Specs HVPNL PDF

HARYANA VIDYUT PRASARAN NIGAM LIMITED
TECHNICAL SPECIFICATION
FOR CONSTRUCTION OF
TWO PHASE 132 KV S/C LINE ON D/C TOWERS

FROM 132KV SUBSTATION KALANAUR TO 132 KV
TSS MANHERU
Chief Engineer/ MM,

Haryana Vidyut Prasaran Nigam Limited
Shakti Bhawan, Sector-6
Panchkula-134109
Tel/Fax: 0172-2591742
MAY-2016
CONTENTS
S. No. PARTICULARS Page No.
1 Scope of the work and BOQ 1-2

2 Technical specification of tower portion 1-74
3 Drawings for 132kV tower accessories 1-15
4 General Information 1-4
5 Technical specification of ACSR Zebra and Panther conductors 1-20
SECTION-VI (PART-II A)
6 Technical Description of Anti fog Disc insulators 1-15
7 Technical Description of Silicone Polymer Insulators 1-14
8 Technical Description of Bus Post Insulators for 145KV 1-5
9 Hardware Fittings for lines with ACSR Zebra and Accessories for 1-41
lines with ACSR Zebra
10 Standard field quality plan for transmission lines 1-14
11 Pre-Commissioning Check List & Testing Of EHV Lines For 1-12
Charging
12 Guaranteed Technical Particulars 1-21
Scope of the work
i) HVPNL contemplates to carry out transmission works involving construction of following
transmission line as per BOQ (prepared on the basis of tentative route plan) and
technical specifications of this package. Brief description of the work is given below:
Sr. Name of line

No.
1. Two phase 132 KV S/C line on D/C Towers with 0.4 Sq” ACSR conductor
from 132KV S/Stn. Kalanaur to 132 KV TSS Manheru
ii) The scope mainly, but not limiting to, covers detailed survey, profiling & check survey,
tower spotting/optimization of tower location, soil resistivity measurements and
Geological investigation, fabrication and supply of 132kV D/C KRR design towers, for
Zebra conductor including bolts, nuts and washers, hanger, D-shackle and all type of
tower accessories like phase plate, circuit plate, number plate, danger plate, anti-
climbing device etc. selecting type of foundation for different tower heights and casting of
foundation for tower footing, erection of towers, tack welding of bolts and nuts including
supply and application of zinc rich paint, tower earthing, providing of tower footing
protection, fixing of insulator string, stringing of conductors and earth wires alongwith all
necessary line accessories and testing and commissioning of the erected transmission
line.
iii) Scope of the work also covers fabrication and supply of Gantry structures as per
HVPNL design for over/under–crossing the various existing 400 kV/220 kV/ 132 kV/
66kV transmission lines including supply of bolts, nuts and washers, hanger, D-shackle
and all type of accessories like phase plate, circuit plate, number plate, danger plate, etc.
selecting type of foundation, casting of foundation for gantry footing as per HVPNL
design, erection of gantries, tack welding of bolts and nuts including supply and
application of zinc rich paint, gantry earthing, fixing of insulator string, stringing of
conductors and earthwire alongwith all necessary line accessories. All the clauses in the
specification will be relevant for the gantry structures also unless stated otherwise.
iv) Scope also covers supply of conductor and earthwire, Silicone Rubber Polymer
Insulators / anti fog insulator strings and their hardwares, earthwire suspension and
tension clamps and all other line accessories for conductor & earthwire i.e. mid-span
compression joints for conductor and earthwire, repair sleeve for conductor, vibration
damper for conductor and earthwire, flexible copper bond, Bus Post Insulators which
shall be supplied by the Bidder during execution of the project. The Bidder shall clearly
indicate in the offer the sources from where he proposes to procure the raw materials
and the components.
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BOQ for creation of two phase 132 KV S/C line on D/C Towers with 0.4 Sq” ACSR
conductor from 132KV S/Stn. Kalanaur to 132 KV TSS Manheru
Supply Part only Tentative length of line =30 km
Sr. DESCRIPTION
UNIT Qty.
No.
A Towers
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts,
1.
hangers, D-shakle etc. of following 132 kV K.R.R. design Towers
1.1 i) DA type (K.R.R. Design)Tower No. 83
ii) +3 mtr. extn. only No. 11
iii) +6 mtr. extn. only No. 8
1.2 i) DB type (K.R.R. Design) tower No. 11
1.3 i) ‘DC’ type (K.R.R. Design) Tower No. 8
1.4 i) ‘DD’ type (K.R.R. Design) Tower No. 24
iii) +6 mtr. extn. only No. 4
iii) +18 mtr. Extn. only No. 4
1.5 132 kV Gantry (KRR Design) Sets 6
2. Supply of earthing of towers
i) Pipe type Sets 132
ii) Counterpoise type Sets 0
3. Supply of following Tower accessories
i) Danger Plate No. 132
ii) Number Plate No. 132
iii) Phase Plate(set of 2) Sets 50
iv) Circuit Plate No. 132
v) Bird Guard No. 166
vi) Anti climbing device Sets 132
B LINE MATERIAL
4 Conductor (ACSR Zebra:54/7/3.18 mm) Km 60.6
5. Earth wire(7/ 3.15 mm) Km 30.3
6. Anti-Fog type Disc Insulator strings or Silicon Rubber Polymer
Insulator strings *
No.
i) 70 kN 179
No.
ii) 120 kN 204
7 132kV Post Insulators No. 12
8. Hardware Fittings
(a) Single ‘I’ Suspension String Set 166
(b) Single suspension pilot string Set 13
(c) Single Tension string Set 196
(d) Double tension string Set 4
9. Conductor & Earth wire Accessories
i) Mid Span Compression Joint for conductor No. 40
ii) Mid Span Compression Joint for earth wire No. 15
iii) Repair sleeves for conductor No. 12
iv) Flexible copper Bond No. 132
v) Vibration damper for conductor No. 676
vi) Vibration damper for earthwire No. 338
vii) Earth-wire tension clamp No. 100
viii) Earth wire suspension clamp No. 83
Note:- The Bidder shall offer only one of the options for the Insulator strings (A/F disc or Polymer)
out of the two mentioned above in his bid
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SECTION – VI (PART-II)
CONTENTS
CHAPTER-I - TECHNICAL SPECIFICATION FOR TOWERS
CHAPTER-II – GENERAL TECHNICAL REQUIREMENTS
CHAPTER-III (A)-TECHNICAL SPECIFICATION OF CONDUCTOR

AND EARTHWIRE.
CHAPTER-III (B)-TECHNICAL SPECIFICATION OF SILICONE

RUBBER POLYMER AND ANTI-FOG DISC
INSULATORS.
CHAPTER-III (C)-TECHNICAL SPECIFICATION OF BUS POST

INSULATORS.
CHAPTER-III (D)-TECHNICAL SPECIFICATION OF HARDWARE

FITTING AND ACCESSORIES.
CHAPTER-IV - TECHNICAL DATA/INFORMATION (GTP) TO BE

SUBMTTED WITH THE BID
SECTION-VI
(PART-II)
CHAPTER-I
(SECTION –VI, CHAPTER-I)
TECHNICAL SPECIFICATIONS
1.1 General Information and scope
1.1.1 Scope:
This specification covers detailed survey, profiling & check Survey, tower
spotting/optimization of tower location, soil resistivity measurements and
Geotechnical investigation, fabrication and supply of 132kV D/C KRR design
towers including bolts, nuts and washers, hanger, D-shackle and all type of tower
accessories like phase plate, circuit plate, number plate, danger plate, anti-climbing
device etc. selecting type of foundation for different tower pole heights and casting
of foundation for tower pole footing as per design, erection of towers, tack welding
of bolts and nuts including supply and application of zinc rich paint, tower earthing,
providing of tower footing protection, fixing of insulator string, stringing of
conductors and Earth wire alongwith all necessary line accessories and testing and
commissioning of the erected transmission line.
1.1.2 This specification also covers fabrication and supply of Gantry structures as per
HVPNL design for over/under–crossing the various existing 400kV/220kV/ 132 kV/
66kV transmission lines including supply of bolts, nuts and washers, hanger, D-
shackle and all type of accessories like phase plate, circuit plate, number plate,
danger plate, etc. selecting type of foundation, casting of foundation for gantry
footing as per HVPNL design, erection of gantries, tack welding of bolts and nuts
including supply and application of zinc rich paint, gantry earthing, fixing of insulator
string, stringing of conductors and earthwire alongwith all necessary line
accessories. All the clauses in the specification will be relevant for the gantry
structures also unless stated otherwise.
1.1.3 This specification includes the supply of conductor and earthwire, Silicone Rubber
Polymer Insulators / anti fog insulator strings and their hardwares, earthwire
suspension and tension clamps and all other line accessories for conductor &
earthwire i.e. mid-span compression joints for conductor and earthwire, repair
sleeve for conductor, vibration damper for conductor and earthwire, flexible copper
bond, Bus post Insulators which shall be supplied by the Bidder during execution of
the project. The Bidder shall clearly indicate in the offer the sources from where he
proposes to procure the raw materials and the components.
1.1.4 Void.
1.1.5 All the raw materials such as steel, zinc for galvanizing, aggregates, reinforcement
steel and cement for tower foundation, coke and salt for tower earthing etc. bolts,
nuts, washers, D-shackles, hangers, links, danger plates, phase plate, number
plate, circuit plate, anti climbing devices etc, required for tower manufacture and
erection shall be included in the Bidder’s scope of supply, Bidder shall clearly
indicate in the offer, the sources from where he proposes to procure the raw
material and the components.
1.1.6 The entire stringing work of conductor and earthwire shall be carried out by
standard stringing practice. The Bidder shall indicate in the offer, the detail
description of the procedure to be deployed for stringing operation.
2. Page-1
1.1.7 Void.
1.1.8 The following 132kV transmission line is included in the scope of the Bidder for
Deposit work :-
S. N. Name of line
12 Two phase 132 KV S/C line on D/C Towers with 0.4 Sq” ACSR conductor
from 132KV S/Stn. Kalanaur to 132 KV TSS Manheru
The tentative bill of quantities for these lines are indicated in the schedule of
quantities. However, any item(s) though not specifically mentioned, but which are
required to commission the line(s) complete in all respect for safe, efficient, reliable
and trouble free operation shall be deemed to supplied and erected by the Bidder.
a) The scope of the supply and installation of plant and equipment project shall
include, but not limited to the following works:
1. Engineering services,
2. Manufacturing, testing, supply of tower and line goods.
3. Transporting of all materials, equipment to the related Site(s), storage and
equipment preservation at related Site including all services to be required at
customs (i.e. unloading, loading, storing at customs stores and other services at
customs). Remark that Bidder shall hire a suitable storing area which shall be
approved by the HVPNL.
Supervision (i.e. Engineer(s) shall be fully responsible at each Site during the
overall job until commissioning). The Bidder shall identify his supervisors with
curriculum vitae, fifteen (15) days after the signing of the Contract and supervisors
shall not be substituted without the written consent of the HVPNL i.e.
b) i) Construction of civil works,

ii) Complete erection and installation,
iii) Commissioning, Site and acceptance testing
c) i) Supply of the measuring instruments and testing equipment necessary

for the preliminary acceptance tests,
ii) Providing of the special tools, instruments and devices to be used in
erection, testing and putting into operation,
iii)Delivery of the materials and equipment which may be supplied or
manufactured in India, or from abroad to Site including all works through
customs,
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d) i) Training of the personnel authorized by HVPNL if mentioned in specifications
ii) Submission of monthly progress reports.
iii) For the Goods which shall be supplied by HVPNL, if any, (in according to the
Appendix-7 of Contract Agreement), transportation, civil works, erection and
Site testing shall be done by the Bidder.
All precaution shall be done for safe erection and operation.

Connection between substations and dead-end towers, shall be done by the
Bidder if the substations do exist.
Demolishing and dismantling works, if any.
All the works, Goods and services, though not expressly called for in these
Specifications, but necessary for complete and proper operation of the Supplied
Goods and of the transmission line, are considered to be included within the scope of
the project.
The provisions under this Section are indented to supplement general requirements
for the equipment, material, works and services covered under other Sections of
these bidding documents and are not exclusive. However, in case of conflict between
the requirements specified in this Section part 1 and requirements specified under
other Sections, more stringent requirements specified under Sections shall prevail.
1.1.9 It is specifically mentioned that the contractor shall be responsible to provide all
necessary testing and commissioning personnel, tools and plant, testing equipment,
etc. All expenses for carrying out the routine tests as specified in relevant standard
shall be to contractor’s account. However the expenses w.r.t. purchaser/purchaser’s
representative for witnessing these tests which contractor shall take into account shall
be as follows:-
a) For Inspections/tests to be carried out for equipment offered from within purchaser’s
country, all tour expenses shall be borne by purchaser.
b) For inspections/tests to be carried out for equipment offered from outside
purchaser’s country:-
It is envisaged that inspection/testing of all such equipment shall be witnessed.
Each inspection shall be carried out by a team of 2 engineers nominated by the
purchaser. Their To & Fro travel expenditure from purchaser’s country to the place
of inspection/testing shall be borne by the bidder including all boarding and lodging
charges.
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1.1.10 LOCATION DETAILS:
The above lines will be laid in the state of Haryana. The contractor shall have to
erect/ modify/re-align/shift the 220kV, 132kV & 66kV transmission lines completely
including interfacing/ termination with existing line(s)/ substations.
1.2 Detail of Transmission Line Routes and Terrain.

The transmission lines under this package will be running almost through
congested Urban/ Industrial/plain /irrigated farm land/cultivated area/ railway
corridor.
Tentative route survey of transmission lines covered under this package indicating
the general topography and major crossings like river, power lines, Railways line &
Roads are enclosed with this specification for Bidder’s reference. There are few
small rivers/distributes/Nalas, small hills etc. to be crossed by the line in the above
package. However, these rivers/Nalas etc are envisaged to be crossed by normal
towers or strengthened normal tower to suit specific locations.
1.3 Result of surveys

The details collected through preliminary surveys viz line route, general soil
characteristics, crossings, accessibility and infra-structure details are attached for
the Bidder’s reference.
1.4 ACCESS TO THE LINE AND RIGHT TO WAY

Right of way and way leave clearance shall be arranged by the HVPNL in
accordance with work schedule. HVPNL will secure way leave and right of way in
the forest area, if any.
1.5 DETAILED SURVEY, OPTIMISATION OF TOWER LOCATION

1.5.1 The HVPNL has carried out the tentative survey of transmission lines under this
package. However, detailed survey including profiling, tower optimization and
spotting shall be carried out by the successful Bidder as stipulated herein.
The Bidder shall finalize complete detailed surveys including any changes and will
submit the route plans within 2 months (60 days) of issue of LoI. The soil
investigation for the obligatory points shall be carried out by the successful bidder.
The Bidder is strongly advised to visit and examine the site of works and its
surroundings and obtain for himself at this own responsibility and expense, all
information regarding terrain of the proposed line, line route, general site
characteristics, crossing, accessibility, infrastructure details etc. The cost of visiting
the site shall be at Bidder’s own expense. The HVPNL will assist the interested
Bidder to see & inspect the site of works. For this purpose Bidders are requested to
contact.
Chief Engineer/TS, HVPNL, Hisar TEL. No. 01662-220794

Page-4
1.5.2 The Bidder should note that HVPNL will not furnish the topographical maps
prepared by survey of India but will make available any assistance that may be
required in obtaining the topographical maps.
1.5.3 Soil resistivity along the route alignment, shall be measured in dry weather by
four-electrode method keeping spacing of 50 metres. For calculating soil
resistivity, formula 2PI ar (where a =50 metres and r=megger reading in ohms,
PI=3.14) shall be adopted. Measurement shall be made at every 2 to 3 km along
the route of transmission lines. In case soil characteristic changes within 2 to 3
km, the value shall also have to be measured at an intermediate locations. The
megger reading and soil characteristics shall also be indicated in the soil
resistivity results.
1.5.4 ROUTE MARKING
At the starting point of the commencement of route survey, an angle iron spike of
65x65x6 mm section and 1000 mm long shall be driven firmly into the ground to
project only 150 mm above the ground level. A punch mark on the top section of
the angle iron shall be made to indicate location of the survey instrument. Teak
wood peg 50x50x650 mm size shall be driven at prominent position at intervals of
not more than 750 meter along the transmission line to be surveyed upto the next
angle point. Nails of 100mm wire should be fixed on the top of these pegs to show
the location of instrument. The pegs shall be driven firmly into the ground to
project 100 mm only above ground level. At angle position stone/concrete pillar
with HVPNL marked on them shall be put firmly on the ground for easy
identification.
1.5.5 PROFILE PLOTTING & TOWER SPOTTING
From the field book entries, the route plan with enroute details and level profile
shall be plotted and prepared to scale of 1:2000 horizontal & 1:200 vertical on 1.0,
10 mm squared paper as per approved procedure. Reference levels at every 20
metres along the profile are also to be indicated on the profile besides, reduced
levels at undulations. Areas along the profile, which, in the view of the Bidder, are
not suitable for tower spotting, shall also be clearly marked on the profile plots. If
the difference in levels be too high, the chart may be broken up according to
requirement. A 10mm overlap shall be shown on each following sheet. The chart
shall progress from left to right. Sheet shall be 594 mm wide in accordance with
the IS. For ‘as built’ profile these shall be in A1 size.
1.5.6 TOWER LOCATION
1.5.6.1 SAG TEMPLATE
Necessary data in respect of conductor, earthwire shall be provided by HVPNL.

On the basis of these, the successful Bidder shall prepare the sag template
drawing for each type of design w.r.t. conductor. Sag template prepared based on
the approved sag-template curve drawing shall only be used for tower sporting on
the profiles. Two numbers of the approved template, prepared on rigid
transparent plastic sheet, shall be provided by the Bidder to the HVPNL for the
purpose of checking the tower spotting. The templates shall be on the same scale
as that of the profile.
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1.5.6.2 TOWER SPOTTING
With the help of approved sag template and tower spotting data, tower locations
shall be marked on the profiles. While locating the towers on the profile sheet,
the following shall be borne in mind.
a) SPAN
The number of consecutive spans between the section points shall not exceed
15 in Plain. A section point shall comprise of tension point as under as
applicable: -
For D/C line ‘DB’ type or DC type or DD type
For M/C line M/C MB, MC or MD type towers
b) EXTENSION
An individual span shall be as near to the normal design span as possible. In

case an individual span becomes too short with normal supports on account of
undulations in ground profile, one or both the supports of the span may be
extended by inserting standard body extension designed for the purpose
according to technical specification.
c) ROAD CROSSING
At all important road crossings, the towers shall be fitted with normal suspension
or tension insulator strings depending on type of tower but the ground clearance
at the highest point on the road under maximum temperature and still air be
such that even with conductor bundle broken in the adjacent, the ground
clearance of the conductor from the road surface will not be less than that
specified in CEA Regulations 2010/ other relevant standards/ statute.
At all National Highways, tension towers with double insulator strings on
crossing side shall be used, the crossing span however will not be more than
250m, in any case.
d) RAILWAY CROSSINGS
All the railway crossings coming enroute the transmission line have already
been identified by the HVPNL. At the time of detailed survey, the Railway
crossings shall be finalized as per the regulation laid down by the Railway
Authorities. The following are the important features of the prevailing regulations
(revised in 1987):
i) The crossing shall be supported on DD type tower on either side
depending on the merits of each case and double tension insulator string
shall be used on both the towers on the side of the crossing.
ii) The crossing shall normally be at right angle to the Railway track.
iii) The minimum distance of the crossing tower shall be at least equal to the
height of the tower plus 6 metres away measured from the center of the
nearest Railway track.
iv) No crossing shall be located over a booster transformer, traction

switching station, traction sub-station or a track cabin location in an
electrified area.
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v) Minimum ground clearance above Rail level of the lowest portion of any
conductor under condition of maximum sag shall be maintained as per
latest Railway regulations amended from time to time.
The approval for crossing Railway track shall be obtained by the HVPNL
from the Railway Authorities, however six copies of profile and plan,
tower and foundation design and drawings, required for the approval from
the Railway Authorities shall be supplied by the Bidder to the HVPNL.
e) In case of major river crossing, towers shall be of suspension type and the
anchor towers on either side of the main river crossing shall be ‘DD’ type tower.
For navigable river, clearance required by navigation authority shall be provided.

For non-navigable river, clearance shall be reckoned with respect to highest
flood level (HFL).
f) POWER LINE CROSSINGS
Where the line is to cross over another line of the same voltage or lower
voltage, the tower with suitable extensions shall be used. Where the line is to
cross under the 400 kV power lines, gantries shall be used. Provisions to
prevent the possibility of its coming into contact with other overhead lines shall
be made in accordance with the India electricity rules, 1956/CBIP Manual. In
order to reduce the height of the crossing towers it may be advantageous to
remove the ground wire of the line to be crossed (if this is possible and
permitted by the HVPNL of the line to be crossed). All the works related to the
above proposal shall be deemed to be included in the scope of the Bidder
except if modifications are required to line below, in which case, the conditions
to be agreed upon. Suitable Extension for towers over 11kV line crossing shall
be used, where requisite electrical as per I.E. rules is not available.
g) TELECOMMUNICATION LINE CROSSING
The angle of crossing shall be as near to 90 o as possible. However, deviation to

the extent of 30o may be permitted under exceptionally difficult situations.
When the angle of crossing has to be below 60 o, the matter will be referred to
the authority inchage of the telecommunication system. On a request from the
Bidder, the permission of the telecommunication authority may be obtained by
the HVPNL. Also, in the crossing span, power line support will be as near the
telecommunication line as possible, to obtain increased vertical clearance
between the wires. However, Assistance will be sought from the Bidder.
Successful bidder would prepare & provide all necessary documents, on
prescribed formats, to enable HVPNL obtain PTCC approval for the
transmission line(s).
h) DETAILS ENROUTE
All topographical details, permanent features, such as trees, building etc. 17.5 m
for 220kV, 13.5m for 132kV & 9.0m for 66kV on either side of the alignment
shall be detailed on the profile plan.
Page-7
1.5.7 CLEARANCE FROM GROUND, BUILDING, TREES ETC.
Clearance from ground, buildings, trees and telephone lines shall be provided in
conformity with the Indian Electricity rules, 1956/ CEA Regulations 2010 as
amended up to date.
1.5.8 The tree cutting shall be the responsibility of the HVPNL except for that required
during survey. However, the Bidder shall count, mark and put proper numbers
with suitable quality of paint at his own cost on all the trees that are to be cut by
the HVPNL at the time of actual execution of the work. Bidder may please note
that HVPNL shall not pay any compensation for any loss or damage to the
properties or for tree cutting due to Bidder’s work.
1.5.9 Any way leave, which may be required by the Bidder, shall be arranged by the
HVPNL as required by work programme.
1.5.10 To evaluate and tabulate the trees and bushes coming within 17.5 m on either
side of the central line alignment, the trees will be numbered and marked with
quality paint serially from angle point 1 onwards and the corresponding number
will be painted on the stem of trees at a height of 1 meter from ground level. The
tree list should contain the following: -
a) Girth (circumference) measured at a height of 1 meter from ground level.
b) Approximate height of the tree with an accuracy of ±2 metres.
c) Name of the type of the species/tree.
d) The bushy and under growth encountered within the 35 m belt should also be
evaluated with its, height, girth and area in square metres, clearly indicating
the growth in the tree/bush statement.
1.5.11 Payment of compensation toward the clearances etc. will be the responsibility
of the HVPNL.
1.5.12 PRELIMINARY SCHEDULE

The profile sheets, duly spotted, alongwith preliminary schedule indicating
type of towers, type of foundations, wind span, weight span, angle of
deviation, river or road crossing and other details shall be submitted for the
approval of the HVPNL. After approval, the Bidder shall submit six more sets
of the approved reports along with one set of reproducible of final profile
drawings to the HVPNL for record purpose.
1.5.13 CHECK SURVEY OF TOWER LOCATION
1.5.13.1 The check survey shall be conducted to locate and peg mark the tower
positions on ground conforming to the approved profile and tower schedule. In
the process, it is necessary to have the pit centers marked according to the
excavation marking charts. The levels, up or down of each pit center with
respect to the center of the tower location shall be noted and recorded for
determining the amount of earthwork required to meet the approved design
parametres.
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1.5.13.2 Changes, if required, after check survey in the preliminary tower schedule
shall be carried out by the Bidder and he shall thereafter submit a final tower
schedule for the approval of HVPNL. The tower schedule shall show position
of all towers, type of towers, span length, type of foundation for each towers
and the deviation at all angles as set out with other details.
1.6 ENVIRONMENTAL CONDITIONS
1.6.1 GENERAL CLIMATIC CONDITIONS
The area is in the extreme climate belt, Monsoons are generally active from the
months of July to September. The working season shall be approximately nine
months per year.
The maximum temperature during summer shall be of the order of 50 o C and the
minimum temperature shall be of the order of -2oC. Normal everyday temperature
is 320C.
1.7 TECHNICAL DATA
Bidders shall furnish all technical data as per relevant schedules in five copies.
1.8 STATUTORY REGULATIONS AND STANDARDS
1.8.1 STATUTROY REGULATIONS
The contractor is required to follow local statutory regulations stipulated in

electricity (supply) Act. 2003, Indian Electricity rules 1956, CEA (Measures
relating to Safety & Electric Supply) Regulations 2010, CEA (Technical
Standards for Construction of Plants & Electric Lines) Regulations 2010 as
amended and other local rules and regulations referred to in this specifications.
1.8.2 REFERENCE STANDARDS
1.8.2.1 The codes and/or standards referred to in specification shall govern. In all cases
wherever such references are made. In case of a conflict between such codes
and/or standards, and the specifications, latter shall govern. Such codes and/or
standards, referred to shall mean the latest revisions, amendments/changes
adopted and published by the relevant agencies.
1.8.2.2 Other in internationally acceptable standards, which ensure equivalent or better

performance than those specified shall also be accepted.
1.9. QUALITY ASSURANCE, INSPECTION AND TESTING
1.9.1 QUALITY ASSURANCE
1.9.1.1 To ensure that the supply and services under the scope of this contract whether
manufactured or performed within the Bidder’s works or at his sub-contactor’s
premises or at site or at any other place of work are in accordance with the
specifications, the Bidder shall adopt suitable quality assurance programme to
control such activities at all points necessary. Such programme shall out lined by
the Bidder shall be finally accepted by the HVPNL after discussion before the
award of the contract. A quality assurance programme of the Bidder shall
generally cover but not limited to the following:
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a) His organization structure for the management and implementation of the
proposed quality assurance programme.
b) Documentation control system.
c) Qualification data for Bidder’s key personnel.
d) The procedure for purchases of materials parts/components and selection of

sub-Bidder’s services including vendor analysis, source inspection, incoming raw
material inspection, verification of material purchase etc.
e) System for shop manufacturing including process controls and fabrication and
assembly controls.
f) Control of non-conforming items and system for corrective action.
g) Control of calibration and testing of measuring and testing equipments.
h) Inspection and test procedure for manufacture.
i) System for indication and appraisal of inspection status.
j) System for quality audits.
k) System for authorising release of manufactured product to the HVPNL.
l) System for maintenance of records.
m) System for handing storage and delivery.
n) A quality plan detailing out the specific quality control procedure adopted for
controlling the quality characteristics relevant to each item of supply.
The quality plan shall be mutually discussed and approved by the HVPNL after
incorporating necessary corrections by the Bidder as may be required.
1.9.1.2 QUALITY ASSURANCE DOCUMENTS
The Bidder shall be required to submit all the quality assurance documents as
stipulated in the quality plan at the time of HVPNL inspection of material.
1.9.1.3 The HVPNL, through his duly authorized representatives, reserves the right to
carry out quality audit and quality surveillance of the system and procedures of
the Bidder’s/his sub-Bidder’s quality management and control activities.
1.9.2 INSPECTION,TESTING AND INSPECTION CERTIFICATE
The provision of the clause regarding inspection, testing and inspection certificate as
described in conditions of contract shall be applicable to the supply and erection
portion of the works. The HVPNL shall have the right to re-inspect at his expenses
any material though previously inspected and approved by him at the Bidder’s works,
before and after the same are erected at site. If following the latter, material is found
defective, then the Bidder shall bear the cost of this inspection and reinstatement
according to specification
Page-10
1.10 TECHNICAL PARAMETRES
a) 66 KV LINE
Electrical system data
a) Nominal voltage 66 kV
b) Maximum system voltage 72.5 kV
c) BlS (Impulse) 325 KV (peak)
d) Power frequency withstand voltage (wet) 140 KV (rms)
b) 132 KV LINE
b) Maximum system voltage 145 kV
c) BIL (Impulse) 650 KV (peak)
c) 220 KV LINE
b) Maximum system voltage 245 kV
c) BIL (Impulse) 1050 KV (peak)
e) Minimum corona extinction 154 KV(rms)

voltage at 50Hz AC system
under dry condition
f) Max. Radio interference voltage 1000 microvolts

at one MHz for phase to earth
voltage of 154 KV under dry condition.
Page-11
2.0 DETAILS OF LINE MATERIAL FOR 220 KV, 132kV & 66kV LINEs:
Particulars of Conductor and Earthwire:
S. N. Particulars Conductor ACSR Earthwire

1 Type Zebra ACSR Glavanised
conductor Panther steel
2 Stranding and wire
diameter
a) Aluminium mm 54/3.18 30/3.00 -
b) Steel mm 7/3.18 7/3.00 7/3.15
3 Total sectional area Sq. mm 484.5 261.5 54.55
4 Approximate mm 28.62 21.00 9.45
overall diameter
5 Approximate mass Kg/km 1621 974 428
6 Calculated DC ohm/km 0.06868 0.140 2.95
resistance at 20
deg. Centigrade
(Max.)
7 Approximate kN 130.32 89.67 57
calculated breaking
load
8 Modulus of Kg/cm2 7034 8158 19369
elasticity
9 Co-efficient of Per 19.30x10-6 17.8x10-6 11.5x10-6
linear expansion degree
centigra
de
10 Mass of zinc Gm/sq. 260 240
coating m
11 Configuration of - vertical formation
conductor
12 Location of One
earthwire - - - continuous
earthwire
to run
horizontally
above the
conductors
Page-12
2.1 PARTICULARS OF SILICONE POLYMER INSULATOR STRINGS FOR 220kV LINES WITH
ACSR ZEBRA & 132kV/66KV LINES WITH 0.4 SQ” ACSR ZEBRA/ 0.2SQ” ACSR PANTHER :
Sr Type of Dia of FRP Minimum No. of EM Mechanical

No String rod & Creepage Individual strength strength of
Length of Distance units per of Insulator
Composite (mm) string Insulator string
Insulator (Nos.) Unit (KN) alongwith
(mm) Hardware
fittings(kN)
220kV LINE ON ACSR ZEBRA (0.4 SQ”)
1 Single 20X2030 7595 1X1 70 70
Suspension
2 Double 20X2030 7595 2X1 70 2X70
Suspension
3 Single pilot 20X2030 7595 1X1 70 70
Suspension
4 Single 20X2175 7595 1X1 120 120
Tension
5 Double 20X2175 7595 2X1 120 2X120
Tension
132kV LINE ON ACSR PANTHER (0.2 SQ”)
1 Single 20X1305 4495 1X1 70 70
Suspension
2 Single pilot 20X1305 4495 1X1 70 70
Suspension
3 Single 20X1450 4495 1X1 90 90
Tension
4 Double 20X1450 4495 2X1 2X90 2X90
Tension
1 Single 20X1305 4495 1X1 70 70
Suspension
2 Single pilot 20X1305 4495 1X1 70 70
Suspension
3 Single 20X1450 4495 1X1 120 120
Tension
4 Double 20X1450 4495 2X1 2X120 2X120
Tension
1 Single 20X725 2248 1X1 70 70
Suspension
2 Single pilot 20X725 2248 1X1 70 70
Suspension
3 Single 20X870 2248 1X1 120 120
Tension
4 Double 20X870 2248 2X1 120 2X120
Tension
Page-13
66kV LINE ON ACSR PANTHER (0.2 SQ”)
1 Single 20X725 2248 1X1 70 70
Suspension
2 Single pilot 20X725 2248 1X1 70 70
Suspension
3 Single 20X870 2248 1X1 90 90
Tension
4 Double 20X870 2248 2X1 90 2X90
Tension
2.2 PARTICULARS OF INSULATOR STRINGS WITH A/F DISC INSULATORS FOR ACSR
ZEBRA AND PANTHER LINES(70KN FOR SUSPENSION STRINGS, 90kN FOR
PANTHER TENSION STRING & 120KN FOR ZEBRA TENSION STRING) :
Sr Particulars Single Double Double tension Single tension
No suspension suspension string string
string /pilot string
Strings
1 Size of disc mm 255x145 255x145 280x145(Zebra) 280x145(Zebra)
255X145(Panther) 255X145(Panther)
2 E&M strength of 70 70 120 (Zebra) 120 (Zebra)
each insulator 90 (Panther) 90 (Panther)
disc (KN)
3 Size & 16, Alt-B 16, Alt-B 20 (Zebra) 20 (Zebra)
designation of 16, Alt-B 16, Alt-B (Panther)
pinball shank (Panther)
mm
4 Minimum 432 432 432 432
creepage
distance of each
disc mm
Note: No. of A/F discs for 132 kV line: 9 nos. for suspension string & 10 nos. for tension string
No. of A/F discs for 66 kV line: 5 nos. for suspension string & 6 nos. for tension string
2.3 INSULATOR STRING HARDWARE
a) Anchor shackle
b) Ball Hook
c) Chain link
d) Yoke plate
e) Ball clevis
f) Arcing horn holding plate
g) Socket clevis
h) Arcing horns
i) Clevis eye
j) Free center type/armour grip suspension clamp for suspension strings and envelope
type clamp for ‘pilot’ suspension string for jumper support.
k) Compression type dead end clamp.
2.4 ACCESSORIES FOR CONDUCTOR AND EARTHWIRE
a) Mid-span compression joints
b) Repair sleeves for conductor
c) Flexible copper bonds
d) Vibration dampers for conductor and earthwire
e) Suspension clamps for earthwire
f) Tension clamps for earthwire
g) Preformed Armour rods.
Page-14
3. TRANSMISSION TOWERS
3.1 General Description of the Towers
3.1.1 The contractor is to fabricate and supply, as per BOQ/ final approved route, the
220kV/132kV/66kV towers of the following types:
a) 220kV D/C towers of TATA Design.
b) 220kV Multi-Ckts. Towers (4-Ckts) MA, MB, MC, & MD type Normal towers and
Special Extension MB & MD type towers with +9m to +15 m Extensions of KRR
Design.
c) 66kV D/C towers of KRR Design with requisite extensions and auxiliary cross
arms.
d) 132KV D/C towers (DA, DB, DC & DD type) of KRR design with requisite
extensions and auxiliary cross arms.
e) 132kV S/C Dead End 4 Pole Structure (Rail pole) as per technical requirement
clause No. 3.4.4.
3.1.2 The towers are of self supporting lattice steel type, designed to carry the line conductors
with necessary insulators, earthwires and all fittings under all loading conditions.
3.1.3 The tower shall be fully galvanized structure. The towers to be fabricated have a
combination of two grades of steel, as detailed in respective structural drawing / bill of
material. One is MS steel and other is HT steel.
3.2 TYPE OF TOWERS, AS APPLICABLE

3.2.1 The Towers are classified as given below :-
a) 220kV TATA DESIGN TOWERS:

The towers are classified as given below for 220 KV & 66 kV lines.
Type of Tower Deviation limit Typical use
DA 0 deg.-2 deg. To be used as tangent tower
DB 2 deg.-15 deg. a) Angle towers with tension

insulators string
b) Tension towers for uplift
forces resulting from an uplift
span up to 200 m.
c) Also designed for anti-
cascading condition.
DB 0 deg. d) To be used as section tower
DC 15 deg.-30 deg. a) Angle towers with tension

insulators string
span up to 200 m.
Page-15
DD 30 deg.-60 deg. a) Angle towers with tension
insulators string
span up to 200 m.
DD 0 deg. a) Complete dead end with 0

deg. To 15 deg. deviation both
on line and sub-station side
(slack span).
b) For river crossing anchoring
with longer wind span with 0
deg. deviation on crossing span
side and 0 deg. to 30 deg.
Deviation on other sides.
Note: The above towers can also be used for longer span with smaller angle of deviations.
b) 220kV M/C KRR DESIGN TOWERS:
The Multi-Circuit KRR design towers of HVPNL are of two(2) types i.e. Normal Multi-
circuit towers to be used upto +6m Extension and Special MB & MD type Multi-circuit
towers to be used with +9m , +12m & +15m Extensions as classified below :-

MA 0 deg.-2 deg. To be used as tangent tower
MB 2 deg.-15 deg. a) Angle towers with tension

insulators string
span up to 188 m.
MB 0 deg. d) To be used as section tower
Special MB 0 to 7 deg. a) Angle towers with tension

Type tower insulators string
With +9m,
+12m & 15m
Extensions.
MC 15 deg.-30 deg. a) Angle towers with tension

insulators string
span up to 188 m.
Page-16
MD 30 deg.-60 deg. a) Angle towers with tension
insulators string
span up to 188 m.
MD 0 deg. a) Complete dead end with 0
deg. To 15 deg. deviation both
on line and sub-station side
(slack span).
b) For river crossing anchoring
deg. deviation on crossing span
side and 0 deg. to 30 deg.
Deviation on other sides.
Special MD 0 deg. Angle towers with tension
Type tower insulators string
With +9m,
+12m & 15m
Extensions.
C) 132 KV D/C KRR DEDIGN TOWERS:-
DA 0 deg.-2 deg. To be used as tangent tower
DB 2 deg.-15 deg. a) Angle towers with tension insulators

string
b) Tension towers for uplift forces
resulting from an uplift span up to 200
m.
c) Also designed for anti-cascading
condition
DB 0 deg. d) To be used as section tower

DC 15 deg.-30 deg. a) Angle towers with tension insulators
string
m.
c) Also designed for anti-cascading
condition
DD 30 deg.-60 deg. a) Angle towers with tension insulators
string
m.
550 When DD type tower used with +12m

to +25m Extension by restricting the
span to 250m.
DD 0 deg. Dead end with 0 deg. To 15 deg.
deviation on sub-station side (slack
span)
Page-17
D) 66 kV D/C KRR DESIGN TOWERS:-
DA/DE 0 deg. to 2 deg. To be used as tangent tower.
Spl. Extn. of DE 0 deg. to be restricted To be used at wind span of

(+9m to +18m) 175m
DB/DF 0 deg. to 15 deg. a) Tension towers with tension

insulators string.
forces resulting from an
uplift span upto 150 m.
c) Also to be designed for anti-
0 deg. d) To be used as Section
Tower
Spl. Extn. of DF 5 deg. to be restricted

(+9m to +12m)
DC/DG 15 deg. to 30 deg. a) Tension towers with tension

insulators string.
c) Also to be designed for anti-
Spl. Extn. of DG 20 deg. to be restricted
(+9m to +12m)
DD/DH 30 deg.-60 deg. a) Tension towers with tension

insulators string.
c) Dead end with 0 deg. to 15
deg. deviation both on line
and substation side (slack
span).
Spl. Extn. of DH 40 deg. to be restricted

(+9m to +18m
DD/DH 0 deg. d) Complete Dead end.

e) For river crossing anchoring
deg. deviation on crossing
span side and 0 to 30 deg.
deviation on other side.
Page-18
3.2.2 EXTENSIONS FOR 220KV D/C TATA DESIGN, 132 kV KRR Design & 66KV KRR
DESIGN
3.2.2.1 The Multi-Circuit KRR design towers of HVPNL are of two (2) types i.e. Normal Multi-
circuit towers to be used upto +6m Extension and Special MB & MD type Multi-circuit
towers to be used with +9m , +12m & +15m Extensions.
3.2.2.2 The towers are designed for adding 3 M, 6 M, 9 M, 12 M, 15 M, 18 M, & 25M body
extensions for 220kV D/C TATA design towers for maintaining adequate ground
clearance without reducing the specified factor of safety in any manner.
3.2.2.3 132 kV D/C KRR Design towers have been designed for adding 3 M, 6 M, 9m, 12m,
15m, 18m & 25m body extensions for maintaining adequate ground clearance without
reducing the specified factor of safety in any manner.
3.2.2.4 The towers are designed for adding 3 M, 6 M, 9 M, 12 M, 15 M, 18 M, body

extensions for 66kV D/C KRR design for maintaining adequate ground clearance
without reducing the specified factor of safety in any manner
3.2.2.5 All above extension provision to normal towers shall be treated as part of normal
tower only.
3.3 SPANS AND CLEARNACES
3.3.1 NORMAL SPAN

A) For 220kV, 132kV & 66kV line towers :-
a) The normal span of 220kV TATA design towers with ACSR Zebra is 350m.
b) The normal span for normal 220kv Multi-circuit towers (i.e. upto +6m Extension) is
250m.
The special Extension “MB+9/+12/+15” tower has been designed with a wind
span of 200m and angle of deviation of 70.. This tower shall be strictly used as
per design.
The Special Extension “MD+9/+12/+15” tower has been designed for Dead End
condition and third cross-arm with 900 deviation (with slack Tension) for a
wind span of 100m. This tower shall be strictly used as per design.
(c) The normal ruling span of 132kV KRR design towers with ACSR ZEBRA shall be
300 meters. However the span length for DD type tower for using it with
+12m, +18m & +25m Extension shall be restricted to 250m with angle of
Deviation of 550 only
d) The normal span of 66kV KRR design towers with ACSR ZEBRA is 275m.
However, the special extn. of DE type tower shall be restricted to 175m.
3.3.2 WIND SPAN

The wind span is the sum of the two half spans adjacent to the support under
consideration. For normal horizontal spans this equal to normal ruling span.
3.3.3 WEIGHT SPAN
The weight span is the horizontal distance between the lowest point of the conductors on
the two spans adjacent to the tower. The weight spans considered for design of towers
are as below:
Page-19
A) For 220kV KRR Design normal M/C Towers:
The weight span is the horizontal distance between the lowest point of the conductors
on the two spans adjacent to the tower. The weight spans considered for design of
towers are as below:
Tower type Normal condition Broken wire condition
Max. Min. Max. Min.
(m) (m) (m) (m)
MA 375 225 188 100
MB, MC, MD 375 0 188 -188
B) For 220kV TATA Design Towers:

Max. Min. Max. Min.
(m) (m) (m) (m)
DA 525 200 315 100
DB, DC, DD 525 0 315 -200
C) For 66kV KRR Design Towers:

Max. Min. Max. Min.
(m) (m) (m) (m)
DA 413 165 248 90
DB, DC, DD 413 0 165 -150
D) For 132kV KRR Design normal D/C Towers:
S.No. Tower type Normal condition Broken wire condition

Max. Min. Max. Min.
(m) (m) (m) (m)
1 DA 450 270 225 100
DB, DC, DD 450 -200 225 -100
2 DD type tower 375 188 0 -100

when used with
+12/+18/+25m
Extns.
Page-20
3.3.4 ELECTRICAL CLEARANCES

3.3.4.1 GROUND CLEARANCE
The minimum ground clearances shall be maintained as per latest relevant CEA
Regulations 2010/ rules. The min. ground clearances from the bottom conductor shall not
be less than 6.1m at the max. sag conditions i.e. at max. temperature (75oC) and still air
for 132kV lines and 7.1m for 220kV lines. However, to achieve the above clearance the
height of tower has been increased in the following manner:
a) An allowance of 150 mm shall be provided to account for errors in stringing.
b) Conductor creep shall be compensated by over tensioning the conductor at
temperature of 210 & 26oC lower than the stringing temperature for ACSR Panther
& Zebra respectively.
For river crossing tower the minimum electrical clearance including ground clearance will
be same as normal towers except an allowance of 4% of maximum sag of conductor
instead of 150 mm for normal towers shall be provided to account for errors in stringing.
3.3.4.2 RAIL CROSSING
In case of Rail crossing the min. height above Rail level of the lowest portion of any
conductor under condition of max. sag, in accordance with the regulation for Electrical
crossing of Railway tracks as prevailing at the time of construction of line shall be
applicable.
3.3.4.3 POWER LINE CROSSING

Minimum clearance between power line to power line shall be as follows:
i) 66 kV to 66 kV and below: 2440 mm

ii) 132 kV to 132 kV and below: 3050 mm
ii) 220 kV to 220 kV and below: 4580 mm
iii) 220 kV to 400 kV 5490 mm
3.3.4.4 LIVE METAL CLEARANCE

The minimum live metal clearance to be provided between the live parts and steel work
of super structure shall be as per IS:5613 (part-ii/sec-1) 1985 as given in table below:
For 220kV
S. N Type of insulator string Swing in deg. Min. live metal clearance in mm
220 kV 132 kV 66 kV
1 Single suspension Nil 2130 1530 915
insulator string 15 1980 1530 915
30 1830 1370 760
45 1675 1220 610
60 - 1070 610
2 Tension insulator string Nil 2130 1530 915
(single/double)
Page-21
3 Jumper Nil 2130 1530 915
10 2130 1530 915
20 1675 1070 610
30 - 1070 610
4 Double suspension string Nil 2130 1530 915
15 1980 1530 915
30 1830 1070 610
45 1675 1070 610
3.3.5 MID SPAN CLEARNACE

