the deviation from straight.
17.20 STEEL REQUIREMENTS

The minimum thickness of the steel used for manufacture of poles shall be 4.5mm or larger unless specified
in the data schedules. The steel used shall be grade S355JR in accordance with EN 10025. If different grades
of steel are used for manufacture these must be approved by the employer before manufacturing commences.
The manufacturer shall ensure that mill certificates are available and traceable to structures manufactured.
All bolts used shall be grade 8.8 bolts. No electroplated bolts will be permitted.
17.21 ULTIMATE LOAD TEST

The ultimate load test shall be completed on all structures being tested and shall be executed once the working
load tests are done. The ultimate loads indicate the loads the structure will carry including factors of safety
as specified. Tests shall be carried out on strong and weak planes of asymmetrical poles. The tests need only
be completed in one direction on symmetrical poles.
The load shall be applied to the structure in increments of 10% up to 90% of the ultimate load, thereafter in
increments of 5% of the ultimate load until failure. This 100% load shall be held for 60 seconds before being
released. Deflection readings shall be taken whilst the load is being applied and once the load has been
released.
The structure shall withstand the applied loads for 60 seconds without failure of any component. Deflections
in excess of those depicted in the deflection requirements shall constitute the failure of the structure.
17.22 DEFLECTION REQUIREMENTS

The horizontal deflection for a structure loaded with safe working loads shall be no greater than 2.2% of the
total pole height. The permanent horizontal set allowed after application and removal of working loads shall
be no greater than 1% of the total pole height.
The horizontal deflection for a structure loaded with ultimate loads shall be no greater than 5.5% of the total
pole height. The permanent horizontal set allowed after application and removal of ultimate loads shall be
no greater than 3% of the total pole height.
17.23 MARKING AND PACKAGING

17.23.1 Marking
All structures and components to be uniquely identified with permanent marking which will enable the details
of the structure to be established at any time after assembly. All identification marks and structure-related
information are to be easily readable after the structure has been assembled. The following information shall
be clearly and indelibly marked with characters at least 20mm high and indented 1mm. This information
shall be 15m above the ground line on finished poles:
 the manufacturers name, trade name or trade mark;
 the overall length of the pole in meters e.g. “23m”;
 the ultimate load design e.g. “ UL = 23kN”;
 the crippling load (if applicable) e.g. “CL = 100kN”
The following information shall be marked on the pole and be in included in an erection procedure to be
issued with every batch of pole dispatch to site:
 the minimum and maximum slip joint penetration limits
 holding-down bolt torque requirements
 maximum axial slip-joint assembly load
 orientation of sections with respect to one another to be clearly and permanently marked
 pole/baseplate orientation with respect to the line to be identified
17.23.2 Packaging
All structures shall be suitably stacked to avoid damage during transport. Dunnage shall be used
between steel members to avoid these touching and damaging each other. No buckled, bent or twisted
structures and associated bracketry will be accepted on site. The manufacturer shall deliver to site, with the
structures, adequate quantities of Zinc-fix squish packs to patch small areas of damaged galvanizing due to
transport. Large areas of damaged galvanizing will not be accepted.
17.24 ACCEPTANCE CRITERIA FOR TESTS

The mast shall resist all working loads without showing signs of buckling or crippling. Any signs of member
buckling, signs of buckling onset, connection failure or deflections in excess of those of the deflection
requirements of this document shall constitute the failure of the structure
17.25 METHOD OF ERECTION

Ensure that a safe working area around the pole and the hole is maintained.
With the truck mounted crane, position the bottom, middle and top sections of the pole as close to the
foundation hole as possible.
Align the bottom, middle and top sections of the pole to slide into one another.
Ensure that the sections are as horizontally level in relation with one another as possible before start of
assembly.
These methods are only typical and must be adjusted to conditions on site.
Bottom section slinging:
 Using the slipknot/choke-hold method sling with 2 x 3m round nylon slings.
 Ensure lowest wrapping end is closest to pole section base.
 Ensure highest ends are below earth attachment-brackets.
 Attach 2 x D-shackles one at each end of the slings.
Figure 21: Strain monopole-horizontal assembly bottom section slinging
Middle section slinging:

 Using the slipknot/choke-hold method, sling with 2 x 3m round nylon slings.
 Ensure highest wrapping end is closest to pole section top.
 Attach 2 x D-shackles, one at each end of the slings.
Figure 22: Strain monopole-horizontal assembly middle section slinging

Attach a coffin hoist to each set of slings on opposite sides of the pole, ensuring that the coffin hoists are
primarily attached in-line, middle section to bottom section.
Figure 23: Strain monopole-horizontal assembly joining middle to bottom section
Measure the length of the pole and see how far the two sections must be pulled together to give the correct
length of the pole as indicated on engineers drawing.
Mark required slip distance of top pole with insulation tape.
With the coffin hoists, tension both sides equally until the two sections have slid together up to insulation
tape mark.
Manually manoeuvre the top section to assist with the sliding together of the sections.
Remove insulation tape after correct slip level has been achieved.
Follow the same procedure as above when joining the middle and top sections of the pole.
No structure shall be erected prior to a final inspection on the pole excavations and approval thereof by the
site supervisor.
Mono-pole structure erection will be subjected to the following criteria:
 All structures shall be erected vertically within 2mm in 1.0m in both transversal and longitudinal
directions. For the correct structure orientations in relation to the line direction refer to detail
drawings;
 During the structure erection, the tension in all stays shall be 10% (±2%) of the minimum breaking
strength of the stay wire, after all rigging equipment has been removed.
 All structures shall be properly cleaned prior to the erection thereof. Sand, mud and other dirt must
be thoroughly cleaned with nylon brushes.
 Structures should only be lifted into place at the identified lifting points as detailed by the design
and the manufacturer of the structures.
17.26 EARTHING
The following standards are applicable:
 IEC 60071 Insulation co-ordination — Part 1 to 3
 IEC 60815 Guide for the selection of insulators in respect of pollution conditions.
The total earthing resistance of the line shall be less than 3.5Ω with 60% of the poles having earth resistances
smaller than 20Ω. The earthing resistance of the poles for the first kilometre from substation shall be less
than 10Ω.
The shield wire shall be earthed to the substation earth.
The underground earthing for the towers shall only be finalised once the footing resistance tests have been
carried out. The required earthing electrode shall be determined from the footing resistance tests.
The terminal structures will be bonded to the substation’s main earth grid.
At all electrified railway crossing & metal pipelines, the line’s earth conductor will be isolated from the
structure for ±800m on both sides of the crossing.
The earthing of each structure must be done as indicated on drawing AUR-OHL-EAR-MP-001 as follows:
 Each structure shall have its own earth.
 The earth shall be concealed, i.e. earth connection to the pole is beneath ground level and no part
of the earthing system may be visible from ground.
 All terminal structures of the OHL shall be bonded to the respective earth mats of the substations
using a 30x3mm Cu bonding strap.
 Earth rods shall be 1,5m copper plated steel.
 Stranding of bare copper conductor shall be 7/1.67mm for 16mm² or 19/1.34mm for 25mm².
 The Contractor shall measure the resistance of every pole installation and submit the test
certificates containing the test results to the Engineer. A copy of the calibration certificate for the
measuring instrument must accompany the test certificate and should not be older than 6 months.
 All joints and connections will be done by means of exothermic welding and covered with
bituminous tape.
 Precautions shall be taken to prevent electrochemical reaction between dissimilar metals.
 The trenches shall be backfilled completely and immediately after the installation of the earth
rods/straps.
Should the earthing of the structures not be as is required, additional earthing can be installed in the form of
a counterpoise as follows
 A combination of horizontal radial and vertical earth electrodes shall be used and connected to the
structures.
 The design made provision for 6m crow’s foot for 70% of the structures.
 Crow’s foot earthing electrodes shall be as per AUR-OHL-EAR-MP-001.
The counterpoise can be further enhanced if required as follows:
 The first 150mm thick backfill layer in the earth trenches to consist of 1 part of agricultural gypsum
properly mixed with 3 parts of clean imported topsoil.
 The backfilling to be slightly watered and thoroughly compacted in layers not exceeding 150mm
in thickness.
 The final backfill layers to consist of clean excavated material from the earth trenches. The
backfilled material to be slightly watered and thoroughly compacted in layers not exceeding
250mm in thickness.
For earth trenches in rocky-terrain where the required earth trench depths can’t be reached:
 The backfilling of earth strap trenches in rocky areas where no proper trenching can be done, a
conductive mixture of carbonaceous aggregate (e.g. graphite, bentonite or any other approved
conductive mixture shall be used.
 A 3:1 sand/conductive cement mixture shall be used.
After the complete installation of a standard structure earthing system at all structures, the footing resistances
shall be measured by the Contractor and in situations where the measured structure footing resistance doesn’t
comply with the required 20Ω requirement, additional earthing systems shall be installed until the required
footing resistance are met or otherwise instructed by the Engineer.
After the complete installation of the additional earthing systems the relevant structure footing resistances
shall be re-measured by the Contractor in the presence of the Engineer and results shall be recorded at each
measuring attempt. Structure footing resistance records shall be submitted to the Engineer for evaluation and
acceptance.

30 years.

clad steel wires.
17.28.1 Stranding
17.28.2 Grease
17.28.3 Lay ratio

17.28.4 Drum length

17.28.5 Tests
of completion.
at tender stage.

erected. Drums shall be marked with the length of conductor on the drum and with an arrow to show the

Shield wires shall be OPGW equal to galvanized steel strand the type 19/2.65 (UTS of 113kN) complying
with BS 183 Grade 700. Steel conductors and their associated fittings shall be tested in the manner specified
for conductors, and the breaking load shall not be less than 95% of the steel conductors breaking load.

paragraphs.
17.30.2 Galvanizing



When properly applied such repair-sleeves shall achieve 95% of the ultimate strength of the conductor, when
2.

17.30.7 Stay wire

load.

6mm.
If the above required stay plate and stay dimensions are not size adequately to withstand the full load the stay
wire then an alternative larger specification can be proposed for approval.

17.30.10 Armour rod

No armour rods are required where stand-off insulators are used to suspend jumpers at strain poles. Take
note that the correct clamp must be used to secure the jumper to the suspension insulator as the sizes will be
different than the size used to clamp the conductor and armour rod at normal suspension poles
17.31 SPECIFICATION FOR SILICON RUBBER INSULATOR

responsibility.
accepted.
IEC 60305.
17.32 HARDWARE ASSEMBLIES

17.32.1Phase conductor assembly for intermediate structures
Figure 24: Phase conductor intermediate assembly

17.32.2Phase conductor jumper support on strain structure
Figure 25: Phase conductor jumper support assembly
17.32.3Strain assembly
Figure 26: Phase conductor strain assembly

17.32.4 Shield wire intermediate assembly
17.32.5 Shield wire strain assembly

17.33 SPECIFICATION FOR FOUNDATIONS

17.33.1Excavation definitions
Soft Ground shall mean ground that can be removed by hand tools and shall include loose ground, clay, made-
up ground, lose or soft shale, loose shale and any boulders less than 75mm in diameter.
Pickable ground shall mean rock that can be loosened by hand pick or crowbar and include hard shale,
compact shale, stone of similar hardness and boulders exceeding 75mm in diameter but not exceeding 0.3m3
in volume.
Hard rock shall mean granite, quarzitic sandstone, solid shale, slate and rock of similar or greater hardness
and boulders exceeding 0.3m3 in volume and can only be excavated by mechanical means or the use of light
charges subject to the consent of the Engineer.
Very soft ground shall mean ground which is of such a nature that causes the foundation excavation to
continuously cave in or fill up and where access to and from the excavations are difficult. This includes sand,
lime and clay including excavations in waterlogged areas.
17.33.2Soil types
17.33.3Foundation design loads

The ultimate simultaneous tower design loads shall be used for foundation design purposes. The foundation
loads thus calculated shall be further factored upwards for foundation design purposes by a load factor as
specified in the Table 3.
Table 3 : Structure type
Structure type Load factor

Self-supporting lattice / monopole 1.2
Guyed lattice / monopole 1.1
Guy anchor 1.3
The foundations shall in addition be designed for the most critical cases that would result from the occurrence
of the maximum permissible tolerance situations as listed above.
17.33.4Directly buried poles

The elongated side of the hole shall be in line with the conductors to limit the effect of wind loading on the
foundation. The foundation sizes shall be designed by the contractor’s civil engineer.
Manhole rings may be used for the installation of the poles. Poles may either be planted directly in the hole
dug and then soil compacted around the pole, or else manhole rings may be used to form the foundation for
the pole and compaction shall then be done around the manhole ring.
The pole shall be stayed temporarily with 4 stays until the foundation have cured enough to take the full
loading of the pole. The pole may only be strung-on 14 days after the foundation is completed.
All structures shall be vertical within a tolerance at the structure top of 0.3% of the overall structure height,
before erection of the conductors.
Poles shall not exhibit either twisting or bowing greater than the approved tolerances. After erection of the
conductors the vertical tolerance of the structures shall not exceed 0.5% of the height and the standoff
insulator transverse alignment shall be square with the line to within half the width measured at the cross-
arm end.
Suitable ladders shall be used whenever necessary during erection of the structures. All ladders shall be
removed when erection work is not in progress.
17.33.5Flanged poles/Pad and chimney foundations

The foundations shall be designed to withstand, with less than 20mm of differential settlement or
displacement, the maximum foundation reactions resulting from the withstand loadings stated in 17.33.3,
with the dead weight of the tower included at unity factor of safety.
The foundations shall be designed for the maximum combinations of compression, uplift and horizontal shear
forces. In addition, a 650mm maximum projection of the pier and stub above ground level shall be
incorporated in the design. The stub only is to be encased in concrete; the tower steel above the diagonal
members is not to be encased.
All concrete subjected to tension, where the permissible tensile stress is exceeded, shall be adequately
reinforced with deformed reinforcing steel bars. The maximum permissible tensile stress in the concrete shall
be 1.75MPa. Piers shall be reinforced for their full length with the reinforcing properly anchored in the pad.
The minimum number of longitudinal bars provided in a pier shall be four 12mm diameter bars with a
minimum yield stress of 450MPa. The links shall be 8mm diameter mild steel bars at a maximum spacing
equal to the smallest lateral dimension of the section, less 100mm.
Pads designed with a full 45° core may be utilised. All faces of such a core where the permissible tensile
stress in the concrete is exceeded are to be adequately reinforced to prevent the development of tension cracks.
After completion of the pad and chimney foundation, the foundation shall be left to cure for at least 14 days
before being subjected to and loads.
Flanged poles shall be lifted in place and bolted down on the bottom flange to the recommended torque in
accordance to SANS 10162.
17.34 SPECIFICATION FOR CONSTRUCTION ACTIVITIES

17.34.1General
Way leaves and right of access facilities, subject to the requirements of landowners and tenants will be
provided by the employer, but the contractor will be responsible for the provision of access routes or tracks
along the line routes to enable him to carry out the erection of the transmission line.
When the contractor is about to commence work on any property he shall be responsible to ascertain from
the engineer whether the servitudes are in order and give the occupier of such property adequate notice of the
commencement of the work.
If the contractor wishes to make a store on any property, he shall first obtain written permission to do so from
the occupier of such property.
All staff shall be provided with the necessary identifications indicating their employment by the contractor
and adequate supervision shall be employed to protect the interests of the occupier of the property.
When the contractor is about to carry out erection of the conductors or installation of earth electrodes or
counterpoise along or across public roads, telegraph or telephone lines, railways or across power lines he
shall be responsible for giving the requisite notice to the appropriate authorities of the date and time at which
he proposes to perform the work.
Where the local authorities and other public undertakings affected deem it necessary for the protection of the
public and the assistance of traffic, to provide flagmen or watchmen or installation of warning lights etc. The
cost of such provision shall be borne by the contractor.
The employer will pay for unavoidable damage to crops but the contractor shall at his own expense make
good to the reasonable satisfaction of the authorities, owners, and tenants concerned, all land, property, rods,
field drains, fences, walls, hedges, gates and the like which are damaged or disturbed during the execution of
the Works and shall remove all surplus material after erection.
During the progress of the work the contractor shall be entirely responsible for the proper fencing, watching
and lighting of excavations, dumps of material, ladders and the like and for the prevention and straying of
and damage to livestock until backfilling of excavations and permanent reinstatement of fences, walls,
hedges, gates and the like be completed. The contractor shall be held responsible for any injury to the public
and damage to livestock due, in the opinion of the engineer, to failure to comply with the above requirements.
In the event of any dispute or questions of damage or for the adequacy of provisions made for permanent or
temporary replacement or repair, the contractor shall at once inform the employer.
17.34.2Route
The contractor will be provided with a set of plans showing the routes of the transmission lines and any setting
out details which may be available. The contractor must gather information about conditions on site during
the tendering phase and price accordingly. The contractor will responsible to gather all information regarding
the ground profile along the route by either with the use of aerial surveying or ground surveying and
observations. The ground profile should be accurate enough to enable the contractor to design the line as
required by this specification.
The contractor will, subject to approval with the employer and an appointed surveyor, peg out all turn
positions for the contractor. The contractor will be responsible to verify and re-peg the turn points if required.
The terminal points at ends of each line will be indicated by the employer.
17.34.3Servitude Preparation and bush clearing

Although most of the servitudes are existing the contractor will be responsible for the preparing the entire
route for construction. This might include pruning or complete removal of trees where necessary along the
routes of overhead lines.
The contractor shall allow for the required bush clearing based on on-site evaluation prior to the closure. The
pruning and cutting of branches are to be included in the stringing rate and not included under the bush
clearing rate.
Where trees are to be removed, the contractor shall completely uproot the relevant trees and stack them in
position approved by the employer or engineer. All holes caused by such uprooting shall be filled in by him
to leave the site clean and tidy, all to the satisfaction of the engineer.
Utmost care shall be taken when uprooting trees, as the contractor will be responsible for all the claims due
to any damage and/or injury caused by such uprooting of trees. Where the branches of trees are to be pruned,
such pruning shall be neatly carried out in an effective and workmanlike fashion to the satisfaction of the
engineer.
Unless specifically indicated otherwise herein or on the accompanying drawing, tenderers shall allow in their
tenders for:
 The removal of trees, except shrubs, with trunks within a vertical plane parallel to and 5m from the
nearest conductor along the routes of all lines;
 The pruning of all trees branches, along the routes of all lines, in such a way that no branch will
project through a vertical plane parallel to and 3m from the nearest conductor, on the understanding
that such branches of which the highest points are below 4m above ground level need not be pruned
unless it is within 3m from any pole.
17.34.4Environmental
The contractor will be responsible to comply with all the local occupational health, safety and environmental
laws and legislations.
This includes all required documentation and must be financially catered for, with sufficient time and
planning allocated to environmental compliance measures.
17.34.5Pegging of structure positions

The contractor shall set out the route of the line determining the alignment of all structures as per the approved
design. The work shall be undertaken by competent surveyors who are familiar with the requirements and
working conditions. The contractor shall be responsible to ascertain the correctness of structure positions on
site according to the drawings and shall, where so required, re-measure and determine positions in conjunction
with the engineer.
The contractor shall notify the engineer to inspect the pegged route at least seven days before excavations
begin.
The contractor will also be responsible to set out all stays whether bisector or inline stays are required.
On completion of the contract, the contractor shall provide the engineer with as-build drawings as specified
elsewhere in this specification.
17.34.6Civil & foundations

17.34.6.1 General
All civil and foundation work will be done in accordance with:
 SP-CSS-001 Civil Works
 SP-ESU-001 Supports and Foundations

 IEC 61773:1996Overhead lines – Testing of foundations for structures
Foundations shall extend 1m above ground level at all structures running close to the mining areas due to the
high corrosive environment.
17.34.6.2 Foundations
Sample holes to be made and soil nomination and foundation designs to be done by the contractor’s certified
civil engineer. The contractor in conjunction with the engineer will approve the foundation type to be used
for each structure. The approval by the engineer of foundation installations shall not relieve the contractor
of this responsibility. Each foundation shall have a completed foundation record signed by the contractor’s
civil engineer, indicating that the soil was nominated and that responsibility is taken for the foundation
construction.
Limited soil analysis will be performed during pegging of structures. The results of which will be made
available to the contractor.
It shall be the responsibility of the contractor to ensure that a foundation record is filled out for each
foundation installed.
17.34.6.3 Excavation
The contractor shall make sure that no existing services are damaged during excavation.
At each structure position the contractor shall excavate, install the appropriate foundation and backfill the
excavation as required.
The contractor shall be responsible for ensuring that the subsoil at each foundation location is suitable to
withstand the design loading which will be imposed upon it by the foundation and shall be responsible for
any subsidence or failure of foundations due to insufficient care having been taken in the examination of the
soil or in the installation of the foundations.
Excavations shall be made to the full dimensions required and shall be finished to the prescribed lines and
levels. The bottom or sides of excavations upon or against which concrete is to be placed shall be undisturbed.
If, at any point in excavation, the natural material is disturbed or loosened it shall be filled with 10MPa
concrete. All excess excavation and over-excavation performed by the contractor for any purpose or reason
shall be at the expense of the contractor.
When the material at foundation depth is found to be partly a soil or material that is compressible, all
compressible material shall be removed for an additional depth of 200mm and filled with 20MPa concrete.
The excavations shall be protected to maintain a clean subgrade until the foundation is placed. Any sand,
mud, silt or other objectionable material which may accumulate in the excavation shall be removed at the
contractor's expense prior to concrete placement.
Where holes, deeper than 1.5m, are dug by hand special care shall be taken to ensure that there is shoring
available for the hole to prevent the hole collapsing. When no construction is taking place, or it is unavoidable
to leave the excavations open overnight, the affected holes must be effectively barricaded to ensure public
and animal safety. This is typically done by means of 1.5m steel or wooden droppers installed 2m apart and
1m from the edge of the excavation together with bright orange HDPE safety netting 1.2m high. Where there
is high traffic volume and pedestrians, small strobe light must be installed as part of the barricading.
17.34.6.4 Approval of excavations

It shall be the responsibility of the contractor to notify the engineer upon completion of the excavation for
foundations. No shuttering, reinforcing steel or concrete shall be placed until the excavation has been
inspected and approved by the engineer.
17.34.6.5 Backfilling
After completion of foundation installation, the contractor shall backfill each excavation with suitable
material.
of not more than 300mm before being compacted. In backfilling, the pad of the foundation shall be covered
The material to be compacted shall contain no stones more than 150mm in diameter, and be free from organic
material such as trees, brush, scraps, etc.
The material shall be compacted by mechanical compaction machines to a minimum of 90% of the density
of the undisturbed material. If required by the engineer, the contractor will test compaction to proof 90% has
been achieved.
The surface of the backfill around the foundation shall be carried to an elevation such that water will not
accumulate.
Material removed from the excavation, which is not suitable for, or is not required for backfill shall be spread
evenly over or adjacent to the site.
Where the excavated material is not suitable for backfill, the contractor shall stabilise the backfill material
with one part cement per ten parts of soil or as an alternative import select backfill material to the site,
provided the cost of select backfill does not exceed the cost of cement-stabilising the excavated material.
Where excavated material primarily consists of broken rock, shale, the contractor shall import select backfill
material.
17.34.6.6 Concrete works