The minimum vertical mid span clearance between the earthwire and the nearest power
conductor shall not be less than 8.5 metres for 220 kV, 6.1 metres for 132 kV and 3.0
meters for 66 kV which shall mean the vertical clearance between earthwire and the
nearest conductor under all temperatures and still air condition in the normal ruling span.
Further, the tensions of the earthwires and power conductors shall be so co-ordinated
that the sag of earthwire shall be at least 10% less than that of power conductors under
all temperature loading conditions.
3.4.1.1 MAXIMUM TENSION
3.4.1.1 Max tension shall be based on either
a) At 0o C with 36% full wind pressure, or
b) At 32o C with full wind pressure whichever is more stringent.
3.4.1.2 The sag-tension calculations for all type of towers is available with HVPNL except
those for panther conductor and will be supplied to successful bidder after award of
contract.
3.4.1.3 The initial conductor tension at 32oC and without wind shall be 22% of the ultimate
tensile strength of the conductor.
3.4.2 LIMITING TENSION OF CONDUCTOR & EARTHWIRE
The ultimate tension of conductor and ground wire shall not exceed 70 percent of their
ultimate tensile strengths.
3.4.3 CONDUCTOR AND EARTHWIRE CONFIGURATION
The three phases shall be in near vertical formation on both sides of tower. The
phase to phase spacing for tower shall be not less than 4.9 metres (vertical) and 8.4
metres (horizontal) for 220kV M/C tower & D/C tower and 2.06 metres (vertical) and
4.88 metres (horizontal) for 66kV towers. The phase to phase spacing for 132kV
tower shall be not less than 4.05 metres (vertical) and 7.06 metres (horizontal).
3.4.4 Technical requirement for 66kV 4 Pole Dead End Structure (Rail pole), if
applicable
3.4.4.1 The structure is designed for a span of 350’ with ACSR conductor 30/.102” +7/.102” &
GSS earthwire 7/0.11”. The structure is designed for a span of 300’ with ACSR
Conductor 30/0.118”+7/0.118” Panther. The structure has been designed to be used
as dead end termination structure.
Page-22
3.4.4.2 For negotiating any other angle, suitable no. of stays be provided in the transverse
direction at 5’ below X-arm level. Suitable No. of stays in the longitudinal direction be
provided at the time of stringing. The structure is designed at a wind pressure of
520Lbs/SQ’.
3.4.4.3 All bolts are of ⅝” dia with 11/6” dia holes, unless otherwise specified.
3.4.3.4 Foundation is designed for normal soil only. In case of water-logged, special foundation
has to be provided, Conductor tension: 5500Lbs. Eathwire tension: 2550 Lbs. Earth
filling in foundation should be properly rammed, watered and consolidated.
All other relevant data required would be as per latest relevant standards.
3.5 MATERIALS
3.5.1 TOWER STEEL SECTIONS
The towers shall be fully galvanized structure. The towers to be fabricated have a
combination of two grades of steel, as detailed in structural drawings/bill of material. One
is MS steel and other is HT steel.
3.5.2 FASTENERS: BOLTS NUTS AND WASHERS
3.5.2.1 All bolts and nuts shall conform to IS:6639-1972. All bolts and nuts shall be
galvanized and shall have hexagonal head and nuts, the heads being forged out of
the solid steel rods and shall be truly concentric, and square with the shank, which
must be perfectly straight.
3.5.2.2 The bolt shall be of 16 mm dia and of property class 5.6 as specified in IS:1367 (part-
III) 1979 and matching nut of property class as specified in IS:1367 (part-VI) 1980.
However, some bolts of MD type 220kV M/C tower are having 24 dia. of 6.8 grade.
3.5.2.3 Bolts up to M 16 and having length upto 10 times the diameter of the bolts should be
manufactured by cold forging and thread rolling process to obtain good and reliable
mechanical Properties and effective dimensional control. The shear strength of bolts
for 5.6 grade should be 310-MPa minimum as per IS: 12427, bolts should be
provided with washer in accordance with IS: 1363 part-I to ensure proper bearing.
3.5.2.4 Nuts should be double chamfered as per the requirement of IS:1363 part-III, 1984.
The manufacturer should ensure that nuts should not be over – tapped beyond 0.4
mm oversize on effective diameter for size upto M16.
3.5.2.5 Fully threaded bolts shall not be used. The length of bolts shall be such that the
threaded portion will not extend into the place of contact of the members.
3.5.2.6 All bolts shall be threaded to take the full depth of the nuts and threaded for enough
to permit firm gripping of the members, but not further. It shall be ensured that the
threaded portion of each bolt protrudes not less than 3 mm and not more than 8 mm
when fully tightened. All nuts shall fit and tight to the point where the shank of the bolt
connects to the head.
3.5.2.7 Flat and tapered washers shall be provided wherever necessary. Spring washers
shall be provided for insertion under all nuts. These washers shall be of steel electro-
galvanised steel, positive lock type and 3.5 mm in thickness for 16 mm dia bolt.
Page-23
3.5.2.8 The bidder shall furnish bolt schedules giving thickness of members connected, the
size of bolts nut and the washer and the length of shank and the threaded portion of
bolts and sizes of bolt holes and any other special details of this nature.
3.5.2.9 To obviate bending stress in bolts or to reduce it to minimum, no bolt shall connect
aggregate thickness of more than three (3) times its diameter.
3.5.2.10 The bolt position in assembled towers shall be as per IS:5613 (Part-II/secton-2-1976).
3.5.2.11 Bolts at the joints shall be so staggered that nuts may be tightened with spanners
with out fouling.
3.5.2.12 To ensure effective in-process quality control it is essential that the manufacturer
should have all the testing facilities for test like weight of zinc coating, shear strength,
other testing facilities etc. in-house. The manufacture should also have proper Quality
Assurance System, which should be in line with the requirement of this specification
and IS:14000 series quality system standard.
3.5.3 TOWER ACCESSORIES
i) STEP BOLTS & LADDERS
Each tower shall be provided with step bolts in one of the main leg confirming to
IS:10238 of not less than 16mm diameter and 175 mm long, spaced not more than
450 mm apart and extending form about 3.5M above the ground level to the top of the
tower. The step bolt shall be fixed on one leg of single circuit tower from 3.5 m above
ground level to top of the towers. Each step bolt shall be provided with two nuts on
one end to fasten the bolt securely to the tower and button head at the other end to
prevent the feet from slipping away. The step bolts shall be capable of withstanding a
vertical load not less than 1.5 KN. For special structures, where the height of the
super structure exceeds 50m, ladders along with protection rings as per the HVPNL
approved design shall be provided in continuation of the step bolts on one face of the
tower from 30 metres above ground level to the top of the special structure. From 3.5
m to 30 m height of super structure step bolts shall be provided. Suitable plat form
using 6 mm thick perforated chequred plates along with suitable railing for access
from step bolts to the ladder and from the ladder to each cross-arm tip and the
groundwire support shall to be provided. The platform shall be fixed on tower by using
countersunk bolts.
ii) INSULATOR STRING AND EARTHWIRE CLAMPS ATTACHMENTS
a) ‘I’ shaped suspension insulator string assemblies shall be used for suspension
towers, the drawing of which is enclosed with specification. For the attachment of
suspension insulator string, a suitable dimensioned swinging hanger on the tower
shall be provided so as to obtain requisite clearance under extreme swinging
condition and free from swinging of the string. The hanger shall be designed to
withstand an UTS of 70 KN for single suspension string and 140 KN for double
suspension string.
b) The Suspension Pilot insulator string assemblies shall be used at Dead end
tension tower at angle of deviation 300 and above.
c) At tension towers, strain plates of suitable dimensions on the underside of each

cross-arm tip and at the top earthwire peak should be provided for taking the
hooks or D-shackle of the tension insulator strings or earthwire tension clamps, as
the case may be. Full details of the attachments shall be submitted by the bidder
for HVPNL approval before starting the mass fabrication.
Page-24
iii) EARTHWIRE CLAMPS
A) SUSPENSION CLAMP
Earthwire suspension clamps will be supplied by the bidder, the reference drawing for
the same is enclosed with the specification. Earthwire peaks/cross-arms are to be
suitably designed to accommodate the shackle of the suspension clamp.
B) TENSION CLAMPS
The bidder shall supply earthwire tension clamps for incorporation on the tension
towers. The reference drawing for the same is enclosed with this specification.
iv) ANTICLIMBING DEVICE
Barbed wire type anticlimbing device/ fencing as per enclosed drawing shall be
provided and installed by the Bidder for all towers/gantries. The height of the
anticlimbing device shall be provided approximately 3m above ground level. The
barbed wire shall conform to IS:278-1978. the barbed wires shall be given chromating
dip as per procedure laid down in IS:1340-1959.
v) DANGER, NUMBER, AND PHASE PLATE
Danger, Number, Circuit and phase plates shall be provided and installed by the
Bidder.
a) Each tower shall be fitted with a number plate, circuit plate (in case of double circuit)
and danger plate. Each tension tower shall be provided with a set of phase plates
also. All the double circuit towers are to be provided with circuit plate fixed near the
legs. The height for fixing these accessories shall not be more than 4.5m above the
ground level.
b) The letters figures and the conventional skull and bones of danger plates shall
conform to IS:2551-1963 and shall be in a signal red on the front of the plate.
c) The corners of the number, danger & circuit plate shall be rounded off to remove
sharp edges.
vi) BIRD GUARDS

To prevent birds perching immediately above the suspension insulator string and
fouling the same with dropping, suitable bird guards shall be provided at cross arm tips
of all suspension towers. The bird guard arrangement shall be such that it shall either
prevent bird from perching in position where they are liable to cause the damages or
ensure that if birds do perch, dropping will fall clear of the insulator string.
3.6 TOWER FABRICATION
The fabrication of towers shall be in conformity with the following:
3.6.1 Except where hereinafter modified, details of fabrication shall conform to IS:802 (Part-
II) 1978 or the relevant international standards.
3.6.2 The tower structure shall be accurately fabricated to connect together easily at site
without any undue strain on the bolts.
3.6.3 The diameter of the hole shall be equal to the diameter of bolt plus 1.5 mm.
3.6.4 All similar parts shall be made strictly inter-changeable. All steel sections before any
work is done on them, shall be carefully leveled, straightened and made true to detailed
drawings by methods which will not damage the materials so that when assembled, the
adjacent matching surfaces are in close contact throughout. No rough edges shall be
permitted in the entire structure.
Page-25
3.6.5 DRILLING AND PUNCHING
3.6.5.1 Before any cutting work is started, all steel sections shall be carefully straightened
and trued by pressure and not by hammering. They shall again be trued after being
punched and drilled.
3.6.5.2 Holes for bolts shall be drilled or punched with a jig but drilled holes shall be
preferred. Punching may be adopted for thickness upto 16mm. tolerances regarding
punched holes are as follows:
a) Holes must be perfectly circular and no tolerance in this respect is permissible.
b) The max. allowable difference in diameter of the holes on the two sides of plates
or angle is 0.8 mm i.e. the allowable taper in a punched hole should not exceed
0.8 mm in diameter.
c) Holes must be square with the plates or angles and have their walls parallel.
3.6.5.3 All burrs left by drills or punch shall be removed completely. When the tower
members are in position the holes shall be truly opposite to each other. Drilling or
reaming to enlarge holes shall not be permitted.
3.7 ERECTION MARK
3.7.1 Each individual member shall have an erection mark conforming to the component
number given to it in the fabrication drawings. This mark shall be made with marking
dies of 16 mm size before galvanizing and shall be legible after galvanizing.
3.7.2 ERECTION MARK SHALL BE

A-BB-CC-DDD
A = HVPNL code assigned to the Bidder -Alphabet
BB = Bidder’s Mark-Numerical
CC = Tower type-Alphabet
DD = Number mark to be assigned by Bidder -Numerical.
H = HT Steel
3.7.3 QUANTITIES VARIATION
3.7.3.1 The provisional quantities required are mentioned in the respective schedule of
prices. Final quantities shall be determined after completion and approval of the
detailed route survey and check survey. The final quantities of towers, gantries, line
materials and foundations shall be confirmed by the HVPNL based on the
requirement of quantities of various items furnished by the Bidder after completion of
detailed survey. Hence it will the responsibility of the Bidder to intimate the exact
requirements of all towers, line materials and foundations required for the line
immediately after the survey. The Empowered officer of the HVPNL will order the final
quantities at the unit rates quoted in the bid.
Page-26
3.7.3.2 The Empowered officer of the HVPNL reserves the right to increase or decrease upto
15% (fifteen percent only) of contract value. The quantity of bid and services specified
without any change in the unit price or other terms and conditions during the
execution of the contract. The quantities of individual items may vary upto any extent
after the final route plans and route profiles of the lines covered in the package are
finalised.
3.7.3.3 The estimated unit weight of each type of tower, stubs and extensions shall be
furnished by the HVPNL. The weight of tower shall mean the weight of tower
calculated by using the black sectional (i.e. ungalvanised) weight of steel members of
the size indicated in the approved fabrication drawings and bills of materials, without
taking into consideration the reduction in weights due to holes, notches and bevel-
cuts etc. but taking into consideration the weight of fastners, anticlimbing devices etc.
For payment purpose, the round plane washers, hangers, D-shackles, U-bolts, step
bolts, spring washers, bolts and nuts etc. shall be termed as fasteners.
3.8 GALVANISING
Fully galvanized towers and stub shall be used for the lines. Galvanizing of the member
of the towers shall conform to IS:2629-1985 and IS:4759-1968. All galvanizing
members shall withstand tests as per IS:2633-1986. For fasteners the galvanizing shall
conform to IS:1367 (Part-13). The galvanizing shall be done after all fabrication work is
completed, except that the nuts may be tapped or re-run after galvanizing. Threads of
bolts and nuts shall have a neat fit and shall be such that they can be turned with finger
throughout the length of the threads of bolts and they shall be capable of developing
full strength of the bolts. Spring washers shall be electro-galvanised as per grade 4 of
IS: 1573-1970.
3.9 EARTHING
3.9.1 The footing resistance of all towers shall be measured by the Bidder in dry weather
after tower erection but before the stringing of earthwire. All the towers are to be
earthed, however, in no case tower footing resistance shall exceed 10 ohms. Pipe type
earthing and counterpoise type earthing wherever required shall be provided in
accordance with the stipulations made in IS:3043-1987 and IS:5613 (part-II/section-2)
1985. The details for pipe and counterpoise type earthing are given in drawing
enclosed with the specification.
3.9.2 The provisional quantities for pipe type earthings and counterpoise earthing, are
furnished in price schedule. The bidders are required to furnish unit rates also for
adjustment purpose with actual quantities. The quoted price shall include fabrication,
supply and installation of earthing material including supply of coke, salt etc. in case of
counterpoise type earthing, the quotation shall be based on 100 metres of wire per
tower.
3.10 INSPECTION AND TESTS
3.10.1 All standards tests, including quality control tests, in accordance with appropriate
Indian/International standard, shall be carried out unless otherwise specified herein.
Page-27
3.10.2 All Goods being supplied shall conform to type tests, sample tests as per the technical
specifications and shall be subject to routine, acceptance and site tests in accordance
with requirements stipulated under the respective Sections, unless otherwise stated.
The HVPNL reserves the right to witness any or all the type and sample tests. The
Bidder shall inform the HVPNL of the detailed program of tests at least two (2) weeks in
advance in case of domestic supplies and four (4) weeks in advance in case of foreign
supplies.
3.10.3 The Bidder shall furnish to HVPNL the reports of all type tests, sample and routine
tests as per technical specification along with the equipment/materials drawings. The
type tests conducted earlier should have been conducted in accredited laboratories
(based on ISO/IEC by a reputed accreditation body) or witnessed by HVPNL or another
electric power utility. The type test reports submitted shall be of the tests conducted
within last five (5) years prior to the date of bid opening. In case the test reports are of a
test conducted five (5) years prior to the date of bid opening, and don’t correspond to
the offered equipment/material, or don’t comply with the Technical Specifications, the
Bidder shall repeat this / these test / tests at no extra cost to the HVPNL before
sample(acceptance) tests. The cost of conducting type tests and additional tests shall
be included in the Bid price .
3.10.4 The HVPNL, his duly authorized representative and/or outside inspection agency acting
on behalf of the HVPNL shall have free access at all reasonable times to the
Bidder’s/sub-vendor’s premises or Works and shall have the power at all reasonable
times to inspect and examine the equipment/materials and workmanship of the Works
during its manufacture or erection. If part of the Works is being manufactured or
assembled at other premises or works, the Bidder shall obtain for the HVPNL, his duly
authorized representatives and/or outside inspection agency permission to inspect as if
the works were manufactured or assembled on the Bidder’s own premises or works.
Inspection may be made at any stage of manufacture, dispatch or at the Site at the
option of the HVPNL, and the equipment if found unsatisfactory due to bad
workmanship or quality or material is liable to be rejected.
When the factory tests have been completed at the Bidder’s or Sup-Bidder’s works, the
HVPNL/Inspector shall issue a certificate to this effect within fifteen (15) days after the
completion of the tests, but if the tests are not witnessed by the HVPNL/Inspector, the
certificate shall be issued within 15 days of receipt of the Bidder’s test certificate by the
HVPNL’s representative. Failure of the HVPNL/Inspector to issue such a certificate
shall not prevent the Bidder from proceeding with the Works (as defined in SCC). The
completion of these tests or the issue of the certificate shall not bind the HVPNL to
accept the equipment/materials should it, on further tests after erection, be found not
comply with the Contract. The equipment/materials shall be dispatched to Site only
after approval of test reports and issuance of the inspection certificate by the HVPNL.
3.10.5 The inspection by the HVPNL and issue of the inspection certificate thereon shall in no
way limit the liabilities and responsibilities of the Bidder in respect to the agreed quality
assurance program forming part of the Contract.
3.10.6 The HVPNL will have the right of having at his own expenses any other test(s) of
reasonable nature carried out at the Bidder’s premises or at any other place in addition
of aforesaid type and routine tests to satisfy that the equipment/materials comply with
the specifications.
Page-28
3.10.7 The HVPNL deserves the right for getting any field tests not specified in the respective
sections of the technical specifications conducted on the completely assembled
equipment at Site. The HVPNL will provide the testing equipment for these tests.
3.10.8 The Bidder shall ensure that his subBidders manufacturing and supplying the goods
(material and equipment) shall perform the routine tests specified in the related
standards and in the Technical Specifications of this Contract regularly.
3.10.9 The Bidder shall notify the HVPNL in writing at the latest four (4) weeks for inspection
outside of India and two (2) weeks for local inspection and testing or as otherwise
directed in advance of the date and place at which any Material or Work will be ready
for inspection and testing.
3.10.10 Should any postponement become necessary, the Bidder shall provide written
notification at least one week prior to the originally scheduled date. The HVPNL shall
give 48 hours' notice in writing to the Bidder, of his intention to attend the tests, or ask
for postponement, if required.
3.10.11 Should the HVPNL explicitly waive to attend the relevant test, the Bidder may proceed
with the test, which shall be deemed to have been made in his presence, and the
Bidder shall forthwith forward to the HVPNL duly certified copies of the test reports for
approval.
3.10.12 All sample and type tests will be performed at the presence of the authorized personnel
of the Bidder or inspectors authorized by the Bidder, if there is no representative of
HVPNL.
3.10.13 HVPNL may or may not be present in any or all sample and type tests but all test
reports shall be approved by HVPNL
3.10.14 This procedure shall not release the Bidder from any of his responsibilities or
obligations under this Contract.
3.10.15 The Bidder shall prepare and agree with HVPNL test programs so that tests to be
performed in foreign countries (i.e., at manufacturer's factory or at internationally
recognized test facilities) are carried out in sequence which would permit HVPNL to
organize in an optimal manner the supervision of the said tests by HVPNL staff.
3.11 Galvanizing Tests:
All fabricated materials shall be tested in accordance with the "Test and Inspection
Procedures for Galvanized Materials "as per Specification and HVPNL shall be notified at
least thirty days in advance of any tests if it is performed in abroad.
3.12 Inspections and Tests: The Bidder shall make adequate tests and inspections to
determine whether the material furnished is strictly in accordance with this Specification.
In addition, HVPNL may inspect and accept or reject the material made under this
Specification either at the Fabricator's plant or at the point of delivery The
representatives of HVPNL shall have access to all parts of the Bidder's plant which
concerns the Work while the Work is being done. The Bidder, without requesting any fee,
shall provide all the reasonable facilities to the HVPNL's representatives so as to satisfy
them that, the towers are manufactured strictly in compliance to this Specification.
Page-29
3.13 Certified Tests: Regardless of whether the material is inspected by HVPNL , the
Bidder shall furnish certified test reports as follows:
a) Steel Mill Test Reports showing chemical, physical and mechanical properties
of the material to be furnished under the Contract.
b) A Manufacturer's Certificate of Inspection for zinc (hot-galvanized) coatings on

structural steel with the following information:
1- Purchase order number
2- Date of inspection
3- Number of pieces tested for weight of zinc coating with maximum-minimum
and average weights of each.
4- Number of pieces tested for adherence of coating.
5- Number of rejections because of defective coating and other reasons.
Certified test reports shall be sent to HVPNL.
3.14 Shop assembly:

One tower of each type and height ordered, including every combination of leg
extensions, shall be assembled in the shop to the extent necessary to assure correct fit
of parts, adequate bolt lengths and proper field erection. Reaming of mismatched holes
will not be permitted. A reasonable amount of drifting will be allowed in assembling
approved by HVPNL. The approved assembled parts shall be dismantled for shipment.
Shop assembly shall be controlled and approved by HVPNL.
3.15 Fabrication:
Fabrication shall be in strict accordance with detail Drawings prepared by the Bidder and
approved by the HVPNL. The drilling, punching, cutting and bending of all fabricated
steelwork shall be such as to prevent any possibility of irregularity occurring which might
introduce difficulties in the erection of the structure on the site.
Built pieces shall, when finished, be true and free from all kinks, twists and open joints
and the Material shall not be defective or strained in any way. Fabrication shall begin
after the approval of the shop assembly.
3.16 IDENTIFICATION AND SHIPPING
Identification: All parts designed for bolting together shall be shipped unassembled
except as noted on the drawings. Tower members shall be bundled together in the
largest practical bundles for shipping and each bundle shall be clearly marked. Small
parts such as U-bolts and clip angles shall be boxed and each box clearly marked for
identification.
Shipping: Railroad cars, ships or trucks in which steel is shipped shall be reasonably
clean and free from foreign materials which could in any way injure the tower material. At
least 8cm clearance shall be maintained between bundles and floor.
3.17 GENERAL
All standards tests, including quality control tests, in accordance with appropriate
Indian/International standard, shall be carried out unless otherwise specified herein.
Page-30
3.18 INSPECTION
3.18.1 In addition to the provision of clause regarding inspection in conditions of contract, the
following shall also apply:
a. The Bidder shall keep the HVPNL informed in advance about the time of starting
and of the progress of manufacture and fabrication of various tower parts at various
stages, so that arrangements can be made for inspection.
b. The acceptance of any part of items shall in no way relieve the Bidder of any part of
his responsibility for meeting all the requirements of the specification.
3.18.2 The HVPNL or his representative shall have free access at all reasonable times to those
parts of the Bidder’s works which are concerned with the fabrication of the HVPNL
material for satisfying himself that the fabrication is being done in accordance with the
provisions of the specifications.
3.18.3 Unless specified otherwise, inspection shall be made at the place of manufacture prior to
dispatch and shall be conducted so as not to interfere unnecessarily with the operation of
the work.
3.18.4 Should any member of the structure be found not to comply with the approved design, it
shall be liable to rejection. No member once rejected shall be re-offered for inspection,
except in cases where the HVPNL or his authorized representative considers that the
defects can be rectified.
3.18.5 Defect which may appear during fabrication shall be made good with the consent of and
according to the procedure proposed by the Bidder and approved by the HVPNL.
3.18.6 All gauges and templates necessary to satisfy the HVPNL shall be supplied by the
manufacture.
3.18.7 The correct grade and quality of steel shall be used by the Bidder. To ascertain the
quality of steel used, the inspector may at his discretion get the material tested at an
approved laboratory.
3.19 Standards
3.19.1The design, manufacturing, fabrication, galvanizing, testing, erection procedure and
materials used for manufacture and erection of towers, design and construction of
foundations shall conform to the following Indian Standards (IS) International standards
which shall mean latest revisions, with amendments/ changes adopted and published,
unless specifically stated otherwise in the specification. In the event of supply of material
conforming to standards other than specified, the bidder shall confirm in his bid that
these standards are equivalent to those specified. In case of award, salient features of
comparison between the standards proposed by the contractor and those specified in
this document will be provided by the contractor to establish their equivalence.
3.19.2 The material and services covered under these specifications shall be performed as per
requirements of the relevant standards/codes (latest version) referred hereinafter against
each set of equipment and services. Other internationally acceptable standards which
ensure equal or higher performance than those specified shall also be accepted.
Page-31
SR INDIAN TITLE INTERNATIONAL&
No. STANDARDS INTERNATIONALLY
RECOGNISED
STANDARDS.
1 2 3 4
1 IS:209-REV, Specification for Zinc ISO/R/752-1968 ASTM B6
2 IS:226-1975 Structural steel ISO/R/630-1967 standard

quality CAN/CSA-G40.21
BS 4360
3 IS:269-1976 Ordinary rapid hardening & ISO/R/597-1967

low heat Portland cement.
4 IS:383-1970 Coarse and fine aggregates CSA A23, 1/A 23.2

from natural sources for concrete.
5 IS:278 Specification for barbed wire. ASTM A 121
6 IS:432-1966 Mild steel and medium tensile bars BS-785-1938 CSA-G-30.

(part-I&II) and hard drawn steel wire for
concrete reinforcement.
7 IS:456-2000 Code of practice for plain ISO/3893-1977
and reinforced concerete.
8 IS:800-1962 Code of practice for use CSA S16.1

of structural steel in
general building construction.
9 a) IS:802 Code of practice for use IEC 826 ASCE 52 BS 8100

(part-1) of structural steel in
overhead transmission
line. Materials loads
and permissible stresses.
b)IS:802 Code of practice for use ASCE 52

(part-2) 1978 of structural steel in
overhead transmission
line. Fabrication,
galvanizing, inspection and
packing.
c)IS:802 Code of practice for use of
(part-3) 1978 structural steel in overhead
transmission line. Tower testing.
10 IS:808 Dimensions for Hot Rolled steel

beam, column, channel and angle
sections
11 IS:875 Code of practice for design loads

(other than earth-quakes) for
buildings & structures.
Page-32
12 IS:1139-1966 Hot rolled mild steel, medium CAN/CSA G30.18
tensile steel and high yield ASTM A615
strength deformed bars for
concrete reinforcements.
13 IS:1367-1967 Technical supply conditions for

threaded fasteners (first revision)
14 IS:1489-1976 Portland pozzolena cement ISO/R/863-1968
15 IS:1786-1989 Cold twisted steel bars for

concrete reinforcement.
16 IS:1893-1965 Critecia of earthquake resistant IEEE 693

design of structures
17 IS:2016-1967 Plain washers ISO/R/887-1968. ANSI

B18.22.1
18 IS:2131-1967 Method of standard penetration

test for soils.
19 IS:2551-1982 Danger notice plates
20 IS:2629-1966 Recommended practice for hot dip

galvanizing of iron & steel.
21 IS:2633-1972 Method of testing uniformity of
coating of zinc coated articles.
22 IS:3043-1972 Code of practice of earthing (with
amendment No. 1and 2)
23 IS:3063-1972 Single coil rectangular section

spring washers for bolts, nuts,
screws.
24 IS:4091-1967 Code of practice for design and
construction of foundation for
transmission line towers and poles.
25 IS:5358-1969 Hot dip galvanizing coatings on

fasteners.
26 IS:5613 (part- Code of practice for design,
2/Sec.-1) 1976 installation and maintenance of
overhead power lines (Sec-1:
(Designs)
27 IS:5613 (part- Code of practice for design,

2/Sec.-2) 1976 installation and maintenance of
overhead power lines (Sec.-2
installation and maintenance)
Page-33
28 IS:6610-1972 Specification for heavy washers for
steel structures.
29 IS:6639-1972 Hexagonal bolts for steel structure.
30 IS:6745-1972 Methods for determination of

weight of zinc coating of zinc
coated iron and steel articles.
31 Indian electricity rules – 1956
32 Publication Regulation for electrical crossing of

No. 19 (N) Railway Tracks.
700-1963
33 IS:8500-1977 Specification for weldable BS: 4360

structural steel (medium and high
strength qualities)
34 IS:2062-1992 Steel for general structural

purposes.
Page-34
The standards mentioned above are available from: -
Reference/Abbreviation Name and address from which the standards are available.
IS Bureau of Indian standards, Manak Bhawan, 9 Bahadur

Shah Zafar Marg, New Delhi, INDIA.
ISO International Organisation for standardization, Danish

Board of Standardisation Danisk Standardisening Sraat,
Aureheeugej-12, DK-2900 Helleprup DENMARK.
CSA Canadian Standard Association, 178, Rezdale Boulevard,

Rexdale, Ontario, CANADA, M9W IR
BS British Standsrds, British Standard Institution, 101,

Pentonvile Road, N-19-ND, UK.
DIN Deutsches Institue Firr Normung Burggafenstrasse 4-10

Post Fach 1107 D-1000, Berlin-30
Indian Electricity Rules Kitab Mahal ,Baba Kharak Singh Marg, New Delhi-110001
1956 Regulation for INDIA.
Electricity Crossing of
Railway Tracks.
ASCE American Society of Civil Engineers, 345, East 47th Street,

New York, NY-10017-2398 USA
IEEE Institute of Electrical and Electronic Engineers ,445, Hoes

Lane PO. Box, 1331 Piscatawa NJ-08855-1355 USA
IEC International Electrotechnical Commission Bureau central

de La commission Electrotechnique internatinale 1. Rue de
varombe Geneva Switzerland
Page-35
4.0 TOWER FOUNDATION
4.1 GENERAL
These specifications provide general guidelines for the construction of tower foundations
as per design supplied by HVPNL and the gantry tower foundations as per design
supplied by HVPNL of the proposed transmission line(s) covered in the tender.
4.2 Before start of work, successful bidder shall carry out trial bore-holes (normally up to 6.0
meter below natural ground level) after every Kilometer en-route or as desired by the
Employer to have a fair idea of soil type/nature and subsoil water position. If the soil
characteristics are changing rapidly or soil up to 6.0 meter is very weak, the depth of
bore-hole be increased beyond 6.0 meters so as to know the soil properties/type below
the foundation. The bore log data containing information such as position of sub-soil
water table, soil strata, the crop pattern in the agricultural fields where the foundation is
to be laid and the suitability for founding the required foundation, shall be submitted to
the Employer for according approval for “Classification of foundation” at each
location.
Contractor shall also ensure to check the entry of kids/ animals in to the excavated pits
by providing suitable warning signs and safety measures as per the approval of
Engineer-In-Charge.
4.3 TYPE OF SOIL

Soil en-route the following proposed transmission lines under the scheme is generally
normal/Sandy/rocky.
Creation of two phase 132kV S/C line on D/C towers with 0.4sq” ACSR conductor
from 132kV S/Stn. Kalanaur to 132kV TSS Manheru.
[[
Ground water table enroute all the above said lines generally vary from 20mtr. to
25mtr. below Natural Ground Level. The sub soil water level at few locations may be
different due to local conditions. The crop pattern enroute all the above said lines is
paddy, wheat, sugarcane, cotton etc. depending on soil and weather conditions.
Page-36
4.4 CLASSIFICATION OF SOIL
a. Dry Soil: Soil shall be termed as dry soil where sub-soil water table is below base
of the tower footing and no de-watering is required.
b. Wet Soil (without de-watering): Soil shall be termed as wet soil (without de-
watering) where sub-soil water is below base of footing and no de-watering is
required but crop pattern is paddy field.
c. Wet Soil (with de-watering): Soil shall be termed as wet soil (with de-watering)
where sub-soil water is above base of footing and de-watering has to be done.
d. Rocky Soil: Hard conglomerate or other soft or fissured rock which can be
quarried or split with crow bars, wedges or pick axes. However, if required, light
blasting may be resorted to for loosening the material.
4.4.1 For excavation purpose, the quoted rates for foundations in wet soil (without de-watering)
shall be considered as applicable for the dry soils. For wet soil (with de-watering), the
quoted rates of de-watering have been asked for separately. The de-watering operation
shall continue to keep the foundation pits dry during concreting and thereafter for at least
24 hrs. Any de-watering carried out for removal of seepage of surface water/rainwater
will not be considered as de-watering and the soil shall be termed as ‘Dry Soil’.
4.5 FOUNDATION TYPES
4.5.1 GENERAL
Reinforced cement concrete footing shall be used for all types of normal towers/
extension towers in conformity with the present day practices followed in the country and
the specifications laid herein. All the four footings of the tower and their extensions, if any
shall be similar irrespective of down thrust and uplift.
4.5.2 Foundation includes supply of materials such as cement, fine and coarse aggregates,
water, reinforcement steel and binding wire etc. Rates quoted for foundations shall
include all items of work relating to supply and installation of foundations such as form
work, excavation and back filing with good soil, compaction, stub setting, shoring &
timbering etc. where ever required, placing of reinforcement in position, concreting and
all other works related for completion of foundation.
4.6 CLASSIFICATION OF FOUNDATIONS
a. Dry Foundation: To be used where sub-soil water table is below 6.0 meter from
Natural Ground Level.
b. Wet Foundation (without de-watering): To be used where sub-soil water table

is below base of footing and up to 6.0 meters from Natural Ground Level or at
location where surface water remains for long periods such as paddy/sugar cane
fields irrespective of sub-soil water depth.
c. Wet Foundation (with de-watering): To be used where sub-soil water table is

above footing base of foundation and actual de-watering has to be carried out for
construction of foundation for which separate rates have been asked for.
Page-37
4.6.1 Design of foundation for Wet (without de-watering) and Wet (with de-watering) shall be
same.
4.7 PROPERTIES OF CONCRETE & REINFORCEMENT
4.7.1. All the properties of concrete regarding its strength under compression, tension, shear,
punching and bond strength etc. as well as workmanship shall confirm to IS: 456 latest.
4.7.2 The concrete used as lean concrete or base concrete shall be as mentioned on
respective drawings. The aggregate size shall be 40 mm nominal. Base concrete shall
be well compacted. The top surface of base concrete shall be leveled before placing the
reinforcement.
During excavation, if excavation exceeds the required depth or if any loose pocket of
earth is met below the base of footing, then the loose earth shall be removed or
excavation depth be increased till normal hard soil is met as per satisfaction of the
Engineer-in-Charge. This extra depth shall be filled with lean concrete. No extra shall be
paid on account of this extra excavation and lean concrete.
4.7.3 The cement concrete used for foundation shall be of grade M-20 {irrespective of any
grade mentioned on the drawing(s)}. The Mix Design (conforming to IS standards) shall
be done prior to start of work, as per specifications, got approved from the Employer and
shall be used for the construction, provided there is no change in the source and the
quality of materials. The source of materials shall be intimated to the Employer and shall
be ensured that Mix Design is with the materials from intimated source only and same is
not changed during construction. In case source of material changes or quality of
material differs from the earlier approved parameters, the Mix Design shall be done
again. Whenever there is uncertainty of availability of aggregates from a fixed source,
nominal mix is to be followed but the quality of aggregates shall not be compromised. To
avoid the delays, the contractor may go for nominal mix after getting the aggregates
tested till such time the mix design is got approved.
4.7.4 The coarse aggregate used shall be 20 mm graded or two types of single size aggregate
mixed in some fixed ratio to have graded 20-mm aggregate. The Coarse aggregate shall
conform to IS 383.
4.7.5 Grading of Fine aggregate shall conform to Zone-II of Table-4 of IS: 383 and shall be
free from deleterious materials.
4.7.6 The environmental exposure condition considered for Mix Design shall be MILD.
4.7.7 For Mix Design the degree of quality control shall be considered as FAIR.
4.7.8 The Water Cement ratio shall be minimum 0.50 and maximum 0.55.
4.7.9 For Transmission Line Tower footings, the minimum Slump shall be 50 mm and
maximum 75 mm.
4.7.10 For volumetric use of ingredients for concrete mix, the contractor along with the Mix
Design shall intimate the size of measuring boxes along with the Mix design.
4.7.11The approval of Mix Design shall not absolve the contractor from the responsibility of
achieving the required strength, workability etc. during actual execution. In case of failure
of concrete samples, the work done is liable to be rejected. In such case the contractor
Page-38
shall recast the foundation at the same location by dismantling the rejected foundation
or at a nearby location as directed by the Employer. In case of honey combing, the
contractor shall do the pressure grouting as directed and to the full satisfaction of
Employer. The construction of new foundation in place of rejected one and pressure
grouting if done shall be without any extra payment.
4.7.12Ordinary Portland_Cement of Grade 43 of reputed make like JK,, ACC, Ambuja, Shree
conforming to IS: 8112 shall be used. However in case of shortage of OPC Cement,
Portland Pozzolona Cement (fly ash based or calcinated clay based) conforming to IS
1489 Part Part – 1 and – 2 respectively may be used in the works other than RCC. In
case, Portland Pozzolona Cement is used then curing period shall be enhanced as
directed by Engineer-in-Charge. In RCC works only Ordinary Portland Cement of Grade
43 shall be used.
4.7.13 The water used for mixing concrete and for curing purpose shall be fresh, clean and free
from oils, acids and alkalis, organic materials or other deleterious substance. Potable
water is generally preferred. Saltish or brackish water shall not be used. Water used
shall conform to clause 5.4 of IS 456.
4.7.14 Reinforcement steel (including TMT) Bars manufactured by TISCO, SAIL, IISCO and
RASHTRIYA ISPAT, Jindal Steel and Power Ltd.(Jindal Panther),JSW Steel Ltd (primary
manufacturers) conforming to IS: 1786 for deformed and cold twisted bars shall only be
used. The bidders shall, however, be allowed to use Amba steel, Rathi steel, Kamdhenu
steel, Barnala steel, P.R.S steel, Shidbali steel (manufactured by secondary
manufacturers) only after obtaining non-availability certificate from the primary
manufacturers. Before using secondary steel, the selected bidder would require to
conduct all physical & chemical tests (lot wise & dia. wise) to establish its conformity to
IS Standards. Required grade of steel shall be Fe-500. All reinforcement shall be clean
and free from loose mill scale, dust, loose rust and coats of paint, oil or other coating,
which may destroy or reduce bond with concrete. Reinforcement bars should be fresh.
Contractor shall supply, fabricate and place reinforcement to shapes and dimensions as
indicated on the drawings or as required to carry out the intent of drawings and
specifications. Adequate nos. of chairs, spacers of required size shall be provided to
ensure the proper placement of reinforcement. The reinforcement bars crossing one
another should be tied together at every intersection with two strands of annealed steel
wires 0.9 to 1.6 mm thick twisted and tied to make the skeleton of the steel work rigid so
that the reinforcement does not get displaced during concrete placement.
All the reinforcement steel should be placed/ stacked at site store on raised (at least 0.5
meter from near surroundings) pucca/brick platform or reinforcement steel should be
placed on MS/GI sheets. The reinforcement steel after stacking should be covered with
Tarpaulin to avoid corrosion. Immediately before concreting (portion of reinforcement to
be embedded in concrete) shall be painted with cement slurry after removing any
rust/corrosion/any other foreign material.
4.7.15 No admixtures shall be used.
4.8 UNIT RATES AND MEASUREMENT
4.8.1 The rates of foundation shall be per tower. These rates shall include excavation, stub
setting, concreting, reinforcement, shuttering, shoring/ timbering, stockpiling, dressing,
curing, back filling (after concreting) with good (excavated/borrowed) earth irrespective of
lead. Rates are inclusive of compaction of earth, carriage of surplus earth to suitable
disposal location as required by Employer or any other activity related to completion of
foundation works in all respects.
Page-39
4.8.2 In case of any change/variation in the foundation drawing(s) attached with bidding
document, due to site conditions or otherwise, the payment shall be made based on
formula given in the commercial clause.
4.9 CONSTRUCTION OF TOWER FOUNDATIONS AS PER DESIGN SUPPLIED BY

HVPNL
4.9.1 EXCAVATION
Excavation work shall start only after the approval of route plan, the tower foundation
schedule, classification of foundations and the profile by the Employer. The reference
natural ground level shall be so chosen that it is not lower than surroundings and in
normal condition water does not accumulate there, preferably it should be slightly higher
than surroundings.
All excavation for footing shall be made to the lines and grades of the foundation. The
excavation wall shall have stable slope and the pit dimensions shall be such as to allow a
clearance of 150 mm on all sides from the foundation RCC pad. The contractor should
ensure clearance of 150 mm from the foundation RCC pad for quality work.
All excavation shall be protected so as to maintain a clean sub-grade until the footing is
placed, using timbering/shuttering, shoring etc., if necessary. Any sand, mud, silt or other
undesirable materials, which may accumulate in the excavated pit, shall be removed by
the contractor before placing concrete.
4.9.2 No extra charges shall be admissible for the removal of the fallen earth in the pit, when
once excavated.
4.9.3 Wherever ground water table is higher than the base of the foundation, it has to be
depressed by de-watering. During de-watering, water shall be thrown at a place as
directed by the Engineer-in-Charge. No pit/open de-watering shall be permitted. Instead,
over all lowering of the water table shall be done by providing sufficient number of bores
around the tower location and by continuous pumping of water through these bores. Well
point system for de-watering of pits can also be adopted. It must be ensured that during
de-watering/pumping operation, no finer particles of soil get displaced or any cavity is
formed below. The boreholes for de-watering shall be located so as to avoid any
hindrance in normal working for construction of foundation. The construction of
foundation shall be carried out in bone-dry condition, which shall be ensured by effective
lowering of water table so that no caving in happens and also the bottom of the pit is free
from slushy conditions. The bores shall be filled with sand after the work at a particular
location is over.
4.10 SETTING OF STUBS
The stubs shall be set correctly in accordance with approved method at the exact
location and aligned precisely at correct levels with the help of stub setting templates and
leveling instruments. Stubs shall be set in the presence of Employer’s representative for
which the Contractor shall give adequate advance intimation to the Employer. All
necessary precautions should be taken to ensure that the stubs finally set in are not
disturbed. If these are disturbed due to any reason, the bidder shall reset the same
without any extra cost.
4.11 STUB SETTING TEMPLATES
For all types of towers viz. with or without extension and also for leg extensions, the
contractor at his own cost shall arrange the stub-setting templates. Stub templates for
standard towers and towers with extension shall be painted. Normally, for each
Page-40
transmission line tower package, sufficient numbers of stub templates should be
deployed. However, if the Employer feels that more number of templates are required for
timely completion of a particular line, the contractor shall have to deploy the same
without any extra cost to the Employer.
After completion of the project, one set of each type of stub setting template as
applicable shall be supplied to the Employer at no extra cost to the Employer.
4.12 MIXING, PLACING AND COMPACTING OF CONCRETE
4.12.1 The concrete shall be mixed in a mechanical mixer. The mixer shall comply with IS: 1791
& IS: 12119. The mixer shall be fitted with water measuring devices. Mixer without trough
should not be brought at site. In case of difficult terrain, the Employer at his discretion
may permit hand mixing but this should not be made a routine. In case of hand mixing,
10% extra cement shall be used without any extra cost.
4.12.2Mixing shall be continued until there is uniform distribution of material and the mix
become uniform in colour and consistency. If there is segregation after unloading from
mixer, the concrete should be re-mixed, but in no case the mixing be done for less than
two minutes. Normally, mixing shall be done close to the foundation, but in case it is not
possible the concrete may be mixed at a nearest convenient place. From mixer the
concrete shall be put on pucca platform or steel troughs, which shall be leak proof to
avoid any loss of water/slurry.
The concrete shall be transported from the place of mixing to the place of final deposit as
rapidly as practicable by methods, which will prevent the segregation or loss of any
ingredient. The concrete shall be placed and compacted before setting commences.
4.12.3 Form boxes of required size as per approved Mix Design volumes shall be used for
casting all type of foundations. Form boxes shall be rigidly tightened so that there are no
distortions in the shape of foundations. Form boxes shall be made sufficiently strong to
withstand all the loads and vibrations. For bottom pad portion sufficiently wide window of
minimum size 450 x 300 mm be left on each side at top for placing of concrete and for
use of vibrators to ensure thorough compaction. After every use, the form box(es) be
checked for any deformation and if necessary be repaired/corrected to original position
for reuse.
4.12.4 On removal of the form-work, if the concrete surface is found damaged, it shall be
repaired with rich cement sand mortar to the satisfaction of the Engineer-in-Charge. The
foundation pits be back-filled only after necessary repairs, if any as required above has
been done.
4.13 BACK-FILLING AND REMOVAL OF STUB TEMPLATE
4.13.1 The formwork shall be removed after 24 hours (minimum). Due care shall be taken not to
injure the concrete by excessive striking the formwork. In case the Portland Pozzolona
cement has been used, the removal of formwork shall be delayed suitably as directed by
the Engineer-in-charge.
4.13.2 After opening of formwork and removal of shoring and timbering, backfilling shall be
started, after repairs, if any, to the foundation concrete as described under para 4.12.4
above. Backfilling shall normally be done with excavated soil. In case the excavated soil
consists of large boulders/stones, it should be broken to a maximum size of 80 mm. If the
excavated earth has harmful salts, it shall not, under any circumstance, be used for
backfilling. In such case excavated earth shall be disposed off as directed by the
Engineer-in-Charge and suitable earth (clean and free from harmful salts, organic and
other foreign materials) be brought for back filling. This shall be done by the contractor at
his own cost irrespective of lead involved for bringing the suitable earth.
Page-41
4.13.3 The earth shall be deposited in layers (maximum 200 mm layers), leveled and wetted
and tampered properly before another layer is deposited. After the pits have been
backfilled to full depth, the stub template may be removed.
4.13.4 The backfilling and final grading shall be carried upto an elevation of about 75 mm above
the finished ground level to drain out water. After backfilling 50 mm high earthen
embankment (bandh) will be made along the side of excavation pits and sufficient water
will be poured in the backfilled.
4.14 CURING
Curing shall start after 24 hours of concreting to keep the concrete wet continuously for a
period of 10 days. However, after a minimum period of 72 hours the pit may be backfilled
with suitable earth sprinkled with necessary amount of water and well consolidated in
layers not exceeding 200mm. Both backfilled earth and exposed chimney top shall be
kept wet for the remainder of the prescribed time of 10 days. The uncovered concrete
chimney above the backfilled earth shall be kept wet by providing gunny bags dipped in
water fully wrapped around the concrete chimney for curing. It must be ensured that the
bags are kept wet by the frequent pouring of water on them. In case Portland Pozolona
cement has been used, curing period shall be increased as decided by the Engineer-in-
charge.
4.15 PROTECTION OF TOWER FOOTING
4.15.1 The work shall include all necessary brick/stone masonry (in C.M. 1:4) revetments, earth
filling above ground level and the clearance from stacking on the site of surplus
excavated soil. Special measures for protection of foundation wherever required shall be
provided after getting prior approval of the Employer and as per directions of the
Engineer-in-Charge.
4.15.2 The excess quantity of earth required for protection of tower (after utilizing the excavated
earth) and to be brought from outside shall be paid as per the rate provided in the letter
of award.
4.15.3 The provisional quantities for foundation protection works are furnished in the Schedule
of Quantities as well as in the Price Schedule. The unit rates shall be applicable for
adjusting with the actual quantities of protection work done.
4.16 FIELD QUALITY CONTROL PLAN
The contractor shall strictly follow the Field Quality Control Plan (given here under) for
effective control on quality of civil works. All costs of testing as per the Field Quality
Control Plan or as directed by Employer shall be borne by the Contractor.
4.17 Technical Specification given in the Contract will govern for the different items/activities.
The items/activities for which detailed specifications have not been given in the Contract
Agreement will be governed by latest ISI/ NBC specifications.
4.18 Wherever IS Code has been mentioned, it shall mean IS Code with latest amendments.
Page-42
CIVIL FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST
(Before start of work)
NAME OF LINE :
PART-A : FOUNDATION ACTIVITY (DETAIL OF CONCRETE MIX)
Grade of
1)
Concrete
Target Mean
a)
Strength
Grade of
b)
Cement
Cement Contents
c) CEMENT WATER SAND COARSE AGGREGATES
per cum
Water Cement
d)
Ratio
e) Slump
Coarse
2)
Aggregate
Nominal size of
i)
aggregate
Source of
ii)
aggregates
Specific
iii)
Gravity
iv) Aggregate confirming to IS: 383
Fine
3)
Aggregates
Source of
i)
aggregates
Specific
ii)
Gravity
Aggregate confirming to Zone as per
iii)
IS: 383
Mix Proportion FOR 1 BAG OF
4) CEMENT WATER SAND COARSE AGGREGATES
CEMENT
i) By Weight
By Volume (By
ii)
conversion)
Adjustments, if
iii)
any suggested
SIZE OF
5) MEASUREMENTS SAND COARSE AGGREGATES
BOXES
NOTE :
1. Material to be tested before the source is approved and Engineer-in-Charge
can test the
material
periodically.
Mix design is to be re-done on change of
2.
source of aggregates.
Page-43
The source of aggregates to be got approved from
3.
Engineer-in-Charge.
4 The cubes will be tested at site/field lab and cubes of 10% of the total locations of
the line will be tested from approved govt lab.
CERTIFICATE
Performed and checked by:
Sub-Contractor:
Name
Name:
:
Signature with Seal: Signature with Seal:
Date: Date:
Haryana Vidyut Prasaran Nigam Ltd.
Name:
Signature with Seal:
Date:
Page-44
FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST
NAME OF LINE :
Location Number Date :
PART-A : FOUNDATION ACTIVITY

A1 : Checking for PIT Marking
a) Foundation Drawing no. followed:
b) Span on both sides:
Preceeding Span Succeeding Span
As per profile Actual As per profile Actual

c) Tangent Tower:
Alignment of the location peg with respect

to other adjacent location or angle, if any
d) Angle Tower: Cut point
Bi-section in case of angle Tower Location and checking of angles:
Angle of deviation Bi-section
As per profile Actual Calculated Actual
e) Reference levels in case of uneven ground:
Matching of ground
f)
profile:
OK detail
CERTIFICATE: Cleared for excavation
Sub-Contractor:
Name : Name:
Date: Date:
Name:
Date:
Page-45
NAME OF LINE :
Location No.: Date :

Checking of PIT Excavation & Soil
A2 :
Classification
b) Details of Soil: Type of Soil and depth
Total Depth
As
Leg-3 Leg-2
per
Soil Investigation
Leg-4 Leg-1
Depth, Strata-wise be indicated for each leg & also indicate actual depth of pits from
reference
level.
Predominant Soil _____________________________________
c) Sub-Soil Water below NGL as on date:
Leg-2
Leg-1 (M) Leg-3 (M) Leg-4 (M)
(M)
d) Location position (Paddy fields, Sugarcane, Forest etc.):

e) Foundation Classification:
Page-46
As proposed by Contractor As approved by HVPN
f) Detail of under cutting, if any:
CERTIFICATE:

Sub-Contractor:
Name : Name:
Signature
with Seal:
Date: Date:
Name:
Date:
Page-47
NAME OF LINE :
A3 : Checking of Stub Setting
b) Alignment of template/prop. :
i) In line in case of tangent Tower Yes/No
ii) On bisection in case of angle Tower Yes/No
c) Clearance between the lowest part of stub and lean pad (Concrete)
Leg 1 ---------------------- cm
Leg 2 ---------------------- cm
Leg 3 ---------------------- cm
Leg 4 ---------------------- cm
d) Levels of template checked by

water level or dumpy
Yes/No
level
e) Cleat at the bottom of the sub is fitted Yes/No

CERTIFICATE:
Sub-Contractor:
Name : Name:
Date: Date:
Name:
Date:
Page-48
NAME OF LINE :
PART-A : FOUNDATION
ACTIVITY
A4 : Checking of Foundation material & availability of T&P :
Fabrication & placement of reinforcement steel as per Drawing

a) Yes/No
no.:
b) Diameter and lengthwise details of reinforcement steel:
Sr.No. Length Diameter Nos. REMARKS

Drgs. Actual Drgs. Actual Drgs. Actual (testing details)
c) Quality of sand as per specification and conforming

to the grade used in Mix Design and sufficient
quantity
is available at location: Yes/No.
d) Quality & quantity of coarse Aggregate, metal conforming

to the grade used in Mix Design and sufficient quantity is
available at
Yes/No.
location:
Source of
e)
collection :
Sand Metal/Aggregate
Approved/Not
Name Approved/Not Approved Name
Approved
f) Quality of Water:
i) Confirming to specification : Yes/No.
ii) pH value of water used :
g) Required T&P such as mixer, vibrator, slump cone, form boxes, shuttering,
dewatering arrangement & cubes for sampling etc., are
available in good condition and required quantity: Yes/No.
Defective T&P required to be repaired/replaced by the
h)
Contractor:
Page-49
CERTIFICATE:
Sub-Contractor:
Name : Name:
Date: Date:
Name:
Date:
Page-50
NAME OF LINE :
A5 : Lean Concrete
a) Foundation Drawing no. followed :
b) Concrete mixing by mixer : Yes/No
c) Dewatering done: Yes/No
d) Lean concreting done upto specified level of all pits: Yes/No
Proper levelling of concrete in all

e) Yes/No
pits:
f) Number of cement bags used for lean concrete:

Reasons
for
Sr.No. Leg-1 Leg-2 Leg-3 Leg-4 variations
from the
drg.
Bags (nos)
Thickness
(mm)
CERTIFICATE:
Sub-Contractor:
Name : Name:
Signature with
Seal:
Date: Date:
Name:
Date:
Page-51
NAME OF LINE :
A6 : Placement of reinforcement steel & form boxes:
a) Foundation Drawing no. followed :
b) Reinforcement steel placed as per drawing: Yes/No
c) Concrete cover to reinforcement maintained with

adequate no. of cover blocks as per specification: Yes/No
d) Form boxes are placed as per drawing & tightened

properly with shuttering oil painted inside: Yes/No
Earthing strip is fixed as per

e) Yes/No
drawing:
CERTIFICATE:
Sub-Contractor:
Name : Name:
Signature
with Seal:
Date: Date:
Name:
Date:
Page-52
NAME OF LINE :
A7 : Checking for foundation casting
Foundation Drawing no. followed

a)
:
b) Concrete mixing by mixer as per Design Mix ratios: Yes/No
c) Mixing by mixer: Yes/No
d) Water cement ratio: ………
e) Use of vibrator for compaction: Yes/No
f) Checking of stub-template level at interval: Yes/No
g) Checking diagonal stub-template level at interval: Yes/No
Casting of leg is done in
h) Yes/No
continuity:
i) Slump ……mm
Number of cement bags
j)
consumed:
As per Design / Drg Actual Reasons for variation
k) Coping is done: Yes/No

l) Top of concrete from average ground level: ………
m) No. of concrete samples taken: ………
CERTIFICATE : Foundation is casted as per drawing
Sub-Contractor:
Name : Name:
Signature with
Seal:
Date: Date:

Name:
Date:
Page-53
NAME OF
LINE :
Location
Date :
No.:
A8 : Checking for curing, form box, template/prop removal & back filling:
a) Curing is started after 24 hrs. of foundation casting
& foundation is kept continuously wet: Yes/No
b) Form boxes are removed after 24 hrs. of casting: Yes/No
Defects in
c) Yes/No
concrete:
No. of
cement
Sr.No. Type of Defect(s) Description Remedial measures
bags
consumed
1 Quality of concrete Honey combing/rough
surface/smooth surface
2 Cover Reinforcement visible/
not visible
3 Shape As per drawing/distorted
4 Nature of defects Major/Minor
Any other defect

5
(s)
d) Back filling done as per specification: Yes/No
Template/prop is removed only after complete back

e) Yes/No
filling:
CERTIFICATE: Foundation is cleared for Tower erection subject to the completion of setting
time as per standards
Sub-
Contractor:
Name : Name:
Date: Date:
Name:
Date:
Page-54
NAME OF
LINE :
SECTION LOC.No. DATED:
A9 : Dimension of location after casting
a) After casting level checked and found OK YES/NO

b) Important measurement for the location is measured
after casting and indicated below and dimensions are
within the tolerance limits.
3 2
4 1
Details As per drawing Actual

1-3
2-4
3-4
4-1
1-2
2-3
Sub-
: _________________
contractor
:
Name : _________________ Name
______________
Signature :
: _________________ Signature with Seal
with Seal ______________
:
Date : _________________ Date
______________
Name:
Signature with
Seal:
Date:
Page-55
NAME OF LINE :
A10 : Procedure for finalisation of Most Techno-Economical Location
1. No level Ground is available in the vicinity along the alignment
2. Tower can not be located on the level Ground even by providing extension
3. Benching/Revetment or both are unavoidable

Comparative Study of alternatives is indicated below :
CASE - I : When Complete Benching is Done
Sl.No. PARTICULARS QTY. RATE COST REMARKS
1. Excavation (Type of soil)

a)
b)
c)
2. Revetment
3. Breast Wall
4. Any other work
TOTAL
CASE - II : When Benching is done partly

a)
b)
c)
2. Revetment
3. Breast Wall
4. Any other work
TOTAL
Page-56
NAME OF LINE :
CASE - III : When No Benching is done

a)
b)
c)
2. Revetment
3. Breast Wall
4. Tower Structure (with leg

extension, if any)
5. Any other work
TOTAL
Note : Relevant Drawings with calculations are to be enclosed.
Sub-contractor : _________________
:
Name : _________________ Name
______________
Signature with :
Signature with Seal : _________________ Seal ______________
:
Date : _________________ Date
______________

Name:
Date:
Page-57
NAME OF LINE :

A-11: Testing of concrete cubes
a) Grade of Concrete:
b) No. of samples taken:
c) Date of casting:
d) Date of testing:
e) Size of Cube
Cube Strength
Sample No. Cube No. Wt. Of cube (Kg.) Load in Kg. at crushing (Kg/Cm2)
7 days 28 days
1. 1
2
3
2. 1
2
3
3. 1
2
3
4. 1
2
3
CERTIFICATE: Cube strength meets the requirement of specification & IS code.