The sand used shall be evenly graded concrete sand free from all debris and growth. The maximum size
stone to be used for all concrete works shall be 26.5mm. The maximum water to cement ratio shall be less
than 0.7.
the concrete. The concrete shall be mechanically vibrated once poured to ensure there will be no honeycombs
in the concrete and that proper compaction of the concrete is attained. Over-vibration of concrete will cause
segregation of the concrete and weaken it. The concrete shall not stand for periods of time and then have
water added to it to make it workable as it weakens the concrete.
If the outside air temperature is less than 5°C, concrete shall not be mixed or poured as the cold will cause
the water to freeze.
17.34.6.7 Aggregates
All aggregates shall be new, clean and free of weeds and roots. The aggregate grading shall be suitable for
concrete and within the aggregate curve of the mix design.
Class

nominal sizes:
5,000µm
92 – 100
4,750µm
90 – 100
150µm
5 - 25
percentage
2
percentage
darker than the colour of the
Organic impurities this requirement shall not be -
impurities.
Presence of sugar -
Soluble deleterious impurities the specimens made with the -
been washed, except that this
Class
Requirement
Property
Grading1), mass
percentage of
material that passes 75.0 53.0 37.5 26.5 19.0 13.2 9.5 6.7
sieves2) of nominal
aperture size, mm
75.0 100 100 100
53.0 0-50 85- 98-100
50.0 0-43 100 85-100 100
37.5 0-25 70- 15-55 90-100
28.0 0-7 85 0-50 85-100
26.5 0-5 0-50 0-28 15-55 100
20.0 0-28 0-25 0-50 90-100
19.0 0-25 0-7 0-28 85-100 100
14.0 0-7 0-5 0-25 15-55 90-100
13.2 0-5 0-7 0-30 85-100 100
10.0 0-5 0-28 15-55 90-
9.5 0-25 0-55 100 100
7.1 0-9 0-30 85- 90-100
6.7 0-5 0-25 100 85-100
5.0 0-7 25- 25-58
4.75 0-5 58 0-55
2.36 0-55 0-28
2.0 0-28 0-25
1.18 0-25 0-5
1.0 0-5 0-4
0-4
Dust content for
material passing
through a 75 µm 2
sieve mass
percentage
Aggregate crushing 29
value (ACV)3), of
Requirement
Property
less than 13,2 mm
and more than 9,5
mm fraction (dry),
mass percentage,
max.
10 % FACT value, of
less than 13,2 mm
and more than 9,5
mm fraction (dry),
kN, min.
17.34.6.8 Water
Water should be clean, free from chlorides, sulphates, other salts and organic matter. Potable water will
generally be suitable.
17.34.6.9 Reinforcing
Where reinforcing is required in the design, it shall be free of loose rust, grease and dirt. The reinforcing
shall be fixed with wire ties that are tightly bound to prevent any movement during the pouring of concrete.
Foundation bolts are to be the hooked kind and must be fastened properly before the concrete is poured.
17.34.6.10 Curing
Where concrete is exposed to the air, curing is required. The concrete shall be covered with a 50mm layer of
river sand and this shall be kept constantly moist for a period of seven days, or a plastic membrane shall be
placed over the exposed concrete and sealed. Curing compounds may also be used for curing permitted that
it is non-corrosive. These shall be approved by the engineer.
17.34.6.11 Construction / Temporary stays

The temporary stays will be the exact same specification as for the permanent kind
The contractor shall make provision for the sufficient quantity of temporary stays at all in-line and angle
strain structures, to ensure the stability and plumpness of the structures, as well as the safety of the contractor’s
workmen.
All temporary stays will remain intact and tensioned until completion of the stringing, regulating and
clamping activities of the phase conductors and shield wires.
The contractor can install temporary stays on the conventional method or alternatively pre-cast stay anchor
blocks per phase can be used.
For both situations, all temporary installed stays and stay anchor blocks must be completely removed from
site after completion of the stringing activities.
All excavations left from the removed conventional installed stay assemblies must be properly backfilled,
compacted and sites re-instated.
A maximum 45° with the horizontal or flatter stay installation angle is required for temporary stays, under all
circumstances.
17.34.7Hardware installation
17.34.7.1 Compression hardware
Only hexagonal compressions, of the “ALCAN” range, will be accepted. Only compression equipment
specified by tension clamp supplier shall be used. Compression equipment and operating personnel shall be
approved by the supplier to ensure the correct installation of the tension clamps. Proof thereof shall be
available on site at all times. The hydraulic tool, dies and fittings shall be designed for a minimum output
force of 890kN. All press equipment to be approved before use.
The conductor in use determines the specific size of the press and full tension clamp to be used. Compressions
to be made for the full area provided on both the aluminium and galvanised steel parts.
17.34.7.2 Vibration dampers

All calculations for the correct placement of the vibration dampers shall be provided to the engineer. The
IEEE Guide for laboratory measurement of the power dissipation characteristics of aeolian vibration dampers
for single conductors will be used for calculations.
17.34.7.3 Repair sleeves

In the case of local damage to isolated strands of a conductor during erection the use of repair sleeves of
approved type may be permitted under extreme circumstances at the discretion and specific approval of the
engineer. If approved the cost of the repair sleeve including transport and labour will be carried by the
contractor.
17.34.7.4 Stay assemblies

No permanent stays required as all structures will be self-supporting.
The stay type or size is not determined by the voltage of the line but by the size of the conductor used as well
as the load requirements. The number of required stays per structure should be determined by the maximum
load experienced by the structure.
Steel stay wire shall be in accordance with IEC 60888: 1987: Zinc-coated steel for stranded conductors
supported by BS183
Holes for conventional stays can be dug by hand, augured by machine or dug with a backactor. A rectangular
stepped hole shall be dug so that the length of the hole is in line to the projected line of the stay wire. The
hole shall be large enough for the stay plate to fit in.
Once the hole is dug, the front face of the lower step shall be undercut to accommodate the stay plate. An
80mm wide slot shall be cut in the steps at 45° to allow for the stay rod. This is essential as without this the
stay rod will cut into the ground during tensioning or after a good rain and cause the pole to lean or possibly
break.
The stay plate shall be placed up against undisturbed soil on the pole side of the hole and the hole shall be
backfilled and compacted as specified.
No stays shall be planted without the relevant stay plates onto the fitted end of the stay rod.
Stay rod assemblies shall be planted to ensure stays are at an angle of 45° and are more than 2m apart to
ensure adequate volume of loading soil on the base plate. Under no circumstances may stay rods be bent.
No damaged steel wires will be used. The direct tension with the specified safety factor will determine the
size of the steel wire as well as the number of stays used per structure.
All stay excavations and compactions shall be done as specified elsewhere in this specification.
The positioning of both the temporary as well the permanent stays on the ground shall be determined by the
contractor’s civil engineer and presented to the engineer for approval.
17.34.7.5 Armour rod

No armour rods are required where stand-off insulators are used to suspend jumpers at strain poles.
Helically formed armour rods to be used on all suspension clamp attachments, included in the trunnion clamp
assembly.
The size of the armour rods to be used at all suspension insulator assemblies shall be suitable for the conductor
used.
17.34.7.6 Jumpers
Jumpers, although not a specific item, are included in the contract.
The jumper conductor will be the same size as the phase conductor used on the line.
17.34.8Road, railway and telecommunication crossings

Where an overhead line crosses a proclaimed road, railway or tramway or a communication line, the
contractor shall comply with the clearance to the requirements as prescribed and shall further ensure:
 The deviation from a right-angle crossing shall be not greater than 30°.
 The supporting structures at the crossing point shall be labelled as required.
 That no mid span joints shall be permitted in the crossing span.
If, in addition, any special guarding of alternative construction is required, this and any material incidental
thereto shall be provided at prices to be approved. Unless otherwise approved, inline or angle strain structures
shall be installed on both sides of railway crossings.
At overhead line or telephone crossings where the line being surveyed crosses between two poles or
structures, the conductor heights of both lines shall be determined using appropriate calculation methods or
computer programs to ensure the safe crossing of these lines. The bottom line shall be templated at minimum
operating temperature and the top line at maximum operating temperature.
At railway crossings, the distance from the crossing point to the nearest railway identification mark shall be
recorded. This may be either a numbered railway telegraph pole or a ground distance marker, or other
identifiable feature.
All crossings shall be co-ordinated with the departments concerned.
17.34.9Stringing of conductors
The conductors and earth wires shall be pulled-up and tensioned according to "Code of Practice for Overhead
Power Lines for Conditions Prevailing in South Africa" as specified in the NRS 041.
Twin conductors or double circuit lines, where required, shall be strung simultaneously to ensure matched
sags.
Conductors and earth wires shall be strung to the design template approved by the employer. The contractor
shall provide suitable dynamometers, sighting rods or other approved apparatus necessary for the proper
checking of the work. Dynamometers shall be tested and if necessary re-calibrated if so required by the
engineer. Unless otherwise approved, after final erection and adjustment the sag in any span shall be to the
satisfaction of the engineer.
The equipment and methods used for stringing the conductors (including earth conductors) shall be such that
the conductors will not be damaged. All equipment shall be in excellent condition. Care shall be taken
always to ensure that the conductors do not become kinked, twisted or abraded in any manner.
The contractor shall make suitable arrangements for temporary staying of structures, and anchoring of
conductors when necessary. Conductors may not be anchored to any portion of any structure, except strain
structures and then only at the points designed for conductor attachment. Temporary anchoring to footings
and guy anchors will not be permitted. Where temporary anchoring is required, suitable temporary anchors
shall be provided. Installation and removal of temporary anchors will be the contractor's responsibility.
Running boards shall pass through blocks smoothly without hanging, catching or causing wide variations in
pulling tensions, damage to the blocks or over stressing of structures. The pulling line shall be a non-rotating
type, which will not impart twist or torque to the running board or conductors. Swivels shall be used to attach
the pulling line and conductors to the running board.
Tensions, while pulling, must be sufficient to clear all obstacles safely without damage to the conductor. At
no circumstances, shall the pulling tension exceed the tension shown on the sag charts. Pulling of more than
one drum length of conductor shall be subject to the engineer's approval.
Adequate protection shall be provided where there may be danger of a conductor being crossed over by
vehicles, or damaged by other equipment and objects. Conductors shall not be left in contact with the ground,
vegetable matter or any conducting or semi-conducting material. Wood lagging, or similar material shall be
used to protect the conductor when working at ground level.
The placement of tensioning and pulling equipment shall be such that the vertical angle of pull on a cross arm
or standoff insulator during stringing operations shall not be more than 20°. Conductors shall not be pulled
around angles which exceed 20°. With tandem-mounted blocks, the pulling angle shall not exceed 40°.
The sheaves shall conform to the conductor manufacturer's recommendation as to the diameter, and to the
size and shape of the groove for the size of conductor used. Sheaves shall have a minimum diameter of fifteen
times the conductor diameter at the base of the groove. Block surfaces which will be in contact with the
conductor, shall be coated with neoprene or rubber. This covering shall be kept clean and free of materials
which might damage the conductor surface.
The conductors, joints and clamps shall be erected using approved tools and shall be erected in such a manner
that no bird caging, over-tensioning of individual wires or layers, or other deformation or damage to the
conductor shall occur. Auxiliary erection clamps or haling devices shall be of approved design and shall,
under erection conditions, allow no relative movement of strands or layers of the conductors. Cutting of
layers of conductors shall be carried out with tools designed not to damage underlying strands.
Cropping or shearing of complete conductors shall not be permitted.
Unless otherwise approved, conductors shall be run under partial tension and erected by means of snatch
blocks and running blocks of approved materials and dimensions, at every intermediate structure and by other
approved means to reduce to a minimum contact between the conductor and the ground or other obstruction
during erection.
Under no circumstances shall any conductor be dragged along the ground.
The contractor shall also make any necessary special arrangements for running out and sagging the conductors
where the route crosses buildings, gardens or other grounds over which erection cannot be carried out in the
normal manner.
The contractor shall also make such special arrangements as the engineer may approve where power lines are
to be crossed.
No additional payments will be made for the erection of the line conductors over roads, railways and
communication circuits, or over or under existing power lines which have been dead for the time being.
The contractor shall include in his price for stringing, the pruning and cutting branches.
1.1 SPECIFCATION FOR LINE TESTS