Sub-Contractor:
Name : Name:
Date: Date:
Name:
Date:
Page-58
5.0 TOWER ERECTION, STRINGING AND INSTALLATION OF LINE MATERIAL.
5.1 GENERAL
5.1.1 The details of the scope of erection work shall include the cost of labour, all tools and
plants and all other incidental expenses in connection with erection and stringing work.
5.1.2 The Bidder shall be responsible for transportation of all the materials as per the scope of
work to site, proper storage and preservation at their own cost till such time the erected
line is taken over by the HVPNL. Bidder shall set up required number of stores along the
line and the exact location of such stores shall be discussed and agreed to between the
Bidder and the HVPNL. It shall be entirely the responsibility of the Bidder to arrange
receipt, unloading and loading and transportation of the supplied items to the stores,
proper storage and safe custody.
5.2 TREATMENT OF MINOR GALVANISNING DAMAGE
In case any minor damage to galvanizing is noticed, the same shall be treated with zinc
rich paint (commercial grade) (having at least 90% zinc content) before erection.
5.3 ASSEMBLY
The method followed for the erection of tower, shall ensure the points mentioned below:
a) Straining of the members shall not be permitted for bringing them into position, it
may, however be necessary to match hole positions at joints and to facilitate this,
tommy bars not more than 450 mm long may be used.
b) Before starting erection of an upper section, the lower section shall be completely
braced and all bolts provided and tightened adequately in accordance with
approved drawings to prevent any mishap during tower erection.
c) All plan diagonals relevant to a section of tower shall be placed in position before
assembly of upper section is taken up.
d) The bolt position in assembled towers shall be as per IS:5613 (Part-II/section-2)-

1976.
e) Tower shall fitted with number plate, danger plate, phase plate, circuit plate and
anti-climbing device barbed wire type as described.
f) All blank holes, if any left, after complete erection of the tower, are to be filled up
by bolts and nuts of correct size.
Page-59
5.4 TIGHTENING AND PUNCHING OF BOLTS AND NUTS.
5.4.1 All nuts shall be tightened properly using correct size spanner/torque wrench. Before
tightening, it will be seen that filler washers and plates are placed in gaps between
members wherever applicable. Bolts of proper size and length are inserted and one
spring washer is inserted under each nut. In case of step bolts, spring washers shall be
placed under the outer nut. The tightening shall progressively be carried out from the top
downwards, care being taken that all bolts at every level are tightened simultaneously.
The threads of bolts projecting outside the nuts shall be punched at their position on the
diameter to ensure that the nuts are not loosened in course of time. If during tightening a
nut is found to be slipping or running over the bolt threads, the bolt together with the nut
shall be replaced.
5.4.2 The threads of all the bolts projected outside the nuts shall be welded at two
diametrically opposite places. The circular length of each welding shall be at least 10mm.
The welding shall be provided from ground level to bottom cross arm level for double
circuit towers. After welding, cold galvanized paint having at least 90% zinc content shall
be applied to the welded portion. At least two coats of the paint shall be applied. The cost
of welding and paint including application of paint shall be deemed to be included in the
erection price.
5.4.3 In addition to the tack welding of nuts with bolts, as described above, the Bidder can also
propose some alternative arrangements, like use of epoxy resin adhesive which can
serve the purpose of locking the nut permanently with the bolt and thus preventing
pilferage of the tower members.
5.5 INSULATOR HOISTING
5.5.1 ‘I’ suspension insulator strings shall be used on suspension towers and tension insulator
strings on angle and dead end towers. These shall be fixed on all the towers just prior to
the stringing. Damaged insulators and fittings, if any, shall not be employed in the
assemblies. Before hoisting all insulators shall be cleaned in a manner that will not spoil,
injure or scratch the surface of the insulator, but in no case shall any oil be used for the
purpose. Corona control rings/arching horn shall be fitted in an approved manner.
Torque wrench shall be used for fixing different line materials and their components, like
suspension clamp for conductor and earthwire etc. Whenever recommended by the
Bidder of the same for river crossing towers.
5.6 HANDING OF CONDUCTOR AND EARTHWIRE
5.6.1 The Bidder shall be entirely responsible for any damage to the towers or conductors
during stringing. While running out the conductors, care shall be taken that the
conductors do not touch or rub against the ground or objects which could cause
scratches or damages to the strands. The conductors shall be run out of the drums from
the top in order to avoid damage due to chafing. Immediately after running out, the
conductor shall be raised at the supports to the levels of the clamps and placed into the
running blocks. The groove of the running blocks shall be of such a design that the seat
is semi-circular and larger than the diameter of the conductor/earthwire and it does not
slip over or rub against the sides. The grooves shall be lined with hard rubber or
neoprene to avoid damage to conductor and shall be mounted on properly lubricated
bearings.
Page-60
5.6.2 The running blocks shall be suspended in a manner to suit the design of the cross-arm.
All running blocks especially those at the tension end, will be fitted on the cross-arm with
jute cloth wrapped over the steel work and under the slings to avoid damage to the slings
as well as to the protective surface finish of the steel work. In case suspension, or
section towers are used even for temporary terminations, if this be unavoidable, they
shall be well guyed and steps shall be taken by the Bidder to avoid damage. Guying
proposal alongwith necessary calculations shall be submitted by the contactor to HVPNL
for the approval. Proper T&P shall also be made available to the HVPNL by the contactor
for checking the tensions in the guy wires. The drums shall be provided with a suitable
braking device to avoid damages, loose running out and kinking of the conductor. The
conductor shall be continuously observed for loose or broken strands or any other
damage. When approaching end of a drum length, at least three coils shall be left when
the stringing operations are to be stopped. These coils are to be removed carefully, and
if another length is required to be run out, a joint shall be made as per the
recommendations of the Bidders.
5.6.3 Repairs to conductors. If necessary, shall be carried out during the running out
operations, with repair sleeves. Repairing of conductor surface shall be done only in
case of minor damage. Scuff marks etc. keeping in view both electrical and mechanical
safe requirements. The final conductor surface shall be clean smooth and without any
projections, sharp points, cuts, abrasions etc.
5.6.4 Conductor splices shall be so made that they do not crack or get damaged in the
stringing operation. The Bidder shall use only such equipment/methods during conductor
stringing which ensures complete compliance in this regard.
5.6.5 Derricks shall be used where roads, rivers, channels, telecommunication or overhead
power line, Railway line, fences or walls have to be crossed during stringing operations.
It shall be seen that normal services are not interrupted or damage caused to property.
Shut down shall be obtained when working at crossing of overhead power line. The
Bidder shall be entirely responsible for the proper handling of the conductor, earthwire
and accessories in the field.
5.6.6 The sequence of running out shall be from top to downwards, i.e. the earthwire shall be
run out first, followed by the conductors in succession. Unbalances of loads on tower
shall be avoided as far as possible.
5.6.7 The proposed transmission line may run parallel for certain distance with the existing
transmission line which may remain energized during the stringing period. As a result
there is a possibility of dangerous voltage build up due to electromagnetic and
electrostatic coupling in the pulling wire, conductors and earthwires, which although
comparatively small during normal operations can be severe during switching. It shall be
the Bidder’s responsibility to take adequate safety precautions to protect his employees
and others from this potential danger.
5.6.8 Towers not designed for one sided stringing shall be well guyed and steps taken by
Bidder to avoid damage. The Bidder has to submit the detailed proposal alongwith the
calculation for guying which shall be approved by the HVPNL. Proper T&P shall be made
available to the HVPNL by the Bidder for checking the tensions in the guy wires. All the
expenditure on account of the above work is deemed to be included in the bid price and
no extra payment shall be made for the same.
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5.7 STRINGING OF CONDUCTOR AND EARTHWIRE
5.7.1 The stringing of the conductor shall be done by standard stringing method.
5.7.2 After being pulled the conductor/earthwire shall not be allowed to hang in the stringing
blocks for more than 96 hours being pulled to the specified sag.
5.7.3 The stringing of conductor shall be done as per initial stringing chart duly approved by
the HVPNL. The Bidder shall prepare the initial stringing chart taking account of
conductor creep in respect of ACSR ‘Zebra’ which shall be compensated by over-
tensioning the conductor at a temperature of 26oC lower than the ambient temperature
during stringing. Conductor creep in respect of ACSR ‘Panther’ shall be compensated by
over-tensioning the conductor at a temperature of 21oC lower than the ambient
temperature during stringing
5.7.4 The Bidder shall give complete details of the stringing methods, which he proposes to
follow. Before the commencement of stringing the Bidder shall submit the stringing charts
for the conductor and earthwire for various temperatures and span, alongwith equivalent
spans for the approval of the HVPNL.
5.8 JOINTING
5.8.1 All the joints on the conductor and earthwire shall be of compression type, in accordance
with the recommendations of the Bidder for which all necessary tools, equipment like
compressors, dies, processes etc. shall have to be arranged by the Bidder. Each part of
the joint shall be cleaned by wire brush to make it free of rust or dirt etc. and properly
greased with anticorrosive compound if required, and as recommended by the Bidder
before the final compression is done with the compressors.
5.8.2 All joints or splices shall be made at least 30 metres away from the structures. No joints
or splices shall be made in span crossing over main Roads, Railways, small rivers with
tension spans. During compression or splicing operation the conductor shall be handled
in such a manner as to prevent lateral or vertical bearing against the dies. After pressing
the joint the aluminum sleeve shall have all corners rounded, burrs and sharp edges
removed and smoothened.
5.8.3 During stringing of conductor to avoid any damage to the joint, the Bidder shall use a
suitable protector with mid span compression joints in case joints are to be passed over
pulley blocks/aerial rollers. The size of the groove of the pulley shall be such that the joint
along with protection can be passed over it smoothly.
5.9 SAGGING-IN-OPERATION
5.9.1 The conductor shall be pulled up to the desired sag and left in running blocks for at least
one hour after which the sag shall be re-checked and adjusted, if necessary before
transferring the conductors from the running blocks to the suspension clamps. The
conductor shall be clamped within 96 hours of sagging in.
5.9.2 The sag will be checked in the first an the last span of the section in case of sections up
to eight spans and in one intermediate span also for sections with more than eight spans.
The sag shall also be checked when the conductors have been drawn up and transferred
from running blocks to the insulator clamps.
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5.9.3 The running blocks, when suspended from the transmission structure for sagging shall
be so adjusted that the conductors on running blocks will be at the same height as the
suspension clamp to which it is to be secured.
5.9.4 At sharp vertical angles, the sags and tensions shall be checked on both sides of the
angle, the conductor and earthwire shall be checked on the running blocks for equality of
tension on both sides. The suspension insulator assemblies will normally assume vertical
positions when the conductor is clamped.
5.9.5 Tensioning and sagging operations shall be carried out in calm weather when rapid
changes in temperatures are not likely to occur.
5.10 TENSIONING AND SAGGING OF CONDUCTORS AND EARTHWIRE
The tensioning and sagging shall be done in accordance with the approved stringing
charts before the conductors and earthwire are finally attached to the towers through the
earthwire clamps for the earthwire and insulator strings for the conductor. The initial
stringing chart for shall be used for the conductor and ‘final’ stringing chart for earthwire
should be employed for this purpose. Dynamometers shall be employed for measuring
tension in the conductor and earthwire. The dynamometers employed shall be
periodically checked and calibrated with the standard dynamometer.
5.11 CLIPPING IN
5.11.1 Clipping of the conductors in position shall be done in accordance with the
recommendations of the Bidder. Conductor shall be fitted with armour rods where it is
made to pass through suspension clamps.
5.11.2 The jumpers at the section and angle towers shall be formed to parabolic shape to
ensure maximum clearance requirements.
5.11.3 Fasteners in all fittings and accessories shall be secured in position. The security clip
shall be properly opened and sprung into position.
5.12 FIXING OF CONDUCTOR AND EARTHWIRE ACCESSORIES
Vibration dampers for conductor and earthwire and other conductor and earthwire
accessories shall be installed by the Bidder as per the design requirement and
respective Bidder’s instructions within 24 hours of the conductor/earthwire clamping.
While installing the conductor and earthwire accessories, proper care shall be taken to
ensure that the surface are clean and smooth and no damage shall occur to any part of
the accessories.
5.13 REPLACEMENT
If any replacements are to be effected after stringing and tensioning or during

maintenance, leg members and bracing shall not be removed without reducing the
tension on the tower with proper guying or releasing the conductor. If the replacement of
cross arms becomes necessary after stringing, the conductor shall be suitably tied to the
tower at tension points or transferred to suitable roller pulleys at suspension points.
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5.14 PREMITTED EXTRA CONSUMPTION OF LINE MATERIALS
5.14.1 The Bidder shall make every effort to minimize the breakages, losses & wastages of the
line material during erection. However, while calculating the quantities of line materials,
HVPNL shall permit the Bidder extra consumption of conductor and earthwire up to the
limit of 1%. The Bidder shall be permitted to dispose off the scraps, if any, at their end. In
case of conductor and earthwire, the permitted extra consumption limit of 1% is inclusive
of sag, stringing damages, losses and wastages etc. The quantity of conductor and
earthwire shall be worked out as per following norms.
a) Quantity of conductor = line length as per detailed survey

x No. of phases (3) x No. of circuits
b) Quantity of earthwire = line length as per detailed survey
The Bidder shall not be required to return to the HVPNL empty conductor and earthwire
drums as the same shall be deemed to become his property.
For other line materials i.e. Disc insulator, Hardware and accessories for conductor and
earthwire the actual quantity incorporated on transmission lines shall be approved as
consumption.
5.14.2 The Bidder shall be permitted to dispose off the empty conductor and earthwire drums at
his cost.
5.15 FINAL CHECKING, TESTING AND COMMISSIONING
After completion of the works, final checking of the line shall be done by the Bidder to
ensure that all the foundation works, tower erection, and stringing have been done
strictly according to the specifications and as approved by the HVPNL. All the works shall
be thoroughly inspected keeping in view of the following main points:
a) Sufficient back filled earth is lying over each foundation pit and it is equately
compacted.
b) Concrete chimneys and their copings are in good finely shaped conditions.
c) All the tower members are correctly used, strictly according to final approved
drawing and are free of any defect or damage whatsoever.
d) All bolts are properly tightened and punched/tack welded and painted Zinc rich
primer and enamel paint.
e) The stringing of the conductors and earthwire has been done as per the approved
sag and tension charts and desired clearances are clearly available.
f) All conductor and earthwire accessories are properly installed.
g) All other requirements to complete the work like fixing of danger plate, phase
plate, number plate, anti climbing device, aviation signal (wherever required) etc.
are properly installed.
h) Wherever required it should be ensured that revetment is provided.
i) The original tracings of profile route alignment and tower, design, structural
drawings, bill of material, shop drawings of all towers other that the towers
designed by the HVPNL are submitted to the HVPNL for reference and record.
j) The insulation of line as a whole is tested by the contactor by providing his own
equipment, labour etc. to the satisfaction of the HVPNL.
k) All towers are to be properly grounded.
l) The line is tested satisfactorily for commissioning purpose.
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6.1 GENERAL TECHNICAL CONDITIONS
6.1.1 The following provisions shall supplement all the detailed technical specifications and
requirements brought out herein. The Bidder’s proposal shall be based on the use of
materials complying fully with the requirements specified herein.
6.2 ENGINEERING DATA
6.2.1 The furnishing of engineering data by the Bidder shall be in accordance with the
schedule as specified in the technical specifications. The review of these data by the
HVPNL will cover only general conformance of the data to the specifications and not
a thorough review of all dimensions, quantities and details of the materials, or items
indicated or the accuracy of the information submitted. This review by the HVPNL
shall not be considered by the Bidder, as limiting any of his responsibilities and
liabilities for mistakes and deviations from the requirements, specified under these
specifications.
6.2.2 All engineering data submitted by the Bidder after review by the HVPNL shall form
part of the contract documents.
6.3 DRAWINGS
In addition to those stipulated in clause regarding drawings in conditions of contract,

the following also shall apply in respect of Bidder’s drawings.
6.3.1 All drawings submitted by the Bidder including those submitted at the time of bid shall
be with sufficient detail to indicate the type, size, arrangement, dimensions, material
description, bill of materials, weight of each component, break-up for packing and
shipment, fixing arrangement required, the dimensions required for installation and
any other information specifically requested in these specifications.
6.3.2 Each drawing submitted by the Bidder shall be clearly marked with the name of the
HVPNL, the specification title, the specification number and the name of the project.
All titles, noting, markings and writings on the drawing shall be in English. All the
dimensions should be to the scale and in metric units.
6.3.3 The drawings submitted by the Bidder shall be reviewed by the HVPNL as far as
practicable within 30 days and shall be modified by the Bidder if any modifications
and/ or corrections are required by the HVPNL. The Bidder shall incorporate such
modifications and/or corrections and submit the final drawings for approval. Any
delays arising out of failure by the Bidder to rectify the drawings in good time shall not
alter the contract completion date.
6.3.4 The drawings submitted for approval to the HVPNL shall be in quadruplicate. One
print of such drawings shall be returned to the Bidder by the HVPNL marked
“approved / approved with corrections”. The Bidder shall thereupon furnish the
HVPNL additional prints as may be required along with one reproducible in original of
the drawings after incorporating all corrections.
6.3.5 The work shall be performed by the Bidder strictly in accordance with these drawings
and no deviation shall be permitted without the written approval of the HVPNL, if so
required.
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6.3.6 All manufacturing, fabrication and erection work under the scope of Bidder, prior to
the approval of the drawings shall be at the Bidder’s risk. The Bidder may make any
changes in the design which are necessary to conform to the provisions and intent of
the Bidder and such changes will again be subject to approval by the HVPNL.
6.3.7 The approval of the documents and drawings by the HVPNL shall mean that the
HVPNL is satisfied that:
a) The Bidder has completed the part of the works covered by the subject document (i.e.
confirmation of progress of work.)
b) The works appear to comply with requirements of specifications.
In no case the approval by the HVPNL of any document does imply compliance with
all technical requirement nor the absence of errors in such documents.
If errors are discovered any time during the validity of the contract, then the Bidder
shall be responsible of their consequences.
6.3.8 The HVPNL may use a 35mm microfilm system in processing drawings. All drawings
shall be suitable for microfilming. Drawings, which are not suitable for microfilming,
will not be accepted.
A copy of each drawing reviewed will be returned to the Bidder as stipulated herein.
6.3.9 Copies of drawings returned to the Bidder will be in the form of a print with the
HVPNL marking, or a print made from a microfilm of the marked up drawing.
6.3.10 The following is the generic list of the documents and drawings that are to be
approved by the HVPNL.
a) Work schedule (master network) plan.
b) Sag-tension calculation and sag-template curve drawings.
c) Tower spotting data.
d) Detailed survey report and profile drawing showing ground clearance and tower
locations.
e) Tower schedule and foundation classification for individual tower locations.
f) Soil investigation report.
g) Tower footing earthing drawing.
h) Stringing procedure and stringing chart.
i) Tower accessories drawings like design plate, name plate etc.
j) Quality plan for fabrication and site activities including quality system.
k) Sub-vendors approval etc.
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6.4 DESIGN IMPROVEMENTS
6.4.1 The HVPNL or the Bidder may propose change in the specification and if the parties
agree upon any such changes and the cost implication, the specification shall be
modified accordingly.
6.4.2 If any such agreed upon change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any change in the
price and/ or schedule of completion before the Bidder proceeds with the change.
Following such agreement, the provision thereof, shall be deemed to have been
amended accordingly.
6.5 DESIGN CO-ORDINATION:
6.5.1 The Bidder shall be responsible for the selection and design of appropriate
material/item to provide the best co-ordinated performance of the entire system. The
basic design requirements are detailed out in this specification. The design of various
components, sub-assemblies and assembles shall be so done that it facilitates easy
field assembly and maintenance.
6.6 DESIGN REVIEW MEETING:
The Bidder will be called upon to attend design review meetings with the HVPNL and
the consultants of the HVPNL during the period of contract. The Bidder shall attend
such meetings at his own cost at Panchkula or at mutually agreed venue as and
when required. Such review meeting will be held generally four times in a year.
6.7 PACKING:
6.7.1 All the materials shall be suitably protected, coated, covered or boxed and crated to
prevent damage or deterioration during transit, handing and storage at site till the
time of erection. The Bidder shall be responsible for any loss or damage during
transportation, handing and storage due to improper packing.
6.7.2 The Bidder shall include and provide for securely protecting and packing the
materials so as to avoid loss or damage during transport by air, sea, Rail and road.
6.7.3 All packing shall allow for easy removal and checking at site. Wherever necessary,
proper arrangement for attaching slings for lifting shall be provided. All packages shall
be clearly marked for with signs showing up and down on the sides of boxes, and
handling and unpacking instructions as considered necessary. Special precaution
shall be taken to prevent rusting of steel and iron parts during transit by sea.
6.7.4 The cases containing easily damageable material shall be very carefully packed and
marked with appropriate caution symbols, i.e. fragile, handle with care, use no hook
etc wherever applicable.
6.7.5 Each package shall be legibly marked by the Bidder at his expenses showing the
details such as description and quantity of contents, the name of the consignee and
address, the gross and net weight of the package, the name of the Bidder etc.
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7. ERECTION CONDITIONS:
7.1 The following shall supplement the conditions already contained in the other parts of
these specifications and documents and shall govern that portion of the work on this
contract to be performed at site.
7.2 REGULATION OF LOCAL AUTHORITIES AND STATUTES:
7.2.1 The contactor shall comply with all the rules and regulations of local authorities during
the performance of his field activities. He shall also comply with the minimum wages
act. 1948 and the payment of wages act (both of the government of India) and the
rules made there under in respect of any employee or workman employed or
engaged by him or his sub-Bidder.
7.2.2 All registration and statutory inspection fees, if any, in respect of his work pursuant to
this contract shall be to the account of the Bidder. However, any registration, statutory
inspection fees lawfully payable under the provisions of the statutory laws and its
amendments from time to time during erection in respect of the transmission line,
ultimately to be owned by the HVPNL, shall be to the account of the HVPNL. Should
any such inspection or registration need to be re- arranged due to the fault of the
Bidder or his sub-Bidder, the additional fees to such inspection and/or registration
shall be borne by the Bidder.
7.3 BIDDER’S FIELD OPERATION
7.3.1 The Bidder shall keep the HVPNL informed in advance regarding his field activity
plans and schedules for carrying out each part of the works. Any review of such plan
or schedule or method of work by the HVPNL shall not relieve the Bidder of any of his
responsibilities towards the filed activities. Such reviews shall also not be considered
as an assumption of any risk or liability by the HVPNL or any of his representatives
and no claim of the Bidder will be entertained because of the failure or inefficiency of
any such plan or schedule or method of work reviewed. The Bidder shall be solely
responsible for the safety, adequacy and efficiency of tools and plants and his
erection methods.
7.4 PROGRESS REPORT
7.4.1 Appropriate visual charts shall accompany the monthly progress reports detailing
out the progress achieved on all erection activities as compared to the schedules.
The report shall also indicate the reasons for the variance between the scheduled
and actual progress and the action proposed for corrective measures, wherever
Necessary.
7.5 MAN POWER DEPLOYMENT REPORT
7.5.1 The Bidder shall submit to the HVPNL, on the first day of every month, a man power
deployment schedule for each activity.
7.5.2 The Bidder shall also submit to the HVPNL on the first day of every month, a man
power deployment report of the previous month detailing the number of persons
scheduled to have been employed and actually employed.
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7.5.3 FACILITIES TO BE PROVIDED BY THE BIDDER
7.5.4 TOOLS, TACKLE AND SCAFFOLDINGS
The Bidder shall provide all the construction equipment, tools, tackle and scaffoldings
required for construction, erection, testing and commissioning of the transmission line
covered under the contract. He shall submit a list of all such materials to the HVPNL
before the commencement of work at site. These tools and tackle shall not be
removed from the site without the written permission of the HVPNL.
7.5.5 FIRST AID AND GENERAL HYGIENE
The contactor shall provide all necessary first aid facilities for all his employees,
representatives and workmen working at the site. Enough number of Bidder’s
personnel shall be trained in administering first aid.
Similarly the labour colony, the offices and the residential areas of the contactor’s
employees and workmen shall be kept clean and neat to the entire satisfaction of the
HVPNL. Proper sanitary arrangements shall be provided by the Bidder, in the work-
areas, office and residential areas of the Bidder. Waste oil shall be disposed off in a
manner acceptable to the HVPNL. Under no circumstances shall waste oil be
dumped into uncontrolled drains.
7.6 FIRE PROTECTION
7.6.1 The work procedures that are to be used during the erection shall be those which
minimise fire hazards to the extent practicable. Combustible materials, combustible
waste and rubbish shall be collected and removed from the site at least once each
day. Fuels, oils and volatile or flammable materials shall be stored away from the
construction site and equipment and material stores in safe containers.
7.6.2 All the contactor’s supervisory personnel and sufficient number of workers shall be
trained for fire-fighting and shall be assigned specific fire protection duties. Enough of
such tainted personnel must be available at the site during the entire period of the
contract.
7.6.3 The Bidder shall provide enough fire protection equipment of the types and number
for the ware house, office, temporary structures, labour colony area etc. Access to
such fire protection equipment, shall be easy and kept open at all time.
7.7 SECURITY
The Bidder shall have total responsibility for all equipment and materials in his
custody, stored, loose, semi-assembled and/or erected by him at site. The Bidder
shall make suitable security arrangements including employment of security
personnel to ensure the protection of all materials, equipment and works from theft,
fire pilferage and any other damages and loss.
7.8 METERIALS HANDLING AND STORAGE
7.8.1 All the supplies under the contract as well as HVPNL supplied items arriving at site
shall be promptly received, unloaded and transported and stored in the stores by the
Bidder.
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7.8.2 Bidder shall be responsible for examining all the shipment and notify the HVPNL
immediately of any damage, shortage, discrepancy etc. for the purpose of HVPNL
information only. The Bidder shall submit to the HVPNL every week a report detailing
all the receipts during the week. However, the Bidder shall be solely responsible for
any shortages or damages in transit, handling and/or in storage and erection at site.
Any demurrage, wharfage and other such charges claimed by the transporters,
Railways etc. shall be to the account of the Bidder.
7.8.3 The Bidder shall maintain an accurate and exhaustive record detailing out the list of
all items received by him for the purpose of erection and keep such record open for
the inspection of the HVPNL.
7.8.4 All items shall be handled very carefully to prevent any damage or loss. The materials
stored shall be properly protected to prevent damage. The materials from the store
shall be moved to the actual location at the appropriate time so as to avoid damage of
such materials at site.
7.8.5 All the materials stored in the open or dusty location must be covered with suitable
weather-proof and flame proof covering material wherever applicable.
7.8.6 The Bidder shall be responsible for making suitable indoor storage facilities, to store
all items/materials, which require indoor storage.
7.9 CONSTRUCTION MANAGEMENT
7.9.1 Time is the essence of the contract and the Bidder shall be responsible for
performance of his works in accordance with the specified construction schedule. If at
any time, the Bidder is falling behind the schedule for reasons attributable to him, he
shall take necessary action to make good for such delays by increasing his work
force or by working overtime or otherwise to accelerate the progress of the work and
to comply with schedule and shall communicate such actions in writing to the HVPNL,
satisfying that his action will compensate for the delay. The Bidder shall not be
allowed any extra compensation for such action.
7.10 FIELD OFFICE RECORDS
The Bidder shall maintain at his site office up-to-date copies of all drawings,
specifications and other supplementary data complete with all the latest revisions
there to. The Bidder shall also maintain, in addition, the continuous record of all
changes to the above contract documents, drawings, specifications, supplementary
data, etc. effected at the field and on completion of his total assignment under the
contract shall incorporate data to indicate as installed conditions of the material
supplied and erected under the contract. Such drawings and engineering data shall
be submitted to the HVPNL in required number of copies.
7.11 PROTECTION OF PROPERTY AND BIDDER’S LIABLILITY

7.11.1 The Bidder will ensure provision of necessary safety equipment such as barriers,
sign-boards, warning lights and alarms, etc. to provide adequate protection to
persons and property. The Bidder shall be responsible to give reasonable notice to
the HVPNL and the HVPNLs of public or private property and utilities when such
property and utilities are likely to get damaged or injured during the performance of
his works and shall make all necessary arrangements with such HVPNLs, related to
removal and/or replacement or protection of such property and utilities.
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7.12 PROTECTON OF MONUMENTS AND REFERENCE POINTS
The Bidder shall ensure that any finds such as relics, antiques, coins, fossils, etc.
which he may come across during the course of performance of his works either
during excavation or elsewhere, are properly protected and handed over to the
HVPNL. Similarly, the Bidder shall ensure that the bench marks, reference points,
etc. which are marked either with the help of HVPNL or by the HVPNL shall not be
disturbed in any way during the performance of its works, if any work, is to be
performed which disturbs such reference, the same shall be done only after these are
transferred to other suitable locations under the direction of the HVPNL. The Bidder
shall provide all necessary materials and assistance for such relocation of reference
points etc.
7.13 WORK AND SAFETY REGULATIONS
7.13.1 The Bidder shall ensure safety of all the workmen, materials plant and equipment
belonging to him or to the others, working at the site. The Bidder shall also provide for
all safety notices and safety equipment required by the relevant legislations and
deemed necessary by the HVPNL.
7.13.2 The Bidder will notify, well in advance to the HVPNL, its intention to bring to the site
any container filled with liquid or gaseous fuel or explosive or petroleum substance of
such chemicals, which may involve hazards. The HVPNL shall have the right to
prescribe the conditions, under which such a container is to be stored, handled and
used during the performance of the works and the Bidder shall strictly adhere to and
comply with such Instructions. The HVPNL shall also have the right, at his sole
discretion, to inspect any such container or such construction plant/equipment for
which materials in the container is required to be used and if in his opinion, its use is
not safe, he may forbid its use.
No claim due to such prohibition or towards additional safety provisions called for by
him shall be entertained by the HVPNL.
Further, any such decision of the HVPNL shall not, in any way, absolve the Bidder of
his responsibilities and in case use of such a container or entry thereof into the site
area is forbidden by the HVPNL, the Bidder shall use alternative methods with the
approval of the HVPNL without any cost implication to the HVPNL or extension of
work schedule.
7.13.3 where it is necessary to provide and/or store petroleum products or petroleum

mixtures and explosives, the Bidder shall be responsible for carrying out such
provision and/or storage in accordance with the rules and regulations laid down in
petroleum act 1934, explosives act 1948 and amendments thereof, and petroleum
and carbide of calcium manual published by the Chief Inspector of explosives of
India. All such storage shall have prior approval of the HVPNL. In case, any approval
is necessary from the Chief Inspector (explosives) or any statutory authorities, the
Bidder shall be responsible for obtaining the same.
7.13.4 All equipment used in construction and erection by Bidder shall meet
Indian/International standards and where such standards do not exist, the Bidder
shall ensure these to be absolutely safe. All equipment shall be strictly operated and
maintained by the Bidder in accordance with manufacture’s operation manual and
safety instructions and as per any existing Guideline/Rules in this regard.
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7.13.5 Periodical examinations and all tests for all lifting/ hoisting equipment and tackle shall
be carried out in accordance with the relevant provisions of factories act. 1948, Indian
Electricity Supply Act and associated Laws/ Rules in force from time to time. A
register of such examinations and tests shall be properly maintained by the Bidder
and will be promptly produced as and when desired by HVPNL or by the persons
authorized by him.
7.13.6 The Bidder shall provide suitable safety equipment of prescribe standard to all
employees and workmen according to the need, as may be directed by the HVPNL
who will also have the right to examine these safety equipment to determine their
suitability, reliability, acceptability and adaptability.
7.13.7 Where explosives are to be used, the same shall be used under the direct control and
supervision of an expert, experienced and qualified competent person, strictly in
accordance with the code of practices /rules framed under Indian Explosives Act
pertaining to handling, storage and use of explosive.
7.13.8 The Bidder employing more than 250 workmen, whether temporary casual,
probationer, regular or permanent or on contract, shall employ at least one full time
officer exclusively as safety officer to supervise safety aspects of the equipment and
workmen. Such an officer will co-ordinate with the project safety officer of the HVPNL.
The name and address of such safety officer of the Bidder will be promptly informed
in writing to the HVPNL with a copy to the safety officer- incharge before he starts
work or immediately after any change of the incumbent is made during currency of
the contract.
7.13.9 In case any accident occurs during the construction/erection or other associated
activities undertaken by the Bidder, thereby causing any minor or major or fatal injury
to his employees due to any reason whatsoever, it shall be the responsibility of the
Bidder to promptly inform the same to the HVPNL and also to all the authorities
envisaged under the applicable laws.
7.13.10 The HVPNL shall have the right to stop the work, if in its opinion the work is being
carried out in such a way as may cause accidents and endanger the safety of the
persons and/or property. In such cases, the Bidder shall be informed in writing about
the nature of hazards and possible injury/accident and he shall remove short-comings
promptly. The Bidder, after stopping the specific work, can, if felt necessary, appeal
against the order of stoppage of work to the HVPNL within 3 days of such stoppage
of work and the decision of the HVPNL in this respect shall be conclusive.
7.13.11 The Bidder shall not be entitled for any damages/compensation for stoppage of
work due to safety reasons as provided in clause 7.13.10 above and the period of
such stoppage of work will not be taken as an extension of time for completion of
work and will not be the ground for waiver of any part of contactor’s liability for timely
completion of the works.
7.13.12 The Bidder shall follow and comply with all safety rules, relevant provisions of
applicable laws pertaining to the safety of workmen, employees, plant and equipment
as may be prescribed from time to time without any demur, protest or contest or
reservation. In case of any conflict between statutory requirement and safety rules
referred above, the most stringent clause shall be applicable.
Page-72
7.13.13 If the Bidder fails in providing safe working environment as per safety rules or
continues the work even after being instructed to stop work by the HVPNL as
provided in clause 7.13.10 above, the Bidder shall promptly pay to the HVPNL on
demand, compensation at the rate of Rs. 5,000/- per day or part thereof till the
instructions are complied with and so certified by the HVPNL. However, in case of
accident taking place causing injury, to any individual, the provisions contained in
clause 7.13.14 below shall also apply in addition to compensation mentioned in this
para.
7.13.14 If the Bidder does not take all safety precautions and/or fails to comply with the
safety rules as prescribed by the HVPNL or as prescribed under the applicable law
for the safety of the equipment, plant and personnel and the Bidder does not prevent
hazardous conditions which may cause injury to his own employees or employees of
other Bidders, or HVPNL or any other person at site or adjacent thereto, the Bidder
shall be responsible for payment of compensation to the HVPNL as per the statutory
provisions.
Permanent disability shall have the same meaning as indicated in workmen’s

compensation act. The compensation mentioned above shall be in addition to the
compensation payable to the workmen/employees under the provision of workmen’s
compensation act and rules framed there under or any other applicable law as
applicable from time to time. In case the HVPNL is made to pay such compensation,
the Bidder will be liable to reimburse the HVPNL such amount(s) in addition to the
compensation indicated above.
7.14 FOREIGN PERSONNEL
7.14.1 In case necessary for the execution of the works, the Bidder shall bring foreign
supervisors for the execution of the contract, at his own cost. The Bidder shall submit
to the HVPNL, data on all personnel he proposes to bring into India for the
performance of the works under the contract, at least sixty (60)days prior to their
arrival in India. Such data shall include the name of each person, his present
address, his assignment and responsibility in connection with the works, and a short
resume of his qualification, experience etc. in relation to the work to be performed by
him.
7.14.2 Any person, unsuitable and unacceptable to the HVPNL, shall not be brought to
India. Any person brought to India, and found unsuitable or unacceptable to the
HVPNL shall be immediately removed from site and repatriated back. If found,
necessary, he may be replaced by another personnel acceptable to the HVPNL.
7.14.3 No person brought to India by the Bidder, for the works shall be repatriated without
the consent of the HVPNL in writing, based on a written request from the Bidder for
such repatriation giving reasons for such an action to the HVPNL. The HVPNL may
give permission for such repatriation provided it is satisfied that the progress of work
will not suffer due to such repatriation.
7.14.4 The cost of passports, visas and all other travel expenses to and from India, shall be
to the Bidder’s account. The HVPNL will not provide any residential accommodation
and/ or furniture for any of the Bidder’s personnel including foreign personnel Bidder
shall make his own arrangements for such facilities.
Page-73
7.14.5 The Bidder and its expatriate personnel shall respect all Indian Acts, Laws, Rules and
Regulations and shall not, in any way, interfere with Indian political and religious
affairs and shall conform to any other rules and regulations which the government of
India, and the HVPNL may establish on them. The contactor’s expatriate personnel
shall work and live in close co-operation and co-ordination with their co-workers and
the community and shall not engage themselves in any other employment either part-
time or full-time nor shall they take part in any local politics.
7.14.6 HVPNL shall assist the Bidder, to the extent possible, in obtaining necessary permits
to travel to India and back, by issue of necessary certificates and other information
needed by the government agencies.
7.15 CODE REQUIREMENTS
The erection requirements and procedures to be followed during the execution of the
project shall be in accordance with the applicable Indian/International
standards/regulations, as indicated in technical specifications, good engineering
practice, the Drawings and another applicable Indian codes, laws and regulations.
Page-74
ANNEXURE-IA
DRAWINGS FOR 132kV TOWER ACCESSORIES
Sr. No. Description Drawing No.