The following tests are required:
 Such tests as may be required by the engineer to prove the load bearing capacity of foundations and
stay anchors;
 Continuity and resistance of the earth conductor;
 Structure footing resistance tests;

 Phase rotation;
 Continuity of OPGW and communications.
1.2 LABELS
With reference to Figure 29 the numbering of the structures will typically be as follows:
 Substrate will be a 1mm thick galvanized steel plate typically 1,260 x 120mm with three sets of
 Background will be bright yellow powder coating.
 The lettering will be 75 x 75mm and made from 3M Scotchcal.
 Each pole number will be strapped to the pole with three stainless steel straps, underneath each
circuit, and shall not obscure the number in any way.
With reference to Figure 30 the phase identification plate will typically be as follows:
 Substrate will be a 1mm thick galvanized steel plate typically 230mm in diameter with one set of
 Background will be bright red, yellow and blue powder coating.
 The lettering will be 150mm high and 100mm wide and made from 3M Scotchcal.
 The phase identification discs will be strapped to the pole with one stainless steel strap typically at
the first pole from the substation, and shall not obscure the number in any way.
Figure 29: Typical pole number
Figure 30: Typical phase identification plates

18. MATERO SUBSTATION EXPANSION


Ambient Temperature
Absolute Max. 45ºC
Absolute Min. 2ºC
Relative Humidity
Maximum 86%
Minimum 39%
Hail Occasional
18.2 PRIMARY PLANT

The detailed Scope of Work is given in the Scope of Work section of this document. All the designs,
equipment, material and construction works shall comply with the details as described in the following
sections of this document.
18.2.1 Insulation levels

The insulation levels shown in Table 7 will be applied to equipment installed for this project.
Impulse Creepage distance over external

System System 60 sec power Hz
withstand insulation
nominal highest withstand voltage
voltage
voltage ( kV) voltage ( kV) (kV) (mm/kV)
(kV)
33 36 170 70 25
18.2.2 Clearances
Minimum Electrical
Voltages Minimum Working Clearance in mm
Clearance in mm
To the nearest part, not
To Nearest
System Nominal System Highest Phase-to- Phase-to- at earth potential, of an
Unscreened live
Voltage Voltage Earth Phase insulator supporting a
conductor in air
( kV) ( kV) (mm) (mm) live conductor
(mm)
(mm)
33 36 320 320 2,750 2,450
18.2.3 Design fault levels

9.
18.2.4 Busbar, Conductor, Clamps and Cables

The existing 33kV busbar is a low-level configuration and consists of 80 x 6mm aluminium tubes installed
post insulator supports. The same will be used for the busbar extension. The busbar support clamps for the
entire north-eastern busbar will be replaced to make provision for expansion and contracting. Only one end
of each section of tubular busbar supports shall be equipped with a fixed clamp. Provision shall be made for
a sliding clamp on the other end of every section of tubular busbar. Tubular busbars shall be equipped with
Centipede conductor on the inside for 60% of the length of the tube and fixed on the one end of the with the
correct clamps and end caps for vibration damping purposes.
All stringing shall be done in accordance with the general arrangement and sections layout drawings as
described in the following sections. Jumpers shall be installed with an adequate loop to allow for shrinking
and expansion.
18.2.4.1 33kV Switchyard


Description
33 kV Line Bay 30 524 Flexible Single Centipede AAC 50 830
18.2.4.2 Clamps
All conductors shall be cleaned to a shiny finish with a steel brush at the point where the conductor clamps
are to be applied.
of gaps will be allowed. It is the contractor’s responsibility to ensure that clamps fit correctly on existing
equipment.
18.2.4.3 Cable Ratings

XLPE Single core copper cables shown in Table 11 are to be installed between cable termination structures
from the substation and the new 33kV lines.
Design Limit Rating

Proposed
Description Amp
MVA kV Amp Conductor/Cable MVA
In Ground
Between substation
1 x 33kV XLPE AWA Cu 1C
and line 33kV cable 36 33 629 35.5 620
500mm² per phase
termination structures
18.2.5 Specific requirements for 33kV switchyard bays

18.2.5.1 Feeder bays
transformers.
 No circuit-breaker side earth switches are allowed on isolators. Make provision for portable earths
and associated portable earth connections throughout.
18.2.5.2 Outdoor HV Circuit Breakers

charging shall be done by means of an 110VDC electric motor.
The circuit breakers shall be in accordance with the requirements of the latest revision of IEC 62271-100
edition 2, with SF6 gas insulation to IEC 40680. Testing of the circuit breakers shall be done in accordance
with the latest revision of IEC 60060-1 Edition 3.
Two tripping circuits and one closing circuit shall be provided and shall not share any common wiring.
External protection trip signal shall not be routed through the circuit breaker local/remote selector switch
while provision shall be made for local open and close control through the selector switch on the circuit
breaker mechanism, without interrupting the protection signals.
level. Operating mechanisms and handles shall be stored in an easily accessible place within the circuit
breaker mechanism box.
18.2.5.3 Isolating Switches

The line isolator shall be of the centre rotate double break motorised operating type mechanisms.
Due to space constraints, the busbar isolator will be the same as the existing which is a single side break and
installed in the same position as the other busbar isolators.
All shaft movements shall be facilitated by means of roller or ball bearings. The centre insulator shall rotate
with the contact arm. Contacts shall be silver plated and spring loaded. Contacts shall be designed in such a
way that current will not pass through any springs used in the contact.
18.2.5.4 Current Transformers

Multiple cores shall be provided for the different protection requirements as well as for metering. The
Contractor will be responsible for the calculation of current transformer ratios to suit the application for each
current transformer, whether it be an incomer feeder, transformer bay or line protection.
18.2.5.5 Voltage Transformers

Voltage transformers shall comply with the requirements as laid down in IEC 60044-2 and shall have two
LV windings. All voltage transformers shall have a secondary voltage of 110V.
Voltage transformers shall be of the inductive type. The position of the voltage transformers will be as
discussed in Section 18.2.5 and shown on the Single Line Diagram.
18.2.5.6 Surge Arresters

18.2.5.7 Earth Ball Joint and Portable Earths

Twelve potable earths must be provided (two per phase on both side of the earthed section) and will each
consist of the following:
18.2.6 Medium Voltage Cables

The medium voltage cable installation shall comply with the requirements in Section 20 and the applicable
Technical Schedules.
Cables must be installed in R-Y-B trefoil formation with a separation distance of 600mm between cable
groups where applicable.
18.2.7 Safety and Health Equipment

 A pin/notice board manufactured from soft board and covered with felt inside an aluminium frame,
1,500mm x 1,000mm must be installed in the substation.
 A white board shall be mounted against the wall of the substation. The size of the white board will
be 1,200mm x 1,000mm.
 An approved First Aid kit shall be provided for the substation.

Signs, danger notices and labels shall be installed in accordance with international standards and
requirements.
18.3 AUXILIARY POWER SUPPLIES

The substation auxiliary supplies are existing. The contractor must verify its suitability according to the
following specifications:
 For AC distribution refer to the “LTDRP Protection Detail Design Specification– 111233-40-SPE-
EE-0005”.
 For DC distribution refer to the “LTDRP Protection Detail Design Specification– 111233-40-SPE-
EE-0005”.
18.4 PROTECTION, CONTROL, AND TELECOMMUNICATION EQUIPMENT

Please refer to:
 LTDRP Telecommunications Detail Design Specification – Document no. 111233-40-SPE-EE-

0004
 ZESCO Technical Specifications for Telecommunications Optical Line Terminal Access

Equipment.
18.5 CIVIL WORK

Contractors should familiarise themselves with site conditions and price accordingly. The contractor must
appoint a registered civil engineer to do a soil profile. All new foundations must be designed according to
18.5.1 Terrace and Drainage

Embankments and fills shall be compacted in layers not exceeding a compacted thickness of 150 mm,
provided that the minimum relative density specified is achieved throughout the layer when compacted. The
contractor shall obtain the Project Manager’s approval of the previous layer before the next layer is spread. If
the Contractor wishes to continue placing fill before density test results are available, he may do so entirely
at his own risk and, should tests fail, then the Contractor must remove both the layer being tested and those
placed above it, all at his own expense. Unless otherwise specified, embankments and fills shall be compacted
to a minimum relative dry density of 91% Mod AASHTO.
Embankments shall be constructed as far as is reasonable in layers parallel to the formation and to the full
width corresponding to the height at which the work is being carried out from time to time. In no circum-
stances may a narrow portion of the embankment be constructed first and material "side-tipped" to make up
the specified width.
Density tests must be taken on every layer at a frequency of one for every 1000 m² of area. The specified
density is a minimum so the Contractor must aim to achieve a higher density than the minimum specified.
The substation platform is existing. All new work should be done taking into consideration any above or sub-
soil services.
The yard must be cleaned from any vegetation after completion.
Any excavations on the existing platform must be re-compacted in layers not exceeding 150mm to the original
density value which is typically 95% MODAASHTO.
If fill material is required, it must be G5 to G7 material with a neutral Ph. value and a low electrical resistivity
≤100Ωm. The use of dump rock from mining activities will not be accepted.
18.5.2 Geo-technical and Environmental

It will be the responsibility of the Contractor to perform the necessary geotechnical tests on the terrace to
determine the bearing pressure for the design of all the foundations. The results of this study must be
The Contractor shall base his designs on these results and all calculations must be submitted for acceptance.
The contractor shall allow for rock drilling and blasting if necessary. Blasting will be of the chemical
expanding type.
Any material to be imported must be from a commercial source. The material must be of G5 – G7 quality
with a neutral PH value and a low electrical resistivity.
18.5.3 Buildings
18.5.3.1 Main substation building
The existing building will be used for the new 33kV feeder protection panel and thus no alterations required.
The internal electrical works will be in accordance with the latest international standards and must be included
as part of the building construction.
The contractor must evaluate the building and ensure that it is water and dust tight. This will include but not
be limited to fixing water leaks in the roof, installing removable dust filters on all the louvered doors, fixing
broken windows etc.
18.5.3.2 Cable access - buildings

Any new cables that must enter the building, must do so in ducts provided therefore. If no spare ducts are
available, a new duct into the cable trench must be installed and sealed afterwards to keep moisture and
rodents out.
18.5.3.3 Electrical installations

For any changes or additions to the electrical installation, the EPC Contractor shall obtain a certificate of
compliance for the electrical installation from the applicable inspection authority.
18.5.3.4 Indoor lighting