1. Tower Number plate 1
2. Circuit Plate 2
3. Tower phase plate 3
4 Tower danger plate 4
5 Pipe type earthing arrangement 5
6 Counterpoise type earthing arrangement 6
7 Detail for flats for earthing 7
8 Detail of anticlimbing device 8
9 Step bolt drawing 9
10 Single suspension string drawing 10
11 Single tension string drawing 11
12. Double tension string drawing 12
13 Compression type tension fitting for earthwire 13
14 Suspension type assembly for earthwire 14

SECTION-VI
PART-II
SECTION-VI
(PART-II A)
CONTENTS
S. No Clause Page No.
1.0 General Information 1
2.0 Scope 1
3.0 Weights and measures 1
4.0 General Technical conditions 1
5.0 Technical Description 4
6.0 Tests and Standards 4
7.0 Guaranteed Technical Particulars 4

SECTION-VI
(PART- IIA)
1. General Information
1.1 The material covered in this specification shall be used in 220kV, 132kV and 66kV
transmission lines of HVPNL.
2. Scope:
2.1 The material shall be designed, manufactured and tested as per the requirements
specified.
2.2 The material covered under various packages shall be supplied complete in all
respect, including all component, fittings and accessories which are necessary or are
usual for their efficient performance and satisfactory maintenance under the various
operating and atmospheric conditions. Such parts shall deemed to be within the
scope of the contract, whether specially included or not in the specifications or in the
contract schedules. The bidder shall not eligible for any charges for such fittings etc.
3. Weights and measures
All weights and measures shall be in system international (SI) units. All fasteners
shall be of metric size only.
4.1 General Technical Conditions
4.1.1 The following provisions shall supplement all the detailed technical specifications and
requirements brought out in the accompanying technical specifications. The bidder’s
proposal shall be based on the use of equipment and materials complying fully with
the requirements, specified herein.
4.2 Equipment performance Guarantee

4.2.1 The performance requirements of the items are detailed separately in this
specification. These guarantees shall supplement the general performance guarantee
provisions covered under General Terms and Conditions of Contract in clause entitles
‘Guarantee”.
4.2.2 Liquidated damages for not meeting specified performance shall be assessed and
recovered from the manufacturer. Such liquidated damages shall be without any
limitation whatsoever an shall be in addition to damage, if any payable under any
other clause of conditions of contract.
4.3 Engineering Data
4.3.1 The furnishing of engineering data by the bidder shall be in accordance with the
appropriate schedule of specification. The review of these data by the HVPNL will
cover only general conformance of the data to the specifications and drawings. This
review by the HVPNL may not indicate a thorough review of all dimensions, quantities
and details of the equipment, materials, any devices or items indicated or the
accuracy of the information submitted. This review and/or approval by the HVPNL
shall not be considered by the manufacturer, as limiting any of his responsibilities and
liabilities for mistakes and deviations from the requirements, specified under these
Specifications and documents.
Page-1
4.3.2 All engineering data submitted by the manufacturer after final process including review
and approval by the HVPNL shall form part of the contract document and the entire
works performed under these specifications shall be performed in strict conformity,
unless otherwise expressly requested by the HVPNL in writing.
4.4 Drawings
4.4.1 All drawings submitted by the manufacturer including those submitted at the time of bid
shall be in sufficient detail to dictate the type, size, arrangement, dimensions, material
description. Bill materials, weight of each component, break-up for packing and
shipment, fixing arrangement required, the dimensions required for installation and any
other information specifically requested in the specifications.
4.4.2 Each drawing submitted by the manufacturer shall be clearly marked with the name of
the HVPNL, the unit designation title, the specification number and the name of the
project. All titles, notings, markings and writings on the drawing shall be in English. All
the dimensions should be to the scale and in metric units.
4.4.3 The drawings submitted by the manufacturer shall be reviewed by the HVPNL as far as
practicable within four weeks and shall be modified by the manufacturer if any
modifications and/or corrections are required by the HVPNL. The manufacturer shall
incorporate such modifications and/or corrections and submit the final drawings for
approval. Any delays arising out of failure by the manufacturer to rectify the drawings in
good time shall not after the Contract completion date.
4.4.4 The drawings submitted for approval to the HVPNL shall be in quadruplicate. One print of
such drawings shall be returned to the manufacturer by the HVPNL marked
“approved/approved with correction”. The manufacturer shall thereupon furnish the
HVPNLadditional print as stipulated in technical specification along with one reproducible
in original in original of the drawings after incorporating all corrections.
4.4.5 Further work by the manufacturer shall be strictly in accordance with these drawings and
no deviation shall be permitted with out the written approval of the HVPNL, it so required.
4.4.6 All manufacturing and fabrication work in connection with the equipment/material prior to
the approval of the drawings shall be at the manufacturer’s risk. The manufacturer may
make any changes in the design which are necessary to make the equipment conform to
the provisions and intent of the contract and such changes will again be subject to
approval by the HVPNL. Approval of manufacturer’s drawing or work by the HVPNL shall
not relieve the manufacturer of any of his responsibilities and liabilities under the
contract.
4.5 Manufacturing Schedule
The manufacturer shall submit to the HVPNL his manufacturing, testing and delivery
schedules of various items within thirty (30) days from the date of the Letter of Award in
accordance with the delivery requirements stipulated. Schedule shall also include the
material and items purchased from outside manufacturers, if any.
Page-2
4.6 Reference Standards
4.6.1 The codes and/or standards referred to in specifications shall govern, in all cases
wherever such references are made. In case of a conflict between such Codes and/or
Standards and the Specifications, latter shall govern. Such Codes and/or Standards,
referred to shall mean the latest revisions, amendments/changes adopted and published
by the relevant agencies. In case of any further conflict in this matter, the same shall be
referred to the HVPNL whose decision shall be final and binding.
4.6.2 Other internationally acceptable standards which ensure equivalent or better

performance than those specified shall also be accepted.
4.7 Design Improvements
4.7.1 The HVPNL or the manufacturer may propose changes in the specification of the
equipment or quality thereof and if the parties agree upon any such changes, the
specification shall be modified accordingly.
4.7.2 If any such agreed upon change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any change in the price
and/or schedule of completion before the manufacturer proceeds with the change.
Following such agreement, the provision thereof, be deemed to have been amended
accordingly.
4.8 HVPNL’S SUPERVISION
4.8.1 To eliminate delays and avoid disputes and litigation if is agreed between the parties to
the contract that all matters and questions shall be referred to the HVPNL and his
decision shall be final.
4.8.2 The manufacturing of the product shall be performed under the direction and supervision
of the HVPNL. The scope of the duties of the HVPNL, pursuant to the contract, will
include but not be limited to the following: -
a) Interpretation of all the terms and conditions of these documents and specifications.
b) Review and interpretation of all the manufacturer’s drawings, engineering data etc.
c) Witness or authorize his representative to witness tests at the manufacturer’s works or at

site, or at any place where work is performed data etc.
d) Inspect accept or reject any equipment, material and work under the contract.
e) Issue certificate of acceptance and/or progressive payment and final payment certificate.
f) Review and suggest modification and improvement in completion schedule from time to
time; and
g) Supervision the Quality Assurance programme implementation at all stages of the works.
Page-3
4.9 Inspection, Testing & Inspection Certificate
4.9.1 The HVPNL, his duly authorized representative and/or outside inspection agency acting
on behalf of the HVPNL shall have at all reasonable times access to the manufacturer’s
premises or works and shall have the power at all reasonable times to inspect and
examine the materials and workmanship of the product during its manufacture and if part
of the product is being manufactured or assembled at other premises or works, the
manufacturer shall obtain from the HVPNL and/or his duly authorized representative
permission to inspect as if the equipment/materials were manufactured or assembled on
the manufacturer’s own premises or works.
4.9.2 The manufacturer shall give the HVPNL/inspector fifteen (15) days written notice of any
material being ready for testing. Such tests shall be to the manufacture’s account except
for the expenses of the inspector. The HVPNL/inspector, unless witnessing of the tests is
virtually waived, will attend such tests within fifteen (15) days of the date of which the
equipment is notified as being ready for test/inspection or on a mutually agreed date,
failing which the manufacturer may proceed and he shall forthwith forward to the
inspector duly certified copies of tests triplicate.
4.9.3 The HVPNL/ inspector shall, within fifteen (15) days from the date of inspector as
defined herein give notice in writing to the manufacturer, of any objection to any drawings
and all or any equipment and workmanship which in his opinion is not in accordance with
the contract. The manufacturer shall give due consideration to such objections and shall
make the modifications that may be necessary to meet the said objections.
4.9.4 When the factory tests have been completed at the manufacturer’s or sub-
manufacturer’s work, the HVPNL/inspector shall issue a certificate to this effect within
fifteen (15) days after completion of tests but if the tests are not witnessed by the
HVPNL/inspector, the certificate shall be issued within fifteen (15) days of receipt of the
manufacturer’s test certificate by the HVPNL/inspector. The completion of these tests of
the issue of the certificate shall not bind the HVPNL to accept the equipment should it, on
further tests after erection, be found not to comply with the contract.
4.9.5 In all cases where the contract provides for tests whether at the premises or works of
the manufacturer or of any sub-manufacturer, the manufacturer except where otherwise
specified shall provide free of charge such item as labour, materials, electricity, fuel,
water, stores, apparatus and instruments as may be reasonably demanded by the
HVPNL/inspector or his authorized representative to carry out effectively such tests of
the equipment in accordance with the contract and shall give facilities to the
HVPNL/inspector or his authorized representative to accomplish testing.
4.9.6 The inspection by HVPNL and issue of inspection certificate thereon shall in no way limit
the liabilities and responsibilities of the manufacturer in respect of the agreed Quality
Assurance Programme forming a part of the contract.
5. Technical Description
5.1 The technical description of conductor, earthwire, insulators, hardware fittings &
conductor and earthwire accessories shall be as specified in part-II of this technical
specification.
6. Tests and Standards
6.1 The tests and standards for conductor, earthwire, insulators, hardware fittings &
conductor and earthwire accessories are specified in part-II B, IIC & II D of this Technical
Specification.
7 Guaranteed Technical Particulars
The Guaranteed Technical Particular of the various items covered under this
specification shall be furnished by the bidders in one original and four (4) copies in the
prescribed schedules of the specifications. The bidder shall also furnish any other
schedule informations as in their opinion is needed to give fully description and details to
judge the item (s) offered by them.
Page-4
SECTION-VI , CHAPTER –III ( A )
CONTENTS
1. Technical Description of Conductor for ACSR Zebra and Panther 1
2 Technical Description of Earth wire 7
3. Tests and Standards 9
4. Annexure-A 18
SECTION-VI
(CHAPTER-III-A)
1.0 TECHNICAL SPECIFICATION OF ACSR ZEBRA
2.1 DETAIL OF CONDUCTOR
2.1.1 The conductor shall generally conform to IS: 398-1998 excepts where otherwise
specified herein. Conductor shall only be accepted from those who have got the ISI
certification or equivalent internationally recognized Standard and documentary proof
for having such certification shall be submitted with the Bid.
2.1.2 The conductor shall be ACSR ‘Zebra’ and the details of the conductor are tabulated
below:
a) Stranding and wire diameter : 54/3.18 mm Aluminium

+7/3.18 mm steel
b) Number of Strands :
Core : 1
1st layer : 6
2nd layer : 12
3rd layer : 18
4th layer : 24
c) Total sectional area Aluminium : 428.9 sq. mm
d) Total sectional area : 484.5 sq.mm
e) Overall diameter : 28.62 mm
f) Approximate weight : 1621Kg/km
g) Calculated DC resistance at : 0.06868 ohm/km

20 deg. Centigrade (Max.)
h) Minimum UTS : 130.32 kN
Page-1
2.1.3 a) The details of Aluminium strands are as follows:
i) Minimum breaking load of strand before stranding : 1.29 KN
ii) Minimum breaking load of strand after stranding : 1.23 KN
iii) Maximum D.C. resistance of strand at 20 deg. : 3.626

Centigrade Ohms/km
b) The details of steel strand are as follows:
ii) Minimum breading load of strand after stranding : 9.95 KN
iii) Minimum number of twists to be withstood : 18 before stranding

in torsion test when tested on gauge length
of 100 times of diameter of wire. : 16 after stranding
2.2 Workmanship:
2.2.1 All the aluminium and steel strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, diemarks, scratches, abrasions and kinks after
drawing and also after stranding.
2.2.2 The finished conductor shall have a smooth surface without any surface cuts, abrasions,
scuff marks and shall be free from dirt, grit, etc.
2.2.3 The steel strands shall be hot dip galvanized and shall have a minimum zinc coating of
260 g/m2 after stranding. The zinc coating shall be smooth, continuous, of uniform
thickness, free from imperfections and shall withstand a minimum of two and one half
dips in the standard preece test. The steel wire rods shall be of such quality and purity
that, when drawn to the size of the strands specified and coated with zinc, the finished
strands and the individual wires shall be of uniform quality and have the same properties
and characteristics as prescribed in IEC:888-1987.
2.2.4 The steel strands shall be preformed and postformed in order to prevent spreading of
strands in the event of cutting of composite core wire. Care shall be taken to avoid
damages to galvanization during preforming and postforming operations.
Page-2
2.3 Joints in Wires:
2.3.1 Aluminium Wires
No joints shall be permitted in the individual wires in the outer most layer of the finished
conductor. However, joints in the 12 wire and 18 wire inner layer of the conductor shall
be allowed but these joints shall be made by cold pressure butt-welding and shall be
such that no two such joints are within 15 metres of each other in the complete stranded
conductor. The joint shall withstand a stress of not less than the breaking strength of
individual strand guaranteed.
2.3.2 Steel Wires
There shall be no joint of any kind in the finished wire entering into the manufacture of
the strand nor strand joint or strand splices in any length of the complete stranded steel
core of the conductor.
2.4 Tolerances
The manufacturing tolerances to the extent of following limits only shall be permitted in
the diameter of individual strands and lay-ratio of the conductor:
a) Diameter of Aluminium & steel Strands
Nominal Maximum Minimum
Aluminium 3.18 mm 3.21 mm 3.15 mm
Steel 3.18 mm 3.24 mm 3.12 mm
b) Lay ratio of Conductor
Max. Min.
6 Wire layer 28 (Steel) 13
12 wire layer 17 (Al.) 10
2.5 Materials
2.5.1 The Aluminium strands shall be hard drawn from electrolytic aluminum rods having a
purity of not less than 99.5% and a copper content not exceeding 0.04%.
2.5.2 The steel wire strands shall be drawn from high carbon steel wire rods produced by
either the acid or basic open hearth process, the electric furnace process, or the basic
oxygen process and shall conform to the following requirements as to the chemical
composition:
Page-3
Element % composition
Carbon 0.50 to 0.85
Manganese 0.50 to 1.10
Phosphorus Not more than 0.035
Sulphur Not more than 0.045
Silicon 0.10 to 0.35
2.5.3 The zinc used for galvanizing shall be electrolytic high grade Zinc of 99.95% purity. It
shall conform to and satisfy all the requirements of IS:209.
2.6 Standard Length
2.6.1 The Standard Length of the conductor shall be 1500 meters. A tolerance of +/- 5% on
the standard length offered by the Bidder shall be permitted. All lengths outside this limit
of tolerance shall be treated as random lengths.
2.6.2 Random lengths will be accepted provided no length is less than 70% of the standard
length and total quantity of such random lengths shall not be more than 10% of the
quantity ordered. When one number random length has been manufactured at any time,
five (5) more individual lengths, each equivalent to the above random length with a
tolerance of +/- 5% shall also be manufactured and all the above six random lengths
shall be despatched in the same shipment. At any point, the cumulative quantity supplied
including such random lengths shall not be more than 12.5% of the total cumulative
quantity supplied including such random lengths. However, the last 20% of the quantity
ordered shall be supplied only in standard lengths as specified.
2.6.3 Bidder shall also indicate the maximum single length, above the standard length, he can
manufacture in the guaranteed technical particulars of offer. This is required for special
stretches like river crossing etc. The HVPNL reserves the right to place orders for the
above lengths on the same terms and conditions applicable for the standard lengths
during pendency of the contract.
2.7 DETAIL OF CONDUCTOR FOR 132KV and 66Kv LINES WITH ACSR PANTHER
2.7.1 The conductor shall generally conform to IS: 398-1998 excepts where otherwise
specified herein. Conductor shall only be accepted from those who have got the ISI
certification or equivalent internationally recognized Standard and documentary proof for
having such certification shall be submitted with the Bid.
2.7.2 The conductor shall be ACSR ‘Panther’ and the details of the conductor are tabulated
below:
a) Stranding and wire diameter : 30/3.00 mm Aluminium

+7/3.00 mm steel
Core : 1
Page-4
1st layer : 6
2nd layer : 12
3rd layer : 18
c) Total sectional area Aluminium : 212.1 sq. mm
d) Total sectional area : 261.5 sq.mm
e) Overall diameter : 21.0 mm
f) Approximate weight : 974Kg/km
g) Calculated DC resistance at : 0.140 ohm/km

20 deg. Centigrade (Max.)
h) Minimum UTS : 89.67 kN

i) Direction of lay of outer : Right hand
j) Modulus of elasticity : 8158 (Kg/sq. mm)
k) Co-efficient of linear
expansion (per oC) : 17.8x10-6
2.7.3 a) The details of Aluminium strands are as follows:

ii) Minimum breaking load of strand after stranding : 1.11 KN
iii) Maximum D.C. resistance of strand at 20 deg. : 4.107
Centigrade Ohms/km
b) The details of steel strand are as follows:

ii) Minimum breading load of strand after stranding : 8.85 KN
2.8 Workmanship:
2.8.1 All the aluminium and steel strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, diemarks, scratches, abrasions and kinks after
drawing and also after stranding.
2.8.2 The finished conductor shall have a smooth surface without any surface cuts, abrasions,
scuff marks and shall be free from dirt, grit, etc.
250g/m2 after stranding. The zinc coating shall be smooth, continuous, of uniform
thickness, free from imperfections and shall withstand a minimum of two and one half
dips in the standard preece test. The steel wire rods shall be of such quality and purity
that, when drawn to the size of the strands specified and coated with zinc, the finished
strands and the individual wires shall be of uniform quality and have the same properties
and characteristics as prescribed in IEC:888-1987.
strands in the event of cutting of composite core wire. Care shall be taken to avoid
damages to galvanization during preforming and postforming operations.
Page-5
2.9 Joints in Wires:
2.9.1 Aluminium Wires
No joints shall be permitted in the individual wires in the outer most layer of the finished
conductor. However, joints in the 12 wire inner layer of the conductor unavoidably broken
during stranding provided such breaks are not associated with either inherently defective
wire or with the use of short lengths of aluminium wires. Such joints shall not be more
than four (4) per conductor lengths. These joist shall be made by cold pressure butt-
welding and shall be such that no two such joints are within 15 metres of each other in
the complete stranded conductor.
2.9.2 Steel Wires
There shall be no joint of any kind in the finished wire entering into the manufacture of
the strand nor strand joint or strand splices in any length of the complete stranded steel
core of the conductor.
2.10 Tolerances
The manufacturing tolerances to the extent of following limits only shall be permitted in
the diameter of individual Aluminium and steel strands and lay-ratio of the conductor:
b) Diameter of Aluminium & steel Strands
Nominal Maximum Minimum
Aluminium 3.0 mm 3.03 mm 2.97 mm
Steel 3.0 mm 3.06 mm 2.94 mm
b) Lay ratio of Conductor
Max. Min.
6 Wire layer 28 (Steel) 16
2.11 Materials
2.11.1 The Aluminium strands shall be hard drawn from electrolytic aluminum rods having a
purity of not less than 99.5% and a copper content not exceeding 0.04%. They shall
have the same properties and characteristics as prescribed in IEC:889-1987.
2.11.2 The steel wire strands shall be drawn from high carbon steel wire rods produced by
either the acid or basic open hearth process, the electric furnace process, or the basic
oxygen process and shall conform to the following requirements as to the chemical
composition:
Carbon 0.50 to 0.85

Page-6
The steel wire stands shall have the same properties and characteristics as proscribed
for regular strength steel wire in IEC:888-1987..
2.11.3 The zinc used for galvanizing shall be electrolytic high grade Zinc of 99.95% purity. It
shall conform to and satisfy all the requirements of IS:209.
3.1 Standard Length
3.1.1 The Standard Length of the conductor shall be 1500 meters. Bidder shall indicate the
standard length of the conductor to be offered by them. A tolerance of +/- 5% on the
standard length offered by the Bidder shall be permitted. All lengths outside this limit of
tolerance shall be treated as random lengths.
length and total quantity of such random lengths shall not be more than 10% of the
quantity ordered. When one number random length has been manufactured at any time,
five (5) more individual lengths, each equivalent to the above random length with a
tolerance of +/- 5% shall also be manufactured and all the above six random lengths
shall be despatched in the same shipment. At any point, the cumulative quantity supplied
including such random lengths shall not be more than 12.5% of the total cumulative
quantity supplied including such random lengths. However, the last 20% of the quantity
ordered shall be supplied only in standard lengths as specified.
3.1.3 Bidder shall also indicate the maximum single length, above the standard length, he can
manufacture in the guaranteed technical particulars of offer. This is required for special
stretches like river crossing etc. The HVPNL reserves the right to place orders for the
above lengths on the same terms and conditions applicable for the standard lengths
during pendency of the contract.
4.0 Technical Description of Earthwire
4.1 Details of Earthwire
4.1.1 The galvanized steel earthwire shall generally conform to the specification of ACSR core
wire as mentioned in IS:398 (part-II)-1976 except where otherwise specified herein.
4.1.2 The details of the earthwire are tabulated below:
a) Stranding and wire diameter : 7/3.15 mm steel
Steel core : 1
Outer steel layer : 6
c) Total sectional area : 54.55 sq.mm

Page-7
d) Overall diameter : 9.45 mm
e) Approximate weight : 428Kg/km
f) Calculated DC resistance at : 2.95 ohm/km

20 deg. Centigrade
g) Minimum ultimate tensile : 57 kN

strength
h) Direction of lay of outer layer : Right hand
i) Minimum tensile strength : 1100 kgf/mm. sq.
4.1.3 All steel strands shall be smooth, uniform and free from all imperfection, such as spills
and splits, diemarks, scratches, abrasions and kinks after drawing and also after
stranding.
4.1.4 The finished material shall have minimum brittleness as it will be subjected to
appreciable vibration while in use.
240 g/m2 after stranding. The zinc coating shall be smooth, continuous, of uniform
thickness, free from imperfections and shall withstand three and a half dips after
stranding in standard preece test. The steel wire rods shall be of such quality and purity
that, when drawn to the size of the strands specified and coated with the finished strands
shall be of uniform quality and have the same properties and characteristics as
prescribed in ASTM designation B498-74.
strands while cutting of composite earthwire. Care shall be taken to avoid damages to
galvanization during performing and postforming operations.
4.1.7 To avoid susceptibility towards wet storage stains (white rust), the finished material shall
be provided with a protective coating of boiled linseed oil.
4.2 Joints in Wires

There shall be no joint of any kind in the finished steel wire strand entering into
manufacture of the earthwire. There shall be no strand joints or strand splice any length
of the complete stranded earthwire.
4.3 Tolerances
The manufacturing tolerance to the extent of the following limits only shall permitted in
the diameter of the individual steel strands and lay length of earthwire.
Standard Maximum Minimum
Diameter 3.15 mm 3.20 mm 3.10 mm
Lay length 160 mm 175 mm 145 mm
Page-8
4.4 Materials
4.4.1 Steel
The steel wire strands shall be drawn from high carbon steel rods and shall conform to
the following requirements as to the chemical composition:
Carbon Not more than 0.55
4.4.2 Zinc
The zinc used for galvanizing shall be electrolytic high grade zinc of 99.95% purity. It
shall conform to and satisfy all the requirements of IS:209/1979.
4.5 Standard Length
4.5.1 The Standard Length of the earthwire shall be 2000 meters. The tolerance on length
shall be +/- 5% on the standard length.
length and total quantity of random lengths is not be more than 10% percent of the total
quantity in each shipment.
5.0 Tests and standards
5.1 Tests
5.1.1 The following acceptance and routine tests and tests during manufacture shall be carried
out on the conductor and earthwire. For the purpose of this clause, the following shall
apply.
5.1.2 Acceptance tests shall mean those tests which are to be carried out on samples taken
from each lot offered for pre-despatch inspection, for the purpose of acceptance of that
lot.
5.1.3 Routine tests shall mean those tests, which are to be carried out on each strand/
spool/length of the conductor and earthwire to check requirements which are likely to
vary during production.
5.1.4 Tests during manufacture shall mean those tests, which are to be carried out during the
process of manufacture and end inspection by the manufacture to ensure the desired
quality of the end product to be supplied by him.
5.1.5 For all acceptance tests, the acceptance values shall be the values guaranteed by the
bidder in the guaranteed technical particulars of his proposal or the acceptance value
specified in this specification, whichever is more stringent for that particular test.
Page-9
5.2 Type Tests
5.2.1 The equipment should be offered type tested. Test reports should not be more than
seven years old reckoned from the date of bid opening in respect of all the tests carried
out in accredited laboratories ( based on ISO/IEC) by a reputed accreditatic body or
witnessed by HVPNL or another electric power utility and be submitted by the successful
Bidder to HVPNL for approval as per schedule given in Bar chart.
a) Surface condition test
b) Test for ultimate breaking load on stranded conductor
c) Stress-strain test
d) Measurement of diameter of individual aluminium and steel wires.
e) Measurement of lay ratio.
f) Breaking load of individual wires.
g) Ductility test
h) Wrapping test
i) Resistance test and
j) Galvanizing test
5.2.2 Acceptance Tests

a) Visual and dimensional check on drum )
) Annexure-A
b) Visual check for joints scratches etc. )
and lengths of conductor by rewinding )
)
c) Dimensional check on steel and )
Aluminium strands )
)
d) Galvanising test on steel strands ) Annexure-A
)
e) Torsion and elongation test )
On steel strands )
)
f) Check for lay-ratios of various layers ) Annexure-A
g) Breaking load test on steel and )

aluminum strands )
)
h) Wrap test on steel and aluminum ) IS:398 (part-II)
strands )
i) DC resistance test on aluminium strands )
j) UTS Test on welded joint of strands ) Annexure-A
Note: All the tests except (j) shall be carried out on Aluminium and steel strands after
stranding only.
Page-10
5.2.3 Acceptance Tests on Earthwire
a) Visual and dimensional check on drum )

)
c) Visual check for joints scratches etc. )
and lengths of Earthwire by rewinding )
)
d) Dimensional check ) Annexure-A
)
d) Lay length check )
)
e) Galvanising test )
)
f) Torsion test )
g) Elongation test ) IS:398 (part-II)-1976

)
h) Wrap test )
)
i) DC resistance test )
)
j) Breaking load test )
k) Chemical analysis of steel ) IS:398 (part-II)-1976
5.3 Routine Tests
5.3.1 Routine tests on Conductor
a) Check to ensure that the joints are as per specification.
b) Check that there are no cuts, fins etc. on the strands.
c) Check that drums are as per specification.
d) All acceptance test as mentioned above to be carried out on each coil.
5.3.2 Routine tests on Earthwire
a) Check for correctness of stranding.
b) Check that there are no cuts, fins etc. on the strands.
c) Check that drums are as per specification.
5.4 Tests during manufacture.
5.4.1 Tests during manufacture on conductor
a) Chemical analysis of zinc )

used for galvanizing ) Annexure-A
)
b) Chemical analysis of aluminium )
used for making aluminium strands ) Annexure-A
Page-11
5.4.2 Tests during manufacture Earthwire.
a) Chemical analysis of zinc )

used for galvanizing ) Annexure-A
)
b) Chemical analysis of steel )
5.5 Testing Expenses
The entire cost of testing for the acceptance and routine tests and tests during
manufacture specified herein shall be treated as included in the quoted unit price except
for the expenses of the inspector/ HVPNL representative.
5.6 Addition Tests
The HVPNL reserves the right of having at his own expenses any other test (s) of
reasonable nature carried out at Manufacturer’s premises, at site, or in any other place in
addition to the aforesaid type, acceptance and routine tests to satisfy himself that
materials comply with the specifications.
5.7 Test Reports
5.7.1 Record of routine test reports shall be maintained by the manufacturer at his works for
periodic inspection by the HVPNL representative.
5.7.2 Test certificates of tests during manufacture shall be maintained by the manufacturer.
These shall be produced for verification as and when desired by the HVPNL.
5.8 Inspection
5.8.1 The HVPNL representative shall at all times be entitled to have access to the works and
all places of manufacture, where conductor shall be manufactured and representative
shall have full facilities for unrestricted inspection of the manufacturer works, raw
materials and process of manufacture for conducting necessary tests as detailed herein.
5.8.2 The manufacturer shall keep the HVPNL informed in advance of the time of starting and of
the progress of manufacture of conductor in its various stages so that arrangements can
be made for inspection.
5.8.3 No material shall be despatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the HVPNL in
writing. In the later case also the conductor shall be despatched only after satisfactory
testing for all tests specified herein have been completed.
5.8.4 The acceptance of any quantity of material shall in no way relieve the manufacturer of
any of his responsibilities for meeting all requirements of the specification, and shall not
prevent subsequent rejection if such material is later found to be defective.
Page-12
5.9 Test Facilities
5.9.1 The following additional test facilities shall be available at the manufacturer’s works:
a) Calibration of various testing and measuring equipment including tensile testing

machine, resistance measurement facilities, burette, thermometer, barometer etc.
b) Standard resistance for calibration of resistance bridges.
c) Finished conductor/Earthwire shall be checked for length verification and surface finish
on separate rewinding machine at reduced speed (variable from 8 to 16 meters per
minute). The rewinding facilities shall have appropriate clutch system and free of
vibrations, jerks etc. with traverse laying facilities.
5.10 Packing for conductor
5.10.1 The Conductor and earthwire shall be supplied in non-returnable, strong, wooden/
steel drums provided with lagging of adequate strength, constructed to protect the
conductor against all damage and displacement during transit, storage and
subsequent handing and stringing operations in the field. The manufacturer shall be
responsible for any loss or damage during transportation, handling and storage due
to improper packing. The drums shall generally conform to IS: 1778-1980, except as
otherwise specified hereinafter.
5.10.2 The drums shall be suitable for wheel mounting and for letting off the
Conductor/earthwire under a minimum controlled tension of the order of 5 KN.
5.10.3 The general outline of the drum for earthwire shall be as per annexed drawing. The
bidder should submit their proposed drawings alongwith the bid.
5.10.4 For conductor, one standard length and for earthwire two standard lengths shall be
wound on each drum.
5.10.5 For Earthwire, each strand shall be individually welded to prevent parting of two
lengths at a tension less than 15 kN. The two ends where the first length finishes and
the second length starts, shall be clearly marked with adhesive tape and no weld
should be present outside these marks. The length between the two marks shall be
treated as scrap and will not be taken into account for measurement purposes.
5.10.6 All wooden components shall be manufactured out of seasoned soft wood free from
defects that may materially weaken the component parts of the drums. Preservative
treatment shall be applied to the entire drum with preservatives of a quality, which is
not harmful to the conductor and earthwire.
5.10.7 The flanges shall be of two ply construction with each ply at right angles to the
adjacent ply and nailed together. The nails shall be driven from the inside face
flange, punched and then clenched on the outer face. The thickness of each ply
shall not very by more than 3 mm from that indicated in the figure. There shall be at
least 3 nails per plank of ply with maximum nail spacing of 75 mm. Where a slot is
cut in the flange to receive the inner end of the conductor, the entrance shall be in
line with the periphery of the barrel.
Page-13
5.10.8 The wooden battens used for making the barrel of the conductor shall be of
segmental type. These shall be nailed to the barrel supports with at least two nails.
The battens shall be closely butted and shall provide a round barrel with smooth
external surface. The edges of the battens shall be rounded or chamfered to avoid
damage to the conductor and earthwire.
5.10.9 Barrel studs shall be used for the construction of drums. The flanges shall be holed
and the barrel supports slotted to receive them. The barrel studs shall be threaded
over a length on either end, sufficient to accommodate washers, spindle plates and
nuts for fixing flanges at the required spacing.
5.10.10 Normally, the nuts on the studs shall stand protruded of the flanges. All the Niles
used on the inner surface of the flanges and the drum barrel shall be counter sunk.
The ends of barrel shall generally be flushed with the top of the nuts.
5.10.11 The inner cheek of the flanges and drum barrel surface shall be painted with
bitumen based paint.
5.10.12 Before reeling, card board or double corrugated or thick bituminised waterproof
bamboo paper shall be secured to the drum barrel and inside of flanges of the drum
by means of a suitable commercial adhesive material. After reeling the conductor
and earthwire, the exposed surface of the outer layer of conductor/earthwire shall
be wrapped with water proof thick bituminised bamboo paper to preserve the
conductor/earthwire from dirt, grit and damage during transport and handling.
5.10.13 A minimum space of 75 mm for conductor and 50 mm for earthwire shall be

provided between the inner surface of the external protective lagging and outer
layer of the conductor/earthwire.
5.10.14 Each batten shall be securely nailed across grains as far as possible to the flange,
edges with at least 2 nails per end. The length of the nails shall not be less than
twice the thickness of the battens. The nails shall not protrude above the general
surface and shall not have exposed sharp, edges or allow the battens to be
released due to corrosion.
5.10.15 The nuts on the barrel studs shall be tack welded on the one side in order to fully
secure them. On the second end, a spring washer shall be used.
5.10.16 Outside the protective lagging, there shall be minimum of two binder consisting of
hoop iron/galvanised steel wire. Each protective lagging shall have two recesses to
accommodate the binders.
5.10.17 The conductor ends shall be properly sealed on the side of one of the flanges to
avoid loosening of the conductor layers during transit and handling.
5.11 Marking
Each drum shall have the following information stenciled on it in indelible ink alongwith
other essential data:
a) Contract / Award letter number.
b) Name and address of consignee.
c) Manufacturer’s name and address.

Page-14
d) Drum number.
e) Size of conductor/earthwire.
f) Length of conductor/earthwire in meters.
g) Gross weight of drum with conductor/earthwire.
h) Gross weight of drum without lagging.
i) Weight of empty drum with lagging.
j) Bevel diameter at three locations and an arrow marking at the location of

measurement.
k) Number of turns in the outer most layer.
l) Arrow marking for unwinding.
m) Position of the conductor/earthwire ends.
n) Distance between outer most layer of conductor and the inner surface of
lagging.
o) The conductor drum should bear ISI Monogram or equivalent internationally
recognized Monogram.
5.12 Verification of conductor and earthwire length.
The HVPNL reserves the right to verify the length of conductor and earthwire after
unreeling at least ten (10) percent of the drums in a lot offered for inspection.
5.13 Standards
The conductor/earthwire shall conform to the following Indian / International standards,

which shall mean latest revisions, amendments /changes adopted and pulished, unless
otherwise specified herein before. International and internationally recognized standards
to which these standards generally correspond are also listed below:
-----------------------------------------------------------------------------------------------------------
Sr. Indian Title International
No Standard Standards
-----------------------------------------------------------------------------------------------------------
1. IS: 209-1979 Specification for Zinc BS: 3436-1986
2 IS: 398-1982 Specification for aluminium BS: 215-1970
conductors for overhead IEC:1089
transmission purposes
3 IS:398-1982 Aluminum conductor BS: 215-1970
Part (II) galvanized steel reinforced
4 IS:1778-1980 Reels and drums for bare BS:1559-1949
conductors
5 IS:1521-1972 Method of tensile testing of ISO:R8901959
steel wire
Page-15
6 IS:2629-1985 Recommended practice for
hot dip galvanizing of iron
and steel
7 IS:2633-1992 Method of testing uniformity
of coating on zinc coated
articles
8 IS:4826-1992 Galvanised coating on ASTM A472-729
round steel wires BS: 443-1969
9 IS:6745-1990 Methods of determination of BS:433-1969
weight of zinc coating of
zinc coated iron and steel
articles
10 Zinc coated aluminium wire IEC 888-1987
for overhead line conductor
11 Hard drawn aluminium wire IEC 889-1987
for overhead line conductor
Page-16
The standard mentioned above are available from:
……………………………………………………………………………………………………
Reference Abbreviation Name and Address
……………………………………………………………………………………………………
BS British Standards, British

Standards Institution 101,
Pentonvile Road, N-19-ND
UK
IEC/CISPR International Electrotechnical

Commission, Bureau Central
De la Commission, Electro
Technique International, 1
Rue de verembe, Geneva
Switzerland
BIS Bureau of Indian Standards,

Mank Bhavan,-9, Bahadur
Shah Zafar Marg, New Delhi
110001, INDIA
ISO International Organisation for

Standardization, Danish Board
Of Standardization Danish
tandardising Sraat, Aurehoegvej-
12, DK-2900, Heeleprup, DENMARK.
NEMA National Electric Manufacture

Association, 155, East 44th Street,
New York, NY 10017
U.S.A.
Page-17
ANNEXURE-A
1. Tests on Conductor
1.1 Surface condition & UTS test on stranded Conductor
Circles perpendicular to the axis of the conductor shall be marked at two places
on a sample of conductor of minimum 5m length suitably fixed by appropriate
fittings on a tensile testing machine. The load shall be increased at a steady rate
upto 50% of UTS and held for one minute. The circles drawn shall not be distorted
due to relative movement of strands. Thereafter the load shall be increased at
steady rate of 100% of UTS and held for one minute. The conductor sample shall
not fail during this period. The applied load shall then be increased until the failing
load is reached and the value recorded.
1.2 D.C Resistance test on stranded conductor
On a conductor sample of minimum 5 m length two contact-clamps shall be fixed

with a pre-determined bolt torque. The resistance shall be measured by a Kelvin
double bridge by placing the clamps initially zero metre and subsequently one
metre apart. The test shall be repeated at least five times and the average value
recorded. The value obtained shall be corrected to the value at 20 o C. The
resistance corrected at 20o C shall conform to the requirement of this specification.
1.3 Chemical Analysis of Aluminium and Steel
Samples taken from the aluminium and steel ingots/coils/strands shall be

chemically/spectrographically analysed. The shall be in conformity to the
requirements stated in this specification.
1.4 Chemical Analysis of Zinc
Samples taken from the zinc ingots shall be chemically/spectrographically

analysed. The same shall be in conformity requirements stated in the
specification.
1.5 Visual and Dimensional Check on Drums
The drums shall be visually and dimensionally checked to ensure that they
conform to the requirements of this specification.
1.6 Visual Check for Joints, Scratches etc.
Conductor drums shall be rewound in the presence of the HVPNL. The HVPNL
shall visually check for scratches, joints etc. and that the conductor generally
conform to the requirements of this specification.
1.7 Dimensional check on strands
The individual strands shall be dimensionally checked to ensure that they conform
to the requirement of this specification.
Page-18
1.8 Check for Lay-ratios of Various Layers
The Lay-ratios of various layers shall be checked to ensure that they conform to
the requirements of this specification.
1.9 Breaking load test on welded Aluminium strands
Two Aluminium wire shall be welded as per the approved quality plan and shall be
subjected to tensile load. The welded joint of the wire shall be able to withstand a
minimum breaking load of the individual strand guaranteed by the manufacturer.
1.10 Galvanising test
The Test procedure shall be as specified in IS:4826. The material shall conform to
the requirements of this specification. The adherence of zinc shall be checked by
wrapping around a mandrel four times the diameter of steel wire.
1.11 Torsion an Elongation tests on steel strands.
The test procedure shall be as specified in IS: 13.6.1 and 13.6.2 of IS:398 part-5.
In the torsion test, the number of complete twists before fracture shall not be less
than 18 on a length equal to 100 times the standard diameter of the strand before
stranding, and should not be less than 16 after stranding. The case test sample
length is less or mode than 100 times the stranded diameter of the strand the
minimum number of twists shall be proportioned to the length with fractional
numbers rounded off to next higher whole number. In the elongation test the
elongation of the strand shall not be less than 4% for a gauge length of 200mm.
2. Tests on earthwire
2.1 UTS test
Circles perpendicular to the axis of the earthwire shall be marked at two places on
a sample of earthwire of minimum 5 m length suitably compressed with dead end
clamps at either end. The load shall be increased at a steady rate upto 50% of
UTS and held for one minute. The circles drawn shall not be distorted due to
relative movement of strands. Thereafter the load shall be increased at steady
rate to 100% of UTS and held for one minute. The earthwire sample shall not fail
during this period. The applied load shall then be increased until the failing load is
reached and the value recorded.
2.2 D.C Resistance Test

On a earthwire sample of minimum 5 m length two contact- clamps shall be fixed
will a pre-determined bolt torque. The resistance shall be measured by a Kelvin
double bridge by placing the clamps initially zero metre and subsequently one
metre. The test shall be repeated at least five times and the average value
recorded. The value obtained shall be corrected to the value at 20 o C. The
resistance corrected at 20o C shall conform to the requirements of this
specification.
Page-19
2.3 Chemical Analysis of zinc
Samples taken from the zinc ingots shall be chemically/spectrographically
analysis. The same shall be in conformity to the requirements stated in the
specification.
2.4 Chemical Analysis of steel
Sample taken from the steel ingots/coils/strands shall be
chemically/specigraphically analysed. The same shall be in conformity to the
requirements stated in this specification.
2.5 Visual and Dimensional Check on Drum
The drum shall be visually and dimensionally checked to ensure that they conform
to the requirements of this specification.
2.6 Visual Check for joints, Scratches etc. and length of earthwire
Ten percent drums from each lot shall be rewound in the presence of the HVPNL.
The HVPNL shall visually check for scratches, joints etc. and see that the
earthwire generally conforms to the requirements of this specification. The length
of earthwire wound on the drum shall be measured with the help of counter meter
during rewinding.
2.7 Dimensional Check
The individual strands shall be dimensionally checked to ensure that they conform
to the requirements of this specification.
2.8 Lay length check
The lay length shall be checked to ensure that they conform to the requirements
this specification.
2.9 Galvanising Test
The test procedure shall be as specified in IS:4826-1968. The material shall
conform to the requirements of this specification. The adherence of zinc shall be
checked by wrapping around a mandrel four times the diameter of steel wire.
2.10 Torsion Test
The minimum number of twists which a single steel strand shall withstand during
torsion test shall be eighteen for a length equal to100 times the standard diameter
of the strand. In case test sample length is less or more than 100 times the
stranded diameter of the strand, the minimum number of twists will be
proportioned to the length and if number comes in the fraction then it will be
rounded off to next higher whole number.
Page-20
SECTION-VI, CHAPTER –III ( B )
CONTENTS
1. Technical Description of Anti- Fog Disc insulators 1
2 Tests and Standards 6
3. Annexure-A 12
SECTION- VI,
CHAPTER-III (B)
1.0 TECHNICAL DESCRIPTION OF ANTI-FOG TYPE DISC INSULATORS .
1.1.1 The Insulator strings shall consist of Anti-Fog Type discs for a three phase, 50 Hz,
effectively earthed 132kV & 66 KV transmission system in a heavily polluted atmosphere.
The discs shall be cap and pin, ball and socket type.
1.1.2 Bidder shall quote for disc insulators made of electro-porcelain.
1.1.3 The size of disc insulator, minimum creepage distance, the numbers to be used in
different type of strings, their electromechanical strength and mechanical strength of
insulator string alongwith hardware fittings shall be as follows:
For 132kV & 66kV Lines with ACSR Zebra:-

Sr. Type of string Size of Minimum No. of discs E & M
No disc Creepage strength of
insulator distance of each
(mm) of each string (kN)
disc(mm)
66kV 132kV
1 2 3 4 5 6 7
1. Single Suspension 255x145 432 1x5 1x9 70
2. Single Tension 280x145 432 1x6 1x10 120
3. Single Suspension Pilot 255x145 432 1x5 1x9 70
4. Double Tension 280x145 432 2x6 2x10 2X120
For 66kV & 132kV Lines with ACSR Panther:-

Sr. Type of string Size of Minimum No. of discs E & M
No disc Creepage 66kV 132kV strength of
insulator distance of each
(mm) of each string (kN)
disc(mm)
1 2 3 4 5 6 7
5. Single Suspension 255x145 432 1x5 1x9 70
6. Single Tension 255x145 432 1x6 1x10 90
7. Single Suspension Pilot 255x145 432 1x5 1x9 70
8. Double Tension 255x145 432 2x6 2x10 90
1.2 Pin and cap
1.2.1 Pin and cap shall be designed to transmit the mechanical stresses to the shell by
compression and develop uniform mechanical strength in the insulator. The cap shall be
circular with the inner and outer surfaces concentric, of such design that will not yield or
distort under load conditions.
The pin ball shall move freely in the cap socket but without danger of accidental
uncoupling during erection or in position. The design of the disc should be such that
stresses due to expansion or contraction in any part of the insulator shall not lead to
deterioration.
Page-1
1.3 Security clip
1.3.1 Security clip for use with ball and socket coupling shall be of R-shaped hump type which
shall provide positive locking of the coupling as per IS: 2486- (part-III)/ IEC:372. The legs
of the security clips shall be spread after installation to prevent complete withdrawal from
the socket. The locking device should be resilient, corrosion resistant and of suitable
mechanical strength. There shall be no rise of the locking device being displaced
accidentally or being rotated when in position. Under no circumstances shall locking
device allow separation of insulator units or fittings.
1.3.2 The hole for the security clip shall be countersunk and the clip shall be of such that the
eye of clip may be engaged by a hot line clip puller to provide for disengagement under
energized conditions. The force required to pull the security clip into its unlocked position
shall not be less than 50 N (5 kg) or more than 500 N (50 kg).
1.4 Ball and socket Designation
The dimensions of the balls and sockets for 70 KN/90kN and 120 kN Anti-Fog Type
discs shall be of 16mm Alt-‘B’ and 20 mm designation respectively in accordance with
the standard dimensions stated in IS:2486- (Part-II)/IEC: 120.
1.5 Dimensional Tolerance of Insulator Disc.

Permitted dimensional tolerances of the Anti-Fog Type disc insulators shall be as under:-
a) On all dimensions for which ± (0.04d + 1.5) mm where
special tolerance do not apply d being the dimension in mm.
b) On spacing of string insulator unit ± (0.03S + 0.3) mm where

S is spacing in mm.
1.6 Interchangeability
The disc insulators inclusive of the ball and socket fittings shall be of standard design
suitable for use with the hardware fittings of any make confirming to relevant
Indian/International standards.
1.7 Corona and RI performance

All surfaces must be clean, smooth, without cuts, abrasions or projections. No part
shall be subjected to excessive localised pressure. The metal parts and porcelain
shall be so designed and manufactured that it shall not generate any Radio
Interference beyond specified limit and not produce any noise generating corona under
all operating conditions.
1.8 Maintenance
1.8.1 The disc insulators offered shall be suitable for employment of hot line maintenance
techniques so that the usual hot line operations can be carried our with ease, speed and
safety.
1.8.2 Bidders shall indicate the methods generally used in the routine hot and dead line
maintenance of EHV line for which similar disc insulators have been supplied by them.
Bidders shall also indicate the recommended periodicity of such maintenance.
Page-2
1.9 Materials
1.9.1 Porcelain
The porcelain used in the manufacture of shells shall be sound, free from defects
thoroughly vitrified and smoothly glazed.
1.9.2 Glaze
The finished porcelain shall be glazed in Brown colour. The glaze shall cover all exposed
parts of the insulator and shell have a good luster, smooth surface and good
performance under the extreme weather conditions of a tropical climate. It shall not be
cracked or chipped by ageing under the normal service conditions. The glaze shall have
the same co-efficient of expansion as that of the porcelain body throughout the working
temperature range.
1.9.3 Cement
Cement used in the manufacture of the insulator shall not cause fracture by expansion or
loosening by contraction. The cement shall not give rise to chemical reaction with metal
fittings and its thickness shall be as small and uniform as possible. Proper care shall be
taken to correctly centre and locate individual parts during cementing.
1.9.4 Pins and Caps

Pins and caps shall be made of drop forged steel and malleable cast iron/ spherodal
graphite iron / drop forged steel respectively, duly hot dip galvanized and shall not be
made by jointing, welding, shrink fitting or any other process from more than one
piece of material.
1.9.5 Security Clips
Security clips shall be made of good quality stainless steel or phosphor bronge
as per IS:1385-1968. 2.5% extra security clip shall be provided.
1.10 Workmanship
1.2.1.1.1 All the material shall be of the latest design and conform to the best modern
practices adopted in the extra High voltage field. Bidders shall offer only such
insulators as are guaranteed by him to be satisfactory and suitable for 66 kV
transmission line and will give continued good service.
1.2.2 The design, manufacturing process and material control at various stages shall
be such as to give maximum working load, highest mobility, best resistance
to corrosion, good finish and elimination of sharp edges and corners to limit
corona and radio interference.
1.2.3 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
Page-3
1.2.4 Metal caps shall be free from cracks, seams, shrinks, air holes, burrs and rough
edges. All surfaces of the metal parts shall be perfectly smooth with no projecting
points or irregularities which may cause corona. All load bearing surfaces shall
be smooth and uniform so as to distribute the loading stresses uniformly.
1.2.5 All ferrous parts shall be hot dip galvanized to give a minimum average coating of
Zinc equivalent to 610 gm/sq m and shall be in accordance with the requirement
of IS: 2629-1966 and shall satisfy the tests mentioned in IS: 2633-1972. The zinc
used for galvanizing shall be of grade Zn 99.95 as per IS:209-1979. The zinc
coating shall be uniform, adherent, smooth, reasonably bright, continous and free
from imperfections such as flux, ash, rust stains, bulky white deposits, and blisters.
The galvanized metal part shall be guaranteed to withstand atleast six successive
dips each lasting for one (1) minute duration under the standard preece test.
1.2.6 Before ball fittings are galvanized, all die flashing on the shank and on the bearing
surface of the ball shall be carefully removed without reducing the dimensions
below the design requirements
1.2.7 The design of the insulators shall be such that the shell shall not engage directly
with hard metal. The design shall also be such that when units are coupled together
there is no contact between the shell of one unit and metal of the next adjacent unit.
The design of the shell ribs shall be such that the security clip of the insulator can
be engaged and disengaged easily with hot stick without damaging the shell ribs.
1.10.8 Insulator units after assembly shall be concentric and co-axial within limits as
permitted by the relevant Indian standards.
1.10.9 The manufacturer of the disc insulators shall guarantee an insulator failure rate not
exceeding 1 (one) per 10000 (ten thousand) per year. In case the annual failure rate
during the first ten years of service exceeds the above figure, the manufacture shall
supply to the HVPNL free of cost spare insulators equal to 10 time the excess
failure.
1.10.10 The manufacture shall guarantee that there shall not be any decapping of insulators
on line under normal operating conditions. In event of any decapping and
subsequent line drop, during the first three years of service the manufacturer shall
have to pay Rs. 50,000/- (Rs. Fifty thousand only) per dropped string towards
expenditure to be incurred by HVPNL for this repair.
1.11 Equipment Marking.
1.11.1 Each insulator disc shall be legibly and indelibly marked with the trademark of the
manufacture and year of manufacture. The guaranteed combined mechanical and
electrical strength shall be indicated in kilo Newton’s followed by the word “kN” to
facilitate easy identification and to ensure proper use.
1.11.2 For porcelain insulator, the marking shall be on porcelain. The marking shall be
printed, not impressed and shall be applied before firing.
Page-4
1.11.3 One 10 mm thick ring of suitable quality of paint shall be marked on the cap of
each insulator of particular strength for easy identification of the type of
insulator. The paint shall not have any deteriorating effect on the insulator
performance. Following codes shall be used as identification mark.
For 70 KN disc : Red
For 90 KN disc : Green
For 120KN disc : Yellow
1.12 Bid Drawings
1.12.1 The successful Bidder shall submit 4 sets of following fully dimensional
drawings complete in all respect for approval to HVPNL as per time
schedule given in Bar Chart:-
a) Shell diameter and ball to ball spacing with manufacturing

tolerances.
b) Minimum creepage distance with positive tolerance.
c) Protected creepage distance.

d) Eccentricity of the disc
i) Axial run out
ii) Radial run out
e) Unit mechanical an electrical characteristics.
f) Size and weight of ball an socket parts
g) Weight of unit insulator disc.
h) Materials
i) Identification mark
j) Manufacturer’s catalogue number
1.12.2 After placement of award, the manufacturer shall submit full dimensioned
insulator drawings containing all the details as given in clause No. 1.12.1
above, in four (4) copies to HVPNL representative for approval. After getting
approval from HVPNL representative and successful completion of all the type
tests, the manufacturer shall submit. 12 more copies of the same drawing to
the HVPNL representative for further distribution and field use at HVPNL
representative ’s end.
1.12.3 After placement of award the manufacture shall also submit fully dimensioned
insulator create drawing for different type of insulators.
Page-5
2. Tests and standards
2.1 TESTS
The following acceptance, routine tests and tests during manufacture shall be
carried on the disc insulator individually and alongiwth hardware fittings. For the
purpose of this clause: -
2.1.1 Acceptance tests shall mean those tests which are to be carried out on samples
taken from each lot offered for pre-despatch inspection for the purpose of
acceptance of that lot.
2.1.2 Routine tests shall mean those tests, which are to be carried out on each disc
insulator/hardware fitting to check requirements which are likely to vary during
production.
2.1.3 Tests during manufacture shall mean those tests which are to be carried out
during the process of manufacture and end inspection by the manufacture to
ensure the desired quality of the end product to be supplied by him.
2.1.4 For all acceptance tests, the acceptance values shall be the values
guaranteed by the bidder in the Guaranteed Technical Particulars of his
proposal or the acceptance value specified in this specification whichever is
more stringent for that particular test.
2.2. Type tests
The equipment should be offered fully type tested for all the type tests
mentioned in IS:731-1971/IEC-60383-1993/IS:8704-1995 (latest version).
Test reports should not be more than seven years old reckoned from the date
of bid opening in respect of all the tests carried out in accredited laboratories (
based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPNL or
another electric power utility and be submitted by the successful Bidder to
HVPNL for approval as per schedule given in Bar chart.
2.3 Acceptance tests
2.3.1 For Disc Insulators
a) Visual examination IS:731-1971
b) Verification of dimensions IS:731-1971
c) Temperature cycle test IS:731-1971

d) Galvanizing test IS:731-1971
e) Electromechanical failing load test IS:731-1971
f) Mechanical Performance test IEC:60383-1993
g) Residual strength test IEC:60383-1993
h) Eccentricity test IEC:60383-1993

i) Test on locking device for ball IS: 2486 (Part-IV)
and socket coupling
j) Vibration test
(only once for each type of disc Annexure-A
Insulator under the contract)
Page-6
2.4 For porcelain insulators
a) Puncture test IEC: 60383-1993/IS:731-

1971
b) Porosity test IS:731-1971
2.5 Routine Tests
2.5.1 For Disc Insulators
a) Visual Inspection )
) IS: 731-1971
b) Mechanical routine test ) Clause 10.13, 10.14 &
10.15
c) Electrical routine test )
2.5.2 Tests During Manufacture
On all components as applicable
a) Chemical analysis of zinc used )

for Glavansing )
)
b) Chemical analysis, mechanical )
metallographic test and magnetic ) Annexure-A
particle inspection for malleable )
castings. )
c) Chemical analysis, hardness )

tests and magnetic particle ) Annexure-A
inspection for forgings )
)
d) Hydraulic internal pressure )
tests on disc insulator shells )
)
e) Metallurgical tests for metal )
Fittings only (in black condition) )
i) Grain size )
ii) Inclusion rating )
iii) Micro structure )
The entire cost of testing for acceptance and routine tests and tests during
manufacture specified herein shall be treated included in the quoted Ex-works
price except for the expenses of the inspector/HVPNL representative.
2.7 Schedule of testing and additional tests
2.7.1 The bidder has to indicate the schedule of following activities in their bids:
a. Submission of drawing for approval.
b. Submission of Quality Assurance programme for approval.
Page-7
2.7.2 The HVPNL representative reserves the right of having at his own expense any
other test (s) of reasonable nature carried out at manufacturer’s premises, at site,
or in any other place in addition to the aforesaid type, acceptance and routine tests
to satisfy himself that the material comply with the specifications.
2.7.3 The HVPNL representative also reserves the right to conduct all the tests
mentioned in this specification at his own expense on the samples drawn from the
site at manufacturer’s premises or at any other test center. In case of evidence of
non compliance, it shall be binding on the part of the manufacture to prove the
compliance of the items to the technical specifications by repeat tests or correction
of deficiencies, or replacement of defective items, all without any extra cost to the
HVPNL representative .
2.8 Co- ordination for testing
The Bidder/insulator manufacturer shall have to co-ordinate testing of insulators
with hardware fittings to be supplied by other manufacturer and shall have to also
guarantee overall satisfactory performance of the insulators with the hardware
fittings.
2.9 Test Reports
periodic inspection by the HVPNL representative ’s representative.
2.9.2 Test certificates of test during manufacture shall be maintained by the manufacturer.
These shall be produced for verification as and when desired by the HVPNL
representative .
2.10 INSPECTION
2.10.1 The HVPNL representative ’s representative shall at all times be entitled to have
access to the works and all places of manufacture, where insulators, and its component
parts shall be manufactured and the representatives shall have full facilities for
unrestricted inspection of the manufacturer’s and sub-manufacturer’s works, raw
materials, manufacture of the material and for conducting necessary test as detailed
herein.
2.10.2 The material for final inspection shall be offered by the manufacturer only under packed
condition as detailed in clause No. 2.12 of the specification. The HVPNL representative
shall select samples at random from the packed lot for carrying out acceptance tests.
2.10.3 The manufacturer shall keep HVPNL informed in advance of the time of starting and
the progress of manufacture of material in their various stages so that arrangements
could be made inspection.
satisfactorily inspected and tested unless the inspection is waived off by the HVPNL
representative in writing. In the latter case also the material shall be despatched only
after satisfactory testing for all tests specified herein have been completed.
2.10.5 The acceptance of any quantity of material shall be in no way relieve the manufacturer
of his responsibility for meeting all the requirements of the specification and shall not
prevent subsequent rejection, if such material are later found to be defective.
Page-8
2.11 Packing and Marking
2.11.1 All insulators shall be packed in strong seasoned wooden crates. The gross weight of
the crates along with the material shall not normally exceed 200 kg. to avoid handling
problem. For marine transportation crates shall be palleted.
2.11.2 The packing shall be of sufficient strength of withstand rough handling during transit,
storage at site and subsequent handling in the field.
2.11.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to

prevent damage or deformation during transit and handling.
2.11.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at
their destination and to avoid the possibility of goods being lost or wrongly despatched
on account of faulty packing and faulty or illegible markings. Each wooden case/crate
shall have all the markings stenciled on it in indeliable ink.
2.12 Standards
2.12.1 The insulators strings and its components shall conform to the following
Indian/international standards which shall mean latest revision, with
amendments/changes adopted and published, unless specifically stated otherwise in
the Specification.
2.12.2 In the event of supply of insulators conforming to standards other than specified the
Bidder shall confirm in his bid that these standards are equivalent to those specified. In
case of award salient features of comparison between the standards proposed by the
manufacturer and those specified in his document will be provided by the manufacturer
to establish equivalence.
Sr. No. Indian Standard Title International

Standards
1. IS: 209-1992 Specification for Zinc BS: 3436-1986
2 IS: 406-1991 Method of chemical
analysis of slab zinc
3 IS: 731-1991 Porcelain insulators for BS: 137-1982
overhead power line with a (I&II)
nominal voltage greater IEC:383-1993
than 1000V
4 IS:2071 Methods of High Voltage IEC:60-1-1989
Part (I)-1993 Testing
Part (II)-1991
Part (III)-1991
5 IS:2486 Specification for Insulator
fittings for overhead power
line with a nominal voltage
greater than 1000V
Part (I)-1993 General Requirements and BS:3288-1979
tests
Part (II)-1989 Dimensional Requirements IEC:120-1984
Page-9
Part (III)-1991 Locking devices IEC:372-1984
6 IS:2629-1990 Recommended practice for ISO:1461 (E)
hot Dip galvanization for
iron and steel
7 IS:2633-1992 Testing of Uniformity of
coating of zinc coated
articles
8 IS:3188-1988 Dimensions for Disc IEC:305-1978
Insulators
9 IS:6745- 1990 Determination of weight of ISO:1460 (E)
zinc coating on zinc coated
iron and steel articles.
10 IS:8263-1990 Methods of RI test on HV IEC:437-1973
insulators NEMA Publication
No. 107/1964/CISPR
11 IS:8269-1990 Methods for switching IEC:506-1975
impulse test on HV
insulators
12 Thermal mechanical IEC:575-1977
performance test and
mechanical performance
test on string insulator
units.
13 Salt fog pollution voltage IEC:507-1991
withstand test
14 Residual strength of string IEC:797-1984
insulator units of glass or
ceramic material for
overhead line after
mechanical damage of the
dielectric
15 Guide for the selection of IEC:815-1986
insulators in respect of
polluted conditions
16 Tests on insulators of IEC:383-1993
ceramic material or glass
for overhead line with a
nominal voltage greater
than 1000V
Page-10
……………………………………………………………………………………
……………………………………………………………………………………………………
……………………………………………………………………………………………………

UK

Switzerland
IS Bureau of Indian Standards,

110001, INDIA

Standardising Sraat, Aurehoegvej-
12
DK-2900, Heeleprup, DENMARK.

New York, NY 10017
U.S.A.
Page-11
ANNEXURE-A
1. Tests on complete strings with Hardware fittings.
1.1 Voltage distribution test
The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage. The voltage
across any disc shall not exceed 20% for suspension insulator string and 22%
for tension insulator string.
1.2 Mechanical strength test
The complete insulator string along with its hardware fitting excluding arcing
horn, and suspension assembly/dead end assembly shall be subjected to a
load equal to 50% of the specified minimum ultimate tensile strength (UTS)
which shall be increased at a steady rate to 67% of the minimum UTS
specified. The load shall be held for five minutes and then removed. After
removal of the load, the string components shall not show any visual
deformation and it shall be possible to disassemble them by hand. Hand tools
may be used to remove cotter pins and loosen the nuts initially. The string
shall then be reassembled and loaded to 50% of UTS and the load shall be
further increased at a steady rate till the specified minimum UTS and held for
one minute. No fracture should occur during this period. The applied load
shall then be increased until the failing load is reached and the value
recorded.
1.3 Vibration test
The suspension string shall be tested in suspension mode, and tension string
in tension mode itself in laboratory span of minimum 30 metres. In the case of
suspension string a load equal to 600 Kg shall be applied along the axis of the
suspension string by means of turn buckle. The insulator string along with
hardware fittings and conductor tensioned at 2500 Kgf shall be secured with
clamps. The system shall be suitable to maintain constant tension on the
conductor throughout the duration of the test. Vibration dampers shall not be
used on the test span. The conductor shall be vertically vibrated at one of the
resonance frequencies of the insulators string (more than 10 Hz) by means of
vibration inducing equipment. The peak to peak, displacement in mm of
vibration at the antinode point nearest to the string shall be measured and the
same shall not be less than 1000 /
f1.8 where is the frequency of vibration in cycles/sec. The insulator string shall
be vibrated for not less than 10 million cycles without any failure. After the test
the disc insulators shall be examined for looseness of pins and cap or any
crack in the cement. The hardware shall be examined for looseness, fatigue
failure and mechanical strength test. There shall be no deterioration of
properties of hardware components and insulators after the vibration test. The
insulators shall be subjected to the following tests as per relevant standards:
Page-12
TESTS PERCENTAGE OF DISC INSULATOR
UNITS TO BE TESTED
a) Temperature cycle test 60

Followed by mechanical
Performance test
b) Puncture test 40
2. On disc insulator units
2.1 Steep wave front test
The following test shall be performed on 10 nos. of disc insulators selected at

random from the lot offered for selection of sample for type test.
a) Each insulator unit shall be subjected to five successive positive and

negative impulse flashovers with a wave having minimum effective rate of
rise of 2500 kV per microseconds.
b) Each unit shall be subjected to three dry power frequency voltage

flashovers.
Acceptance Criteria
An insulator shall be deemed to have met the requirement of this test if,
having been successfully subjected to the ten impulse flashovers, the
arithmetic mean of the three subsequent dry power frequency voltage
flashover values equals or exceeds 95% of the rated dry power frequency
flashover voltage.
An insulator shall be deemed to have failed to meet the requirement of above

testing , if
a) It has not flashed over when the oscillogram or peak voltage indicator
shows a marked reduction in voltage.
or
b) Any one of the subsequent three dry power frequency voltage flashover
value is less than 80% of the value specified. Failure of any one unit either
in the steep front of wave or subsequent low frequency voltage test shall
be cause for testing on double number of units.
Page-13
2.2 Hydraulic Internal Pressure Test on Shells
The test shall be carried out on 100% shells before assembly. The details
regarding test will be as discussed and mutually agreed to by the
manufacturer and HVPNL in Quality Assurance Programme.
2.4 Thermal Mechanical Performance Test
Thermal Mechanical Performance Test shall be performed in accordance with

IEC-383-1-1993 clause 20 with the following modifications:
(1) The applied mechanical load during this test shall be 70% of the
rated electromechanical strength value.
(2) The acceptance criteria shall be
a) X greater than or equal to R+3S.
Where
X Mean value of the individual mechanical failing load.
R Rated electromechanical strength test.

S Standard deviation
b) The minimum sample size shall be taken as 20.
c) The individual electromechanical failing load shall be at least equal to
the rated value. Also puncture shall not occur before the ultimate
fracture.
2.5 Electromechanical Failing Load Test

This test shall be performed in accordance with clause 18 and 19 of IEC-383
with the following acceptance.
i) X gareater than or equal to R+3S
Where
X Mean value of the Electromechanical strength test.
R Rated electromechanical strength test.
S Standard deviation
ii) The minimum sample size shall be taken as 20. However for larger lot size
IEC 591 shall be applicable.
iii) The individual electro-mechanical strength shall be at least equal to the

rated value. Also electrical puncture shall not occur before the ultimate
fracture.
Page-14
2.6 Residual strength test
The above test shall be performed as per clause 4.4 and 4.5 of IEC 797
preceded by the temperature cycle test, on orcelain disc insulators. The
sample size shall be 25 and the evaluation of the results and acceptance
criteria shall be as per clause No 4.6 of IEC 797.
3. Tests on all components (As applicable)

3.1 Chemical Analysis of Zinc used for Galvanizing
Samples taken form the zinc ingot shall be chemically analysed as per IS: 209-
1979. The purity of zinc shall not be less than 99.95%.
3.2 Tests for Forgings
The chemical analysis, hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognized procedures for these
tests. The sampling will be based on heat number and heat treatment batch
the details regarding test will be as discussed and mutually agreed to by the
manufacturer and HVPNL in quality assurance Programme.
3.3 Tests on castings
The chemical analysis, mechanical and metallographic tests and magnetic
particle inspection for castings will be as per the internationally recognized
procedures for these tests. The samplings will be based on heat umber and
heat treatment batch. The details regarding test will be as discussed and
mutually agreed to by the manufacturer and HVPNL in quality assurance
programme.
Page-15
`
SECTION- VI, PART-II, CHAPTER-III (B)
TECHNICAL SPECIFICATION OF
SILICONE RUBBER POLYMER INSULATORS
CONTENTS
1. Technical Description of Silicone Polymer Insulators 1
3. Annexure-A 12
SECTION- VI, PART-II, CHAPTER-III (B)
TECHNICAL SPECIFICATIONS OF COMPOSITE LONG ROD INSULATORS
1.1 Details of Composite Long Rod Insulators
1.1.1 The insulators of the strings shall consist of composite long rod insulators for a three
phase, 50 Hz, effectively earthed 220kV/132kV/66kV transmission system application in
a very heavy polluted environment. Couplings shall be ball and socket type.
1.1.2 Bidder shall quote such composite insulators which have proven use under foggy/humid
operational conditions in polluted industrial environment combined with smoke and dust
particles. The Bidder shall furnish evidence in the form of certification from the power
utilities that the similar type of product supplied to them had been performing
satisfactory. The Bidder shall also submit certified test report for an accelerated ageing
test of 5000 hours such as that described in Appendix-C of IEC-61109.
1.1.3 Insulators shall have sheds of the “open aerodynamic profile without any under ribs” with
good self-cleaning properties. Insulator shed profile, spacing projection etc. shall be
strictly in accordance with the recommendation of IEC-60815.
1.1.4 The size of long rod insulator, minimum creepage distance, the number to be used in
different type of strings, their electromechanical strength and mechanical strength of
insulator string alongwith hardware fittings shall be as follows:
1.2 PARTICULARS OF SILICONE POLYMER INSULATOR STRINGS:-
FOR ACSR ZEBRA OF 220kV LINE:-
Sr TYPE of Dia of FRP Min. No. of EM Mechanical
No String Rod and Creepage Individual strength strength of
Length of Distance units per of Insulator string
Composite (mm) string Insulator alongwith H/W
Insulator(mm)* (Nos.) Unit (KN) fittings (kN)
1 Single 20X2030 7595 1X1 70 70
Suspension
2 Double 20X2030 7595 2X1 70 2X70
Suspension
3 Single pilot 20X2030 7595 1X1 70 70
Suspension
4 Single 20X2175 7595 1X1 120 120
Tension
5 Double 20X2175 7595 2X1 120 2X120
Tension
FOR ACSR PANTHER for 132kV Lines:-
Sr TYPE of Dia of FRP Min. No. of EM Mechanical
No String Rod and Creepage Individual strength strength of
Length of Distance units per of Insulator string
Composit (mm) string Insulator alongwith
Hardware
e Insulator (Nos.) Unit (KN)
fittings (kN)
(mm)*
1 Single 20X1305 4495 1X1 70 70
Suspension
2 Single pilot 20X1305 4495 1X1 70 70
Suspension
4 Single 20X1450 4495 1X1 120 120
Tension
5 Double 20X1450 4495 2X1 2X120 2X120
Tension
Page-1
1.3 PARTICULARS OF SILICONE POLYMER INSULATOR STRINGS:-
FOR ACSR ZEBRA & PANTHER OF 66kV LINES:-
S. TYPE of Dia of FRP Min. No. of EM Mechanical

N. String Rod and Creepage Individu strength strength of
Length of Distance al units of Insulator string
Composit (mm) per Insulator alongwith
e Insulator string Unit (KN) Hardware
(mm)* (Nos.) fittings (kN)
1 Single 20X725 2248 1X1 70 70
Suspension
2 Single pilot 20X725 2248 1X1 70 70
Suspension
Tension Polymer Insulators for ACSR Zebra Lines
1 Single 20X870 2248 1X1 120 120
Tension
2 Double 20X870 2248 2X1 2X120 2X120
Tension
Tension Polymer Insulators for ACSR Panther Lines
1 Single 20X870 2248 1X1 90 90
Tension
2 Double 20X870 2248 2X1 2X90 2X90
Tension
Note: *The core dia (FRP rod) of composite insulators mentioned at column No.3 is
minimum requirement. The bidder shall offer composite long rod insulators of
suitable core dia to meet specified E&M strength requirements. For offered core dia,
the bidder shall submit documentary evidence of past supplies & satisfactory
operation of the same for minimum period of three years. However, the overall
string length shall be within the limits specified in the drawing.
1.4 Pin and Cap
1.4.1 Pin and cap shall be designed to transmit the mechanical stress and develop uniform
mechanical strength in the insulator. The cap shall be circular with the inner and outer
surfaces concentric of such design that it will not yield or distort under load conditions.
1.4.2 The design shall be such as to permit easy removal of replacement of either insulator
units or fittings under the live line conditions.
1.5 Ball and Socket Designation
The dimensions of the Ball and Socket shall be of 16mm (Alt-B) for 70kN/90kN and 20
mm for 120 kN Insulators in accordance with the standard dimensions stated in IEC/
IS:2486 (Part-II).
1.6 Dimensional Tolerance of Composite Insulators

The tolerances on all dimensions e.g. diameter, length and creepage distance shall be
allowed as follows:
± (0.04d+1.5) mm when d≤300 mm.
± (0.025d+6) mm when d>300 mm.
Where, d being the dimensions in millimeters for diameter, length or creepage distance
as the case may be. However, no negative tolerance shall be applicable to creepage
distance.
Page-2
The composite long rod insulators inclusive of the ball & socket connection shall be
standard design suitable for use with the hardware fittings of any make conforming to
relevant IEC standards.
1.8 Corona and R1 Performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall
be subjected to excessive localized pressure. The insulator and metal parts shall be so
designed and manufactured that it shall avoid local corona formation and shall not
generate any radio interference beyond specified limit under the operating conditions.
1.9 Maintenance
1.9.1 The long rod insulators offered shall be suitable for employment of hot line maintenance
technique so that usual hot line operation can be carried out with ease, speed and
safety.
1.9.2 All insulators shall be designed to facilitate cleaning and insulators shall have the
minimum practical number of sheds and grooves. All grooves shall be so proportioned
that any dust deposit can be removed without difficulty either by wiping with a cloth or by
remote washing under live line condition.
1.10 Materials
1.10.1 Core
It shall be a glass-fiber reinforced (FRP rod) epoxy resin rod of high strength. Glass
fibers and resin shall be optimized. The rod shall be electrical grade corrosion resistant
(ECR), boron free glass and shall exhibit both high electrical integrity and high resistance
to acid corrosion.
1.10.2 Housing & Weathersheds

The FRP rod shall be covered by a seamless sheath of a silicone rubber compound of a
thickness of minimum 3mm. The housing & weathersheds should have silicon content of
minimum 30% by weight. It should protect the FRP rod against environmental influences,
external pollution and humidity. It shall be extruded or directly molded on the core. The
interface between the housing and the core must be uniform and without voids. The
strength of the bond shall be greater than the tearing strength of the polymer. The
manufacturer shall follow non-destructive technique (N.D.T.) to check the quality of
jointing of the housing interface with the core. The technique being followed with detailed
procedure and sampling shall be furnished along with the bid. The details for this shall be
finalized during detailed engineering and finalization of MQP.
The weathersheds of the insulators shall be of alternate shed profile. The weathersheds
shall be vulcanized to the sheath (extrusion process) or molded as part of the sheath
(injection moulding process) and free from imperfections. In case of injection moulding,
moulding process shall be followed by crimpling process. The vulcanization for extrusion
process shall be at high temperature and for injection moulding shall be at high
temperature & high pressure. Any seams / burrs protruding axially along the insulator,
resulting from the injection moulding process shall be removed completely without
causing any damage to the housing. The track resistance of housing and shed material
shall be class 1A4.5 according to IEC60587. The strength of the weathershed to sheath
interface shall be greater than the tearing strength of the polymer. The composite
insulator shall be capable of high pressure washing.
Page-3
1.10.3 End Fittings
End fittings transmit the mechanical load to the core. They shall be made of malleable
cast iron spheroidal graphite or forged steel. They shall be connected to the rod by
means of a controlled compression technique. The manufacturer shall have in-process
Acoustic emission arrangement or some other arrangement to ensure that there is no
damage to the core during crimping. This verification shall be in-process and done on
each insulator. The gap between fitting and sheath shall be sealed by a flexible silicone
rubber compound. The system of attachment of end fitting to the rod shall provide
superior sealing performance between housing and metal connection. The sealing must
be humidity proof and durable with time.
1.10.4 Grading Rings

Grading rings shall be used at both ends of each composite insulator unit for reducing
the voltage gradient on and within the insulator and to reduce radio and TV noise to
acceptable levels. The size and placement of the metallic grading rings shall be
designed to eliminate dry band arcing/corona cutting/ exceeding of permissible electrical
stress of material. The bidder shall furnish calculations along with the proposed
placement and design of corona ring in support of the above. Grading rings shall be
capable of installation and removal with hot line tools without disassembling any other
part of the insulator assembly.
The supply of grading rings shall be in the scope of the composite insulator supplier.
1.10.5 Workmanship
1.10.5.1 All the materials shall be of latest design and conform to the best modern practices
adopted in the extra high voltage field. Bidders shall offer only such insulators as are
guaranteed by him to be satisfactory and suitable for transmission lines specified and
will give continued good service.
1.10.5.2 The design, manufacturing process and material control at various stages shall be
such as to give maximum working load, highest mobility, best resistance to corrosion,
good finish and elimination of sharp edges and corners to limit corona and radio
interference.
1.10.5.3 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
1.10.5.4 The core shall be sound and free of cracks and voids that may adversely affect the
insulators.
1.10.5.5 Weathersheds shall be uniform in quality. They shall be clean, sound, smooth and
free from gross defects and excessive flashing at parting lines.
1.10.5.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges.
End fittings should be effectively, sealed to prevent moisture ingress, effectiveness of
sealing system must be supported by test documents. All surfaces of the metal parts
shall be perfectly smooth with the projecting points or irregularities which may cause
corona. All load bearing surfaces shall be smooth and uniform so as to distribute the
loading stresses uniformly.
1.10.5.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of
zinc equivalent to 600 gm/sq.m. and shall be in accordance with the requirement of
ISO:1461 (E) and shall satisfy the tests mentioned in ISO:1460 (E). The zinc used for
galvanizing shall be of purity of 99.95%. The zinc coating shall be uniform, adherent,
smooth, reasonably bright continuous and free from imperfections such as flux, ash
rust stains, bulky white deposits and blisters. The galvanized metal parts shall be
guaranteed to withstand at least six successive dips each lasting for one (1) minute
duration under the standard preece test. The galvanizing shall be carried out only
after any machining.
Page-4
2.0 Equipment Marking
2.1 Each composite long rod unit shall be legibly and indelibly marked with the trade mark of
the manufacturer, name of HVPNL and month & year of manufacture. The guaranteed
combined mechanical and electrical strength shall be indicated in kilo Newton followed
by the word ‘kN’ to facilitate easy identification and to ensure proper use.
2.2 One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on
the cap/end fitting of each composite long rod of particular strength for easy identification
of the type of insulator. The paint shall not have any deteriorating effect on the insulator
performance. Following codes shall be used as identification mark :
For 70 KN disc : red
For 90KN disc : Green
For 120KN disc : yellow
3.0 Bid Drawings

3.1 The Bidder shall furnish full description and illustration of the material offered.
3.2 The Bidder shall furnish along with the bid the outline drawing (6 copies) of each
insulator unit including a cross sectional view of the long rod insulator unit. The drawing
shall include but not limited to the following information :
(a) Long rod diameter and ball to ball spacing with manufacturing tolerances
(b) Minimum Creepage distance with positive tolerance
(c) Protected creepage distance
(d) Eccentricity of the long rod unit
(i) Axial run out
(ii) Radial run out
(e) Unit mechanical and electrical characteristics
(f) Size and weight of ball and socket parts
(g) Weight of composite long rod units
(h) Materials
(i) Identification mark
(ii) Manufacturer's catalogue number
3.3 After placement of award, the Supplier shall submit full dimensioned insulator drawings
containing all the details as given in Clause No. 3.2 above, in four (4) copies to Employer
for approval.
3.4 After placement of award the Supplier shall also submit fully dimensioned insulator crate
drawing for different type of insulators.
3.5 After placement of award, the Supplier shall submit full dimensioned manufacturing
drawing of composite long rod insulator unit in six (6) copies to the Employer for
reference and record.
Page-5
4.0 Tests and Standards

4.1 Type Tests
The equipment should be offered fully type tested for all the type tests as detailed below
. Test reports should not be more than seven years old reckoned from the date of bid
opening in respect of all the tests carried out in accredited laboratories ( based on
ISO/IEC) by a reputed accreditatic body or witnessed by HVPNL or another electric
power utility and be submitted by the successful Bidder to HVPNL for approval as per
schedule given in Bar chart :-
4.1.1 On the complete composite Long Rod Insulator String with Hardware Fittings
(a) Power frequency voltage withstand test with IEC:383-1993/

corona control rings/grading ring and arcing horns Annexure A
under wet condition
(b) Switching surge voltage withstand test under wet IEC:383-1993
condition
(c) Impulse voltage withstand test under dry condition IEC:383-1993
(d) Corona and RIV test under dry condition Annexure-A

(e) Mechanical Strength test Annexure-A
(f) Vibration test Annexure-A
(g) Salt-fog pollution withstand test Annexure-A
4.1.2 On Composite Insulator Units

(a) Tests on interfaces and connections of metal fittings (Tests IEC: 61109
to be performed on the same samples in the sequence given
below)
Dry power frequency voltage test
Sudden load release test
Thermal mechanical test
Water immersion test
Steep front impulse voltage test
Dry power frequency voltage test
(b) Assembled core load time test IEC: 61109
i) Determination of the average failing load of the
core of the assembled unit
ii) Control of the slope of the strength time curve of
the insulator
(c) Brittle fracture resistance test Annexure-A
(d) Test of housing, Tracking and erosion test IEC: 61109
(e) Tests for the core material IEC:61109
i) Dye penetration test
ii) Water diffusion test
(f) Flammability test IEC:61109
(g) Recovery of Hydrophobicity test Annexure-A
(h) Mechanical Load Time test and test of tightness between IEC:61109
end firings and insulator housing
(i) Silicone content test Annexure-A
(j) High Pressure washing test Annexure-A
Page-6
4.1.3 All the type test given in Clause No. 4.1.1 shall be conducted on Single ‘I’ suspension,
Single Tension, Double tension insulator string along with hardware fittings. All the type
tests given in Clause No. 4.1.1 (a) to (e) shall also be conducted on Single 'I' Pilot
suspension insulator string along with hardware fittings.
4.2 Acceptance Tests:
4.2.1 For Composite Long Rod Insulators
(a) Verification of dimensions ) IEC : 61109
(b) Galvanising test ) IEC : 60383
(c) Verification of locking system ) IEC : 60383
(d) Verification of tightness ) IEC : 61109

of interface between end fittings and )
insulator housing and of specified )
mechanical load )
(e) Recovery of Hydrophobicity ) Annexure-A
Tests on interfaces and connections of ) IEC: 61109

metal fittings (Tests to be performed on )
the same samples in the sequence given below)
i) Dry power frequency voltage test

ii) Sudden load release test
iii) Thermal mechanical test
iv) Water immersion test
v) Steep front impulse voltage test
vi) Dry power frequency voltage test
(f) Silicone content test Annexure-A
The test 4.2.1.(e) shall be carried out in case total quantity of insulators of a
particular rating exceeds 5000 nos.
The test 4.2.1.(f) shall be done against each lot or against every 5000 nos. of
insulators whichever is less.
In the event of failure of the sample to satisfy the acceptance test(s) specified in
4.2 above, the retest procedure shall be as per clause 7.6 of IEC 61109.
4.3 Routine Tests
4.3.1 For Composite Long Rod Insulator Units
a) Visual Inspection As per IEC:61109
b) Mechanical routine test As per IEC:61109
Page-7
4.4 Tests During Manufacture
a) Chemical analysis of zinc used for galvanising As per Annexure-A
b) Chemical analysis, mechanical, metallographic As per Annexure-A

test and magnetic particle inspection for
malleable castings.
c) Chemical analysis hardness tests and magnetic As per Annexure-A
particle inspection for forgings
d) Tracking and erosion test on insulating material IEC 60587

4.5.1 The entire cost of testing for acceptance and routine tests and tests during
manufacture specified herein shall be treated included in the quoted Ex-works
price except for the expenses of the inspector/HVPNL representative.
4.6 Schedule of testing and additional tests

4.6.1 The bidder has to indicate the schedule of following activities in their bids:
4.6.2 The HVPNL representative reserves the right of having at his own expense any
other test (s) of reasonable nature carried out at manufacturer’s premises, at site,
or in any other place in addition to the aforesaid type, acceptance and routine tests
to satisfy himself that the material comply with the specifications.
4.6.3 The HVPNL representative also reserves the right to conduct all the tests
mentioned in this specification at his own expense on the samples drawn from the
site at manufacturer’s premises or at any other test center. In case of evidence of
non compliance, it shall be binding on the part of the manufacture to prove the
compliance of the items to the technical specifications by repeat tests or correction
of deficiencies, or replacement of defective items, all without any extra cost to the
HVPNL representative .
4.7 Co- ordination for testing

The Bidder/insulator manufacturer shall have to co-ordinate testing of insulators
with hardware fittings to be supplied by other manufacturer and shall have to also
guarantee overall satisfactory performance of the insulators with the hardware
fittings.
4.8 Test Reports

4.8.1 Copies of type test reports shall be furnished in at least six (6) copies along with one
original. One copy shall be returned duly certified by the Employer only after which the
commercial production of the concerned material shall start.
4.8.2 Copies of acceptance test reports shall be furnished in at least six (6) copies. One copy
shall be returned duly certified by the Employer, only after which the material shall be
dispatched
Page-8
periodic inspection by the HVPNL representative.
4.8.4 Test certificates of test during manufacture shall be maintained by the manufacturer.
These shall be produced for verification as and when desired by the HVPNL
representative.
4.9 Inspection
4.9.1 The HVPNL representative shall at all times be entitled to have access to the works
and all places of manufacture, where insulators, and its component parts shall be
manufactured and the representatives shall have full facilities for unrestricted
inspection of the manufacturer’s and sub-manufacturer’s works, raw materials,
manufacture of the material and for conducting necessary test as detailed herein.
4.9.2 The material for final inspection shall be offered by the manufacturer only under packed
condition. The HVPNL representative shall select samples at random from the packed
lot for carrying out acceptance tests.
4.9.3 The manufacturer shall keep HVPNL informed in advance of the time of starting and
the progress of manufacture of material in their various stages so that arrangements
could be made inspection.
satisfactorily inspected and tested unless the inspection is waived off by the HVPNL
representative in writing. In the latter case also the material shall be despatched only
after satisfactory testing for all tests specified herein have been completed.
4.9.5 The acceptance of any quantity of material shall be in no way relieve the manufacturer
of his responsibility for meeting all the requirements of the specification and shall not
prevent subsequent rejection, if such material are later found to be defective.

4.10.1 All insulators shall be packed in suitable PVC/ plastic tubes along with temporary wrap-
on shields/shrouds for each insulator unit. The packing shall provide protection against
rodent. The shields/shrouds shall be for protection during transport and for preventing
bird pecking during erection. Further, the shields/shrouds shall be made of opaque,
weather proof material of adequate strength and shall be colour coded. The
shields/shrouds shall have smaller diameter than the insulator to stay in place against
winds & weather and shall be designed so as to leave only the end fittings exposed for
attachment of insulator to tower and line hardware until line construction is complete. The
shield/shroud shall have suitable pull off loop for easy detachment just prior to charging
of the line without causing any damage to the insulator. The contractor shall furnish
detailed design of the packing and shield/shroud along with attachment and detachment
procedure in this regard. For marine transportation, crates shall be palleted.
4.10.2 The packing shall be of sufficient strength to withstand rough handling during transit,
storage at site and subsequent handling in the field.
4.10.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to
4.10.4 The Supplier shall guarantee the adequacy of the packing and shall be responsible for
any loss or damage during transportation, handling, storage and installation due to
improper packing.
Page-9
4.10.5 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at
their destination and to avoid the possibility of goods being lost or wrongly dispatched on
account of faulty packing and faulty or illegible markings. Each case/crate shall have all
the markings stenciled on it in indelible ink.
4.11 Standards
The insulator strings and its components shall conform to the following Indian/
International Standards which shall mean latest revision, with amendments/
changes adopted and published, unless specifically stated otherwise in the Specification.
4.11.1 In the event of supply of insulators conforming to standards other than specified, the
Supplier shall confirm in his bid that these standards are equivalent or better to those
specified. In case of award, salient features of comparison between the standards
proposed by the Supplier and those specified in this document will be provided by the
Supplier to establish equivalence.
Srl. Indian Standard Title International
No. Standard
1. IS:209-1992 Specification for zinc BS:3436
IS:406-1991 Method of Chemical Analysis of Slab Zinc BS:3436 2.
3. IS:731-1991 Porcelain insulators for overhead Power lines BS:137- (I&II)
with a nominal voltage greater than 1000 V IEC:60383
4. IS:2071 Part Methods of High Voltage Testing IEC:60060-1
(I) – 1993
(Part(II)-1991
Part(III)-1991
5. IS:2486 Specification for Insulator fittings for Overhead
Part-I-1993 Power Lines with a nominal voltage greater than
Part-II-1989 1000V
Part-III-1991 General Requirements and Tests BS:3288
Dimensional Requirements IEC:60120
Locking Devices IEC:60372
6. IS:2629-1990 Recommended Practice for Hot, Dip ISO-1461 (E)
Galvanisation for iron and steel
7. IS:2633-1992 Testing of Uniformity of Coating of zinc coated
articles
8. IS:3188-1988 Dimensions for Disc Insulators IEC:60305
9. IS:6745-1990 Determination of Weight of Zinc Coating on Zinc BS:433-1969
coated iron and steel articles ISO:1460-1973
10. IS:8263-1990 Methods of RI Test of HV insulators IEC:60437
NEMA Publi- cation
No.07/ 1964/ CISPR
11. IS:8269-1990 Methods for Switching Impulse test on HV IEC:60506
insulators
12. Thermal Mechanical Performance test and IEC: 60575
mechanical performance test on string insulator
units
13. Salt Fog Pollution Voltage Withstand Test IEC:60507
14. Composite insulators for A.C. Overhead lines IEC 61109
with nominal voltage greater than 1000V –
Definitions, test methods and acceptance criteria
15. Guide for the selection of insulators in respect of IEC:60815
polluted conditions
16. Tests on insulators of Ceramic material or glass IEC:60383
or glass for overhead lines with a nominal voltage
greater than 1000V
17. Characteristics of string insulator units of the long IEC : 60433
rod type
Page-10
The standards mentioned above are available from:
BS British Standards,
British Standards Institution
101, Pentonvile Road,
N - 19-ND, UK
IEC/CISPR International Electro technical
Commission,
Bureau Central de la Commission,
electro Technique international,
1 Rue de verembe,
Geneva, SWITZERLAND
BIS/IS Beureau Of Indian Standards.
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110001. INDIA
Standardization.
Danish Board of Standardization
Danish Standardizing Sraat,
Aurehoegvej-12
DK-2900, Heeleprup, DENMARK
Association,
155, East 44th Street.
New York, NY 10017 U.S.A.
ASTM American Society for Testing and
Materials,
1916 Race St. Philadelphia, PA19103
USA
Page-11
ANNEXURE-A
1.0 Tests on Complete Strings with Hardware Fittings
1.1 Voltage distribution test
The voltage across each insulator unit shall be measured by sphere gap method.
The result obtained shall be converted into percentage. The voltage across any
disc shall not exceed 20% for suspension insulator string and 22% for tension
insulator string.
1.2 Mechanical Strength Test
The complete insulator string along with its hardware fitting excluding arcing horn,
corona control ring, grading ring and suspension assembly/dead end assembly
shall be subjected to a load equal to 50% of the specified minimum ultimate tensile
strength (UTS) which shall be increased at a steady rate to 67% of the minimum
UTS specified. The load shall be held for five minutes and then removed. After
removal of the load, the string components shall not show any visual deformation
and it shall be possible to disassemble them by hand. Hand tools may be used to,
remove cotter pins and loosen the nuts initially. The string shall then be
reassembled and loaded to 50% of UTS and the load shall be further increased at
a steady rate till the specified minimum UTS and held for one minute. No fracture
should occur during this period. The applied load shall then be increased until the
failing load is reached and the value recorded.
1.3 Vibration Test
The suspension string shall be tested in suspension mode, and tension string in
tension mode itself in laboratory span of minimum 30 metres. In the case of
suspension string a load equal to 600 Kg shall be applied along the axis of the
hardware fittings and conductor tensioned at 2500 Kgf shall be secured with
clamps. The system shall be suitable to maintain constant tension on the
conductor throughout the duration of the test. Vibration dampers shall not be used
on the test span. The conductor shall be vertically vibrated at one of the
resonance frequencies of the insulators string (more than 10 Hz) by means of
vibration inducing equipment. The peak to peak, displacement in mm of vibration
at the antinode point nearest to the string shall be measured and the same shall
not be less than 1000 /f1.8 where is the frequency of vibration in cycles/sec. The
insulator string shall be vibrated for not less than 10 million cycles without any
failure. After the test the disc insulators shall be examined for looseness of pins
and cap or any crack in the cement. The hardware shall be examined for
looseness, fatigue failure and mechanical strength test. There shall be no
deterioration of properties of hardware components and insulators after the
vibration test. The insulators shall be subjected to the Mechanical performance
test followed by mechanical strength test as per relevant standards.
1.4 Salt-fog pollution withstand test

This test shall be carried out in accordance with IEC : 60507. The salinity
level for composite long rod insulators shall be 160 Kg/m3 NACL.
Page-12
2.0 Composite Longrod Insulator Units
2.1 Brittle Fracture Resistance Test
Assembled core load time test with container that contains1n-HNO3 concentric
acid that is applied at the naked rod. The rod should be held at 80% of SML for
the duration of the test.
The rod should not fail within the 96 hour test duration
2.2 Recovery of Hydrophobicity Test
(1) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow
the surface to dry and spray with water. Record the HC classification. Dry the
sample surface.
(2) Treat the surface with corona discharges to destroy the hydrophobicity. This can
be done utilizing a high frequency corona tester, Holding the electrode
approximately 3mm from the sample surface, slowly move the electrode over an
area approximately 1” x 1”. Continue treating this area for 2 – 3 minutes,
operating the tester at maximum output.
(3) Immediately after the corona treatment, spray the surface with water and record
the HC classification. The surface should be hydrophilic, with an HC value of 6 or
7. If not, dry the surface and repeat the corona treatment for a longer time until an
HC of 6 or 7 is obtained. Dry the sample surface.
(4) Allow the sample to recover and repeat the hydrophobicity measurement at
several time intervals. Silicone rubber should recover to HC 1 – HC 2 within 24 to
48 hours, depending on the material and the intensity of the corona treatment.
2.3 Silicone content test
Minimum content of silicone as guaranteed by supplier shall be verified through

FT-IR spectroscopy & TGA analysis or any other suitable method mutually agreed
between Employer & Supplier in Quality Assurance Programme .
2.4 High Pressure washing test
The test is to be carried out at 3800 kPa with nozzles of 6 mm diameter at a

distance of 3m from nozzles to the insulator, followed by a dry power frequency
voltage test as per IEC 61109.
Page-13
3. Tests on All components (As applicable)
Samples taken from the zinc ingot shall be chemically analysed as

per IS:209-1979. The purity of zinc shall not be less than 99.95%.
The chemical analysis hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognised procedures for these tests.
The sampling will be based on heat number and heat treatment batch. The details
regarding test will be as discussed and mutually agreed to by the Supplier and
Employer in Quality Assurance Programme.
3.3 Tests on Castings
The chemical analysis, mechanical and metallographic tests and magnetic,

particle inspection for castings will be as per the internationally recognised
procedures for these tests. The samplings will be based on heat number and heat
treatment batch. The details regarding test will be as discussed and mutually
agreed to by the Supplier and Employer in Quality Assurance Programme.
Page-14
SECTION- VI, PART-II, CHAPTER-III (C)
BUS POST INSULATORS
CONTENTS
1. Technical Description of Bus Post Insulators 1

TECHNICAL SPECIFICATION FOR 145 kV BUS POST INSULATORS
1. SCOPE
This specification covers design, Engineering, manufacture, stage testing, inspection and
testing before despatch packing, forwarding and delivery at site of 145 kV outdoor type
bus Post Insulators and its clamps at the Gantries.
It is not the intent to specify completely all the details of design and construction of the
insulator. However, the insulator shall conform in all respects to the high standard of
engineering design and workmanship and shall be capable of performing in continuous
commercial operation up to the Bidder’s guarantee in a manner acceptable to the
HVPNL. The equipment offered shall be complete in all components necessary for its
effective and trouble free operation. Such components shall be deemed to be within the
scope of supply irrespective of whether those are specially brought out in this
specification or not. All similar parts particularly movable ones shall be interchangeable.
2. STANDARD
The Post Insulators and their Hardwares shall comply as regards general requirements,
test voltages and test with the latest edition of IS 2544/1973 IS-5350 (P-II) 1973 IS-5350
(P-III) 1971/IEC-168/1979 except in so far as the same may be modified by this
Specification.
3. TYPE AND RATING

The 145 kV Bus Post Insulators are required for outdoor-system conforming to IS
2544/1973 or latest version thereof suitable for heavily polluted atmosphere. The Post
Insulators shall be specifically suitable to meet the particular requirements of ultimate
torsional strength and cantilever loads etc. which they will be called upon to resist during
service at the rated voltage.
The principal rating of bus Post Insulators shall be as under: -
Sr. Particulars Unit

No.
i. Nominal system kV 132
voltage
ii. Highest system kV 145
voltage
iii. Rated frequency 50+/-2.5H
iv. Minimum creepage mm 3625
distance
v. One minute power kV(rms) 275
frequencywithstand
voltage
vi. Impulsewithstand kV(peak) 550
voltage
(+ve & -ve)
vii. Minimum visual kV(rms) -
discharge voltage
level (extinction)
Page-1
viii. Radio interference Micro Volt >500
voltage (Micro volt at
1 MHz) at a system
voltage of 156 kV.
ix. Cantilever strength Kg. 400
(Upright)
x. Torsion strength nm 3000
xi. Bending strength N 4000
xii. Tensile strength N 50000
xiii. Compressive strength N 100000
xiv. Applicable standard
xv. Pitch Circle Dia:
a. Top mm 127
b. Bottom mm 178
xvi. Height of insulator mm 1220+1
xvii. No. of Insulator per No. 1
stack
4. CLIMATIC CONDITION
As per 1.6 of SECTION-VI, Part-1.
5. GENERAL REQUIREMENT
145 kV Bus Post Insulator shall be either solid core or polycon type insulators complete
with all fittings and accessories required for holding single ACSR Panther /ACSR Zebra
as the case of line may be . The bus Post Insulator pedestal shall be suitable for fixing on
the Gantries.
The bus Post Insulator shall be provided with a completely galvanised steel base
designed for mounting on the Gantries. The base and mounting arrangement shall be
such that the insulator shall be rigid and self supporting and no guying or cross bracings
between phases shall be necessary.
Cap to be provided on top of the insulator shall be of high grade cast iron or malleable
steel casting. It shall be machine faced and hot dip galvanised. The cap shall have four
nos. of tapped holes spaced on a pitch circle diameter to accommodate the terminal
clamp . The holes shall be suitable for bolts with threads having anticorrosive protection.
The effective depth of threads shall not be less than the nominal diameter of the bolt.
The Post Insulator clamps are to be fitted on the top of the bus Post Insulator
for holding single conductor ACSR Panther/ACSR Zebra tightly and rigidly. The clamps
shall be made of Aluminium alloy and shall comply with relevant ISS. The clamps shall
be supplied with galvanised steel studs of the suitable size and maintain the requisite
pressure to ensure good and tight joint of low resistance.
The insulators shall be entirely free from sharp edges, ridges or points and shall not
exhibit appreciable corona formation during service.
Castings shall be free from blow holes, flaws, cracks and other defects and shall be
smooth, close grained and of true forms and dimensions.
Page-2
The porcelain shall be white, finished brown glazed, non-porous of high di-electric,
mechanical and thermal strength, free from defects and thoroughly vitrified. Cement used
shall be of high quality, durable and high strength Portland cement. Cement is not to be
treated as an adhesive medium between the porcelain and metal parts of an insulator.
Preference will be given to a fixing medium of an approved metal alloy. Cement shall be
a replenishment material for filling gap between the porcelain and metal parts to fix them.
6. GALVANISING
All the ferrous metal parts shall be hot dip galvanised smoothly, as per IS 3638 (as
amended up to date). IS 2633 or any other equivalent authoritative standard. The
material shall be galvanised only after shop operations upon it have been completed.
The metal parts before galvanising should be thoroughly cleaned of any paint, grease,
rust, scales or alkalis, or any foreign deposit which are likely to come in the way of
galvanising process. The metal parts coating shall withstand minimum four for one
minute dips in copper sulphate solution as per IEC-168.
The bus Post Insulator unit shall be assembled in a suitable jig to ensure correct
positioning of the top and bottom metal fittings relative to one another. The faces of the
metal fittings shall be parallel and at right angles to the axis of the insulator and the
corresponding holes in the top and the bottom metal fittings shall be in a vertical plane
containing the axis of the insulator.
All nuts, bolts and spring washers etc. required for the assembly of the complete
insulator stack shall be in scope of supply. The bolts and nuts shall be hot dip galvanised
and shall be of high strength generally conforming to IS-136 or any other equivalent
international standard.
7. TESTS
7.1 Type Tests
The equipment should be offered type test. Test reports should not be more than seven
years old reckoned from the date of bid opening in respect of all the tests carried out in
accredited laboratories ( based on ISO/IEC) by a reputed accreditatic body or
witnessed by HVPNL or another electric power utility and be submitted by the
successful bidder to HVPNL for approval as per schedule given in Bar chart.
1. Visual examination
2. Verification of dimensions
3. Visible discharge test
4. Impulse voltage withstand test
5. Dry power frequency voltage withstand test.
6. Wet power frequency voltage withstand test.
7. Temperature cycle test
8. Test for mechanial strength
9. Puncture test
10. Porosity test
11. Galvanising test
Page-3
7.2 Acceptance and Routine Tests
7.2.1 All the acceptance and routine tests as detailed below shall be carried out by the supplier
in the presence of HVPNL representative. No material shall be dispatched without the
approval of test certificates:-
1. Verification of dimensions
2. Temperature cycle test
3. Test for mechanial strength
4 Puncture test
5. Porosity test
6. Galvanising test
8. INSPECTION
The inspection may be carried by the HVPNL at any stage of manufacture. The
successful Bidder shall grant free access to the HVPNLrepresentative at a reasonable
time when the work is in progress. Inspection and acceptance of any equipment under
this Specification by the HVPNL shall not relieve the supplier of his obligation of
furnishing equipment in accordance with the Specification and shall not prevent
subsequent rejection if the equipment is found to be defective.
The Bidder shall keep the HVPNL informed in advance about the manufacturing
programme so that arrangement can be made for inspection.
The HVPNL reserves the right to insist for witnessing the acceptance/routine testing of
the bought out items.
9. GUARANTEED DATA
Guaranteed technical particulars and other technical data in respect of

equipment/material offered should be furnished duly signed in the performa given in
GTPs. Any other particulars considered necessary may also be given in addition to those
listed in the schedule.
10. DRAWING AND LITERATURE
The successful bidder shall submit 4 sets of following fully dimentional drawings
complete in all respect for approval to HVPNL as per time schedule given in Bar Chart.
11. MARKING
Each porcelain insulator unit shall legibly and indelibly be marked to show the following:
a) Name or Trade Mark of the manufacture.
b) Month and year of manufacture.
c) Country of manufacture.
Marking on the porcelain shall be printed and shall be applied before firing.
Page-4
12. PACKING AND FORWARDING
12.1 The equipments shall be packed in crates suitable to withstand handling during transport
and outdoor storage during transit. The supplier shall be responsible for any damage to
the equipment during transit, due to improper and inadequate packing. The easily
damageable material shall be carefully packed and marked with the appropriate caution
symbols. Wherever necessary, proper arrangement for lifting, such as lifting hooks etc.
shall be provided. Any material found short inside the packing cases shall be supplied by
supplier without any extra cost.
12.2 Each consignment shall be accompanied by a detailed packing list containing the
following information: -
a) Name of the consignee.