The illumination required in various applications is given in Table 12. Lighting should be evaluated and
upgraded according to the following:
The normal lighting design must be done according to IEC standards and to the levels provided in Table 12.
 Normal lighting on the inside of the building will be done by the installation of 1.2m double tube
fluorescent light fittings.
 The lights will be controlled with an ON/OFF switch located on the inside of each door.
 The light fittings will be mounted horizontally against the walls at 1m from the ceiling.
 The fittings will have clear polycarbonate covers.
The emergency lighting design must be done according to IEC standards and to the levels provided in Table
12
 Emergency lights will be of the same kind as the normal lights.
 The lights will be controlled with an ON/OFF switch located on the inside of each door. The switch
must be distinguishable from the normal light switch.
 The light fittings will be mounted horizontally against the walls at 1m from the ceiling.
 The fittings will have clear polycarbonate covers.
 The lighting in each room shall be provided with a separate emergency light switch and timer, 0 –
30 minutes. This timer shall only switch the emergency lights.
 Emergency lights shall be self-contained units, fitted with internal power packs and inverters to
operate independently from the emergency switch. The batteries in the lights shall be charged under
normal power conditions.
Table 12: Required illumination
LEVEL
LOCATION
(LUX)
Offices and control desks 800
Control room in front of panels 300
Control room at rear of panels 150
High voltage yard operating positions 20
High voltage yard in general 10
Emergency lighting 5

The missing outside light fitting that must be the same as the existing. The open channel fluorescent light
fittings must be replaced with a waterproof bulkhead with a LED fitting producing the same light as a 70W
HPS globe. These lights must be controlled by means of a daylight switch mounted against the building.
The required lighting levels is specified in Table 12. Outdoor lighting shall be provided by luminaires with
LED lamps, installed on lighting towers. There shall be ladders on the lighting towers to access the
luminaires, with a safety cage around the ladder above 2 m.
The outdoor yard lighting must comply with international standards. A detailed lighting study must be
performed by the Contractor to provide the appropriate lux levels in the substation yard. The required lighting
levels should be 20lux on the operating positions and a general average lighting level of the yard must be
approximately 10lux.
The yard lighting will be installed on the new 14m lighting mast to be installed in the yard as indicated on
the drawing as well as the existing lighting mast. The lighting supply must be taken from the outdoor AC
distribution board where the control mechanism for the lighting must be housed.
The power supply cable to the masts is to be buried, and the steel armouring is only to be earthed on one side
of the cable to prevent circulating currents in the armouring. The foundation must have two sleeves at
opposite ends of the foundation to make provision for the supply cable. The contractor must prove that the
combined positioning of the masts will provide cover.
18.5.4 Lightning protection

The outdoor equipment is currently partly protected by means of two termination gantries, one lightning mast
as well as a lattice radio tower. As a result of the one gantry being removed and one new mast installed, the
lightning protection for the entire yard must be re-evaluated according to the specification in Table 13.
The positioning of lightning masts must be evaluated by the contractor according to the rolling ball method
as set out in IEC 62305 all parts.
The contractor must bond all the steel roofing sheets together on both sides of the roof and connect the corners
to the earthmat. The unit rate must make provision for all bonding conductors, down conductors, fixing of
the conductors to the wall as well as any requirements to connect down conductors to the earthmat. The down
conductors must be fixed to the wall with purposefully manufactured hardware at intervals no larger than
500mm. Where there is a change in direction this distance must be lowered to 250mm for 1m on either side
of the bend.
Proper precaution must be taken when bonding dissimilar materials together.
Table 13: Lightning protection specification
STANDARD DESCRIPTION
IEC 62305 (ALL PARTS) Protection against lightning
18.5.5 Indoor fire protection

The Matero Substation building already has an automatic gas flooding system installed.
18.5.6 Cable Trenches

Within switchyards, control cables will run in covered cable trenches. The trenches shall be wide enough
and deep enough to accommodate the minimum allowable bending radii of the cables. Trenches shall have
concrete strip footings and reinforced concrete walls. Cable trench covers shall weigh no more than 40kg
each, must be removable by hand, and must support a load of 200kg at the centre without being damaged.
Where a cable route crosses a roadway, either the covers must be able to support the full axle load of
transformer delivery vehicles, or cable ducts under the road capable of supporting this load must be installed.
The top of the trenches must be ±150mm above the finished terrace level.
Cable racking are not required for control cables in cable trenches.
Small power and control cables must be installed in the new and existing trenches therefore as well is through
the existing entry into the building.
18.5.7 Yard Stone

Yard cover is existing. The yard stone in the affected area must be removed and set aside for later re-
incorporation into the affected area. After completion of the scope of work the yard must be cleaned and free
of weeds.
18.5.8 Steel Support Structures

standards and specifications. All structures shall be hot dipped galvanized in accordance with ISO 1461
edition 3.
which is in use throughout Southern Africa and must be designed for the specific equipment to be installed
on it.
Structures shall be erected and aligned correctly in the horizontal and vertical planes before the final torque
of the bolts are done. Foundation bolts shall be tightened once the structure has been levelled and an epoxy
based grout must then be used to seal under the base.
equipment. Adaptor plates and shims will not be used to straighten equipment. After installation of all
equipment the space between the footing and foundation will be filled in with non-shrinking grout.
equipment holes. No modifications after galvanizing.
18.5.9 Galvanising and pole treatment

following:
 Hot air drying

 Zink bath
18.5.10Earth Grid and Connections

There is an existing earth grid. The contractor must install an additional earth grid to make provision for the
new equipment typically in 1m blocks from the edge of the existing earth grid as is required and measure the
earth mat resistance and measure to determine if it is compliant with IEEE-80 – 2000. The grid must cover
the operating positions of all switchgear. Earth mat shall have a resistance not exceeding 1Ω. Should this
not be the case mitigating measures must be discussed with the engineer. The design parameters in Table 14
shall be used for the earthing grid design.
Round annealed copper rod with a 10mm diameter, is to be used for the main earth grid. All earth tails
between the main earth grid and equipment must be 50 x 3mm flat copper, bolted to the structures. Each
piece of equipment shall be connected to the earth grid, in at least two positions. The new lightning mast will
have 4 bonding leads with 4 x 1,5m Cu plated earth rods.
All connections shall be cleaned from any dirt or paint to ensure proper electrical connection from structures
to the earthing grid.
The trench bottom shall be free of rocks and stones and shall be compacted before placing the copper
conductor in the trench. The copper conductor shall be placed on this bed of compacted soil.
No joint in earth tails shall be made above the ground level.
The main earth grid trenches shall be back-filled and compacted with the excavated soil, in layers not
exceeding the civil engineer’s recommendations. The re-compacted areas will match that of the undisturbed
and must be proven by means of a DCP test.
Flat straps must be curled halfway around the round bar to ensure sufficient surface connection. The straps
shall exit the ground directly next to the foundation and must be bent and profiled to suit the equipment shape
as close as possible. Where necessary and on runs on concrete of more than 600mm, the strap must be fixed
to the concrete.
The new lightning mast shall be positioned as indicated on the approved general arrangement drawing, and
must be bonded to the earth mat in four places. At each of these places a 1.8m earth rod must be installed.
The continuity of the earth path from the equipment to the earth grid shall be measured after the equipment
has been installed. The earth resistance of all new equipment shall be measured after installation and bonding
before the connections to the terminal towers are done. The measurements shall be carried out and logged
by the contractor in the presence of the Engineer.
Description Detail
Design Parameters
Body Weight 50kg
Earthing material size:
Earthing Grid 10mm round Cu
Connections 50x3mm Cu strap
Wenner method.
Soil resistivity measurements 5 Readings at electrode spacing of 1, 2, 4, 8 and 16
meter
Safety Parameters
18.5.11Concrete Foundations
All equipment shall be mounted on support structures, secured on concrete bases by means of 24mm
galvanized anchor bolts. The length of the bolt shall suit the application. Anchor bolts must protrude at least
80mm above the finished level of the concrete and shall be provided with two nuts and two washers to allow
for levelling of the structures.
The gaps under the structures must be filled with an approved grout mix after the structures have been levelled
out.
used for substation equipment support structures in soil, and alternative designs may be proposed for hard
rock.
The Contractor will be required to carry out a geotechnical investigation, with special attention to the
positions of the gantries, transformers and the building.
Concrete bases shall be finished smoothly above the platform compacted level and shall protrude 150mm
above the finished ground level. This will allow the foundations to protrude ± 50mm above the 100mm yard
stone cover. All foundations shall have 45º chamfer along the entire edge.
All new foundations will be provided with a 45º chamfer.
18.5.12Equipment Labels
The substation currently has very little equipment labels and signs. The contractor shall replace all safety
signs and install labels on all the structures new and existing. The proposed label set must be submitted to the
engineer for approval before the order is placed.
Labels shall conform to international standards. All equipment in the substation will be supplied with new
labels. The following guidelines shall be followed.
Each piece of electrical equipment shall be provided with a designation label, manufactured from 1.5mm
sheet steel and shall be coated in vitreous enamel, and shall be orange with black letters. Uniformity of the
labels will be a priority. Labels will be fixed to structures by means of galvanized bolts and nuts.
Label material Chromadek or enamel paint (not vinyl stickers)
Application of phasing discs Both sides of isolators, at line entries
All new panels shall be provided with identification label.

 Room designation labels mounted above each door.
 Warning of electrical shock.
Each building must be provided with a first aid kit contained in a wall mounted metal box close to the
switchroom main door.
19. DEMOLISHING OF EXISTING INFRASTRUCTURE

Any demolishing of the two existing 33kV overhead lines must be strictly done in accordance with “111233-
40-SPE-EE-0018 - Dismantling of Overhead Line and Substation Equipment Specifications”. All materials
recovered must be taken to the Zesco farm that is typically 18km from site and is indicated in Figure 31.
Figure 31: Zesco Farm location
20. 33KV CABLE INSTALLATION

20.1 SPECIFICATIONS
from 1 kV (Um = 1,2kV) up to 30kV (Um = 36kV) –
IEC 60502-2
Part 2: Cables for rated voltages from 6kV (Um = 7,2kV) up to
30kV (Um = 36kV)
IEC 61941
fibres

Figure 32: MV cable construction
8. Binder tape.
9. Inner sheath.
20.2 EXCAVATIONS
Existing services will be pointed out to the contractor as far and as accurate as possible with the information
that is available, however the responsibility will remain with the contractor to find and safely expose all
existing services by hand. The contractor must survey the proposed route to determine the optimal placement
of the cable with regards to obstacles, road crossings and existing services, as follows:
 Due to the amount of existing services the unit rates must make provision for the most efficient way
of exposing these services without damages. The use of compressed air excavation tools like an
“Air Knife” or similar must be provided for in the unit rates for excavations.
Hard/dense soil
 Generally, any soil which requires the close application of picks, jumpers or scarifiers to loosen; for
 Note: Cobble stone is rock fragments usually rounded or semi-rounded having maximum diameter
in any direction between 80mm and 300mm.

 This shall include rock or boulders, which can be excavated by barring, wedging and splitting
manually or using pneumatic tools. It shall also include embedded boulders measuring not more than
one metre in any one direction.
 Note: The mere fact that the contractor resorts to blasting to loosen the material shall not mean that
it will be classified as hard rock.