b) Details of the consignment.
c) Destination.
d) Total weight of consignment.
e) Sign showing upper/lower side of the crate.
f) Handling and unpacking instructions.
g) Bill of material indicating contents of each package.
Page-5
SECTION- V, PART-II, CHAPTER-III (E)
HARDWARE FITTINGS & ACCESSORIES
CONTENTS
1. Hardware Fittings for lines with ACSR Zebra 1
2 Accessories for lines with ACSR Zebra 11
3. Earthwire Accessories for lines with ACSR Zebra . 17
5. Type Tests 32
6 Annexure-A 32
7 Annexure-B 40
SECTION-V
(CHAPTER-III E)
TECHNICAL SPECIFICATIONS
1.0 TECHNICAL DESCRIPTION OF HARDWARE FITTINGS FOR LINES WITH

ACSR ZEBRA CONDUCTOR
1.1 Details of Hardware Fittings
1.1.1 The hardware fittings shall be as per the specification drawings enclosed with this
part of the specification. Each hardware fitting shall be supplied complete in all
respects and shall include the following hardware parts.
1.1.2 Single suspension, Single Tension, Single suspension (Pilot), Double Suspension
and Double Tension hardware fittings, shall be supplied suitable for attaching to
hanger/strain plate fixed to tower.
1.1.3 Suitable arcing horn/intermediate arcing horns as specified in clause 4.8

hereinafter.
1.1.4 Suitable yoke plates complying with the specifications given hereunder.
1.1.5 Suspension and dead end assembly to suit conductor size as detailed in clause
4.10 and 4.11 hereinafter.
1.1.6 Other necessary fittings as eye links, ball clevis, socket clevis, clevis eye, U-clevis
and chain link etc. to make the hardware fittings complete.
1.1.7 2.5% extra fasteners and Aluminum filler plugs.
1.2 Dimensions of Insulator String Alongwith Hardware Fitting
The various limiting dimensions of the various Suspension, pilot and tension
insulator strings alongwith hardware fittings shall be as per the specification
drawings enclosed with this part of the specification.
The hardware for insulator strings with disc insulators together with ball and
socket fittings shall be of standard design, so that these hardware are
interchangeable with each other and suitable for use with disc insulators of any
make conforming to relevant Indian/International Standard.
1.4 Corona and RI Performance
Sharp edges and scratches on all the hardware fittings shall be avoided. All
surfaces must be clean, smooth, without cuts and abrasions or projections. The
Bidder must give suitable assurance about the satisfactory corona and radio
interference performance of the materials offered by him.
Page-1
1.5 Maintenance
1.5.1 The hardware fittings offered shall be suitable for employment of hot line
maintenance techniques so that usual hot line operations cab be carried out
with ease, speed and safety. The technique adopted for hot line maintenance
shall be generally bare hand method & hot stick method. The Bidder should
clearly establish in the bid, the suitability of his fittings for hot line maintenance.
1.5 Designation
1.6.1 Ball and Socket Designation
The dimensions of the ball and socket shall be of 16mm designation for 70 KN disc
Insulators and 20 mm for 120 KN insulators. The designation should be in accordance
with the standard dimensions stated in IS 2486 (Part-II)/ IEC: 120. The dimensions shall
be checked by the appropriate gauge after galvanising only.
1.7 Security Clips and Split Pins
1.7.1 Security clips for use with ball and socket coupling shall be R-shaped, hump type which
provides positive locking of the coupling as per IS:2486 (Part-III) /IEC : 372. The legs of
the security clips shall be spread after assembly in the works to prevent complete
withdrawal from the socket. The locking device should be resilient, corrosion resistant
and of suitable mechanical strength. There shall be no risk of the locking device being
displaced accidentally or being rotated when in position. Under no circumstances shall
the locking devices allow separation of fittings.
1.7.2 The hole for the security clips shall be countersunk and the clip should be of such design
that the eye of clips may be engaged by a hot line clip puller to provide for
disengagement under energised conditions. The force required to pull the security clip
into its unlocked position shall not be less than 50 N (5 kg) or more than 500 N (50 kg).
1.7.3 Split pins shall be used with bolts & nuts.
1.8 Arcing Horn/Intermediate Arcing Horn
1.8.1 The arcing horn shall be either ball ended rod type or tubular type.
1.8.2 For insulators strings with disc insulators, the arcing horn shall be provided as shown on
the drawings of the hardware fittings in this specification.
1.8.3 The spark gap shall be so adjusted to ensure effective operation under actual field
conditions.
1.9 Yoke Plates
The strength of yoke plates shall be adequate to withstand the minimum ultimate tensile
strength, as specified in the bid drawings.
Page-2
The plates shall be either triangular or rectangular in shape as may be necessary. The
design of yoke plate shall take into account the most unfavourable loading conditions likely
to be experienced as a result of dimensional tolerances for disc insulators as well as
components of hardware fittings within the specified range. The plates shall have suitable
holes for fixing arcing horn. All the corners and edges should be rounded off with a radius
of at least 3 mm. Design calculations i.e. for bearing & tensile strength, for deciding the
dimensions of yoke plate shall be furnished by the bidder. The holes provided for bolts in
the yoke plate should satisfy shear edge condition as per Clause No. 8.10 of IS: 800-1984.
1.10 Suspension Assembly

1.10.1 The suspension assembly shall be suitable for ACSR Zebra Conductor.
1.10.2 The suspension assembly shall include either free centre type suspension clamp
alongwith standard preformed armour rods or armour grip suspension clamp except for
pilot insulator string for which only suitable envelope type suspension clamps shall be
used.
1.10.3 The suspension clamp alongwith standard preformed armour rods set shall be designed
to have maximum mobility in any direction and minimum moment of inertia so as to have
minimum stress on the conductor in the case of oscillation of the same.
1.10.4 The suspension clamp alongwith standard preformed armour rods/armour grip
suspension clamp set shall have a slip strength between 16 to 24 KN.
1.10.5 The suspension assembly shall be designed, manufactured and finished to give it a
suitable shape, so as to avoid any possibility of hammering between suspension
assembly and conductor due to vibration. The suspension assembly shall be smooth
without any cuts, grooves, abrasions, projections, ridges or excrescence which might
damage the conductor.
1.10.6 The suspension assembly/clamp shall be designed so that it shall minimise the static &
dynamic stress developed in the conductor under various loading conditions as well as
during wind induced conductor vibrations. It shall also withstand power arcs & have
required level of corona/RIV performance.
1.10.7 FREE CENTER TYPE SUSPENSION CLAMP
For the free Center Suspension Clamp seat shall be smoothly rounded and curved into a
bell mouth at the ends. The lip edges shall have rounded bead. There shall be at least
two U-bolts for tightening of clamp body and keeper pieces together.
1.10.8 STANDARD PREFORMED ARMOUR ROD SET

1.10.8.1 The preformed Armour Rod Set suitable for ACSR Zebra (61/3.18) conductor shall be
used to minimise the stress developed in the conductor due to different static and
dynamic loads because of vibration due to wind, slipping of conductor from the
suspension clamp as a result of unbalanced conductor tension in adjacent spans and
broken wire condition. It shall also withstand power arcs, chafing and abrasion from
suspension clamp and localised heating effect due to magnetic power losses from
suspension clamps as well as resistance losses of the conductor.
1.10.8.2 The preformed Armour rods set shall have right hand lay and the inside diameter of
the helics shall be less than the outside diameter of the conductor to have gentle but
permanent grip on the conductor. The surface of the Armour rod when fitted on the
conductor shall be smooth and free from projections, cuts and abrasions etc.
Page-3
1.10.8.3 The pitch length of the rods shall be determined by the Bidder but shall be less than
that of the outer layer of conductor and the same shall be accurately controlled to
maintain uniformity and consistently reproducible characteristic wholly independent of
the skill of linemen.
1.10.8.4 The length of each rod and diameter shall be as follows:
Length dia
ACSR Zebra 2540 ± 25 7.87 ± .10
The tolerance in length of the rods in complete set should be within 13 mm

between the longest and shortest rod. The ends of Armour rod shall be parrot
billed.
4.10.8.5 The number of Armour rods in each set shall be twelve. Each rod shall be marked
in the middle with paint for easy application on the line.
4.10.8.6 The amour rod shall not loose their resilience even after five applications.
4.10.8.7 The conductivity of each rod of the set shall not be less than 40% of the
conductivity of the International Annealed Copper Standard (IACS).
4.10.9 ARMOUR GRIP SUSPENSION CLAMP
4.10.9.1 The Armour grip suspension clamp shall comprise of retaining strap, support
housing, elastomer inserts with aluminum re-enforcement’s and AGS
preformed rod set.
4.10.9.2 Elastomer insert shall be resistant to the effects of temperature up to 750 C,

Ozone ultraviolet radiations and other atmospheric contaminants likely to be
encountered in service. The physical properties of the elastomer shall be of
approved standard. It shall be electrically shielded by a cage of AGS preformed
rod set. The elastomer insert shall be so designed that the curvature of the AGS
rod shall follow the contour of the neoprene insert.
4.10.9.3 The AGS preformed rod set shall be as detailed in clause 4.10.10.1 to 4.10.10.7 in
general except for the following.
4.10.9.4 The length of the AGS preformed rods shall be such that it shall ensure
sufficient slipping strength as detailed under clause 1.10.4 and shall not
introduce unfavorable stress on the conductor under all operating conditions.
4.10.10 ENVELOPE TYPE SUSPENSION CLAMP
The seat of the envelope type suspension clamp shall be smoothy rounded and
suitably curved at the ends. The lip edges shall have a rounded bend. There shall
be at least two U-Bolts for tightening of clamp body and keeper pieces together.
Hexagonal bolts and nuts with split pins shall be used for attachment of the clamp.
Page-4
4.11 DEAD END ASSEMBLY
4.11.1 The dead end assembly shall be suitable for ACSR Zebra (61/3.18) mm
conductor.
4.11.2 The dead end assembly shall be compression type with provision for compressing
jumper terminal at one end. The angle of jumper terminal to be mounted should be
300 with respect to the vertical line. The area of bearing surface on all the
connections shall be sufficient to ensure positive electrical and mechanical contract
and avoid local heating due to I2 R losses. The resistance of the clamp when
compressed on Conductor shall not be more than 75% of the resistance of
equivalent length of Conductor.
4.11.3 Die compression areas shall be clearly marked on each dead-end assembly
designed for continuous die compressions and shall bear the words ‘COMPRESS
FIRST’ suitably, inscribed near the point on each assembly where the compression
begins. If the dead end assembly is designed for intermittent die compressions, it
shall bear identification marks ‘COMPRESSION ZONE’ AND ‘NON-
COMPRESSION ZONE’ distinctly with arrow marks showing the direction of
compressions and knurling marks showing the end of the zones. Tapered
aluminum filler plugs shall also be provided at the line of demarcation between
compression & non-compression zone. The letters, number and other marking on
the finished clamp shall be distinct and legible. The dimensional tolerances of the
cross section of aluminum for dead end assembly for ACSR Zebra conductor shall
be as per the table given below: -
TABLE-I
Sl. Item Dimension before Dimension after

No. Compression Compression
Inner Outer Corner to Face

dia dia corner to face
width width
(mm) (mm) (mm) (mm)
Dead end Assembly
1. Aluminum 31±0.5 48±1 46±0.5 40±0.5
2. Steel 10±0.2 20±0.5 19±0.5 16±0.5
4.11.4 The assembly shall not permit slipping of, damage to, or failure of the complete
conductor or any part there of at a load less than 95% of ultimate tensile strength
of the conductor.
Page-5
4.12 FASTENERS: BOLTS, NUTS AND WASHERS
4.12.1 All bolts and nuts shall conform to IS: 6639-1972. All bolts and nuts shall be
galvanized. All bolts and nuts shall have hexagonal heads, the heads being forged
out of solid truly concentric, and square with the shank, which must be perfectly
straight.
4.12.2 Bolts up to M 16 and having length up to 10 times the diameter of the bolt should
be manufactured by cold forging and thread rolling process to obtain good and
reliable mechanical properties and effective dimensional control. The shear
strength of bolt for 5.6 grade should be 310 MPa minimum as per IS: 12427. Bolts
should be provided with washer face in accordance with IS: 1363 Part-I to ensure
proper bearing.
4.12.3 Nuts should be double chamfered as per the requirement of IS: 1363 Part-III,
1984. It should be ensured by the manufacturer that nuts should not be over-
tapped beyond 0.4 mm oversize on effective diameter for size up to M 16.
4.12.4 Fully threaded bolts shall not be used. The length of the bolt shall be such that
the threaded portion shall not extend into the place of contact of the component
parts.
4.12.5 All bolts shall be threaded to take the full depth of the nuts and threaded
enough to permit the firm gripping of the component parts but no further. It shall
be ensured that the threaded portion of the bolt protrudes not less than 3 mm
and not more than 8 mm when fully tightened. All nuts shall fit and tight to the
point where shank of the bolt connects to the head.
4.12.6 Flat washers and spring washers shall be provided wherever necessary and shall
be of positive lock type. Spring washers shall be electro-galvanized. The thickness
of washers shall conform to IS: 2016-1967.
4.12.7 The Bidder shall furnish bolt schedules giving thickness of components
connected, the nut and the washer and the length of shank and the threaded
portion of bolts and size of holes and any other special details of this nature.
4.12.8 To obviate bending stress in bolt, it shall not connect aggregate thickness more
than three time its diameter.
4.12.9 Bolts at the joints shall be so staggered that nuts may be tightened with
spanners without fouling.
4.12.10 Fastners of grade higher than 8.8 are not to be used.
4.13 Materials
4.13.1 The materials of the various components shall be as specified hereunder.

However components made of alternative materials giving equivalent or better
performance shall also be considered. The Bidder shall indicate the material
proposed to be used for each and every component of hardware fittings stating
clearly the class grade or alloy designation of the material, manufacturing process
& heat treatment details and the reference standards.
Page-6
4.13.2 The details of material for different component are listed as in Table No. II.
4.16 Workmanship
4.16.1 All the equipment shall be of the latest design and conform to the best modern
practices adopted in the Extra High Voltage field. The Bidder shall offer only such
equipment as guaranteed by him to be satisfactory and suitable for 66 kV
transmission line and will give continued good performance.
4.16.2 The design, manufacture process and quality control of all the materials shall be
such as to give the specified mechanical rating, highest mobility, elimination of
sharp edges and corners to limit corona and radio-interference, best resistance
corrosion and a good finish.
4.16.3 All ferrous parts including fasteners shall be hot dip galvanised, after all machining
has been completed. Nuts may, however, be tapped (threaded) after galvanising
and the threads oiled. Spring washers shall be electro-galvanised. The bolt
threads shall be undercut to take care of the increase in diameter due to
galvanising. Galvanising shall be done in accordance with IS: 2629-1985 and shall
satisfy the tests mentioned in IS: 2633-1986. Fasteners shall withstand four dips
while spring washers shall withstand three dips of one-minute duration in the
standard preece test. Other galvanised materials shall be guaranteed to withstand
at least six successive dips each lasting one (1) minute under the standard preece
test for galvanising.
4.16.4 Before ball fittings are galvanised, all die flashing on the shank and on the bearing
surface of the ball shall be carefully removed without reducing the dimensions
below the design requirements.
4.16.5 The zinc coating shall be perfectly adherent, of uniform thickness, smooth
reasonably bright, continuous and free from imperfections such as flux, ash, rush
stains, bulky white deposits and blisters. The zinc used for galvanising shall be
grade Zn 99.95 as per IS: 209-1979.
4.16.6 Pin balls shall be checked with the applicable “GO” gauges in at least two
directions, one of which shall be across the line of die flashing, and the other 90 0
to this line. ‘NO GO’ gauges shall not pass in any direction.
4.16.7 Socket ends, before galvanising, shall be of uniform contour. The bearing surface
of socket ends shall be uniform about the entire circumference without
depressions of high spots. The internal contours of socket ends shall be
concentric with the axis of the fittings as IS: 2486/IEC: 120.
The axis of the bearing surfaces of socket ends shall be coaxial with the axis of
the fittings. There shall be no noticeable tilting of the bearing surfaces with the
axis of the fittings.
4.16.8 In case of casting, the same shall be free from all internal defects like shrinkage,
inclusion, blowholes, cracks etc. Pressure die casting shall not be used for casting
of components with thickness more than 5 mm.
4.16.9 All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum.
Page-7
4.16.10 No equipment shall have sharp ends or edges, abrasions or projections and
cause any damage to the conductor in any way during erection or during
continuous operation which would produce high electrical and mechanical
stresses in normal working. The design of adjacent metal parts and mating
surfaces shall be such as to prevent corrosion of the contact surface and to
maintain good electrical contact under service conditions.
4.16.11 All the holes shall be cylinderical, clean cut and perpendicular to the plane of the
material. The periphary of the holes shall be free from burrs.
4.16.12 All fasteners shall have suitable corona free locking arrangement to guard against
vibration loosening.
4.16.13 Welding of aluminum shall be by inert gas shielded tungesten arc or inert gas
shielded metal arc process. Welds shall be clean, sound, smooth, uniform without
overlaps, properly fused and completely sealed. There shall be no cracks, voids
incomplete penetration, incomplete fusion, under-cutting or inclusions. Porosity
shall be minimized so that mechanical properties of the aluminum alloys are not
affected. All welds shall be properly finished as per good engineering practices.
4.17 Bid Drawings
4.17.1 The successful Bidder shall submit 4 sets of following fully dimensional
drawings complete in all respect for approval to HVPNL as per time
schedule given in Bar Chart:-
(i) Attachment of the hanger or strain plate.
(ii) Suspension or dead end assembly.
(iii) Arcing horn/intermediate Arcing Horn attachment to the string as specified

in clause 1.8 of this technical Specification.
(iv) Yoke plates.
(v) Hardware fittings of ball and socket for interconnecting units to the top and
bottom Yoke plates.
(vi) Links with suitable fittings.
4.17.2 All drawings shall be identified by a drawing number and contract number. All
drawing shall be neatly arranged. All drafting & lettering shall be legible. The
minimum size of lettering shall be 3 mm. All dimensions & dimensional tolerances
shall be mentioned in mm:
(i) Dimensions and dimensional tolerance.
(ii) Material, fabrication details including any weld details & any specified finishes &
coatings. Regarding material, designation & reference of standards are to be
indicated.
Page-8
(iii) Catalogue No.
(iv) Marking.
(v) Weight of assembly.
(vi) Installation instructions.
(vii) Design installation torque for the bolt or cap screw.
(viii) Withstand torque that may be applied to the bolt or cap screw without failure of
component parts.
(ix) The compression die number with recommended compression pressure.
(x) All other relevant terminal details.
4.17.3 After placement of award, the Manufacturer shall submit fully dimensioned drawing
including all the components in four (4) copies to the HVPN for approval.
Table-II
Details of Materials
………………………………………………………………………………………………………...
Sr. No. Name of Item Material Process of Reference Remark
Treatment Standard
………………………………………………………………………………………………………...
1. Security Clips Stainless -- AISI 302

Steel/Phos 304-L-As per
Pher Bronze IS-1385-1968
2. Arcing Horn/ Mild Steel Hot dip As per IS-226

Intermediate Rod/Tube galvanized 1975 or equivalent
Arching Horn Type
3. Ball Fittings, Class-IV Drop As per IS:2004

Socket, All Steel or forged & 1978 or equivalent
Shackles links equivalent normalized
Hot dip
galvanized
4. Yoke Plate Mild Steel Hot dip As per IS:226

galvanized 1975 or equivalent
standard
Page-9
5. Free Centre
Clamp
(a) Clamp Body/ High Stre- Casted IS: 617 or
Keeper Piece gth Al. Alloy /forged equivalent
4600 or LM Heat
-6 or equiv- treated
alent/6061
(b) Cotter bolts, Galvanized Hot dip IS: 226-1975

Hangers, Mild Steel Galvanized IS: 2062-1992
Shackles,
Brackets -
(c) U Bolts Stainless Forged & AISI 302 or 304-L

Steel or heat treated
High Stren-
gth Al. Alloy
6. P.A. Rod High Stren- Heat ASTM-B429 Minimum

gth Al. Alloy treatment tensile
type 6061 or during strength
equivalent manufacturing of 35 Kg
/mm2
7. AGS Clamp High Stren- Cast IS: 617 or

(a) Supporting gth Corros forged equivalent
House -ion resistant Heat
AL. Alloy LM6, treated
4600 or
equivalent/6061
(b) Al. Insert & High Strength Forged & ASTM-B429

Retaining Al. Alloy of type Heat treated
strap 6061 or
equivalent.
(c) Elastomer Moulded on Al.

Cushion reinforcement
8. Dead End Assembly
(a) Outer Sleeve EC grade Al. of

dead end purity not less
assembly than 99.5% or
for ACSR aluminum alloy
Zebra 6201/or equivalent
Conductor
(b) Steel Sleeve Mild Steel

Hot dip As per IS: 2062
Galvanised or equivalent
………………………………………………………………………………………………………
Page-10
5. CONDUCTOR ACCESSORIES FOR LINES WITH ACSR ZEBRA
5.1 General
5.1.1 This portion details the technical particulars of the accessories for ACSR
Zebra 61/3.18 Conductor.
5.1.2 2.5% extra fasteners and retaining rods shall be provided.
5.2 Mid Span Compression Joint.
5.2.1 Mid Span Compression Joint shall be used for joining two lengths of conductor.
The joint shall have a resistively less than 75% of the resistivity of equivaler length
of conductor. The joint shall not permit slipping off, damage to, or failure of the
complete conductor or any part thereof at a load less than 95% of the ultimate
tensile strength of the conductor.
5.2.2 The joint shall be made of Steel and aluminum sleeves for jointing the conductor.
The aluminum sleeve shall have aluminum of purity not less than 99.5%. If whole
of the sleeve is not to be compressed than tapered aluminum filler plugs shall also
be provided on the line of demarcation between compression and non-compresion
zone. The steel sleeve should not crack nor fail during compression. The Brinnel
Hardness of steel sleeve shall not exceed 160. The steel sleeve shall be hot dip
Galvanised. The dimensions and dimensional tolerances of mid span
compression joint shall be as per Table-III.
5.3 Repair Sleeve
Repair Sleeve of compression type shall be used to repair conductor with not
more than two strands broken in the outer layer. The sleeve shall be
manufactured from 99.5% pure aluminum and shall have a smooth surface. The
repair sleeve shall comprise of two pieces with a provision of seat for sliding of the
keeper piece. The edges of the seat as well as the keeper piece shall be so
rounded that the conductor strands are not damaged during installation. The
dimensions and dimensional tolerances of repair sleeve shall be as per Table-III.
5.4 Vibration Damper
5.4.1 Vibration dampers of 4R-stockbridge type with four (4) different resonances
spread with the specified aeolian frequency band width corresponding to wind
speed of 1m/s to 7 m/s shall be used at suspension and tension points on each
conductor in each span to damp out aeolian vibrations as mentioned herein after.
5.4.2 Alternate damping systems or offering equivalent or better performance also shall
be accepted provided the manufacturer meets the qualifying requirements
stipulated in the Specifications. Relevant technical documents to establish the
technical suitability of alternate systems shall be furnished by the Bidder along
with the bid.
5.4.3 One damper minimum on each side of conductor for suspension points and two
dampers minimum on each side of conductor for tension points shall be used.
Page-11
5.4.4 The Bidder may offer damping system involving more number of dampers per
ruling design span than the specified. However suitable price compensation shall
be considered for evaluation. For the purposed of price compensation 80% of the
towers as suspension locations and 20% of the towers as tension locations and all
the spans shall be assumed to be ruling design spans.
5.4.5 The clamp of the vibration damper shall be made of high strength aluminum alloy
of type LM-6 or equivalent. It shall be capable of supporting the damper and
prevent damage or chafing of the conductor during erection or continued
operation. The clamp shall have smooth and permanent grip to keep the damper
in position on the conductor without damaging the strands or causing premature
fatigue failure of the conductor under the clamp. The clamp groove shall be in
uniform contact with the conductor over the entire clamping surface except for the
rounded edges. The groove of the clamp body and clamp cap shall be smooth,
free form projections, grit or other materials which could cause damage to the
conductor when the clamp is installed. Clamping bolts shall be provided with self
locking nuts and designed to prevent corrosion of threads or loosening in service.
5.4.6 The messenger cable shall be made of high strength galvanized steel/stainless
steel with a minimum strength of 135 kg/sq mm. It shall be of preformed and
postformed quality in order to prevent subsequent droop of weight and to maintain
consistent flexural stiffness of the cable in service. The number of strands in the
messenger cable shall be 19. The messenger cable other than stainless steel
shall be hot dip galvanized in accordance with the recommendations of IS: 4826-
1979 for heavily coated wires.
5.4.7 The damper mass shall be made of hot dip galvanized mild steel/cast iron or a
permanent mould cast zinc alloy. All castings shall be free from defects such as
cracks, shrinkage, inclusions and blowholes etc. The surface of the damper
masses shall be smooth.
5.4.8 The damper clamp shall be casted over the messenger cable and offer sufficient
and permanent grip on it. The messenger cable shall not slip out of the grip at a
load less than the mass pull-off value of the damper. The damper masses made
of material other than zinc alloy shall be fixed to the messenger cable in a suitable
manner in order to avoid excessive stress concentration on the messenger cables
which shall cause premature fatigue failure of the same. The messenger cable
ends shall be suitably and effectively sealed to prevent corrosion. The damper
mass made of zinc alloy shall be casted over the messenger cable and have
sufficient and permanent grip on the messenger cable under all service
conditions.
5.4.9 The damper assembly shall be so designed that it shall not introduce radio
interference beyond acceptable limits.
5.4.10 The vibration damper shall be capable of being installed and removed from
energized line by means of hot line techniques. In addition, the clamp shall be
capable of being removed and reinstalled on the conductor at the designated
torque without shearing or damaging of fasteners.
Page-12
5.4.11 The manufacturer must indicate the clamp bolt tightening torque to ensure that the
slip strength of the clamp is maintained between 2.5 kN. and 5 kN. The clamp
when installed on the conductor shall not cause excessive stress concentration on
the conductor leading to permanent deformation of the conductor strands and
premature fatigue failure in operation.
5.4.12 The vibration damper shall not have magnetic power loss more than 1 watt at 500
Amps. 50 Hz alternating current in conductor.
5.4.13 The vibration analysis of the system, with and without damper and dynamic
characteristics of the damper as detailed under Annexure-A, shall have to be
submitted by the Bidder along with his bid. The technical particulars for vibration
analysis and damping design of the system are as follows.
………………………………………………………………………………………...
Sr. No. Description Technical Particulars
………………………………………………………………………………………...
ACSR ‘Zebra’ 61/3.18
1. Configuration
Single ACSR Zebra

Double Circuit conductor per
Phase in vertical
Formation
2. Span length in meters
(i) Ruling design span : 300 Meters
(ii) Maximum span : 1100 Meters
(iii) Minimum span : 100 Meters
3. Wind Zone : 4 (47 m/s)

As per IS:875-1987
4. Tensile Load in Conductor

At temperature of 0 deg. C : 3473 Kgf
And still air
5. Armour rods used : Standard preformed

: armour rods/AGS
6. Maximum permissible
dynamic strain : ± 150 microstrains
………………………………………………………………………………………...
Page-13
5.4.14 The damper placement chart for spans ranging from 100m to 1100m shall be
submitted by the Bidder. Placement charts should be duly supported with relevant
technical documents and sample calculations.
5.4.15 The damper placement charts shall include the following: -
(1) Location of the dampers for various combinations of spans and line
tensions clearly indicating the number of dampers to be installed per
conductor per span.
(2) Placement distances clearly identifying the extremities between which the
distances are to be measured.
(3) Placement recommendation depending upon type of suspension clamps

(viz Free centre type/Armour grip type etc.)
(4) The influence of mid span compression joints, repair sleeves and armour
rods (standard and AGS) in the placement of dampers.
5.5 Material and Workmanship
5.5.1 All the equipments shall be of the latest proven design and conform to the best
modern practice adopted in the extra high voltage field. The Bidder shall offer only
such equipment as guaranteed by him to be satisfactory and suitable for 66 kV
transmission line application and will give continued good performance.
5.5.2 The design, manufacturing process and quality control of all the materials shall be
such as to achieve requisite factor of safety for maximum working load, highest
mobility, elimination of sharp edges and corners, best resistance to corrosion and
a good finish.
5.5.3 All ferrous parts shall be hot dip galvanized, after all machining has been
completed. Nuts may, however, be tapped (threaded) after galvanising and the
threads oiled. Spring washers shall be electro galvanised. The bolt threads shall
be undercut to take care of increase in diameter due to galvanising. Galvanising
shall be done in accordance with IS: 2629-1985 and satisfy the tests mentioned in
IS: 2633-1986. Fasteners shall withstand four dips while spring washers shall
withstand three dips. Other galvanised materials shall be guaranteed to withstand
at least six dips each lasting one minute under the standard Preece test for
galvanising unless otherwise specified.
5.5.4 The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash, rust
stains, bulky white deposits and blisters. The zinc used for galvanising shall be of
grade Zn 99.95 as per IS: 209-1979.
Page-14
5.5.5 in case of castings, the same shall be from all internal defects like shrinkage inclusion,
blow holes, cracks etc.
5.5.6 All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum and localized heating phenomenon is averted.
5.5.7 No equipment shall have sharp ends or edges, abrasions or projections and shall not
cause any damage to the conductor in any way during erection or during continuous
operation which would produce high electrical and mechanical stresses in normal
working. The design of adjacent metal parts and mating surfaces shall be such as to
prevent corrosion of the contact surface and to maintain good electrical contact under
all service conditions.
5.5.8 Particular care shall be taken during manufacture and subsequent handling to ensure
smooth surface free from abrasion or cuts.
5.5.9 The fasteners shall conform to the requirements of IS: 6639-1972. All fasteners and
clamps shall have corona free locking arrangement to guard against vibration
loosening.
5.6 Compression Markings
Die compression areas shall be clearly marked on each equipment designed for
continuous die compressions and shall bear the words ‘COMPRESS FIRST’ suitably
inscribed on each equipment where the compression begins. If the equipment is
designed for intermittent die compressions, it shall bear the identification marks
‘COMPRESSION ZONE’ and ‘NON-COMPRESSION ZONE’ distinctly with arrow marks
showing the direction of compression and knurling marks showing the end of the zones.
The letters, number and other markings on finished equipment shall be distinct and
legible.
5.7 Bid Drawings
5.7.1 The successful Bidder shall submit 4 sets of following fully dimensional drawings
complete in all respect for approval to HVPNL as per time schedule given in Bar Chart:-
5.7.2 The drawings shall include:
i) Dimensions and dimensional tolerences.
ii) Material, fabrication details including any weld details and any specified
finishes and coatings. Regarding material, designations and reference of
standards are to be indicated.
iii) Catalogue No.
iv) Marking
v) Weight of assembly
vi) Installation Instructions
vii) Design installation torque for the bolt or cap screw.

Page-15
viii) Withstand torque that may be applied to the bolt or cap screw without
failure of component parts.
ix) The compression die number with recommended compression pressure.
x) All other relevant technical details.
5.7.3 Placement charts for Vibration damper
5.7.4 The above drawings shall be submitted in five copies with all the details as stated
above along with the bid document. After the placement of award, the
Manufacturer shall again submit the drawings in four copies to the HVPN for
approval.
Table-III
Dimensions & Dimensional Tolerances for Mid Span Compression

Joint and Repair Sleeve for ACSR Zebra Conductor
………………………………………………………………………………………
Sr. No. Item Dimension before Dimensions
Compression after compression
………………………………………………………………………………………
Inner Outer Length Corner Face
dia. dia. To to
Corner face
width width
(mm) (mm) (mm) (mm) (mm)
………………………………………………………………………………………
1. Mid Span 31±0.5 48±1 710±5. 47±0.5 41±0.5
Compression
Joint Aluminum
Sleeve
Steel Sleeve 10±0.2 20±0.5 240±5. 19±0.5 16±0.5
2. Repair Sleeve 31±0.5 48± 1 275±5. 47±0.5 41±0.5
………………………………………………………………………………………………………..
Page-16
6. EARTHWIRE ACCESSORIES FOR LINES
5.1 General
5.1.1 This portion details the technical particulars of the accessories for Galvanized
Steel Earthwire.
5.1.2 2.5% extra fasteners shall be supplied.
5.2 Mid Span Compression Joint
Mid Span Compression Joint shall be used for joining two lengths of earthwire.
The joint shall be made of mild steel with aluminium encasing. The steel sleeve
should not crack or fail during compression. The Brinnel Hardness of stainless
steel should not exceed 200. The steel sleeve shall be hot dip galvanized. The
aluminium sleeve shall have aluminium of purity not less than 99.5%. Filler
aluminium sleeve shall also be provided at the both ends. The joints shall not
permit slipping off, damage to or failure of the complete earthwire or any part
thereof at a load not less than 95% of the ultimate tensile strength of the
earthwire. The joint shall have resistivity less than 75% of resistivity of equivalent
length of earthwire. The dimensions and the dimensional tolerances of the joint
shall be as per the table given below: -
………………………………………………………………………………………...
Sr. No. Item Dimensions before Dimensions after
Compression Compression
………………………………………………………………………………………...
Inner Outer Length Corner Face
Dia. Dia. To to
Corner face
Width width
(mm) (mm) (mm) (mm) (mm)
………………………………………………………………………………………...
1. Aluminium
Sleeve 22±0.5 30±0.5 315±5 29.4±0.5 25.0±0.5
2. Steel
Sleeve 10±0.2 21±0.5 230±5 20.2±0.5 17.5±0.5
3. Filler
Aluminium
Sleeve 11.5±0.2 21±0.5 25±2 - -
…………………………………………………………………………………………………………..
Page-17
6.3 Vibration Damper
6.3.1 Vibration dampers of 4R-Stockbridge type with four (4) different frequencies
spread within the specified aeolian frequency band-width corresponding to wind
speed of 1m/s to 7 m/s shall be used for suspension and tension points on
earthwire in each span to dampout aeolian vibrations as mentioned hereinafter.
6.3.2 Alternate damping systems offering equivalent or better performance also shall be
acceptable provided the manufacturer meets the qualifying requirements
stipulated in the Specifications. Relevant technical documents to establish the
technical suitability of alternate systems shall be furnished by the Bidder along
with the bid.
6.3.3 One damper minimum on each side per earthwire at suspension points and two
dampers on each side at tension points shall be used.
6.3.4 The Bidder may offer damping system involving more number of dampers per
ruling design span than the specified. However suitable price compensation shall
be considered for evaluation. For the purpose of price compensation 80% of
towers as suspension towers and 20% of the towers as tension locations and all
the spans shall be assumed to be ruling design spans.
6.3.5 The clamp of the vibration damper shall made of aluminium alloy. It shall be
capable of supporting the damper during installation and prevent damage or
chafing of the earthwire during erection or continued operation. The clamp shall
have smooth and permanent grip to keep the damper in position on the earthwire
without damaging the strands or causing premature fatigue failure of the earthwire
under the clamp. The clamp groove shall be in uniform contact with the conductor
over the entire clamping surface except for the rounded edges. The groove of the
clamp body and clamp cap shall be smooth, free from projections, grit or materials
which could cause damage to the earthwire when the clamp is installed. Clamping
bolts shall be provided with self locking nuts designed to prevent corrosion of the
threads or loosening during service.
6.3.6 The messenger cable shall be made of high strength galvanized steel/stainless
steel with a minimum strength of 135 Kg/sq. mm. It shall be of preformed and post
formed quality in order to prevent subsequent droop of weights and to maintain
consistent flexural stiffness of the cable in service. The number of strands in the
messenger cable shall be 19. The messenger cable ends shall be suitably and
effectively sealed to prevent corrosion.
6.3.7 The damper mass shall be made of hot dip galvanized mild steel/cast iron or a
permanent mould cast zinc alloy. All castings shall be free from defects such as
cracks, shrinkages, inclusions and blow holes etc. The inside and outside
surfaces of the damper masses shall be smooth.
Page-18
6.3.8 The vibration analysis of the system, with and without damper, dynamic
characteristic of the damper as detailed under Annexure-A, shall have to be
submitted by the Bidder along with his bid. The technical particulars for vibration
analysis and damping design of the system are as follows: -
………………………………………………………………………………………...
Sr. No. Description Technical Particulars
………………………………………………………………………………………...
1. Configuration : One galvanized steel Earthwire
2. Span length in meters : 66 kV Line
(i) Ruling design : 200 Meters

span
(ii) Maximum span : 1100 meters
(iii) Minimum span : 100 meters
3. Wind Zone : 4
(47m/s)
As per IS: 875-1987
4. Tensile load in Earthwire

at temperature of 0 deg. C : 1240 Kgf
and still air :
5. Maximum permissible : +/- 150 micro strains

Dynamic strain :
………………………………………………………………………………………...
6.3.9 The damper placement chart for spans ranging from 100 m to 1100 m shall be
submitted by the Bidder. All the placement charts should be duly supported by
relevant technical documents.
6.3.10 The damper placement charts shall include the following: -
(1) Location of the dampers for various combinations of spans and line
tensions clearly indicating number of dampers to be installed per earthwire.
(2) Placement distances clearly identifying the extremities between which the
distances are to be measured.
(3) Placement recommendation depending upon type of suspension (viz, free

centre type/trunion type etc.)
(4) The influence of mid span compression joints in the placement of dampers.
Page-19
6.4 Flexible Copper Bond
The flexible copper bond shall be circular in cross-section of minimum 34 sq mm

equivalent copper area and not less than 500 mm in length. It shall consist of 259
wires of 0.417 mm dia. tinned copper conductor. It shall be laid up as 7 stranded
ropes, each of 37 bunched wires. The tinning shall be as per relevant Standard.
Two tinned copper connection lugs shall be press jointed to either of the flexible
copper cable. One lug shall be suitable for 12 mm, dia. Bolt and other for 16 mm
dia. bolt. The complete assembly shall also include one 16 mm dia. 40 mm long
HRH MS Bolt hot dip galvanized with nut and lock washer.
6.5 Suspension Clamp
6.5.1 Standard twisted shackle for earthwire suspension clamp shall be supplied
attaching to the hanger.
6.5.2 At all suspension towers, suitable suspension clamps shall be used to support
earthwire of 7/3.15 mm size. The clamps shall be of either free-centre type or
trunion and shall provide adequate area of support to the earthwire. The groove of
the camp shall be smooth, finished in an uniform circular or oval shape and shall
slope downwards in a smooth curve to avoid edge support and hence to reducing
the intensity of bending moment on earthwire.
6.5.3 There shall be no sharp point in the clamps coming in contact with earthwire.
There shall not be any displacement in the configuration of the earthwire strands
nor shall the strands be unduly stressed in final assembly during working
conditions.
6.5.4 The clamping piece and the clamp body shall be clamped by at least two U-bolts
of size not less than 10 mm diameter having one nut and one 3 mm thick lock nut
with washer on each of its limbs. Suspension clamps shall be provided with
invented type U-bolts. One limb of the U-bolts shall be long enough to
accommodate the lug of the flexible copper bond.
6.5.5 The Manufacturer shall supply al the components of the suspension assembly
including shackles, bolts, nuts, washers, split pin etc. The total drop of suspension
assembly from the centre point of the attachment to the centre point of the
earthwire shall not exceed 150 mm. The design of the assembly shall be such that
the direction of run of the earthwire shall be same as that of the conductor.
6.5.6 The complete assembly shall be guaranteed for slip strength not less than 9 kN
and not more than 14 kN. The breaking strength of the assembly shall not less
than 25 kN.
6.6 Tension Camp
6.6.1 At all tension towers suitable compression type tension clamps shall be used to
hold 7/3.15 mm galvanized steel earthwire. Anchor shackle shall be supplied
which shall be suitable for attaching the tension clamp to strain plates.
6.6.2 The clamps shall have adequate area of bearing surface to ensure positive
electrical and mechanical contact and shall not permit any slip to the earthwire
under working tension and vibration conditions. The angle of jumper terminal to be
mounted should be 30 deg. with respect to the vertical line.
Page-20
6.6.3 The clamps shall be made of mild steel with aluminum encasing. The steel should
not crack or fail during compression. The Brinnel hardness of steel sleeve shall
not exceed 200. The steel sleeve shall be hot dip galvanized. The aluminum
encasing shall have aluminum of purity not less than 99.5% Filler aluminum
sleeve shall also be provided at the end.
6.6.4 The complete assembly shall be so designed as to avoid undue bending in any
part of the clamp and shall not produce any hindrance to the movements of the
clamps in horizontal or vertical directions.
6.6.5 The slip strength of the assembly shall not be less than 95% of the ultimate
strength of the earthwire.
6.6.6 The clamps shall be complete with all the components including anchor shackle
bolts, nuts, washers, split pin, jumper arrangement etc.
6.7 Material and Workmanship
Same as Clause 5.5 of this part of this section.
6.8 Compression Marking
6.9 Bid Drawings
7. Tests and Standards
7.1 The acceptance and routine tests and tests during manufacture shall be carried
out. For the purpose of this clause, the following shall apply: -
7.1.1 Acceptance Tests shall mean those tests, which are to be carried out on
samples taken from each lot offered for pre-despatch inspection for the
purpose of acceptance of that lot.
7.1.2 Routine Tests shall mean those tests, which are to be carried out on each item of
the material to check requirements, which are likely to vary during production.
7.1.3 Tests during Manufacture shall mean those tests, which are to be carried out
during the process of manufacture and end inspection by the HVPNL to ensure
the desired quality of the end product to be supplied by him.
7.1.4 For all acceptance tests, the acceptance values shall be the values guaranteed by
the Bidder in the data requirement sheets of this proposal or the acceptance value
specified in this Specification, whichever is more stringent for that particular test.
Page-21
7.2 Type Tests
The equipment should be offered type tested. Test reports should not be more
than seven years old reckoned from the date of bid opening in respect of all the
tests carried out in accredited laboratories ( based on ISO/IEC) by a reputed
accreditatic body or witnessed by HVPNL or another electric power utility and be
submitted by the successful Bidder to HVPNL for approval as per schedule
givenin Bar chart.
7.2.1 On Suspension Hardware Fittings only:
a. Slip strength test )

b. Mechanical test )
c. Verifications of dimensions ) IS: 2486 (Part-I)
d. Galvanizing )
e. Visual examination test )
f. Tensile Strength test )

g. Electrical resistance test )
h. Bend test for Armour Rod Set ) IS: 2121 (Part-I)
i. Resilient test for Armour Rod Set )
7.2.2 On Tension Hardware Fittings only: -
a. Slip strength test )

b. Mechanical test )
c. Verifications of dimensions ) IS: 2486 (Part-I)
d. Galvanizing )
e. Visual examination test )
f. Electrical Resistance test )
g. Heating cycle test )
7.2.3 Mid Span Compression Joint for Conductor and Earthwire:
a. Visual Examination )
b. Dimensional verification )
c. Failling Load test/Slip Strength test )
d. Electrical Resistance test )
e. Heating cycle test (Not Applicable for ) IS: 2121 (Part-II & III)
Earthwire) )
f. Galvanizing test )
g. Chemical composition test )
7.2.4 Repair Sleeves for Conductor:
b. Dimensional verification )
c. Failing Load set ) IS: 2121 (Part-II)
d. Electrical Resistance test )
Page-22
7.2.5 Flexible Copper Bond:
a. Visual Examination & Dimensional )

Verification )
b. Slip Strength test )
c. Chemical composition test ) IS: 2121 (Part-III)
d. Galvanizing test )
7.2.6 Vibration Damper for Conductor & Earthwire:
a. Visual examination )
b. Verification of dimensions )
c. Resonance frequency test )
d. Fatigue test )
e. Mass pull off test )
f. Dynamic characteristics test ) IS: 9708-1993
g. Damping efficiency test )
h. Clamp slip test )
i. Clamp bolt torque test )
j. Galvanizing/electroplating test )
k. Magnetic power loss test )
7.2.7 Earthwire Suspension Clamp Assembly:
a. Visual examination & Dimensional )

verification )
b. Slip strength test )
c. Mechanical strength test ) IS: 2121 (Part-III)
d. Chemical composition test )
e. Galvanizing test )
7.2.8 Earth Tension Clamp Assembly:
a. Visual examination & Dimensional )

verification )
b. Electrical resistance test )
c. Mechanical strength test ) IS: 2121(Part-III)
d. Chemical composition test )
e. Galvanizing test )
Page-23
7.3 Acceptance Tests
7.3.1 On Both Suspension and Tension Hardware Fittings
) IS: 2486-(Part-I)
b. Verification of dimensions ) Clause 5.8& 5.9
)
c. Galvanizing/Electroplating test )
d. Mechanical strength test of each component )

(excluding arcing horn) ) Annexure-A
)
e. Mechanical Strength test of welded joint )
f) Mechanical strength test for corona ) BS: 3288-(Part-I)

control rings/grading ring and arcing horn ) Clause 7.3.2
g. Test on locking device for ball and socket ) IEC:372 (2)-1984

coupling )
h. Chemical analysis, hardness tests, )

grain size, inclusion rating & magnetic ) Annexure-A
particle inspection forgings /castings )
7.3.2 On Suspension Hardware Fittings Only
a. Clamp Slip strength Vs Torque ) Annexure-A

test for suspension clamp )
)
b. Shore hardness test of )
Elastomer cushion for AG )
Suspension clamp )
c. Bend test for Armour rod set ) IS: 2121 (Part-I)

) Clause 7.5, 7.10,7.11
d. Resilience test for Armour )
Rod set )
)
e. Conductivity test for Armour )
rods set )
7.3.3 On Tension Hardware Fittings Only
a. Slip strength test for ) IS:2486 (Part-I)

Dead end assembly ) 1971,Clause 5.4
7.3.4 Mid Span Compression Joint for Conductor and Earthwire

a. Visual examination and dimensional ) IS: 2121 (Part-II)
verification ) Clause 6.2, 6.3 & 6.7
)
b. Galvanizing test )
c. Hardness test ) Annexure-B

Page-24
7.3.5 Repair Sleeve for Conductor
a. Visual examination and ) IS: 2121 (Part-II)

dimensional verification ) Clause 6.2, 6.3.
7.3.6 Flexible Copper Bond
a. Visual examination and ) IS: 2121 (Part-II)

dimensional verification ) Clause 6.2, 6.3.
b. Slip strength test ) Annexure-B
7.3.7 Vibration Damper for Conductor and Earthwire
a. Visual examination and )

dimensional verification )
) IS: 2121 (Part-II)
) Clause 6.2, 6.3, & 6.7
)
)
i. On damper masses )
)
ii. On messenger cable )
c. Verification of resonance )
frequencies )
) Annexure-B
d. Clamp slip test )
)
e. Clamp bolt torque test )
)
f. Strength of the messenger )
cable )
g. Mass pull off test )

) Annexure-B
h. Dynamic characteristics test )
(To be conducted as a special test
once against complete supply)
7.3.8 Earthwire Suspension Clamp Assembly
a. Visual examination and ) IS; 2121 (Part-II)

dimensional verification )
)
c. Clamp slip strength test )

) Annexure-A
d. Mechanical strength test )
on each component )
Page-25
7.3.9 Earthwire Tension Clamp Assembly
a. Visual examination and )

dimensional verification ) IS: 2121 (Part-II)
)
)
c. Slip strength test ) Annexure-A

for tension clamp )
)
d. Mechanical strength )
test on each component )
(excluding clamp) )
)
e. Hardness test )
7.4 Routine Tests
7.4.1 For Hardware Fittings
a. Visual examination ) IS: 2486 (Part-I) 1971
b. Proof Load Test ) Annexure-A
7.4.2 For Conductor and Earthwire Accessories
a. Visual examination and ) IS: 2121 (Part-II)1981

dimensional verification ) Clause 6.2 & 6.3
7.5 Tests During Manufacture
a. Chemical analysis )
of zinc used for )
galvanizing )
)
)
b. Chemical analysis )
mechanical metallographic )
test and magnetic particle ) Annexure-A
inspection for malleable )
castings. )
)
c. Chemical analysis )
hardness tests and )
magnetic particle )
inspection for forgings )
Page-26
The entire cost of acceptance and routine tests and tests during manufacture specified
herein shall be treated as included in the quoted Ex-works/price except for the expenses
of the Inspector/HVPNL representative.
9.0 Schedule of Testing and Additional Tests

9.1 The Bidder has to indicate the schedule of following activities in their bids.
9.2 The HVPNL reserves the right of having at his own expense another test(s) of
reasonable nature carried out at Manufacturer’s premises, at site, or in any other place in
addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
material comply with the specifications.
9.3 The HVPNL also reserves the right to conduct all the tests mentioned in this specification
at his own expense on the samples drawn from the site at Manufacturer’s premises or at
any other test center. In case of evidence of non compliance, it shall be binding on the
part of Manufacturer to prove the compliance of the items to the technical specifications
by repeat tests, or correction of deficiencies, or replacement of defective items all without
any extra cost to the HVPNL.
9.4 Co-ordination for testing
The Manufacturer shall have to co-ordinate testing of hardware fittings with insulators
and shall have to also guarantee overall satisfactory performance of the hardware fittings
with the insulators.
9.5 Tests Reports
9.5.1 Record of routine test report shall be maintained by the Manufacturer at his
works for periodic inspection by the HVPNL representative.
9.5.2 Test certificates of tests during manufacture shall be maintained by the

Manufacturer. These shall be produced for verification as and when desired by
the HVPNL.
9.6 Inspection
9.6.1 The HVPNL representative shall at all times be entitled to have access to the works and
all places of manufacture, where the material and/or its component parts shall be
manufactured and the representatives shall have full facilities for unrestricted inspection
of the Manufacturer’s, sub-Manufacturer’s works, raw materials, manufacturer’s of all the
material and for conducting necessary tests as detailed herein.
9.6.2 The material from final inspection shall be offered by the Manufacturer only under
packed condition as detailed in clause 5.12 of this part of the Specification. The engineer
shall select samples at random from the packed lot for carrying out acceptance tests.The
Manufacturer shall keep the HVPNL informed in advance of the time of starting and of
the progress of manufacture of material in its various stages so that arrangements could
be made for inspection.
Page-27
9.6.3 Material shall not be despatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the
HVPNL in writing. In the latter case also the material shall be despatched only
after all tests specified herein have been satisfactorily completed.
9.6.4 The acceptance of any quantity of accessories shall in no way relieve the
Manufacturer of his responsibility for meeting all the requirements of the
Specification, and shall not prevent subsequent rejection, if such material are later
found to be defective.
9.7.1 All material shall be packed in strong and weather resistant wooden cases/crates.
The gross weight of the packing shall not normally exceed 200 kg to avoid
handling problems.
9.7.2 The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field.
9.7.3 Suitable cushioning, protective padding, dunnage or spacers shall be provided to

9.7.4 Bolts, nuts, washers, cotter pins, security clips and split pins etc. shall be packed
duly installed and assembled with the respective parts and suitable measures
shall be used to prevent their loss.
9.7.5 Each component part shall be legibly and indelibly marked with trademark of the
manufacturer and year of manufacture.
9.7.6 All the packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and to avoid the possibility of goods being lost or
wrongly despatched on account of faulty packing and faulty or illegible markings.
Each wooden case/crate shall have all the markings stencilled on it in indelible
ink.
10 Standard
10.1 The Hardware fittings; conductor and earthwire accessories shall conform to
the following Indian/International Standard which shall mean latest revisions,
with amendments/changes adopted and published, unless specifically stated
otherwise in the Specification.
Page-28
10.2 In the event of the supply of hardware fittings, accessories conforming to standards
other than specified, the Bidder shall confirm in his bid that these standards are
equivalent to those specified. In case of award, salient features of comparison between
the Standards proposed by the Manufacturer and those specified in this document will
be provided by the Manufacturer to establish their equivalence.
……………………………………………………………………………………………
Sr. No. Indian Standard Title International
Standards
……………………………………………………………………………………………
1. IS: 209-1992 Specification for BS: 3436-

Zinc 1986
2. IS: 398-1992 Specification for IEC: 1089-

Aluminium condu- 1991
ctors for Overhead
Transmission purpose
Part-V Aluminum Conductor IEC: 1089-

Galvanised Steel- 1991
Reinforced for
Extra High Voltage
(400 kV ) and above
3. IS: 1573-1976 Electroplated Coat-

ing of Zinc on Iron
and Steel.
4. IS: 2121-1981 Specification for

Part-I Conductor and
Earthwire Accessories
For Overhead Power
Line.
Part-II Mid span joints and

Repair Sleeves for
Conductors
5. IS: 2486 Specification for

Insulator Fittings for
Overhead power line
With Nominal voltage
Greater than 1000 V
Part-I, 1991 General requirements

And tests
6. IS: 2629-1990 Recommended Practice

for Hot Dip Galvanising
of Iron and Steel
Page-29
7. IS: 2633-1990 Method of Testing Uniformity
of Coating on Zinc Coated
Articles
8. Ozone test on Elastomer ASTM-D1171
9. Tests on insulators of IEC:383-1993

Ceramic material or glass
For overhead line with a
Nominal voltage greater
Than 1000 V
10. IS: 4826-1992 Galvanized Coating ASTM A472-

on rounded steel wires 729 BS: 443-
1969
11. IS: 6745-1990 Methods of Determi- BS: 433-1969

nation of weight of ISO: 1460
zinc coating of zinc
coated iron and steel
articles
12. IS: 6639-1990 Hexagonal bolts for ISO/R272

steel structures 1968
13. IS: 9708-1980 Specification for stock

bridge vibration dampers
for overhead power line
14. IS: 8263-1990 Method of radio interfere- IEC: 437-1973

nce tests on high voltage NEMA: 107-1964
insulators. CIS PR
Page-30
……………………………………………………………………………………………………
……………………………………………………………………………………………………

UK

Switzerland
BIS/IS Bureau of Indian Standards,

110001, INDIA

Standardising Sraat, Aurehoegvej-
12
DK-2900, Heeleprup, DENMARK.

New York, NY 10017
U.S.A.
Page-31
ANNEXURE-A
TYPE TEST
1.0 Test on Complete Strings with Hardware Fittings
1.1 Voltage Distribution Test For Insulator String with Disc Insulators
The voltage across each insulator unit shall be measured by sphere gap method.
The result obtained shall be converted into percentage. The voltage across any
disc shall not exceed 20% for suspension insulator strings and 22% for tension
insulator strings.
1.2 Mechanical Strength Test
The complete insulator string along with its hardware fitting excluding arcing horns
and suspension assembly/dead end assembly shall be subjected to a load equal
to 50% of the specified minimum ultimate tensile strength (UTS) which shall be
increased at a steady rate to 67% of the minimum UTS specified. The load shall
be held for five minutes and then removed. After removal of the load, the string
components shall not show any visual deformation and it shall be possible to
disassemble them by hand. Hand tools may be used to remove cotter pins and
loosen the nuts initially. The string shall then be reassembled and loaded to 50%
of UTS and the load shall be further increased at a steady rate till the specified
minimum UTS and held for one minute. No fracture should occur during this
period. The applied load shall then be increased until the failing load is reached
and the value recorded.
1.3 Vibration Test
The suspension string shall be tested in suspension mode, and tension string in
tension mode itself in laboratory span of minimum 30 metres. In the case of
suspension string a load equal to 600 kg shall be applied along the axis of the
hardware fittings and conductors tensioned at 2530 kgf in respect of 66kV strings
with ACSR Panther Conductor shall be secured with clamps. The system shall be
suitable to maintain constant tension on conductor throughout the duration of the
test. Vibration dampers shall not be used on the test span. The conductor shall be
vertically vibrated at one of the resonance frequencies of the insulators string
(more than 10 Hz) by means of vibration inducing equipment. The peak to peak,
displacement in mm of vibration at the antinode point nearest to the string shall be
measured and the same shall not be less than 1000/f 1.8 where f is the frequency
of vibration in cycles/sec. The insulator string shall be vibrated for not less than 10
million cycles without any failure. After the test the disc insulators shall be
examined for looseness of pins and cap or any crack in the cement. The hardware
shall be examined for looseness, fatigue failure and mechanical strength test.
There shall be no deterioration of properties of hardware components and
insulators after the vibration test. The insulators shall be subjected to the following
tests as per relevant standards:
Page-32
Tests Percentage of insulator
Units to be tested
Disc
a) Temperature cycle test 60

followed by mechanical
performance test
b) Puncture test 40
2. Tests on Hardware Fittings
2.1 Magnetic Power Loss Test for Suspension Assembly
One hollow aluminum tube of diameter equivalent to conductor Dia shall be placed. An
alternating current over the range of 200 to 500 amps for ACSR Panther shall be passed
through the tube. The reading of the wattmeter with and without suspension assemblies
shall be recorded. Not less than three suspension assemblies shall be tested. The
average power loss for suspension assembly shall be plotted for each value of current.
The value of the loss corresponding to 350 amperes for 66kV Suspension assembly shall
be read off from the graph.
2.2 Galvanising/Electroplating Test
The test shall be carried out as per Clause no. 5.9 of IS: 2486 (Part-I) 1972 except that
both uniformity of zinc coating and standard preece test shall be carried out and the
results obtained shall satisfy the requirements of this specification.
2.3 Mechanical Strength Test of Each Component
Each component shall be subjected to a load equal to the specified minimum ultimate
tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum
UTS specified. The load shall be held for five minutes and then removed. The
component shall then again be loaded to 50% of UTS and the load shall be further
increased at a steady rate till the specified UTS and held for one minute. No fracture
should occur. The applied load shall then be increased until the failing load is reached
and the value recorded.
2.4 Mechanical Strength Test of Welded Joint
The welded portion of the component shall be subjected to a Load of 2000 kgs for one
minute. Thereafter, it shall be subjected to die penetratration/ultrasonic test. There shall
not be any crack at the welded portion.
Page-33
2.5 Clamp Slip Strength Vs Torque Test for Suspension Clamp
The suspension assembly shall be vertically suspended by means of a flexible
attachment. A suitable length of Conductor shall be fixed in the clamp. The clamp slip
strength at various tightening torques shall be obtained by gradually applying the load at
one end of the conductor. The clamp slip strength vs torque curve shall be drawn. The
above procedure is applicable only for free centre type suspension clamp. For AG
suspension clamp only clamp slip strength after assembly shall be found out. The clamp
slip strength at the recommended tightening torque shall be more than 11 kN but less
than 16 kN.
2.6 Shore Hardness Test for Elastomer Cushion for AG Suspension Assembly
The shore hardness at various points on the surface of the elastomer cushion shall be
measured by a shore hardness meter and the shore hardness number shall be
between 65 to 80.
2.7 Proof Load Test
Each component shall be subjected to a load equal to 50% of the specified minimum
ultimate tensile strength which shall be increased at a steady rate to 67% of the
minimum UTS specified. The load shall be held for one minute and then removed. After
removal of the load the component shall not show any visual deformation.
2.8 Tests for Forging Casting and Fabricated Hardware
The chemical analysis, hardness test, grain size, inclusion rating and magnetic particle
inspection for forging, castings and chemical analysis and proof load test for fabricated
hardware shall be as per the internationally recognized procedures for these tests. The
sampling will be based on heat number and heat treatment batch. The details regarding
test will be as in the Quality Assurance programme.
2.9 Mechanical Strength Test for Suspension/Tension Hardware Fittings
The complete string without insulators excluding arcing horn, and suspension
assembly/dead end assembly shall be subjected to a load equal to 50% of the specified
minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to
67% of the minimum UTS specified. This load shall be held for five minutes and then
removed. After removal of the load, the string component shall not show any visual
deformation and it shall be possible to disassemble them by hand. Hand tools may be
used to remove cotter pins and loosen the nuts initially. The string shall then be
reassembled and loaded to 50% of UTS and the load shall be further increased at a
steady rate till the specified minimum UTS is reached and held for the one minute. No
fracture should occur during this period. The applied load shall then be increased until
the failing load is reached and the value recorded.
2.10 Ozone Test for Elastomer
This test shall be performed in accordance with ASTM D-1171 by the Ozone chamber
exposure method (method B). The test duration shall be 500 hours and the ozone
concentration 50 PPHM. At the test completion, there shall be no visible crack under a
2 x magnification.
Page-34
3.1 Mid Span Compression Joint for Conductor and Earthwire
(a) Slip Strength Test
The fitting compressed on conductor/earthwire shall not be less than one metre in
length. The test shall be carried out as per IS: 2121-(Part-II)-1981 clause 6.4
except that the load shall be steadily increased to 95% of minimum ultimate
tensile strength of conductor/earthwire and retained for one minute at this load.
There shall be no movement of the conductor/earthwire relative to the fittings and
no failure of the fittings during this one minute period.
3.2 Flexible Copper Bond
(a) Slip Strength Test
On applying a load of 3 kN between the two ends, stranded flexible copper cable
shall not come out of the connecting lugs and none of its strands shall be
damaged. After the test, the lugs shall be cut open to ascertain that the gripping of
cable has not been affected.
3.3 Vibration Damper for Conductor
(a) Dynamic Characteristics Test
The damper shall be mounted with its clamp tightened with torque recommended
by the manufacturer on shaker table capable of simulating sinusoidal vibrations for
aeolian vibration frequency band ranging from 8 to 60Hz for damper for conductor.
The damper assembly shall be vibrated vertically with a ± 1 mm amplitude from 5
to 15 Hz frequency and beyond 15 Hz at ± 0.5 mm to determine following
characteristics with the help of suitable recording instruments:
i. Force Vs frequency
ii. Phase angle Vs frequency
iii. Power dissipation Vs frequency
The Force Vs frequency curve shall not show steep peaks at resonance frequencies and
deep troughs between the resonance frequencies. The consonance frequencies shall be
suitably spread within the aeolian vibration frequency-band between the lower and upper
dangerous frequency limits determined by the vibration analysis of conductor/earthwire
without dampers.
Acceptance criteria for vibration damper.
(i) The above dynamic characteristics test on five damper shall be conducted.
(ii) The mean reactance and phase angle Vs frequency curves shall be drawn with
the criteria of best fit method.
Page-35
(iii) The above mean reactance response curve should lie within 0.099f to 0.495f
Kgf/mm limits for ACSR Panther conductor damper
(iv) The above mean phase angle response curve shall be between 25 0 to 1300 within
the frequency range of interest.
(v) If the above curve lies within the envelope, the damper design shall be considered
to have successfully met the requirement.
(vi) Visual resonance frequencies of each mass of damper is to be recorded and to be

compared with the guaranteed values.
(b) Vibration Analysis
The vibration analysis of the conductor/earthwire shall be done with and without
damper installed on the span. The vibration analysis shall be done on a digital
computer using energy balance approach. The following parameters shall be
taken into account for the purpose of analysis:
(i) The analysis shall be done for single conductor/earthwire without armour
rods as per the parameters given under clause 2.4.13 and 3.3.8 of this part
of the Specification. The tension shall be taken as 2530 kgf for ACSR
Panther for a span ranging from 100m to 1100m.
(ii) The self damping factor and flexural stiffness (EI) for conductor shall be
calculated on the basis of experimental results. The details for
experimental analysis with these data should be furnished.
(iii) The power dissipation curve obtained from Dynamic Characteristics Test
shall be used for analysis with damper.
(iv) Examine the Aeolian vibration level of the conductor/earthwire with and
without vibration damper installed at the recommended location or wind
velocity ranging from 0 to 30 Km per hour, predicting amplitude, frequency
and vibration energy input.
(v) From vibration analysis of conductor without damper, antinode vibration

amplitude and dynamic strain levels at clamped span extremities as well
as antinodes shall be examined and thus lower and upper dangerous
frequency limits between which the Aeolian vibration levels exceed the
specified limits shall be determined.
(vi) From vibration analysis of conductor with damper/dampers installed at the

recommended location, the dynamic strain level at the clamped span
extremities, damper attachment point and the antinodes on the
conductor/earthwire shall be determined. In addition to above damper
clamp vibration amplitude and antinode vibration amplitudes shall also be
examined.
The dynamic strain levels at damper attachment points, clamped span

extremities and antinodes shall not exceed the specified limits. The damper
clamp vibration amplitude shall not be more than that of the specified
fatigue limits.
Page-36
(c) Clamp Slip and Fatigue Tests
(i) Test Set Up
The clamp slip and fatigue tests shall be conducted on a laboratory set up
with a minimum effective span length of 30m. The conductor shall be
tensioned at 2530 kgf and shall not be equipped with protective armoured
rods at any point. Constant tension shall be maintained within the span by
means of lever arm arrangement. After the conductor/earthwire has been
tensioned, clamps shall be installed to support the conductor at both ends
and thus influence of connecting hardware fittings are eliminated from the
free span. The clamps shall not be used for holding the tension on the
conductor/earthwire. There shall be no loose parts, such as suspension
clamps, U bolts, on the test span supported between clamps mentioned
above. The span shall be equipped with vibration inducting equipment
suitable for producing steady standing vibration. The inducting equipment
shall have facilities for step less speed control as well as stepless
amplitude arrangement. Equipment shall be available for measuring the
frequency, cumulative number of cycles and amplitude of vibration at any
point along the span.
(ii) Clamp Slip Test
The vibration damper shall be installed on the test span. The damper
clamp, after tightening with the manufacturer’s specified tightening torque,
when subjected to a longitudinal pull of 2.5 kN parallel to the axis of
conductor for a minimum duration of one minute shall not slip i.e. the
permanent displacement between conductor/earthwire and clamp
measured after removal of the load shall not exceed 1.0 mm. The load shall
be further increased till the clamp starts slipping. The load at which the
clamp slips shall not be more than 5 kN.
(iii) Fatigue Test
The vibration damper shall be installed on the test span with the
manufacturer’s specified tightening torque. It shall be ensured that the
damper shall be kept minimum three loops away from the shaker to
eliminate stray signals influencing damper movement.
The damper shall then be vibrated at the highest resonant frequency of

each damper mass. For dampers involving torsional resonant frequencies
tests shall be done at torsional modes also in addition to the highest
resonant frequencies at vertical modes. The resonance frequency shall be
identified as the frequency at which each damper mass vibrates with the
maximum amplitude on itself. The amplitude of vibration of the damper
clamp shall be maintained not less than ± 25/f mm, where f is the frequency
in Hz.
The test shall be conducted for minimum ten million cycles at each
resonant frequency mentioned above. During the test if resonance shift is
observed the test frequency shall be tuned to the new resonant frequency.
Page-37
The clamp slip test as mentioned hereinabove shall be repeated after
fatigue test without retorquing or adjusting the damper clamp, and the
clamp shall withstand a minimum load equal to 80% of the slip strength for
a minimum duration of one minute.
After the above tests, the damper shall be removed from conductor and
subjected to dynamic characteristics test. There shall not be any major
deterioration in the characteristic of the damper. The damper then shall be
cut open and inspected. There shall not be any broken, loose, or damaged
part. There shall not be significant deterioration or wear of the damper. The
conductor/earthwire under clamp shall also be free from any damage.
For the purpose of acceptance, the following criteria shall be applied.
(1) There shall not be any frequency shift by more than ± 2 Hz for
frequencies lower than 15 Hz and ± 3 Hz for frequencies higher than
15 Hz.
(2) The force response curve shall generally lie within guaranteed %
variation in reactance after fatigue test in comparison with that
before fatigue test by the Manufacturer.
(3) The power dissipation of the damper shall not be less than
guaranteed % variation in power dissipation before fatigue test by
the Manufacturer. However, it shall not be less than minimum power
dissipation which shall be governed by lower limits of reactance and
phase angle indicated in the envelope.
3.4 Magnetic Power Loss Test for Vibration Damper
The sample involving ferrous parts shall be tested in a manner to simulate

service conditions for 50 Hz pure sine-wave. The test should be carried out
at various currents ranging from 200 to 500 amperes and the magnetic
power loss at various currents should be specified in tabulated graphical
form. The difference between the power losses without and with sample at
room temperature shall be limited to 1 watt for 350 amperes. The losses
shall be determined by averaging the observations obtained from at least
four samples.
3.5 Chemical Analysis Test
Chemical analysis of the material used for manufacture of items shall be

conducted to check the conformity of the same with Technical Specification
and approved drawing.
Page-38
4. Test on All components (As applicable)
Samples taken from the zinc ingot shall be chemically analysed as per IS:
209-1979. The purity of zinc shall not be less than 99.95%.
The chemical analysis, hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognized procedures for these
tests. The sampling will be based on heat number and heat treatment
batch. The details regarding test will be as discussed and mutually agreed
to by the Manufacturer and HVPNL in Quality Assurance Programme.
4.3 Tests on Castings
The chemical analysis, mechanical and metallographic tests and magnetic

particle inspection for castings will be as per the internationally recognized
procedures for these tests. The samplings will be based on heat number
and heat treatment batch. The details regarding test will be as discussed
and mutually agreed to by the Manufacturer and HVPNL in Quality
Assurance Programme.
Page-39
ANNEXURE-B
Acceptance Tests
1. Mid Span Compression Joint for Conductor and Earthwire
(a) Hardness Test
The Brinnel hardness at various points on the steel sleeve of conductor

core and of the earthwire compression joint and tension clamp shall be
measured.
2. Flexible Copper Bond
(b) Slip Strength Test
Same as clause 3.2 (a) of Annexure-A.
3. Vibration Damper for Conductor
(a) Verification of Reasonance Frequencies
The damper shall be mounted on a shaker table and vibrate at damper

clamp displacement of +/0.5 mm to determine the resonance frequencies.
The resonance shall be visually identified as the frequency at which
damper mass vibrates with maximum displacement on itself. The
resonance frequency thus identified shall be compared with the guaranteed
value. A tolerance of ± 1 Hz at a frequency lower than 15 Hz and ± 2 Hz at
a frequency higher than 15 Hz only shall be allowed.
(b) Clamp Slip Test
Same as Clause 3.3 (c) (ii) of Annexure –A.
(c) Clamp Bolt Torque Test
The clamp shall be attached to a section of the conductor/earthwire. A

torque of 150 % of the manufacturer’s specified torque shall be applied to
the bolt. There shall be no failure of component parts. The test set up is as
described in Clause 3.3 (c) (i), Annexure-A.
(d) Strength of the Messenger Cable
The messenger cable shall be fixed in a suitable tensile testing machine

and the tensile load shall be gradually applied until yield point is reached.
The load shall be not less than the value guaranteed by the Manufacturer.
Page-40
(e) Mass Pull of Test
Each mass shall be pulled off in turn by fixing the mass in one jaw and the
clamp in the other of a suitable tensile testing machine. The longitudinal
pull shall be applied gradually until the mass begins to pull out of the
messenger cable. The pull off loads shall not be less than the value
guaranteed by the Manufacturer.
(f) Dynamic Characteristics Test
The test will be performed as acceptance test with the procedure

mentioned for type test with sampling mentioned below: -
Vibration Damper of - 1 Sample for 1000 Nos. & below.

Conductor
- 3 Samples for lot above 1000 & up to
5000 nos.
- Additional 1 sample for every additional

1500 pieces above 5000.
The Acceptance criteria will be as follows :
(i) The above dynamic characteristics curve for reactance & phase angle will
be done for frequency range of 8 Hz to 60 Hz for vibration damper for
conductor
(ii) If all the individual curve for dampers are within the envelope as already
mentioned for type test for reactance & phase angle, the lot passes the
test.
(iii) If individual results do not fall within the envelope, averaging of

characteristics shall be done.
(a) Force of each damper corresponding to particular frequency shall be

taken & average force of three dampers at the frequency calculated.
(b) Similar averaging shall be done for phase angle.
(c) Average force Vs frequency and average phase Vs frequency

curves shall be plotted on graph paper. Curves of best fit shall be
drawn for the entire frequency range.
(d) The above curves shall be within the envelope specified.
Page-41
STANDARD FIELD QUALITY PLAN FOR TRANSMISSION LINES
page 1
S. Description of Items to be Checked Tests/Checks to be Ref. documents Check/Testing Counter Check/Test by HVPNL Accepting
No. Activity done authority
Agency Extent
1. Detailed Survey a. Route alignment Optimization of route a. Preliminary survey. Bidder 100% at Field 100% based on record documents Engineer-in-
length charge of HVPNL
b. Topographical map
c. Tower spotting data
b. Route profiling & 1. Ground clearance. a. Sag template Bidder 100% at Field 100% based on record Engineer-in-
documents
tower spotting. 2. Cold wt. Span charge of HVPNL
-do- -do-
-do-
3. Hot wt. Span b. Tower Spotting data -do- -do-
-do-
4. Sum of Adj. Span c. Route alignment -do- -do-
(wind span)
-do-
5. Angle of
Deviation. -do- -do-
2. Check Survey Tower Location & i) Alignment a. Route alignment Bidder 100% at Field i) All angle towers in plains Engineer-in-
and 50% in hilly terrains.
Final Length charge of HVPNL
ii) Final Length b. Tower Schedule -do- -do-
ii) Final length to be checked
c. Profile on 100% basis based on
records/documents
3. Tower
Foundation
A. Materials 1. Source approval Source meeting HVPNL Bidder As proposed by Bidder To verify the proposal based Engineer-in-
1. Cement Specification/Approved on the supply made and
charge of HVPNL
vendor factory test results.
( 43 grade) as per
Annexure-A
Agency Extent
2. Physical tests As per document at Samples to be taken Review of all MTC’s 100% review of lab test results Engineer-in-
Annexure-A of this FQP jointly with HVPNL and one sample for charge of HVPNL
and tested at HVPNL every 500 MT
approved lab
3. Chemical Tests -do- Bidder to submit 100% review of MTC 100% review of MTC Engineer-in-
Chemical MTC by Bidder charge of HVPNL
composition of
Cement
2. Reinforcement 1. Source approval To be procured from Bidder As proposed by Bidder To review the proposal based Engineer-in-
on the documents.
Steel main producers only. charge of HVPNL
2. Physical and As per annexure-B Bidder to submit MTC All MTC’s 100% review of MTC Engineer-in-
Chemical analysis charge of HVPNL
test
3. Coarse 1. Source approval Source meeting HVPNL Bidder Proposed by the To review the proposal based Engineer-in-
on the documents
Aggregates Specification Bidder, indicating the charge of HVPNL
location of the quarry
and based on the test
results of Joint
samples tested in
approved lab
2. Physical tests As per document at Samples to be taken One sample per lot of 100% review of lab test results Engineer-in-
Annexure-C of this FQP jointly and tested in 200 cum or part charge of HVPNL
HVPNL approved lab thereof
4. Fine aggregate 1. Source approval Source meeting HVPNL Bidder Proposed by the To review the proposal based Engineer-in-
Bidder, indicating the on the documents.
Specification charge of HVPNL
location of the quarry
and based on the
results of Joint
samples tested in
HVPNL approved lab.
Page 2
Agency Extent
2. Physical test As per Annexure-D of Samples to be taken One sample per lot of 100% review of lab test results Engineer-in-
this FQP jointly and tested in 200 cum or part charge of HVPNL
HVPNL approved lab thereof
5. Water 1. Cleanliness (Water HVPNL Specification Bidder 100% visual check at 1. Verification at random Engineer-in-
shall be fresh , Field 2. Lab. test before start of work charge of HVPNL
clean and potable) from approved Lab.
2. Suitability of water HVPNL Specification Bidder 100% Visual Check 1. Verification at random Engineer-in-
for concreting at Field 2. Lab. test before start of work charge of HVPNL
from approved Lab.
B. Foundation 1. Visual observation HVPNL Specification Bidder 100% at Field 100% at Field
Classification
of soil strata
2. Ground water level

Engineer-in-
3. History of water charge of HVPNL
table in adj.
Area/surface water
4. Soil Investigation
wherever required.
5 Crop pattern
C. Concrete Works
a. Before concreting
1. Bottom of Depth of foundation Appd. Drgs. Bidder 100% at Field 100% check by HVPNL Engineer-in-
excavated earth
charge of HVPNL
2. Stub setting 1) Centre Line -do- -do- -do- -do- -do-
2) Diagonals
3. Reinforcement 3) Level of stubs

steel
b. During Placement Bar bending schedule -do- -do- -do- -do-
concreting
Page 3
Agency Extent
1. Workability Slump test As per HVPNL Bidder 100% at field 20% check at random Engineer-in-
Specification and charge of HVPNL
document at Annexure-
E of this FQP
2. Concrete Cubes Comp Strength As per HVPNL Casting of cubes at site. One sample of 6 100% review of lab test Engineer-in-
results. Cubes at 20% location
Strength Specification and Cubes to be tested at cubes in each charge of HVPNL
are to be taken in presence of
document at Annexure- HVPNL appd. Lab for 7 tower locations HVPNL officials
E of this FQP days & 28 days strength
4. Tower 1. Materials Visual checking for Appd. Drgs./BOM Bidder 100% at stores 100% verification of Engineer-in-
records charge of HVPNL
Erection
a. Tower 1. Stacking
member/bolts &
2. Cleanliness
nuts/washers/acces
3. Galvanizing
sories
4. Damages
2. Erection of 1. Sequence of As per approved Bidder 100% at field 100% check Engineer-in-
Super-structure erection Drgs./HVPNL charge of HVPNL
specification
2. Check for -do- -do- -do- -do- -do-

completeness
3. Tightening of -do- -do- -do- -do- -do-

nuts and bolts
4. Check for -do- -do- -do- -do- -do-

verticality
5. Tack welding for HVPNL Specification Bidder 100% at Field ---do---

bolts & nuts
100% Check
3. Tower footing TFR at locations HVPNL Specification Bidder 100% at Field 20% locations to be ---do---
before and after
resistance (TFR) verified
earthing. Page-4
Agency Extent
5. Stringing 1. Materials
a. Insulators 1. Visual check for HVPNL Specification Bidder 100% at Field 100% verification of Engineer-in-
cleanliness/glazing/
cracks/and white records and to carry charge of HVPNL
spots. random checks 10%
2. IR Value (min. 50M Ohms) -do- One test per sample To verify Bidder’s -do-
size of 20 for every records 100% and joint
lot of 10,000 check 20% of total
tests
3. E&M test - Insulator supplier a. 20 per 10,000 for Collection of samples, Inspecting
officer of
discs sealing them and HVPNL
handing over by
b. 3 per 1500 for
long rod HVPNL to Insulator
supplier
Traceability(Make/b Packing list/CIP Bidder 100% at field Engineer-in-
atch No./Locations
100% Review of charge of HVPNL
where installed) records
b. Conductor On receipt, Packing list Bidder 100% at stores Engineer-in-
1. Visual check of
20% check charge of HVPNL
drum.
2. Check for seals -do- -do- -do- -do-
at both ends, and
-do-
HVPNL sticker on
outer end
3. Check depth -do- -do- -do- -do-
from top of flange
-do-
to the top of the
outer most layer
c. Earthwire Check for seals at Packing list Bidder 100% at stores -do-
both ends
20% check
2. Field activity
a. Before Readiness for Stringing procedures Bidder Readiness Engineer-in-

Stringing stringing as per HVPNL certificate to be
Review of Certificate charge of HVPNL
specification submitted by the
Bidder
b. During (Conductor/Earth-
stringing wire)
Page 5
Agency Extent
1. Scratch/cut Appd. Drawings/ Bidder 100% at Field 100% record & Field Engineer-in-
check (Visual) HVPNL Specn. check 20% charge of HVPNL
2. Repair sleeve -do- -do- -do- -do- -do-
3. Mid span Joints -do- -do- -do- -do- -do-
4. Guying (in case Appd. Guying -do- -do- 100% Engineer-in-
of towers not arrangement/HVPNL charge of HVPNL
designed for one specn.

side stringing)
c. After stringing Check for,
1. Sag/Tension Sag tension -do- -do- 100% record & Field Engineer-in-
chart/tower Spotting check 20% charge of HVPNL
data
2. Electrical As per appd. -do- -do- -do- -do-

clearances Drgs./HVPNL
specifications
i) Ground -do- -do- -do- -do- -do-

clearance
ii) Live metal -do- -do- -do- -do- -do-

clearance etc.
3. Jumpering -do- -do- -do- -do- -do-
Page 6
Agency Extent
4. Copper bond As per Appd. Bidder 100% at Field 100% record & Field Engineer-in-
Drgns./HVPNL Check 20% charge of HVPNL
Specification
5. Placement of As per Specn./drgs/ -do- -do- -do- -do-

spacer/damper placement chart
6. Final Testing
a. Pre- a. Readiness of 1. Completeness of Refer pre Bidder 100% 100% joint checking Engineer-in-
commissionin lines for pre- line. commissioning charge of HVPNL
g of lines commissioning Check list & testing

2. Meggar test of
of EHV lines for
line
charging formats
attached with this
FQP
b. Commi- Readiness of lines - a. Owner latest pre- -do- -do- -do-

commissioning
-do-
ssioning of for commissioning procedures . As per
line annexure enclosed.
b. Pre-
commissioning
Report
c. CEA clearance
3. Electrical -do- -do- -do-

Inspectors clearance
-do-
from CEA.
Page 7
Annexure A
ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR CEMENT
ORDINARY PORTLAND CEMENT

S. Name of the test Ordinary Portland Cement Remarks
No. 43 grade as per IS 8112
a) Physical tests
(i) Fineness Specific surface area shall not be less than 225 sq.m. per Kg
or 2250 Cm2/gm.
(ii) Compressive 72+/- 1 hour : Not less than 23 Mpa (23 N/mm2)
strength
To be conducted in apprd. Lab on every lot of 500 MT.
168+/-2 hour : Not less than 33 Mpa (33 N/mm2)
672+/-4 hour : Not less than 43 Mpa (43 N/mm2)
(iii) Initial & Final Initial setting time : Not less than 30 minutes
setting time
Final setting time : Not more than 600 minutes
(iv) Soundness Unaerated cement shall not have an expansion of more than
10mm when tested by Le chatlier and 0.8% Autoclave test
Page 8
S. No. Name of the test Ordinary Portland Cement Remarks
43 grade as per IS 8112
b) Chemical composition tests Review of MTC only
a) Ratio of percentage of lime to percentage of silica, alumina % iron oxide

0.66 to 1.02
a) Ratio of percentage of alumina to that of iron oxide Minimum 0.66
c) Insoluble residue, percentage by mass Max. 4.00%
d) Magnesia percentage by mass Max. 6%
e) Total sulphur content calculated as sulpuric anhydride (SO3), percentage by

mass Not more than 2.5 and 3.0 when tri-calcium aluminate percent by
mass is 5 or less and greater than 5 respectively.
c) Total loss on Ignition Not more than 5 percent
Page 9
Annexure B
ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR REINFORCEMENT STEEL
S. Name of the test Mild and medium tensile steel as per IS 432 Cold twisted Deformed bars Fe 415 as Remarks
No. per IS 1786
i) Chemical analysis Carbon (For 20 mm dia and below) 0.23% Max.

test
Carbon (For over 20 mm dia) 0.25% Carbon 0.30% Max
Sulpher 0.055% Sulpher 0.060%
Phosphorus 0.055% Phosphorus 0.060%

MTCs of Primary Producers to be reviewed.
Sulpher & Phosphorus 0.11%
ii) Physical tests a) Ultimate Tensile stress a) Ultimate Tensile stress
For all dia bars 410 N/Sq.mm. (min.) 10% more than actual 0.2% proof
stress but not less than 485
N/Sq.mm.)
b) Yield stress (N/Sq.mm) min. b) 0.2% of proof stress/Yield stress

(N/Sq.mm) min.
For bars upto 20 mm dia 250
For bars upto 20 mm dia 415
For bars above 20 mm dia 240
c) Percentage of elongation 14.5%
c) Percentage of elongation 23% (min.)
iii) Bend & Rebend Pass Pass

tests
Page 10
Annexure C
ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR COARSE AGGREGATES AS PER IS 383
3. Coarse Aggregates
i) Physical Tests
a) Determination a. IS Sieve %age passing for Single-Sized Aggregate Percentage Passing for grades Aggregate of nominal
of particles size Designation of nominal size size
40 mm 20 mm 16 mm 12.5 mm 10 40 mm 20 mm 16 mm 12.5
mm mm
63 mm 100 - - - - - - - -
40 mm 85 to 100 100 - - - 95 to 100 100 - -
20 mm 0 to 20 85 to 100 100 - - 30 to 70 95 to 100 100 100
16 mm - - 85 to 100 100 - - - 90-100 -
12.5 mm - - - 85 to 100 100 - - - 90 to

100
10 mm 0 to 5 0 to 20 0 to 30 0 to 45 85 to 10 to 35 25 to 35 30 to 70 40 to
100 85
4.75 mm - 0 to 5 0 to 5 0 to 10 0 to 0 to 5 0 to 10 0 to 10 0 to 10
20
2.36 mm - - - - 0 to 5 - - - -
b. Flakiness index Not to exceed 25%
c. Crushing Value Not to exceed 45%
d. Presence of deleterious material Total presence of deleterious materials not to exceed 5%
e. Soundness test (for concrete 12% when tested with sodium sulphate and 18% when tested with magnesium sulphate
work subject to frost action)
Page 11
Annexure D
ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR FINE AGGREGATES AS PER IS 383
4. Fine aggregates
i) Physical Tests Percentage passing for graded aggregate of nominal size
IS Sieve
a) Determination of particle size Designation F.A. Zone I F.A. Zone II F.A. Zone
III
10 mm 100 100 100
4.75 mm 90-100 90-100 90-100
2.36 mm 60-95 75-100 85-100
1.18 mm 30-70 55-90 75-100
600 microns 12.5 15-34 35-59 60-79
mm
300 microns 5 to 20 8 to 30 12 to 40
150 microns 0-10 0-10 01-0
b) Silt content Not to exceed Not to exceed Not to

8% 8% exceed 8%
c) Presence of deleterious material Total presence of deleterious materials shall not exceed 5%
d) Soundness Applicable to concrete work 12% when tested with sodium sulphate and 15% when tested with magnesium sulphate
subject to frost action
Page 12
Annexure E
ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR CONCRETE WORK
1) Concrete a) Workability Slump shall be recorded by slump cone method and it shall between 50-75 mm.
as per site requirement. However the water cement ratio shall be maintained as
per approved mix design.
b) Compressive strength Six samples of 15cm cubes, three for 7 days testing and balance three for 28
days testing shall be taken.
Notes :
1) For nominal (volumetric) concrete mixes, compressive strength for 1:1.5:3 (Sand : Fine aggreagates : Coarse aggregates) concrete shall
be 265 kg/Sq.cm. for 28 days and for 1:2:4 nominal mix, it shall be 210 kg/Sq.cm.
2) ACCEPTANCE CRITERIA BASED ON 28 DAYS COMPRESSIVE STRENGTHS FOR NOMINAL MIX CONCRETE :
a) the average of the strength of three specimen be accepted as the compressive strength of the concrete, provided the strength of any
individual cube shall neither be less than 70% nor higher than 130% of the specified strength.
b) If the actual average strength of accepted sample exceeds specified strength by more than 30%, the Engineer-in-charge, if he so desires,
may further investigate the matter. However, if the strength of any individual cube exceeds more than 30% of the specified strength, it
will be restructed to 30% only for computation of strength.
c) If the actual average strength of accepted sample is equal to or higher than specified upto 30%, the strength of the concrete shall be
considered in order and the concrete shall be accepted at full rates.
d) If the actual average strength of accepted sample is less than specified strength but not less than 70% of the specified strength, the
concrete may be accepted at reduced rate at the discretion of Engineer-in-charge.
e) If the actual average strength of accepted sample is less than 70% of specified strength, the Engineer-in-charge shall reject the defective
portion of work represent by sample and nothing shall be paid for the rejected work. Remedial measures necessary to retain the structure
shall taken at the risk and cost of Bidder. If, however, the Engineer-in-charge so desires, he may order additional tests to be carried out to
ascertain if the structure can be retained. All the charges in connection with these additional tests shall be borne by the Bidder.
Page 13
General Notes :
1. This standard Field Quality Plan is not to limit the supervisory checks which are otherwise required to be carried out during execution of
work as per drawings/Technical specifications etc.
2. Bidder shall be responsible for implementing/documenting the SFQP. Documents shall be handed over by the Bidder to HVPNL after the
completion of the work.
3. Project incharge means over all incharge of work. Line Incharge means incharge of the line. Section in-charge means incharge of the
section.
4. In case of deviation the approving authority will be one step above the officer designated for acceptance in this quality plan subject to
minimum level of Line incharge.
5. Acceptance criteria and permissible limits for tests are indicated in the Annexures. However for further details/tests HVPNL
specification and relevant Indian standards shall be referred.
6. Tests as mentioned in this FQP shall generally be followed. However E.I.C. reserves the right to order additional tests wherever required
necessary at the cost of the agency.
7. All counter checks/tests by HVPNL shall be carried out by HVPNL’s officials atleast at the level of Jr. Engr.
Page 14
PRE-COMMISSIONING CHECK LIST & TESTING OF EHV LINES FOR CHARGING
NAME OF THE LINE ROUTE KM CKT KM LINE CHARGING

DATE
A. GENERAL DATA AND INFORMATION
1. Package No. :
2. Maint HQ :
3. Voltage rating :
4. Type of circuit :
5. Type of towers 0-2º 2–15º 15–30º 30–60 º Dead Spl. Others Total
End
Single Circuit A B C D D
Number of SC
Double Circuit DA DB DC DD DD
Number of DC
Normal Extn. (Metre) +3 +6 +9 +12 +18 +25
Number of Extns.
Leg Extn. (Metre) +/-1.5 +/-3.0 +4.5 +6.0 +7.5 +9.0
Number of Extns.
6. Foundation Type Dry Wet PS FS BC SR HR Pile

Numbers
7. Type of Conductor :
8. No. of conductors in bundle Single Twin Triple Quad Other
9. Crossing Details :
From Loc No. To Loc No. Name of X-ing No. of compression joint
R Y B R Y B
Power Line
PTCC Line
Railway Line
River
Lake
10. Other Informations

All weather approachable sections :
Submerged sections in monsoon :
Forest stretch sections :
Hilly terrain sections :
Page 1
11. Name of towns Distance from line Approx. time to reach
along the line route (km) Hr. Min.
A.
B.
C.
D.
E.
12. Any other special features of the line :

B. CHECK LIST ON CONSTRUCTION
S.NO. DESCRIPTION STATUS REMARKS

YES NO Record Deficiencies if
any
1. FOUNDATION
a. Check any damage/ uneven
settlement of foundation.
b. Check back filling of foundation is
properly filled up to the ground level
of all legs.
c. Check surface earth/ concrete after
foundation casting is removed from
platform of the tower to beyond a
distance of 30 meters.
d. Check crack or break in chimney.
e. Check coping is proper
f. Check crack or damage to retaining
wall/ revetment and proper weep
holes are provided for flushing water.
g. Check that all foundation chimneys
are covered with soil and compacted
specially in hilly terrain and river/
nalahs banks upto ground level.
2. TOWER
a. Check for deformed/ rusted or
damaged tower members.
b. Check for missing tower members.
c. Check for missing bolts & nuts.
d. Check for tightening of all bolts &
nuts.
e. Check for punching, tack welding (at
least 10 mm circular length) and zinc
coating of bolts & nuts.
f. Check filling of blank holes in tower
members with bolts & nuts.
g. Check verticality of tower.
h. Check that no tower leg is suspected
to be in sinking land or soil erosion
field of river bank, if so, proper and
adequate protection has been
provided.
Page-2
i. Check fixing of all tower accessories
namely step bolts, anti climbing
device (ACD), earthing/ counterpoise-
earthing.
j. Check visibility of danger/ number/
phase & circuit plate along
longitudinal section of line.
k. Check correct sequence of fixing of
phase/ circuit plate at transposition
towers.
3. Removal of T&P and foreign materials

a. Check temporary earthing/ guys used
during stringing and jumpering are
removed.
b. Check all foreign materials on tower
e.g. dense spider webs, any handling
rod/ wire, kites, bird nests and left
over T&P on tower/ cross arm are
removed.
c. Check read and white paints on
towers above 45m which fall in
aviation route.
d. Check aviation warning signals on tall
towers near Airport/ Airstrip as per
rules.
4. Insulators
a. Check that all insulator discs are free
from damage and clean.
b. Check for unusual deflection of
suspension string.
c. Check whether verticality of string
restored.
5. Hardware and accessory fittings

a. Check that proper fixing of hardware
fittings like corona control ring/ arcing
horns etc. are provided as per the
approved drawing/ specification/
b. Check randomly the condition of cotter
pins and ensure that proper size cotter
pins have provided as per the approved
drawing.
c. Check that the conductors/ sub-
conductors are free from scratches/
rubs.
d. Check that all joints on conductor/ earth
wire are away from the tower as per the
specified distance (at least 30 meters)
and joints are as per the approved
drawings/ specification.
e. Check that not more than one joint in a
sub-conductor is provided in one span.
Page 3
S.NO. DESCRIPTION STATUS REMARKS
YES NO Record Deficiencies if
any
f. Check that no mid span joints or
repair sleeves are provided in major
crossings for highway, railway and
major rivers.
g. Check that all mid span joints on
conductors/ earth wire and repair
sleeves of compression type are free
from sharp edges, rust and dust.
h. Check that conductor is properly
clipped in the suspension clamp.
i. Check that armour rods are provided
on suspension towers.
j. Check that spacers are provided
between two sub conductors on each
phase as per the approved chart/
specification.
k. Check that all spacers are properly
tightened and neoprene cover is
intact.
l. Check that spacing of vibration
dampers from the tower and spacing
between damper to damper where
two vibration dampers provided are
properly fixed and tightened as per
the damper placement chart/
specification.
m. Check that all jumpers are properly
fixed and torque tightened as per the
approved drawing/ specification.
n. Check horizontality of sub/ quad
conductors.
o. Check that on conductors/ earth
wires/ hardware fittings are free from
all foreign material like dead bird/
fallen tree/ bird nests etc.
Erection Agency Supplier Agency HVPNL

Representative Representative Representative
Signature
Date
Name
Organization
Page 4
Name of line Circuit Date of Energisation
REMAINING ACTIVITIES/ TEMPORARY ARRANGEMENTS LISTED AFTER JOINT INSPECTION

WITH ERECTION AGENCY
Package Location Observation Completion Inspection

Section Sl. Tower From To Date Sign Date Sign Date Sign
A/ B/C No. No.
Description
Erection Agency Line In-charge Erection Area In-charge

Representative (HVPNL) (HVPNL)
Signature
Date
Name
Organization
Details of sections to be mentioned in this format:
a. Outstanding activities remaining in any part of the line.

b. A list of temporary arrangements introduced.
c. Checklist records properly completed and signed as per Format-01.
d. Original tracing of profile, route alignment, tower design, structural drawings, bill of material, shop
drawings, stringing charts indicating initial and final sag etc. of all towers submitted to HVPNL.
e. For space, separate sheets to be enclosed for details of sectional incompleteness jointly signed by
Agency and HVPNL.
Page 5
Name of line Circuit Line Section
HANDLING OVER RECORD FOR ENERGIZATION
GENERAL STATUTORY ISSUES CHECK LIST

Package Type of towers S/C D/C
kV
Voltage rating Tower locations From To
Total no. of towers Total length Kms
Details:
S. No. Description Status Remarks
Yes No Record deficiencies if any
1. Check list of entire section of the
line along with towers and
accessories under this division have
carried out and documented in the
format no.01.
2. Inspection has been carried out in
all towers and the outstanding
issues along with temporary
arrangements are documented in
the format no. 02.
3. No. of remaining activities/ points
are listed below and these are minor
in nature and do not stop charging
the line.
Handing over check points

Section Points according to format no. Points completed Points accepted
PTL/TL.Const./10/Format/10 and confirmed
(Nos. of remaining activities) Date Sign Date Sign
A
B
C
D

4. All electrical and ground clearances are as
per the approved drawings issued from
Engg. Dept. have been checked and no
deviation has been noted.
5. All men and material and temporary
antitheft electrical connection, if any, have
been removed from all the locations under
this division.
6. All electrical clearance has been received
from CEA electrical inspector for charging
of the line vide order no. dated
(copy enclosed).
Page-6
7. PTCC clearance has been received from
Ministry of Communication Dept for charging
of the line vide order no. dated
(copy enclosed).
8. Railway Crossings clearance has been
received for all the crossings vide order no.
…………… dated ………. (copy enclosed).
9. All statutory rules and regulations pertaining
to line charging has been carried out and
nothing is pending.
10. All working agencies involved in
construction/ erection of this line are
intimated regarding charging of this line and
further work, if any, are to be carried out
only after availing the Permit to Work (PTW)
from the concerned sub-station operating
staff.
The above line is handed over for energization with/ without remaining activities
Handed over by Accepted for energization