 This shall include all rock occurring in large masses which cannot be removed except by blasting.
Hard varieties of rock such as granite with or without veins and secondary minerals which in the
opinion of the engineer requires blasting shall be considered as hard rock. Boulders of hard rock
larger than one metre in any one direction lying in the overburden and requiring blasting for easy
and efficient removal shall also be classified as hard rock. All blasting shall be of the non-explosive,
chemical expanding type.
Claims for excavations will be processed according to the trench dimensions provided. Over excavation will
not be considered.
Generally, the centre line of trenches will be 1m from the stand boundary. Obstructions encountered should
be brought under the attention of the engineer.
No trees shall be cut during the execution of the contract unless specifically arranged with the engineer.
Should any trees have to be removed, the contractor shall arrange for the complete uprooting and trimming
of tree trunks, as well as the stacking of all trunks and branches. Holes caused by the uprooting shall be filled
and consolidated. Rubble shall be removed to leave the site neat and tidy. The contractor shall be held
responsible for any damage that may occur during the felling of trees.
Provision shall be made at road crossing to keep the roads open during the cable installation period by
installing heavy-duty steel plates across the open trenches. The contractor shall include this in the tender
price.
All railway lines plus all tarred roads are to be crossed with sleeves by boring (drilling) underneath to a depth
of at least 1.5m into which the cable is to be laid. Sleeves are to be strong enough not to buckle under the
load of the ground above, and correctly sized for the cable. In addition to these sleeves at crossings, cable
manholes will be constructed on either side of each crossing. This will be done by means of brick and mortar
and at the same depth as the accompanying cable trench. The design of the manhole must make provision to
keep out any ground water but the use of a subsoil drain can be considered. The top of the manhole must be
a minimum of 300mm above NGL. All power cables, spare sleeves, as well as the fibre-optic cable on the
same route, will enter the manhole. All subsoil entries into the manhole will be sealed watertight. The
manholes must be positioned to act as a transition point where a change in direction can be done. Lockable
watertight lids must also be provided, the size of which must be able to cater for both power and fibre optic
during installation.
Where the cable is installed along a tarred road and crosses a dirt road that might become a tarred road sleeves
must be installed for each cable plus one spare. The unit rate for sleeves will make provision for joint
couplings as well as end-caps where require.
It is preferred that trenches not be left open overnight. If it is unavoidable, however, the contractor must, as
a minimum, install orange trench barrier netting. The netting must be a bright orange colour, a minimum of
1.2m high and supported every 2m by a wooden or iron pole of 1.5m to prevent injury to passers-by. In areas
where the open excavation is not very well lit, the contractor may, in addition to the netting, make use of red
strobe lights positioned in intervals of 5m. The contractor remains responsible for safety in and around the
open excavation until it is backfilled.
200mm x 6m Sleeves must be installed for each individual MV cable at each of the substations where the
cable enters substation underneath the fence and onto the platform.
20.3 BEDDING AND BLANKET LAYERS

If the trench is rocky, the bottom of the trench shall be filled across the full width with a 75mm layer of
suitable soil sifted through a 6mm mesh and levelled off.
Only sandy clay or loam soil with a satisfactory thermal resistivity (not exceeding 1.2C m/W) may be used
for this purpose. Sea or river sand, ash, chalk, peat clinkers or clayey soil shall not be used.
20.4 BACKFILLING
present in the backfill material for the first section above the blanket layer as per the design. Thereafter all
soil used for backfilling shall pass through an 80mm mesh to ensure that the maximum allowable diameter
of stones present in the backfill material is 75mm.
of not more than 300mm before being compacted. In backfilling, the bedding on top of the cable shall be
covered first with a 200mm layer of well graded material containing no pieces larger than 20mm, before any
coarse material is deposited.
required for the purpose of compaction, and the moisture content shall be uniform throughout the layers.
The material shall be compacted by compaction machines to a minimum of 95% MOD AASHTO.
Compaction certificates will be required.
20.5 CABLE MARKERS AND LABELLING

Brass or aluminium plates shall be cast into the top of the cable marker blocks in such a manner that they
cannot be pried loose. The wording "ELECTRICAL CABLE" shall be stamped on the plates as well as
direction arrows and the cable voltage rating.
normal ground level unless the projected markers could be a hazard to pedestrian or other traffic in which
case they shall be installed flush with the surface.
Type B route markers will be installed on the outskirts of town and in areas where a high possibility exists
that cables will be damaged by development.
Cable markers shall be installed at the beginning and ending of a cable run (e.g. where a cable enters a
substation or building), at changes of direction, above all joints, above cable pipe/sleeve entries and exits at
road crossings. On long cable runs it must be installed every 50m.
consideration:
1. Voltage
2. Cable size
4. Connected from
5. Connected to
20.6 CABLE INSTALLATION

Danger tape shall be installed above all MV cables, only at the depth as indicated, along the entire trench
length. The tape must be 450mm wide and must be a minimum of 200 microns thick. It must be bright
orange or yellow with red skull and crossbones and the words "ELECTRIC CABLE" printed on not more
than 1m intervals.
Interlocking Plastic tiles must be installed above all MV cables.
Concrete slabs (900x300x65mm) will also be installed where any other services are crossed, either 300mm
above or 300mm below so that the new cable is comprehensively protected. In areas where a high risk of
damage exists, the entire trench will be packed with concrete slabs.
Pulling eyes shall be provided on both ends of a cable drum length. The pulling eye shall be securely
connected to both the cable conductor and the sheath to avoid elongation of the sheath during installation.
Cable rollers shall be used to run out cables. Rollers shall be spaced so that the length of cable in the trench
will be totally suspended during the laying operation and sufficiently close to prevent undue sagging and the
cable from touching the ground. Rollers shall also be placed in the trench in such a manner that they will not
readily capsize.
Where cables have to be drawn around corners, well-lubricated skid plates shall be used. The skid plates
shall be securely fixed between rollers and shall constantly be examined during cable laying operations.
Where cables have to be drawn through sleeves or ducts, a suitable cable sock shall be used and particular
care shall be exercised to avoid abrasion, elongation or distortion of any kind.
The maximum allowable tension when pulling a cable is 70N/mm2 of conductor area. The contractor remains
responsible to confirm the limitations of the cable from his supplier. It will be assumed that the price or rates
contained in the tender includes for the installation of cables in pipes and ducts or below existing or newly
installed services. The Engineer shall be informed timeously of the intention to carry out all cable laying
operations to allow an inspection of the works if so required.
The cable shall be installed using a winch and care shall be taken not to exceed the maximum permissible
pulling force specified by the manufacturer.
The maximum permissible bending radius of a cable is typically fifteen times the cable diameter. This must
be confirmed in the technical schedules according to a specific supplier’s requirements. Any damage resulting
from ignoring this value will be rectified by the contractor at his own expense to the satisfaction of the
engineer.
20.7 Joints and terminations

20.7.1 General
available on site.
Remove water blocking material from within the conductors with care before inserting into lugs and
connectors for crimping.
Where a visual representation of the phase rotation colours are required for MV cables it shall be:
 L1 – R(red)
 L1 – B(blue)
20.7.2 Terminations
When cutting away insulation from cable conductors to fit into lugs, care shall be taken that no strands are
left exposed. Under no circumstances may any of the conductor strands be cut away to fit into lugs.
Suitable lugs shall be used and preferably be solidly seated to cable conductor ends. Lugs may be crimped
using mechanical, hydraulic or pneumatic tools specifically designed for this purpose. Under no
circumstances may a lug be crimped by means of a hammer and/or punch.
by the engineer.
Contact surfaces shall be thoroughly cleaned and smoothed and fixing bolts shall match the hole size of the
lug and shall be manufactured of cadmium plated tensile steel.
The kits shall include suitable boots for the covering of the terminal studs on the equipment. The ends shall
be terminated strictly in accordance with the termination manufacturer's specification and shall withstand the
same test voltage as the rest of the cable.
The cores of all cables terminated shall be completely covered with a shrunk-on protective layer against
surface tracking, ultra-violet radiation and weathering.
Cables shall be terminated in accordance with the recommendations laid down by the manufacturers of the
cables and the terminations employed.
20.7.3 Cable Joints

continuity shall be accomplished within the joints, i.e. no external earth continuity conductor that will be
subject to corrosion, is acceptable. The joints shall be completely covered by a watertight sheath to prevent
corrosion.
In the case of joints in cables with an outer PVC anti-electrolysis sheath, the joints shall be subject to the
same electrical insulation test as the outer sheath of the cable.

Cable joints for heat shrinkable materials shall be packed as a complete joint kit in a container that is marked
for the type of cable insulation and construction as well as the voltage range for which materials are suitable.
The contractor shall leave slack in the form of two coils 2m on either side of the joint. The coils must comply
around the cable. The following information shall be punched on to the stainless-steel tape for the cable
under consideration:
c) Type of cable
20.8 CABLE TESTS

and IEC60060-1.
Outer sheath tests shall routinely be performed immediately after the installation and backfilling of a length
of cable, so that repairs, if required, can be done at that stage.
20.9 COORDINATION OF SERVICES

All new infrastructure lines and cables will be installed on the same route as other existing services such as
water, sewerage, electric cables, stormwater and fibre optics. The contractor must coordinate the installation
of the new cables and fibre optics with all existing services by gathering information from all service
providers involved as to positioning of the said services as well as trench cross cuts on the planned routes.
C. DRAWINGS
STEEL MONOPOLE
STEEL MONOPOLE
STEEL MONOPOLE
JUMPER SUPPORT ASSEMBLY DRAWING
STEEL MONOPOLE
STEEL MONOPOLE
MATERO 33/11KV SUBSTATION
111233-0000-DRG-EE-GA-0002
GENERAL ARRANGEMENT
MATERO 33/11KV SUBSTATION
111233-60-DRG-EE-SL-0026
33/11kV SINGLE LINE DIAGRAM GENERAL ARRANGEMENT
INDUSTRIAL TO MUNGWI TO LIVERPOOL TO MATERO 33 KV
111233-IND/MAT-PP-1 SHT 1-14 DISTRIBUTION LINEIndustrial to Mungwe to Liverpool to Matero33 kV
Distribution Line
AURECON STANDARD DRAWINGS
AUR-OHL-EAR-MP-001 TYPICAL EARTHING ARRANGEMENT FOR PAD AND CHIMNEY
STRUCTURE
TERMINAL POLE EARTHED
GH9727
SECTION ANGLE POLE CONSTRUCTION
GH9728
33kV EARTHED STRUCTURE FOR 200mm² & 300mm² ACSR
INTERMEDIATE POLE EARTHED
GH9729
33kV CONSTRUCTION FOR 200mm² & 300mm² ACSR
ZAM-GEN-41-G-12827
33kV UNDERGROUND CABLE
ZAM-GEN-DE-G-12831 33kV STAYS
33kV OVERHEAD LINE
DISK INSULATOR SUSPENSION ASSEMBLY
33kV OVERHEAD LINE
DISC STRAIN ASSEMBLY

20.9.1.2 Protection philosophy block diagrams

D. SUPPLEMENTARY
INFORMATION
1. LTDRP SCADA Detail Design Specification – 111233-40-SPE-EE-0003.
2. LTDRP Telecommunications Detail Design Specification – 111233-40-SPE-EE-0004.
3. LTDRP Protection Detail Design Specification – 111233-40-SPE-EE-0005.
4. ZESCO Technical Specifications for Telecommunications Optical Line Terminal Access Equipment.
5. ZESCO LTDRP - ENVIRONMENTAL AND SOCIAL MANAGEMENT PLAN_ 1st Draft.
6. ZESCO LTDRP HSMP.
7. ZESCO Waste Management Procedure Version 1 Signed.

8. 111233 REP011 Dismantling of OHL and Substation Equipment - Rev 2.

E. SCHEDULE OF TECHNICAL
REQUIREMENTS
Tenderers shall only offer equipment as called for in the specifications as part of their main offer. Alternatives
shall be listed separately from these Tender documents.
Where such alternative equipment is offered subject to final approval, the Tenderer shall submit detailed
information to enable the Engineer to evaluate the equipment with the tender. If the information submitted
is not adequate to satisfy the Engineer that the equipment is acceptable such an alternative offer will not be
considered.
___________________________________________________________________________________________________________________________________________________
LTDRPP4
Technical Schedule (Lot 3)

Lot 3: Matero 33kV Network Upgrade
Task 1: OHL from Industrial Substation to Mungwi Substation
Task 2: OHL from Mungwi Substation to Liverpool Substation
Task 3: OHL from Liverpool Substation to Matero Substation
Task 4: 33kV feeder bay Matero Substation
Name of Bidder
Lot 3 Rev 5
Section____________________________________________________________________________________________________________________________________________
VII. Employer's Requirements Part 2-319
Lot 1 Rev 5
_______________________________________________________________________________________________________
LOT 3 - MATERO SUBSTATION 33kV CORIDOR
TECHNICAL SCHEDULES
Table of Contents
Sequence No Item No Description

1 1 33kV Circuit Breakers - Incomers, Bus-Sections and Bus Couplers
197 9 500mm² 19.05/33kV 1C Cu XLPE AWA
222 10 Inside Termination -500mm² 19.05/33kV AWA XLPE 1-Core Cu Cable
262 12 Free-standing Panel and Junction Box
301 13 Relay Technical Specification
360 14 33kV Feeder Protection
390 15 Insulators
426 16 Tension clamps
450 17 Conductors
485 18 Armour rods
501 19 Repair sleeves
509 20 Vibration dampers
523 21 Steel monopole
Lot 3 Rev 5
_______________________________________________________________________________________________________
LOT 3 - MATERO SUBSTATION 33kV CORIDOR
The provided typical 132kV, 33kV and 11kV combined control, protection and telecommunication panels shall be strictly used

1 1 33kV Circuit Breakers - Incomers, Bus-Sections and Bus Couplers -----
36 3.5 Yes
3min - CO
40
Lot 3 Rev 5
_______________________________________________________________________________________________________

76 3.5 Yes
3min - CO
80
90 1.8 Deg 90
Open)
105
Lot 3 Rev 5
_______________________________________________________________________________________________________

122 1.15 Note
123 1.16 Type Post
800A
Multi ratio
1,600A
Multi ratio
126
138 1.10
139 1.11 Type Ring
140
163
Lot 3 Rev 5
_______________________________________________________________________________________________________

182
196
197 9 500mm² 19.05/33kV 1C Cu XLPE AWA -----
201 4 Voltage kV 19.05/33
215 ZESCO
218 Voltage
219 Cable size
221
222 10 Inside Termination -500mm² 19.05/33kV AWA XLPE 1-Core Cu Cable -----
226 4 Voltage kV 19.05/33
231 9 Earth kit Yes
241 19 Indoor / Outdoor Indoor/Outdoor
242
247 4 Voltage kV 19.05/33
Lot 3 Rev 5
_______________________________________________________________________________________________________

252 9 Earth kit Yes
261
271 1.8 Yes
274 1.11 Yes
equivalent
control building
with bid
286 2 -----
per kiosk type)
VTJB, CTJB,
294 2.8 Application
equivalent
with bid
300
302 1 -----
Lot 3 Rev 5
_______________________________________________________________________________________________________

Yes - SCADA & Local
Yes - SCADA & Local
selection via relay
Yes - SCADA & Local
selection via relay
Yes - SCADA & Local
320 2.14 Yes
certificates
321 3 -----
333 4.8 V AC/DC Yes
certificates
334 5
safe Output Contact
353 5.19 Yes
Fibre - Ethernet
access
of 1kHZ
358 5.24 Yes
certificates
359
Lot 3 Rev 5
_______________________________________________________________________________________________________

overhead lines
386 3.16 Yes
certificates
389
390 15 Insulators -----
391 1 Post Insulator -----
394 1.3 Type of Insulators Silicon Rubber
395 1.4 Mechanical Strength including fittings -----
396 1.5 Failing Load kN 13.25
397 1.6 Cantilever Strength (40% of failing) kN 5.3
404 1.13 Dry Arcing Distance Specify
405 1.14 Creepage Distance 900
408 2 Strain/Suspension Insulator -----
413 3 Mechanical Strength including fittings -----
414 3.1 Failing Load kN 120
421 3.8 Dry Arcing Distance mm specify
422 3.9 Creepage Distance mm 900
425
426 16 Tension clamps -----
427 1 Tension End Clamp (Bear) -----
Lot 3 Rev 5
_______________________________________________________________________________________________________

Hexagon ‘ALCAN’
Range
436 1.9 Current Transfer Through Jumper Terminal Lug Min A 650
437 1.10 Jumper Attachment 2×M12 bolted
438 2 Inline Full tension joint (Bear) -----
Hexagon ‘ALCAN’
Range
448 2.10 Current Transfer Min A 650
449
450 17 Conductors -----
454 1.3 Type Bear
455 1.4 Current Rating A 650
456 1.5 Overall Diameter mm 23.45
457 1.6 Strand And Wire Diameter mm 30/7/3.35
458 1.7 Aluminium Area mm² 264.42
459 1.8 Ultimate tensile strength kN 112
460 1.9 Final modules elasticity MPa 83,400
461 1.10 Coefficient of linear expansion (1/°C) 18.43 x 10E-6
462 1.11 Standard drum length (min) m 2,000
463 2 Optical Ground Wire -----
464 2.1 Grease Conductor Yes
465 2.2 Type of Fibre Carrier Specify
467 2.4 1 S Burn-Off Current kA 21.5
468 2.5 Strand and Wire Diameter mm Specify
469 2.6 Breaking Strength kN Specify
470 2.7 Diameter mm Specify
471 2.8 Mass N/m 8.1 max
472 2.9 Standard drum length m Specify
473 3 Optical Fibre -----
475 3.2 Type of Fibre Single Mode ITU-T G.652
476 3.3 Mass per Length of Cable kg/km < 200
477 3.4 Cable Diameter mm ≤ 15
478 3.5 Cabled Cut-Off Wavelength nm ≤ 1,260
479 3.6 Anti-Tracking Sheath Yes
480 3.7 Maximum Design Span Length m >400
481 3.8 Ultimate Tensile Strength kN ≥ 35
Maximum Working Load (Where Fibre Strain Does Not
482 3.9 kN Specify
Exceed 0.2 % in the Fibres)
483 3.10 Maximum Continuous Load (Fibre Under No Strain) kN Specify
484
485 18 Armour rods -----
489 1.3 Type Spiral
490 1.4 Size mm 23.45
491 1.5 Length mm 1,450
493 2 Shield Wire -----
496 2.3 Type Spiral
497 2.4 Size mm 13.2
498 2.5 Length mm 1,000
500
Lot 3 Rev 5
_______________________________________________________________________________________________________

501 19 Repair sleeves -----
Hexagon ‘ALCAN’
Range
507 1.5 Length mm 220
508
509 20 Vibration dampers -----
513 1.3 Type Stockbridge
514 1.4 Size mm 23.45
515 1.5 Length mm 520
516 2 EARTH WIRE -----
519 2.3 Type Spiral
520 2.4 Size mm 11.7-14.3
521 2.5 Length mm 1346
522
523 21 Steel monopole -----
524 1 Intermediate double circuit -----
532 1.8 Conductor configuration
533 1.9 Suspension 2 x Vertical circuits
536 1.12 kN Specify
537 1.13 Safety factor
538 1.14 On calculated strength 2.5
539 1.15 On type tested breaking strength 2.2
541 1.17 Insulator
baseplate
542 2 Strain double circuit -----
550 2.8 Conductor configuration 2 x Vertical circuits
Tip load 0-30 degree angle (based on wind span 250m, weight
553 2.11 kN Specify
span 450m)
554 2.12 kN Specify
weight span 450m)
555 2.13 kN Specify
weight span 450m)
baseplate
560 2.18 Terminal/strain insulators Plate bracket
561 3 Intermediate triple circuit -----
Lot 3 Rev 5
_______________________________________________________________________________________________________

572 3.11 kN Specify
575 3.14 Minimum Conductor Attachment Height (Shortest Pole) m Specify
baseplate
577 4 Strain triple circuit -----
Tip Load 0-30 degree angle (based on wind span 250m, weight
588 4.11 kN Specify
span 450m)
589 4.12 kN Specify
weight span 450m)
590 4.13 kN Specify
weight span 450m)
593 4.16 Minimum conductor attachment height (shortest pole) m Specify
Lot 3 Rev 5
Forms and Procedures

Form of Completion Certificate .......................................................................................... 332
Form of Operational Acceptance Certificate ...................................................................... 333
Change Order Procedure and Forms ................................................................................... 334
Change Order Procedure...................................................................................................... 335
Annex 1. Request for Change Proposal ............................................................................. 336
Annex 2. Estimate for Change Proposal ............................................................................ 338
Annex 3. Acceptance of Estimate ...................................................................................... 340
Annex 4. Change Proposal ................................................................................................. 341
Annex 5. Change Order ...................................................................................................... 344
Annex 6. Pending Agreement Change Order .................................................................... 345
Annex 7. Application for Change Proposal ....................................................................... 347
Form of Completion Certificate
Date:
Loan/Credit No:
IFB No:
______________________________
To: _________________________________
Dear Ladies and/or Gentlemen,
Pursuant to GC Clause 24 (Completion of the Facilities) of the General Conditions of the

Contract entered into between yourselves and the Employer dated _____________, relating to
the ____________________, we hereby notify you that the following part(s) of the Facilities was
(were) complete on the date specified below, and that, in accordance with the terms of the
Contract, the Employer hereby takes over the said part(s) of the Facilities, together with the
responsibility for care and custody and the risk of loss thereof on the date mentioned below.
1. Description of the Facilities or part thereof: ______________________________
2. Date of Completion: __________________
However, you are required to complete the outstanding items listed in the attachment hereto
as soon as practicable.
This letter does not relieve you of your obligation to complete the execution of the Facilities
in accordance with the Contract nor of your obligations during the Defect Liability Period.
Very truly yours,
Title
(Project Manager)
Form of Operational Acceptance Certificate
Date:
Loan/Credit No:
IFB No:
_________________________________________
To: ________________________________________
Dear Ladies and/or Gentlemen,
Pursuant to GC Sub-Clause 25.3 (Operational Acceptance) of the General Conditions of the

Contract entered into between yourselves and the Employer dated _______________, relating to
the ___________________________________, we hereby notify you that the Functional
Guarantees of the following part(s) of the Facilities were satisfactorily attained on the date
specified below.
1. Description of the Facilities or part thereof: _______________________________
2. Date of Operational Acceptance: _______________________
This letter does not relieve you of your obligation to complete the execution of the Facilities
in accordance with the Contract nor of your obligations during the Defect Liability Period.
Very truly yours,
Title
(Project Manager)
Change Order Procedure and Forms
Date:
Loan/Credit No:
IFB No:
CONTENTS
1. General
2. Change Order Log
3. References for Changes
ANNEXES
Annex 1 Request for Change Proposal

Annex 2 Estimate for Change Proposal
Annex 3 Acceptance of Estimate
Annex 4 Change Proposal
Annex 5 Change Order
Annex 6 Pending Agreement Change Order
Annex 7 Application for Change Proposal
Change Order Procedure
1. General
This section provides samples of procedures and forms for implementing changes in the
Facilities during the performance of the Contract in accordance with GC Clause 39
(Change in the Facilities) of the General Conditions.
2. Change Order Log
The Contractor shall keep an up-to-date Change Order Log to show the current status of
Requests for Change and Changes authorized or pending, as Annex 8. Entries of the
Changes in the Change Order Log shall be made to ensure that the log is up-to-date.
The Contractor shall attach a copy of the current Change Order Log in the monthly
progress report to be submitted to the Employer.
3. References for Changes
(1) Request for Change as referred to in GC Clause 39 shall be serially numbered