Signature
Date
Name
Organization Line in-charge (Constn.) Commissioning in-charge
Page 7
Name of line Circuit Date of charging
COMMISIONING FORMAT
GENERAL DATA AND INFORMATION
Package Type of towers S/C D/C

kV
Voltage rating Tower locations From To
Total no. of towers Total length Km

Yes No Record deficiencies
if any
1. The entire section of the line handed over for
energization as per Powerlinks format no. 03 on
dated……
2. No. of remaining activities/ points are listed as
per format no. 02 and these are minor in nature
and do not stop charging the line.
3. All the equipments involved in charging of the
line are tested and documented as per the pre-
commissioning formats of bay equipment.
4. Pre-commissioning tests of bay/ feeder as per
approved document has been completed and
test results are documented by substation in-
charge.
5. In case reactor provided in this line all tests are
carried out as per prescribed format and all test
results are documented by substation in-charge.
6. All electrical clearance has been received from
CEA electrical inspector for charging of the line
vide order no. ………. Dated ……. (copy to be
enclosed)
Page 8
7. All man and material and temporary antitheft
electrical connection, if any, removed from
all the locations.
8. All electrical clearances have been received
from CEA electrical inspector for charging of
the line vide order no. dated
9. PTCC clearance has been received from
Ministry of Communication Dept. for
charging of the line vide order no.
dated
10. Railway Crossings clearance has been
received for all the crossings vide order no.
…………… dated ………. (copy enclosed).
11. All statutory rules and regulations pertaining
to line charging has been carried out and
nothing is pending.
12. All working agencies involved in
construction/ erection of this line are
intimated regarding charging of this line and
further work, if any, are to be carried out
only after availing the Permit to Work (PTW)
from the concerned sub-station operating
staff.
13. All the protections are checked and put into
service as per standard format no. and
documented by substation in-charge.
Measurement of tower footing resistance by earth resistance tester or any other suitable
instrument (The value should not be more than 10 ohms)
Location Value (Ohms) Remarks
The above inspection and measurements are carried out in the location mentioned above and the
remaining activities, temporary arrangements etc. are documented in format no.02.
Page 9
MEASUREMENT OF INSULATION RESISTANCE FOR BUS BAR (using 5kV motorized megger)
BETWEEN MEASURED VALUE IN REMARK CONDITION
M – OHM
R-PHASE & GROUND All breakers and
Y-PHASE & GROUND isolators to be closed
B-PHASE & GROUND for section of the bus
R-PHASE & Y-PHASE bar to be energized and
Y-PHASE & B-PHASE all ground switches
B-PHASE & R-PHASE opened.
MEASUREMENT OF INSULATION RESISTANCE FOR LINE (using 5 kV/ 10 kV motorized

megger):
BETWEEN MEASURED VALUE IN REMARK CONDITION

M – OHM
R-PHASE & GROUND All ground switches at
Y-PHASE & GROUND other end are opened.
B-PHASE & GROUND Min. value should be
R-PHASE & Y-PHASE approx. 150 mega ohm
Y-PHASE & B-PHASE (value may change with
B-PHASE & R-PHASE weather condition)
CONTINUITY TEST OF THE LINE
For phase marking confirmation
SENDING END RECEIVING END MEASURE VALUE REMARK

CONDITIONS Megger between IN OHMS
CLOSE R – PHASE GS R-PHASE & GROUND LOW
OPEN Y – PHASE GS Y-PHASE & GROUND HIGH
OPEN B – PHASE GS B-PHASE & GROUND HIGH
OPEN R – PHASE GS R-PHASE & GROUND HIGH
CLOSE Y – PHASE GS Y-PHASE & GROUND LOW
OPEN B – PHASE GS B-PHASE & GROUND HIGH
OPEN R – PHASE GS R-PHASE & GROUND HIGH
OPEN Y – PHASE GS Y-PHASE & GROUND HIGH
CLOSE B – PHASE GS B-PHASE & GROUND LOW
CONNECT R&Y PHASE, R-PHASE & GROUND LOW
ALL GS OPEN Y-PHASE & GROUND HIGH
B-PHASE & GROUND HIGH
CONNECT R&B PHASE, R-PHASE & GROUND HIGH
ALL GS OPEN Y-PHASE & GROUND HIGH
B-PHASE & GROUND LOW
CONNECT Y&B PHASE, R-PHASE & GROUND HIGH
ALL GS OPEN Y-PHASE & GROUND LOW
B-PHASE & GROUND HIGH
Note:
If the test values are as per the remark, phase marking at both ends are correct.
If this test is to be done if the megger value do not show short circuit of the line with ground or between
phases in IR measurement.
Page 10
Measurement of phase sequence
After closing the breaker from one end only the line can be charged.
Check the phase sequence by the phase sequence meter by connecting at the secondary of the CVT.
Ok Not Ok
Check the phase sequence by the help of multi-meter in case of a charged sub-station at the
secondary of the CVT (old & new) in the control panel as per the measurement indicated below:
Voltage measurement between Measured voltage Remarks

New Circuit Charged old (volts)
circuit
1. R-phase R-phase In case of correct phase
2. R-phase Y-phase sequence, the voltage measured
3. R-phase B-phase between R&R phase, Y&Y phase,
4. Y-phase R-phase B&B phase of old charged line
5. Y-phase Y-phase and newly charged circuit will be
6. Y-phase B-phase zero or very small and all other
7. B-phase R-phase measurements will show full line
8. B-phase Y-phase CVT phase to phase secondary
9. B-phase B-phase voltage.
Once the correct phase sequence is established, the charging instruction received from HVPNL Engg.
to be followed and properly documented regarding status of various parameters with other lines
and generators, if any.
Charging Dated (Copy enclosed)

Instruction No.
a. Charging details
Date Time
b. Pre-charging conditions for sending end

a. Voltage kV
b. Generator Details
c. Lines connected
Line reactor
S. No. Name of the line MW MVAR
In Service Capacity
1
2
3
4
5
d. Status of bus reactor, if any
S.No. Rating Status
Page 11
e. On charging condition
Details Sending end Receiving end

Voltage
MVAR
Open end voltage
f. Post charging condition
Details Sending end Receiving end

Voltage
MW
MVAR
THE LINE HAS BEEN/ NOT HAS BEEN SUCESSFULLY TEST CHARGED WITH OR WITHOUT
FOLLOWING OPERATIONAL CONSTRAINTS:
1.
2.
3.
4.
Signature
Name
Designation HVPNL HVPNL
Organization Line Erection S/S Erection Line In-charge S/S in-charge
Date
Page 12
VOLUME-II, PART-II,
CHAPTER-IV
TECHNICAL DATA SHEETS
FOR
66 kV/132kV/220kV TRANSMISSION LINES, AS

APPLICABLE
The following information on the proposed equipment and material

shall be submitted in four (4) copies by the bidder alongwith this
proposal as separate appendices to the proposal.
220kV/ 132KV/ 66KV TRANSMISSION LINE
Bidder’s Name & Address As per HVPNL Requirement As per Bidder
1.0 132 kV KRR FURINSIHED

Design Towers
1.1 Bidder’s Yes/No
Experience as
per Qualifying
Requirement
1.2 Stringing Procedure
The details of the stringing procedure proposed and all other
necessary tools and plants the bidder whishes to deploy for
timely completion of the work. (Yes/No)
2.0 Particular of 132kV D/C HVPN KRR Design Towers
2.1 Mass in kilogram Extension

for D/C towers Std. 3m 6m 9m 12m 15m 18m 25m
(1) (2) (3) (4) (5) (6) (7) (8)
2.1.1 DA type As per HVPNL
suspension Drawings / BOM
tower
As per HVPNL
a) Fabricated parts Drawings / BOM
(Black)
As per HVPNL
b) Nuts & Bolts Drawings / BOM
(Galvanised)
As per HVPNL
c) Total weight Drawings / BOM
2.1.2 DB type
Tension tower
As per HVPNL
a) Fabricated parts Drawings / BOM
(Black)
As per HVPNL
b) Nuts & Bolts Drawings / BOM
(Galvanised)
As per HVPNL
2.1.3 DC type Tension tower

As per HVPNL
a) Fabricated parts (Black) Drawings / BOM
b) Nuts & Bolts (Galvanised) As per HVPNL Page-1

Drawings / BOM
As per HVPNL
2.1.2 DD type Tension tower

As per HVPNL
As per HVPNL
b) Nuts & Bolts (Galvanised) Drawings / BOM
As per HVPNL
2.2 Standard specifications As per IS-2062
according to which the quality
of steel for the sections have
been assumed.
2.3 Standard to which fabrication, IS-802
galvanizing etc. will conform. Galvanizing IS-2629
2.4 Quality of zinc used for 99.95%
galvanizing (purity)
(%)
3.0 132 KV D/C Gantry
3.1 Particulars of 132 KV Gantry
3.1.1 Structure type T2

As per HVPNL
As per HVPNL
As per HVPNL
3.1.2 Structure type B1

As per HVPNL
As per HVPNL
As per HVPNL
3.2 Standard specifications according As per IS-2062

to which the quality of steel for the
sections have been assumed.
3.3 Standard to which fabrication,

galvanizing etc. will conform.
3.4 Quality of zinc used for galvanizing

(purity) (%)
Page-2
GUARANTEED TECHNICAL PARTICULARS OF ACSR ZEBRA CONDUCTOR
Sl.No Description Unit As per HVPNL As per Bidder

Requirement
1.0 Name & Address of manufacturer
2.0 PARTICULARS OF RAW MATERIALS
2.1 Aluminium
(a) Maximium Purity of aluminium %
(b) Maximum Copper Content %
2.2 Steel Wires / Rods
2 Carbon %
3 Manganese %
4 Phosphorous %
5 Sulphur %
6 Silicon %
2.3 Zinc
(a) Minimum Purity of Zinc %
3.0 ALUMINIUM STRANDS AFTER
STRANDING
3.1 Diameter
1 Nominal Mm
2 Maximum Mm
3 Minimum Mm
3.2 Minimum Breaking load of strand KN

3.3 Maximum Resistance of 1m length of Ohm
strand at 20 C
4.0 STEEL STRANDS AFTER STRANDING
4.1 Diameter
(a) Nominal Mm
(b) Maximum Mm
(c) Minimum Mm
4.2 Minimum Breaking load of strand KN
4.3 Galvanising
(a) Minimum weight of zinc coating per Gm
sqm. of uncoated wire surface
(b) Minimum number of one minute dips Nos.
that the galvanised strand can withstand
in the standard piece test
(c) Min. No. of twists in a guage length Nos.
equal to 100 times dia of wire which the
strand can withstand in the torsion test.
Page-3
5.0 ACSR CONDUCTOR
5.1 UTS of Conductor KN
5.2 Lay ratio of conductor

(a) Outer steel layer
(b) 12 Wire aluminium layer
(c) 18 Wire aluminium layer
(d) 24 Wire aluminium layer
5.3 DC resistance of conductor at 20 C Ohm/KM
5.4 Min. corona extinction voltage (line to kV (rms)

ground) under dry condition
5.5 RIV at MHz at 154 KV (rms) under dry Micro volts
condition
5.6 Standard length of conductor M
5.7 Maximum length of conductor M
5.8 Tolerance on standard length of conductor %
5.9 Direction of lay for outside layer N.A.
6.0 Linear mass of the Conductor

(a) Standard Kg/km
(b) Minimum Kg/km
(c) Maximum Kg/km
Drum is as per specification

No. of cold pressure butt welding Nos.
equipments available at works
Page -4
SILICONE COMPOSITE LONG ROD INSULATORS FOR 220kV/ 132kV / 66kV LINEs
WITH ACSR ZEBRA
Page 1 of 2
Sr. Description Unit 70kN 120kN As per Bidder

No.
1. Name & address of manufacture
2. Weight of single unit Kg
3. Size and designation of ball & mm
socket assembly
4. Core diameter mm
5. Tolerance on core diameter ±mm
6. Nominal length (section length) Mm
7. Tolerance on Nominal length ±mm
8. Dry arcing distance Mm
9. Number of sheds Nos.
10. Sheds profile (type)
11. Shed spacing mm
12. Sheds profile (regular alternating )
13. Shed diameter mm
14. Tolerance on shed diameter ±mm
15. Minimum creepage distance mm
16. Tolerance on Creepage distance mm
17. Guaranteed mechanical strength kN
18. Routine mechanical load KN
19. Material
a) FRP rod
b) Weather sheds with %
contents of silicon
c) Housing
d) End fittings
e) Grading rings
20. Minimum thickness of sheath mm

covering over the core
21. Power frequency withstand voltage
of single unit
f) Dry KV
(rms)
b) Wet KV
(rms)
22. Power frequency flashover voltage
of single unit
g) Dry KV
(rms)
b) Wet KV
(rms)
Page-5
Page 2 of 2
23. Impulse withstand voltage of single

unit (dry)
h) Positive KV
i) Negative (peak)
KV
(peak)
24. Impulse flashover voltage of single
unit (dry)
j) Positive KV
b) Negative (peak)
KV
(peak)
25. Purity of zinc used for galvanizing %
end fittings
26. Number of dips which the end Nos.
fittings can withstand in standard
preece test
27. Certified test report of accelerated Yes/No.
ageing test of 5000 hours (enclosed)
(appendix-C of IEC-61109)
28. Drawing enclosed Yes/No.
Page-6
GUARANTEED TECHNICAL PARTICULARS OF SUSPENSION HARDWARE FITTINGS
(SUITABLE FOR ACSR ZEBRA CONDUCTOR)
Sl.No Description Unit As per HVPNL As per

. Requirement Bidder
1. Name of manufacturer
2. Address of manufacturer
3. Dimensioned drawings of insulator strings
enclosed
4. Detailed dimensional drawings of all
hardware components enclosed
5. Material of all components indicated in
drawings
6. Maximum magnetic power loss of
suspension assembly at conductor current Watts
of 500 Ampere
7. Slipping strength of suspension assembly

(clamp torque Vs slip curve shall be KN
enclosed
8. Particulars of standard / AGS preformed
armour rod set for suspension assemble
(a) No. of rods per set No.
(b) Direction of lay
(c) Overall length after fitting on Mm
Conductor
(d) Actual length of each rod along its helix Mm
(e) Diameter of each rod Mm
(f) Tolerance in
(i) Diameter of each rod + mm
(ii) Length of each rod + mm
(iii) Difference of length mm
Between the longest and shorted rod in a
set Kg/
(g) Type of Aluminium alloy used for mm
manufacture of PA rod set
(h) UTS of each rod
9. Particulars of Elastometer (for AGS Clamp
only)
(a) Supplier of elastometer
(b) Type of elastometer
(c) Shore hardness of elastometer
(d) Temperature range for which
elastometer is designed
(e) Moulded on insert
Page-7
10. Total weight of Assembly
(a) Single Suspension Kg.
(b) Single Suspension ‘pilot’ Kg.
(c) Double Suspension Kg.
11. UTS of string hardware

(a) Single Suspension KN
(b) Single Suspension ‘pilot’ KN
(c) Double Suspension KN
12. Purity of Zinc used for galvanising %

13. Min. No. of dips in standard piece test, the No.
ferrous parts can withstand
14. Design calculations for yoke plates
enclosed
Page-8
GUARANTEED TECHNICAL PARTICULARS OF TENSION HARDWARE FITTINGS
(SUITABLE FOR ACSR ZEBRA CONDUCTOR)

. Requirement
3. Dimensioned drawings of insulator strings

enclosed
4. Detailed dimensional drawings of all
hardware components enclosed
5. Material of all components indicated in
drawings
6. Electrical resistance of dead end assembly Ohms
7. Slip strength of dead end assembly KN
8. Total Weight of Assembly

(a) Single Tension Kg.
(b) Double Tension Kg.
9. UTS of string hardware

(a) Single Tension KN
(b) Double Tension KN
10. Purity of Zinc used for galvanizing %
11. Min. No. of dips in standard piece test, the No.

ferrous parts can withstand
Page-9
PARTICULARS OF MID SPAN COMPRESSION JOINT FOR ACSR ‘ZEBRA’
Sr. Description Unit As per As per
No. HVPNL Bidder
Requirement
1. Manufacturer’s Name and Address
2. Drawing enclosed
3. Suitable for Conductor size mm
4. Purity of Aluminium used for Aluminium sleeve.
5. Material for steel sleeve
i) Type of material with chemical
composition.
ii) Hardness of material (Brinnel Hardness)
iii) Weight of zinc coating (gm/mm2)
6. Outside diameter of sleeve before compression

(a) Aluminium (mm)
(b) Steel (mm)
7. Inside diameter of sleeve before compression
(a)Aluminium (mm)
b) Steel (mm)
8. Length of Aluminium Sleeve
i) Before compression (mm)
ii) after compression (mm)
9. Dimensions of sleeve after compression
(a) Aluminium
(i) Corner to corner (mm)
(ii) Surface to surface (mm)
b)Steel
(i) Corner to corner
(mm)
10. Length of Steel sleeve
i) Before compression (mm)
ii) after compression (mm)
11. Weight of sleeve
(a) Aluminium (Kg.)
(b) Steel (Kg.)
(c) Filler Al-Sleeve (Kg.)
12. Slipping Strength (kN)
13. Conductivity of the compressed unit expressed %
as percentage of the conductivity of equivalent
length of bare conductor
Page-10
PARTICULARS OF REPAIR SLEEVE FOR ACSR ‘ZEBRA’ CONDUCTOR

. Requirement
2. Drawing enclosed
3. Suitable for conductor size (mm)
4. Purity of aluminium used for (%)
aluminium sleeve
5. Inside diameter of sleeve before (mm)
compression
6. Outside dimensions of sleeve
(a) Dia Before compression (mm)
(b) After Compression

7. Length of sleeve
(a) Before compression (mm)
(b) After compression (mm)
8. Weight of Sleeve (Kg)
Page-11
GUARANTEED TECHNICAL PARTICULARS OF VIBRATION DAMPER FOR ACSR
‘ZEBRA’ CONDUCTOR
Sl.No Description Unit As per As per
HVPNL Bidder
Requirement
1. Manufacturer’s Name & Address
2. Drawing enclosed As per make
(a) Design drawing
(b) Placement chart
3. Suitable for conductor size mm
4. Total weight of one damper Kg
5. Diameter of each damper mass mm

6. Length of each damper mass mm
7. Weight of each damper mass Kg
8. Material of damper masses

9. Material of the stranded messenger cable
10. Number of strands in stranded messenger mm

cable
11. Lay ratio of stranded messenger cable
12. Minimum ultimate tensile strength of (Kg/

stranded messenger cable mm)
13. Slipping strength of stranded messenger KN

cable (mass pull off)
14. Resonance frequencies
(a) First frequency Hz
(b) Second frequency Hz
15. Designed clamping torque Kg-m

16. Slipping strength of damper clamp
(a) Before fatigue test KN
(b) After fatigue test KN
17. Magmetic power loss per vibration damper Watts

for 500 amps. 50 Hz altemating current
18 Material of Clamp
Page-12
GUARANTEED TECHNICAL PARTICULARS OF ANTI-FOG DISC INSULATOR UNITS
FOR LINES WITH ACSR ZEBRA CONDUCTOR FOR 220KV/132kV / 66KV LINES
As per HVPNL As per Bidder
Requirement
S.N Description Unit 70KN 120KN 70KN 120KN
3. Weight of single disc Kg.
4. Size and Designation of pin ball shank mm
5. Diameter of disc mm
6. Tolerance on Diameter
7. Ball to ball spacing between Disc mm
8. Tolerance on spacing
9. Minimum nominal creepage distance of single mm
disc
10 Tolerance on creepage distance
11. Electromechanical strength of disc kN
12. Material of shell (Porcelain )
13. Power frequency flashover voltage of single
disc
(a) dry kV(rms)
(b) wet kV(rms)
14. Power frequency withstand voltage of single
disc
(a) Dry kV(rms)
(b) Wet kV(rms)
15. Power frequency puncture voltage of single kV(rms)
disc
16. Impulse flashover voltage of single disc (dry)
(a) Positive kV(peak)
(b) Negative kN(peak)
17. Impulse withstand voltage of single disc (dry)
(a) Positive kV(peak)
(b) Negative kN(peak)
18. Steepness of impulse voltage which the disc kV /
insulators can withstand in steep wave front microsec.
test
19. Visible discharge test of single disc (dry) kV(rms)
20. Maximum RIV at 1MHz and 10kV AC (rms) Microvolts
voltage of single disc
21. Purity of zinc used for galvanizing %
22. No. of dips in standard piece test
(a) Socket
(b) Ball Pin
23. Axial and Radial run out (According to IEC)
(a) As per pointer A mm
(b) As per pointer B mm
24. Drawings enclosed
Note:- If there is any error or mission in the above GTPs, the same shall conform to
technical specification / relevant ISS. If there is any change in GTPs so warranted by
specific make of equipment, the same shall be taken care of the time of approval of drawings
Page-13
GUARANTEED TECHNICAL PARTICULARS OF 7/3.15 mm EARTH WIRE
1.0 Name & Address of manufacturer
2.0 PARTICULARS OF RAW MATERIALS

2.1 Steel Wires/Rods
(a) Carbon %
(b) Manganese %
(c) Phosphorous %
(d) Sulphur %
(e) Silicon %
2.2 Zinc
(a) Minimum purity of Zinc %
3.0 STEEL STRANDS AFTER STRANDING
3.1 Diameter
(a) Nominal mm
(b) Maximum mm
( c)Minimum mm
3.2 Minimum Breaking load of strand kN
3.3 Galvanising
(a) Minimum weight of zinc coating per gm
sq.m of uncoated wire surface
(b) Minimum number of one minute dips
that the galvanised strand can Nos.
withstand in the standard preece test
(c) Min. No. of twists in guage length equal
100 times the dia. of wire which the Nos.
strand can withstand in the torsion test
4. STRANDED EARTH WIRE

4.1 UTS of earth wire kN
4.2 Lay length of outer steel layer mm
4.3 DC resistance of earthwire at 200C ohm
4.4 Standard length of earth wire m
4.5 Tolerance on standard length +m
4.6 Direction of lay of outer layer
4.7 Linear mass of earth wire
(a) Standard kg/km
(b) Minimum kg/km
(c) Maximum kg/km
5.0 Drum is as per specification Yes/No
Page-14
PARTICULARS OF VIBRATION DAMPER FOR GALVANISED STEEL EARTHWIRE (7/3.15 mm)

. Requirement
2. Drawing enclosed
(a) Design drawing
(b) Placement chart
3. Suitable for earth wire size (mm)
4. Total weight of one damper (Kg)
5. Diameter of each damper mass (mm)
6. Length of each damper mass (mm)
7. Weight of each damper mass (Kg)
8. Material of damper masses
9. Material of the stranded messenger cable
10. Number of strands in stranded messenger

cable
11. Lay ratio of stranded messenger cable
12. Minimum ultimate tensile strength of (Kg/

stranded messenger cable mm2)
13. Slipping strength of stranded messenger (kN)
cable (mass pull off)
14. Resonance frequencies
(a) First frequency (Hz)
(b) Second frequency (Hz)
15. Designed clamping torque Kg-m
16. Slipping strength of damper clamp
(a) Before fatigue test
(b) After fatigue test
17
Page-15
PARTICULARS OF SUSPENSION CLAMP FOR GALVANISED STEEL EARTHWIRE
(7/3.15 mm)

. Requirement
2. Drawing enclosed
3. Material
(i) Shackle
(ii) Clamp Body &
Keeper
(iii) U – Bolt
4. Total drop (maximum) (mm)
5. Weight (Kg)
6. Breaking Strength (minimum) (kgf)
8. Tightening Torque (kg-m)
Page-16
PARTICULARS OF TENSION CLAMP FOR GALVANISED STEEL EARTHWIRE (7/3.15
mm)

2. Drawing enclosed
3. Material
(i) Shackle
(ii) (a) Compression clamp
(b) Hardness of the material

(BHN)
4. Inside diameter of the clamp before (mm)
compression
(b) After compression
6. Length of clamp
7. Weight (Kg)
8. Slip strength (minimum) (kN)

9. Compression Pressure (T)
10. Minimum breaking strength of (kgf)
assembly (excluding clamp)
Page-17
PARTICULARS OF MID SPAN COMPRESSION JOINT FOR GALVANISED STEEL
EARTHWIRE (7/3.15 mm)

. Requirement
2. Drawing enclosed
3. Material of Joint
(i) Type of material with chemical
composition
(ii) Hardness of the material
(Brinnel Hardness)
4. Inside diameter of sleeve before

compression
(i) Steel sleeve (mm)
(ii) Aluminium sleeve (mm)
(iii) Aluminium filler sleeve (mm)
(a) Steel sleeve (mm)
(b) Aluminium filter sleeve (mm)
6. Outside dimensions of sleeve after
compression
(a) Steel sleeve
(b) Aluminium cover
7. Length of steel sleeve
Page-18
8. Length of Aluminium sleeve
9. Weight of sleeve
(a) Steel (Kg)
(b) Aluminium (Kg)
(c) Filler Al-sleeve (Kg)
11. Conductivity of the compressed unit (%)
expressed as a percentage of the
conductivity of equivalent length of bare
earthwire.
Page-19
PARTICULARS OF FLEXIBLE COPPER BOND

. Requirement
2. Drawing enclosed
3. Stranding
4. Cross sectional area (Sq.mm)
5. Minimum copper equivalent area (Sq.mm)
6. Length of copper cable (mm)
7. Material of lugs
8. Bolt Size
(i) Diameter (mm)
(ii) Length (mm)
9. Resistance (Ohm)
10. Total weight of flexible copper bond (kg)
Page-20
GUARANTEED TECHNICAL PARTICULARS & OTHER TECHNICAL DATA OF 220KV/ 132KV
POST INSULATOR
Sl.No. Description Unit As per Bidder

1. Height mm
2. Power frequency dry one minute KVrms
withstand voltage
3. Impulse withstand voltage KVpeak
4. Total creepage distance mm
5. Protected creepage distance mm
6. Cantilever strength inverted Kg
7. Cantilever strength upright Kg
8. Tensile strength N
9. Torsional strength Nm
10. Compression strength N
11. Bending strength N
12. Type and make
13. Total weight Kg
14. Pitch circle diameter
a. Bottom mm
b. Top mm
15. Max. diameter of Insulators mm
16. Drawing Reference No.
Page-21
4.0 TOWER FOUNDATION
4.1 GENERAL
These specifications provide general guidelines for the construction of tower
foundations as per design supplied by HVPNL and the gantry tower foundations as
per design supplied by HVPNL of the proposed transmission line(s) covered in the
tender.
4.2 Before start of work, successful bidder shall carry out trial bore-holes (normally up to
6.0 meter below natural ground level) after every Kilometer en-route or as desired by
the Employer to have a fair idea of soil type/nature and subsoil water position. If the
soil characteristics are changing rapidly or soil up to 6.0 meter is very weak, the depth
of bore-hole be increased beyond 6.0 meters so as to know the soil properties/type
below the foundation. The bore log data containing information such as position of
sub-soil water table, soil strata, the crop pattern in the agricultural fields where the
foundation is to be laid and the suitability for founding the required foundation, shall be
submitted to the Employer for according approval for “Classification of foundation”
at each location.
Contractor shall also ensure to check the entry of kids/ animals in to the excavated
pits by providing suitable warning signs and safety measures as per the approval of
Engineer-In-Charge.
4.3 TYPE OF SOIL
Soil en-route the following proposed transmission lines under the scheme is generally
normal/Sandy/rocky.
1. BOQ for shifting/re-alignment of 220kV D/C line from 400kV BBMB Bhiwani to
220kV HVPNL Bhiwani from TL No. 03 to 06 as a deposit work of RVNL.
2. BOQ for creation of two phase 132kV S/C line on D/C towers with 0.4sq” ACSR
conductor from 132kV S/Stn. Kalanaur to 132kV TSS Manheru.
3. BOQ for raising the height of 132kV S/C line Ckt-I & II BBMB Hisar to Hansi line
at km 136/7-8 in front of 220kV S/Stn. BBMB Hisar.
4. BOQ for raising the height of 132kV S/C Hansi-Miran line between tower
location no. 6-7.
[[
Ground water table enroute all the above said lines generally vary from 20mtr. to
25mtr. below Natural Ground Level. The sub soil water level at few locations may
be different due to local conditions. The crop pattern enroute all the above said
lines is paddy, wheat, sugarcane, cotton etc. depending on soil and weather
conditions.
4.4 CLASSIFICATION OF SOIL
a. Dry Soil: Soil shall be termed as dry soil where sub-soil water table is below
base of the tower footing and no de-watering is required.
b. Wet Soil (without de-watering): Soil shall be termed as wet soil (without de-
watering) where sub-soil water is below base of footing and no de-watering is
required but crop pattern is paddy field.
c. Wet Soil (with de-watering): Soil shall be termed as wet soil (with de-
watering) where sub-soil water is above base of footing and de-watering has to
be done.
d. Rocky Soil: Hard conglomerate or other soft or fissured rock which can be
quarried or split with crow bars, wedges or pick axes. However, if required, light
blasting may be resorted to for loosening the material.
4.4.1 For excavation purpose, the quoted rates for foundations in wet soil (without de-
watering) shall be considered as applicable for the dry soils. For wet soil (with de-
watering), the quoted rates of de-watering have been asked for separately. The de-
watering operation shall continue to keep the foundation pits dry during concreting and
thereafter for at least 24 hrs. Any de-watering carried out for removal of seepage of
surface water/rainwater will not be considered as de-watering and the soil shall be
termed as ‘Dry Soil’.
4.5 FOUNDATION TYPES
4.5.1 GENERAL
Reinforced cement concrete footing shall be used for all types of normal towers/
extension towers in conformity with the present day practices followed in the country
and the specifications laid herein. All the four footings of the tower and their
extensions, if any shall be similar irrespective of down thrust and uplift.
4.5.2 Foundation includes supply of materials such as cement, fine and coarse aggregates,
water, reinforcement steel and binding wire etc. Rates quoted for foundations shall
include all items of work relating to supply and installation of foundations such as form
work, excavation and back filing with good soil, compaction, stub setting, shoring &
timbering etc. where ever required, placing of reinforcement in position, concreting
and all other works related for completion of foundation.
4.6 CLASSIFICATION OF FOUNDATIONS
a. Dry Foundation: To be used where sub-soil water table is below 6.0 meter
from Natural Ground Level.
b. Wet Foundation (without de-watering): To be used where sub-soil water

table is below base of footing and up to 6.0 meters from Natural Ground Level
or at location where surface water remains for long periods such as
paddy/sugar cane fields irrespective of sub-soil water depth.
c. Wet Foundation (with de-watering): To be used where sub-soil water table is
above footing base of foundation and actual de-watering has to be carried out
for construction of foundation for which separate rates have been asked for.
4.6.1 Design of foundation for Wet (without de-watering) and Wet (with de-watering) shall
be same.
4.7 PROPERTIES OF CONCRETE & REINFORCEMENT
4.7.1. All the properties of concrete regarding its strength under compression, tension, shear,
punching and bond strength etc. as well as workmanship shall confirm to IS: 456
latest.
4.7.2 The concrete used as lean concrete or base concrete shall be as mentioned on
respective drawings. The aggregate size shall be 40 mm nominal. Base concrete shall
be well compacted. The top surface of base concrete shall be leveled before placing
the reinforcement.
During excavation, if excavation exceeds the required depth or if any loose pocket of
earth is met below the base of footing, then the loose earth shall be removed or
excavation depth be increased till normal hard soil is met as per satisfaction of the
Engineer-in-Charge. This extra depth shall be filled with lean concrete. No extra shall
be paid on account of this extra excavation and lean concrete.
4.7.3 The cement concrete used for foundation shall be of grade M-20 {irrespective of any
grade mentioned on the drawing(s)}. The Mix Design (conforming to IS standards)
shall be done prior to start of work, as per specifications, got approved from the
Employer and shall be used for the construction, provided there is no change in the
source and the quality of materials. The source of materials shall be intimated to the
Employer and shall be ensured that Mix Design is with the materials from intimated
source only and same is not changed during construction. In case source of material
changes or quality of material differs from the earlier approved parameters, the Mix
Design shall be done again. Whenever there is uncertainty of availability of
aggregates from a fixed source, nominal mix is to be followed but the quality of
aggregates shall not be compromised. To avoid the delays, the contractor may go for
nominal mix after getting the aggregates tested till such time the mix design is got
approved.
4.7.4 The coarse aggregate used shall be 20 mm graded or two types of single size
aggregate mixed in some fixed ratio to have graded 20-mm aggregate. The Coarse
aggregate shall conform to IS 383.
4.7.5 Grading of Fine aggregate shall conform to Zone-II of Table-4 of IS: 383 and shall be
free from deleterious materials.
4.7.6 The environmental exposure condition considered for Mix Design shall be MILD.
4.7.7 For Mix Design the degree of quality control shall be considered as FAIR.
4.7.8 The Water Cement ratio shall be minimum 0.50 and maximum 0.55.
4.7.10 For Transmission Line Tower footings, the minimum Slump shall be 50 mm and
maximum 75 mm.
4.7.10 For volumetric use of ingredients for concrete mix, the contractor along with the Mix
Design shall intimate the size of measuring boxes along with the Mix design.
4.7.11The approval of Mix Design shall not absolve the contractor from the responsibility of
achieving the required strength, workability etc. during actual execution. In case of
failure of concrete samples, the work done is liable to be rejected. In such case the
contractor shall recast the foundation at the same location by dismantling the rejected
foundation or at a nearby location as directed by the Employer. In case of honey
combing, the contractor shall do the pressure grouting as directed and to the full
satisfaction of Employer. The construction of new foundation in place of rejected one
and pressure grouting if done shall be without any extra payment.
4.7.12Ordinary Portland_Cement of Grade 43 of reputed make like JK,, ACC, Ambuja, Shree
conforming to IS: 8112 shall be used. However in case of shortage of OPC Cement,
Portland Pozzolona Cement (fly ash based or calcinated clay based) conforming to IS
1489 Part Part – 1 and – 2 respectively may be used in the works other than RCC. In
case, Portland Pozzolona Cement is used then curing period shall be enhanced as
directed by Engineer-in-Charge. In RCC works only Ordinary Portland Cement of
Grade 43 shall be used.
4.7.13 The water used for mixing concrete and for curing purpose shall be fresh, clean and
free from oils, acids and alkalis, organic materials or other deleterious substance.
Potable water is generally preferred. Saltish or brackish water shall not be used.
Water used shall conform to clause 5.4 of IS 456.
4.7.14 Reinforcement steel (including TMT) Bars manufactured by TISCO, SAIL, IISCO and
RASHTRIYA ISPAT, Jindal Steel and Power Ltd.(Jindal Panther),JSW Steel Ltd
(primary manufacturers) conforming to IS: 1786 for deformed and cold twisted bars
shall only be used. The bidders shall, however, be allowed to use Amba steel, Rathi
steel, Kamdhenu steel, Barnala steel, P.R.S steel, Shidbali steel (manufactured by
secondary manufacturers) only after obtaining non-availability certificate from the
primary manufacturers. Before using secondary steel, the selected bidder would
require to conduct all physical & chemical tests (lot wise & dia. wise) to establish its
conformity to IS Standards. Required grade of steel shall be Fe-500. All reinforcement
shall be clean and free from loose mill scale, dust, loose rust and coats of paint, oil or
other coating, which may destroy or reduce bond with concrete. Reinforcement bars
should be fresh. Contractor shall supply, fabricate and place reinforcement to shapes
and dimensions as indicated on the drawings or as required to carry out the intent of
drawings and specifications. Adequate nos. of chairs, spacers of required size shall be
provided to ensure the proper placement of reinforcement. The reinforcement bars
crossing one another should be tied together at every intersection with two strands of
annealed steel wires 0.9 to 1.6 mm thick twisted and tied to make the skeleton of the
steel work rigid so that the reinforcement does not get displaced during concrete
placement.
All the reinforcement steel should be placed/ stacked at site store on raised (at least
0.5 meter from near surroundings) pucca/brick platform or reinforcement steel should
be placed on MS/GI sheets. The reinforcement steel after stacking should be covered
with Tarpaulin to avoid corrosion. Immediately before concreting (portion of
reinforcement to be embedded in concrete) shall be painted with cement slurry after
removing any rust/corrosion/any other foreign material.
4.7.15 No admixtures shall be used.
4.8 UNIT RATES AND MEASUREMENT

4.8.1 The rates of foundation shall be per tower. These rates shall include excavation, stub
setting, concreting, reinforcement, shuttering, shoring/ timbering, stockpiling, dressing,
curing, back filling (after concreting) with good (excavated/borrowed) earth
irrespective of lead. Rates are inclusive of compaction of earth, carriage of surplus
earth to suitable disposal location as required by Employer or any other activity related
to completion of foundation works in all respects.
4.8.2 In case of any change/variation in the foundation drawing(s) attached with bidding
document, due to site conditions or otherwise, the payment shall be made based on
formula given in the commercial clause.
4.9 CONSTRUCTION OF TOWER FOUNDATIONS AS PER DESIGN SUPPLIED BY

HVPNL
4.9.1 EXCAVATION
Excavation work shall start only after the approval of route plan, the tower foundation
schedule, classification of foundations and the profile by the Employer. The reference
natural ground level shall be so chosen that it is not lower than surroundings and in
normal condition water does not accumulate there, preferably it should be slightly
higher than surroundings.
All excavation for footing shall be made to the lines and grades of the foundation. The
excavation wall shall have stable slope and the pit dimensions shall be such as to
allow a clearance of 150 mm on all sides from the foundation RCC pad. The
contractor should ensure clearance of 150 mm from the foundation RCC pad for
quality work.
All excavation shall be protected so as to maintain a clean sub-grade until the footing
is placed, using timbering/shuttering, shoring etc., if necessary. Any sand, mud, silt or
other undesirable materials, which may accumulate in the excavated pit, shall be
removed by the contractor before placing concrete.
4.9.2 No extra charges shall be admissible for the removal of the fallen earth in the pit, when
once excavated.
4.9.4 Wherever ground water table is higher than the base of the foundation, it has to be
depressed by de-watering. During de-watering, water shall be thrown at a place as
directed by the Engineer-in-Charge. No pit/open de-watering shall be permitted.
Instead, over all lowering of the water table shall be done by providing sufficient
number of bores around the tower location and by continuous pumping of water
through these bores. Well point system for de-watering of pits can also be adopted. It
must be ensured that during de-watering/pumping operation, no finer particles of soil
get displaced or any cavity is formed below. The boreholes for de-watering shall be
located so as to avoid any hindrance in normal working for construction of foundation.
The construction of foundation shall be carried out in bone-dry condition, which shall
be ensured by effective lowering of water table so that no caving in happens and also
the bottom of the pit is free from slushy conditions. The bores shall be filled with sand
after the work at a particular location is over.
4.10 SETTING OF STUBS
The stubs shall be set correctly in accordance with approved method at the exact
location and aligned precisely at correct levels with the help of stub setting templates
and leveling instruments. Stubs shall be set in the presence of Employer’s
representative for which the Contractor shall give adequate advance intimation to the
Employer. All necessary precautions should be taken to ensure that the stubs finally
set in are not disturbed. If these are disturbed due to any reason, the bidder shall
reset the same without any extra cost.
4.11 STUB SETTING TEMPLATES
For all types of towers viz. with or without extension and also for leg extensions, the
contractor at his own cost shall arrange the stub-setting templates. Stub templates for
standard towers and towers with extension shall be painted. Normally, for each
transmission line tower package, sufficient numbers of stub templates should be
deployed. However, if the Employer feels that more number of templates are required
for timely completion of a particular line, the contractor shall have to deploy the same
without any extra cost to the Employer.
After completion of the project, one set of each type of stub setting template as
applicable shall be supplied to the Employer at no extra cost to the Employer.
4.12 MIXING, PLACING AND COMPACTING OF CONCRETE
4.12.1 The concrete shall be mixed in a mechanical mixer. The mixer shall comply with IS:
1791 & IS: 12119. The mixer shall be fitted with water measuring devices. Mixer
without trough should not be brought at site. In case of difficult terrain, the Employer at
his discretion may permit hand mixing but this should not be made a routine. In case
of hand mixing, 10% extra cement shall be used without any extra cost.
4.12.2Mixing shall be continued until there is uniform distribution of material and the mix
become uniform in colour and consistency. If there is segregation after unloading from
mixer, the concrete should be re-mixed, but in no case the mixing be done for less
than two minutes. Normally, mixing shall be done close to the foundation, but in case
it is not possible the concrete may be mixed at a nearest convenient place. From
mixer the concrete shall be put on pucca platform or steel troughs, which shall be leak
proof to avoid any loss of water/slurry.
The concrete shall be transported from the place of mixing to the place of final deposit
as rapidly as practicable by methods, which will prevent the segregation or loss of any
ingredient. The concrete shall be placed and compacted before setting commences.
4.12.3 Form boxes of required size as per approved Mix Design volumes shall be used for
casting all type of foundations. Form boxes shall be rigidly tightened so that there are
no distortions in the shape of foundations. Form boxes shall be made sufficiently
strong to withstand all the loads and vibrations. For bottom pad portion sufficiently
wide window of minimum size 450 x 300 mm be left on each side at top for placing of
concrete and for use of vibrators to ensure thorough compaction. After every use, the
form box(es) be checked for any deformation and if necessary be repaired/corrected
to original position for reuse.
4.12.4 On removal of the form-work, if the concrete surface is found damaged, it shall be
repaired with rich cement sand mortar to the satisfaction of the Engineer-in-Charge.
The foundation pits be back-filled only after necessary repairs, if any as required
above has been done.
4.14 BACK-FILLING AND REMOVAL OF STUB TEMPLATE

4.13.1 The formwork shall be removed after 24 hours (minimum). Due care shall be taken not
to injure the concrete by excessive striking the formwork. In case the Portland
Pozzolona cement has been used, the removal of formwork shall be delayed suitably
as directed by the Engineer-in-charge.
4.13.2 After opening of formwork and removal of shoring and timbering, backfilling shall be
started, after repairs, if any, to the foundation concrete as described under para 4.12.4
above. Backfilling shall normally be done with excavated soil. In case the excavated
soil consists of large boulders/stones, it should be broken to a maximum size of 80
mm. If the excavated earth has harmful salts, it shall not, under any circumstance, be
used for backfilling. In such case excavated earth shall be disposed off as directed by
the Engineer-in-Charge and suitable earth (clean and free from harmful salts, organic
and other foreign materials) be brought for back filling. This shall be done by the
contractor at his own cost irrespective of lead involved for bringing the suitable earth.
4.13.3 The earth shall be deposited in layers (maximum 200 mm layers), leveled and wetted
and tampered properly before another layer is deposited. After the pits have been
backfilled to full depth, the stub template may be removed.
4.13.4 The backfilling and final grading shall be carried upto an elevation of about 75 mm
above the finished ground level to drain out water. After backfilling 50 mm high
earthen embankment (bandh) will be made along the side of excavation pits and
sufficient water will be poured in the backfilled.
4.14 CURING
Curing shall start after 24 hours of concreting to keep the concrete wet continuously
for a period of 10 days. However, after a minimum period of 72 hours the pit may be
backfilled with suitable earth sprinkled with necessary amount of water and well
consolidated in layers not exceeding 200mm. Both backfilled earth and exposed
chimney top shall be kept wet for the remainder of the prescribed time of 10 days. The
uncovered concrete chimney above the backfilled earth shall be kept wet by providing
gunny bags dipped in water fully wrapped around the concrete chimney for curing. It
must be ensured that the bags are kept wet by the frequent pouring of water on them.
In case Portland Pozolona cement has been used, curing period shall be increased as
decided by the Engineer-in-charge.
4.15 PROTECTION OF TOWER FOOTING
4.15.1 The work shall include all necessary brick/stone masonry (in C.M. 1:4) revetments,
earth filling above ground level and the clearance from stacking on the site of surplus
excavated soil. Special measures for protection of foundation wherever required shall
be provided after getting prior approval of the Employer and as per directions of the
Engineer-in-Charge.
4.15.2 The excess quantity of earth required for protection of tower (after utilizing the
excavated earth) and to be brought from outside shall be paid as per the rate provided
in the letter of award.
4.15.3 The provisional quantities for foundation protection works are furnished in the
Schedule of Quantities as well as in the Price Schedule. The unit rates shall be
applicable for adjusting with the actual quantities of protection work done.
4.16 FIELD QUALITY CONTROL PLAN

The contractor shall strictly follow the Field Quality Control Plan (given here under) for
effective control on quality of civil works. All costs of testing as per the Field Quality
Control Plan or as directed by Employer shall be borne by the Contractor.
4.17 Technical Specification given in the Contract will govern for the different
items/activities. The items/activities for which detailed specifications have not been
given in the Contract Agreement will be governed by latest ISI/ NBC specifications.
4.18 Wherever IS Code has been mentioned, it shall mean IS Code with latest
amendments.

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HARYANA VIDYUT PRASARAN NIGAM LIMITED

TWO PHASE 132 KV S/C LINE ON D/C TOWERS

Chief Engineer/ MM,

S. No. PARTICULARS Page No.

1 Scope of the work and BOQ 1-2

Sr. Name of line

CHAPTER-I - TECHNICAL SPECIFICATION FOR TOWERS

CHAPTER-II – GENERAL TECHNICAL REQUIREMENTS

CHAPTER-III (A)-TECHNICAL SPECIFICATION OF CONDUCTOR

CHAPTER-III (B)-TECHNICAL SPECIFICATION OF SILICONE

CHAPTER-III (C)-TECHNICAL SPECIFICATION OF BUS POST

CHAPTER-III (D)-TECHNICAL SPECIFICATION OF HARDWARE

CHAPTER-IV - TECHNICAL DATA/INFORMATION (GTP) TO BE

b) i) Construction of civil works,

c) i) Supply of the measuring instruments and testing equipment necessary

All precaution shall be done for safe erection and operation.

Demolishing and dismantling works, if any.

1.2 Detail of Transmission Line Routes and Terrain.

1.3 Result of surveys

1.4 ACCESS TO THE LINE AND RIGHT TO WAY

1.5 DETAILED SURVEY, OPTIMISATION OF TOWER LOCATION

Chief Engineer/TS, HVPNL, Hisar TEL. No. 01662-220794

1.5.4 ROUTE MARKING

1.5.5 PROFILE PLOTTING & TOWER SPOTTING

1.5.6 TOWER LOCATION

1.5.6.1 SAG TEMPLATE

Necessary data in respect of conductor, earthwire shall be provided by HVPNL.

An individual span shall be as near to the normal design span as possible. In

iv) No crossing shall be located over a booster transformer, traction

For navigable river, clearance required by navigation authority shall be provided.

f) POWER LINE CROSSINGS

g) TELECOMMUNICATION LINE CROSSING

The angle of crossing shall be as near to 90 o as possible. However, deviation to

a) Girth (circumference) measured at a height of 1 meter from ground level.

b) Approximate height of the tree with an accuracy of ±2 metres.

c) Name of the type of the species/tree.

1.5.12 PRELIMINARY SCHEDULE

1.5.13 CHECK SURVEY OF TOWER LOCATION

1.6 ENVIRONMENTAL CONDITIONS

1.6.1 GENERAL CLIMATIC CONDITIONS

1.7 TECHNICAL DATA

1.8 STATUTORY REGULATIONS AND STANDARDS

1.8.1 STATUTROY REGULATIONS

The contractor is required to follow local statutory regulations stipulated in

1.8.2 REFERENCE STANDARDS

1.8.2.2 Other in internationally acceptable standards, which ensure equivalent or better

1.9. QUALITY ASSURANCE, INSPECTION AND TESTING

1.9.1 QUALITY ASSURANCE

b) Documentation control system.

c) Qualification data for Bidder’s key personnel.

d) The procedure for purchases of materials parts/components and selection of

f) Control of non-conforming items and system for corrective action.

g) Control of calibration and testing of measuring and testing equipments.

h) Inspection and test procedure for manufacture.

i) System for indication and appraisal of inspection status.

j) System for quality audits.

k) System for authorising release of manufactured product to the HVPNL.

l) System for maintenance of records.

m) System for handing storage and delivery.

1.9.1.2 QUALITY ASSURANCE DOCUMENTS

1.9.2 INSPECTION,TESTING AND INSPECTION CERTIFICATE

Electrical system data

b) Maximum system voltage 72.5 kV