CR-X-nnn.
(2) Estimate for Change Proposal as referred to in GC Clause 39 shall be serially

numbered CN-X-nnn.
(3) Acceptance of Estimate as referred to in GC Clause 39 shall be serially numbered

CA-X-nnn.
(4) Change Proposal as referred to in GC Clause 39 shall be serially numbered CP-X-

nnn.
(5) Change Order as referred to in GC Clause 39 shall be serially numbered CO-X-

nnn.
Note: (a) Requests for Change issued from the Employer’s Home Office and the
Site representatives of the Employer shall have the following respective
references:
Home Office CR-H-nnn

Site CR-S-nnn
(b) The above number “nnn” is the same for Request for Change, Estimate for
Change Proposal, Acceptance of Estimate, Change Proposal and Change
Order.
Annex 1. Request for Change Proposal
(Employer’s Letterhead)
To: ____________________________________ Date:
Attention: ______________________________________
Contract Name: _________________________________

Contract Number: _______________________________
Dear Ladies and/or Gentlemen:
With reference to the captioned Contract, you are requested to prepare and submit a Change
Proposal for the Change noted below in accordance with the following instructions within
_______________ days of the date of this letter ____________________ .
1. Title of Change: ________________________
2. Change Request No. __________________
3. Originator of Change: Employer: _______________________________

Contractor (by Application for Change Proposal No. _______1:
4. Brief Description of Change: _________________________________________________
5. Facilities and/or Item No. of equipment related to the requested Change: _____________
6. Reference drawings and/or technical documents for the request of Change:
Drawing No./Document No. Description
7. Detailed conditions or special requirements on the requested Change: ________________
8. General Terms and Conditions:
(a) Please submit your estimate to us showing what effect the requested Change will
have on the Contract Price.
(b) Your estimate shall include your claim for the additional time, if any, for
completion of the requested Change.
4
Costs shall be in the currencies of the Contract.
(c) If you have any opinion negative to the adoption of the requested Change in
connection with the conformability to the other provisions of the Contract or the
safety of the Plant or Facilities, please inform us of your opinion in your proposal
of revised provisions.
(d) Any increase or decrease in the work of the Contractor relating to the services of
its personnel shall be calculated.
(e) You shall not proceed with the execution of the work for the requested Change
until we have accepted and confirmed the amount and nature in writing.
(Employer’s Name)
(Signature)
(Name of signatory)
(Title of signatory)
Annex 2. Estimate for Change Proposal
(Contractor’s Letterhead)
To: ______________________________ Date:
Attention: _______________________________
Contract Name: _______________________________

Contract Number: _____________________________
With reference to your Request for Change Proposal, we are pleased to notify you of the
approximate cost of preparing the below-referenced Change Proposal in accordance with GC
Sub-Clause 39.2.1 of the General Conditions. We acknowledge that your agreement to the
cost of preparing the Change Proposal, in accordance with GC Sub-Clause 39.2.2, is required
before estimating the cost for change work.
1. Title of Change: ________________________
2. Change Request No./Rev.: ____________________________
3. Brief Description of Change: __________________________
4. Scheduled Impact of Change: ___________________________
5. Cost for Preparation of Change Proposal: _______________1
(a) Engineering (Amount)
(i) Engineer hrs x rate/hr =

(ii) Draftsperson hrs x rate/hr =
Sub-total hrs
Total Engineering Cost
(b) Other Cost
Total Cost (a) + (b)
5
Costs shall be in the currencies of the Contract.
(Contractor’s Name)
(Signature)
(Name of signatory)
Annex 3. Acceptance of Estimate
To: ______________________________ Date:
Attention: ________________________________
Contract Name: _____________________________

Contract Number: ___________________________
We hereby accept your Estimate for Change Proposal and agree that you should proceed with
the preparation of the Change Proposal.
1. Title of Change: ___________________________
2. Change Request No./Rev.: _______________________________
3. Estimate for Change Proposal No./Rev.: _______________________________
4. Acceptance of Estimate No./Rev.: _______________________________
5. Brief Description of Change: _______________________________
6. Other Terms and Conditions: In the event that we decide not to order the Change
accepted, you shall be entitled to compensation for the cost of preparation of Change
Proposal described in your Estimate for Change Proposal mentioned in para. 3 above in
accordance with GC Clause 39 of the General Conditions.
(Employer’s Name)
(Signature)
(Name and Title of signatory)

Annex 4. Change Proposal
To: _______________________________ Date:
Attention: _______________________________
Contract Name: _______________________________

Contract Number: _______________________________
In response to your Request for Change Proposal No. _______________________________, we

hereby submit our proposal as follows:
1. Title of Change: _______________________________
2. Change Proposal No./Rev.: _______________________________
3. Originator of Change: Employer: [_______________________________

Contractor: _______________________________
5. Reasons for Change: _______________________________
6. Facilities and/or Item No. of Equipment related to the requested Change:

_______________________________
7. Reference drawings and/or technical documents for the requested Change:
Drawing/Document No. Description
8. Estimate of increase/decrease to the Contract Price resulting from Change Proposal:1
(Amount)
(a) Direct material
(b) Major construction equipment
2
Specify where necessary.
(c) Direct field labour (Total hrs)
(d) Subcontracts
(e) Indirect material and labour
(f) Site supervision
(g) Head office technical staff salaries
Process engineer hrs @ rate/hr

Project engineer hrs @ rate/hr
Equipment engineer hrs @ rate/hr
Procurement hrs @ rate/hr
Draftsperson hrs @ rate/hr
Total hrs
(h) Extraordinary costs (computer, travel, etc.)
(i) Fee for general administration, % of Items
(j) Taxes and customs duties
Total lump sum cost of Change Proposal

(Sum of items (a) to (j))
Cost to prepare Estimate for Change Proposal

(Amount payable if Change is not accepted)
9. Additional time for Completion required due to Change Proposal
10. Effect on the Functional Guarantees
11. Effect on the other terms and conditions of the Contract
12. Validity of this Proposal: within [Number] days after receipt of this Proposal by the
Employer
13. Other terms and conditions of this Change Proposal:
(a) You are requested to notify us of your acceptance, comments or rejection of this
detailed Change Proposal within ______________ days from your receipt of this
Proposal.
(b) The amount of any increase and/or decrease shall be taken into account in the
adjustment of the Contract Price.
(c) Contractor’s cost for preparation of this Change Proposal:2
(Signature)
(Name of signatory)
Annex 5. Change Order
To: _______________________________ Date:
Attention: _______________________________
Contract Name: _______________________________

Contract Number: _______________________________
We approve the Change Order for the work specified in the Change Proposal (No. _______ ),
and agree to adjust the Contract Price, Time for Completion and/or other conditions of the
Contract in accordance with GC Clause 39 of the General Conditions.
1. Title of Change: _______________________________
2. Change Request No./Rev.: _______________________________
3. Change Order No./Rev.: _______________________________
4. Originator of Change: Employer: _______________________________

Contractor: _______________________________
5. Authorized Price:
Ref. No.: _______________________________ Date: __________________________

Foreign currency portion __________ plus Local currency portion __________
6. Adjustment of Time for Completion
None Increase _________ days Decrease _________ days
7. Other effects, if any
Authorized by: Date:

(Employer)
Accepted by: Date:

(Contractor)
Annex 6. Pending Agreement Change Order
To: _______________________________ Date:
Attention: _______________________________
Contract Name: _______________________________

Contract Number: [_______________________________
We instruct you to carry out the work in the Change Order detailed below in accordance with
GC Clause 39 of the General Conditions.
1. Title of Change: _______________________________
2. Employer’s Request for Change Proposal No./Rev.: _______________________________

dated: __________
3. Contractor’s Change Proposal No./Rev.: _______________________________ dated:

__________
5. Facilities and/or Item No. of equipment related to the requested Change:

_______________________________
6. Reference Drawings and/or technical documents for the requested Change:
Drawing/Document No. Description
7. Adjustment of Time for Completion:
8. Other change in the Contract terms:
9. Other terms and conditions:

(Employer’s Name)
(Signature)
(Name of signatory)
Annex 7. Application for Change Proposal
To: _______________________________ Date:
Attention: _______________________________
Contract Name: _______________________________

Contract Number: _______________________________
We hereby propose that the below-mentioned work be treated as a Change in the Facilities.
1. Title of Change: _______________________________
2. Application for Change Proposal No./Rev.: _______________________________ dated:

_______________________________
4. Reasons for Change:
5. Order of Magnitude Estimation (in the currencies of the Contract):
6. Scheduled Impact of Change:
7. Effect on Functional Guarantees, if any:
8. Appendix:
(Signature)
(Name of signatory)

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ZESCO Limited

BIDDING DOCUMENT FOR

Lot 1: Woodlands 33/11kV Substation Upgrade,

Lot 2: Coventry – Kafue 33kV Overhead Line

Lot 3: Industrial – Matero 33kV Corridor Upgrade

This is a blank page

Bidding Document for the Procurement of Transmission Lines

SBD for Procurement of Plant Design, Supply, and Installation

PART 1 – BIDDING PROCEDURES

Section I: Instructions to Bidders (ITB)

Section II. Bid Data Sheet (BDS)

Section III.Evaluation and Qualification Criteria

Section IV: Bidding Forms

Section V. Eligible Countries

Section VI. Bank Policy – Corrupt and Fraudulent Practices

PART 2 – EMPLOYER’S REQUIREMENTS (Volume 1 of 3 )

Section VII. Employer’s Requirements

PART 3 – CONDITIONS OF CONTRACT AND CONTRACT FORMS

Section VIII. General Conditions (GC)

Section IX. Particular Conditions (PC)

contents of this Section modify or supplement the General Conditions and

Section X: Contract Forms

Standard Bidding Document

PART 1 – Bidding Procedures ................................................................................................... 1

This page left blank

This is a blank page.

OPTION A: Single Stage Bidding

This is a blank page.

Section I. Instructions to Bidders

26. Bid Opening ...............................................................................................................22

Section I. Instructions to Bidders

sub-consultants, service providers or suppliers and to permit

(b) the JVA shall nominate a Representative who shall have

4.2 A Bidder, and all partners constituting the Bidder, originating

(a) they have a controlling partner in common; or

(b) they receive or have received any direct or indirect

(c) they have the same legal representative for purposes of

(d) they have a relationship with each other, directly or

(e) a Bidder submits more than one bid in this bidding

4.4 An individual or entity shall be ineligible to be prequalified

Charter of the United Nations, the Borrower’s country

Contents of Bidding Document

 Section I. Instructions to Bidders (ITB)

 • Section VI Bank Policy- Corrupt and fraudulent

 Section VII. Employer’s Requirements

PART 3 Conditions of Contract and Contract Forms

 Section VIII. General Conditions (GC)

 Section X. Contract Forms

7.4 The Bidder’s designated representative is invited to attend a

be in another language provided they are accompanied by an

Section IV, Bidding Forms.

(iii) The total price for the item.

of Bid the price reductions applicable to each package, or

(c) a cashier’s or certified check; or

partners as named in the letter of intent referred to in ITB 4.1.

21.4 Any interlineations, erasures, or overwriting shall be valid

Submission and Opening of Bids

obligations of the Employer and Bidders previously subject to

with the corresponding bid being substituted, and the

Evaluation and Comparison of Bids

time of Contract award, if any Bidder wishes to contact the

prevail and the latter will be corrected accordingly; and

(b) type, quantity and long-term availability of mandatory

AC = 0.12C + 511Fe + 154*Cu

Dated on ______________ day of _, _