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August 2012

United Republic of Tanzania Tanzania Electric Supply Company Limited

Tanzania, Iringa-Shinyanga Backbone Transmission Investment Project (BTIP)

400kV Transmission Line Lot 1, 2 & 3

Final Tender Documents Part 2 FICHTNER


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Table of Contents

Part 1 Bidding Procedures:


SECTION I SECTION II SECTION III SECTION IV SECTION V INSTRUCTIONS TO BIDDERS BID DATA SHEETS EVALUATION & QUALIFICATION CRITERIA BIDDING FORMS ELIGIBLE COUNTRIES

Part 2 Employers Requirements:


SECTION VI EMPLOYERS REQUIREMENTS GUIDANCE LIST FOR COMPILING OVERALL BID B0 - GENERAL TECHNICAL REQUIREMENTS B1 - PARTICULAR TECHNICAL REQUIREMENTS C - DRAWINGS FORMS AND PROCEDURES

Part 3 Condition of Contract and Contract Forms:


SECTION VII SECTION VIII SECTION VIII SECTION VIII GENERAL CONDITIONS PARTICULAR CONDITIONS Lot 1 PARTICULAR CONDITIONS Lot 2 PARTICULAR CONDITIONS Lot 3

SECTION IX SECTION IX SECTION IX

CONTRACT FORMS Lot 1 CONTRACT FORMS Lot 2 CONTRACT FORMS Lot 3

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TANESCO Bidding Documents Section VI

Section VI
Employers Requirements

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SECTION VI - EMPLOYERS REQUIREMENTS GUIDANCE LIST FOR COMPILING OVERALL BID B0 - GENERAL TECHNICAL REQUIREMENTS B1 - PARTICULAR TECHNICAL REQUIREMENTS C - ANNEXES FORMS AND PROCEDURES

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Guidance List for Compiling overall Bid


Each individual Bid for each Lot, shall be submitted in same order as indicated herein below and should comprise of the following: Volume 1: 1. Letter of Bid in the format attached in Section A4, duly completed in the manner and detail indicated therein and signed by the Bidder. 2. Power of attorney according to ITB clause 21.2 3. Bidder Information Sheet / Party to JVA Information Sheet as per the format included in Section A4 (Form ELI 1.1 / ELI 1.2) 4. Joint Venture Agreement, if any 5. Bid security furnished in accordance with ITB Clause 20. 6. Certification according to ISO 9001 or equivalent and Description of the Quality Assurance System 7. Organization chart showing the intended project organization in the Contractor's head office and at site 8. Time and personnel schedule for erection indicating: number and qualification as well as period of stay of key personnel total number of local personnel required plus the calculated man-months qualification and experience of expatriates and local personnel

9. Mobilization & Construction schedule and work program depicting mainly mobilization, the design / submission of drawings, manufacturing, factory acceptance testing, shipping time, custom clearance, inland transport, civil works, erection works, commissioning, trial run, training, and final completion date. The time schedule must be accompanied by a detailed step by step work program including milestones, describing how the contractor intends to perform the works. The Bidder shall clearly show all major and important activities, number of staff involved, expected progress. 10. Tentative training schedule 11. Tentative testing program: Tests in the factory and on site, which are planned to be performed. In the factory:

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TANESCO Bidding Documents Section VI

during plant manufacturing during Factory Acceptance Test On site: during plant installation and execution of civil engineering works during test run during technical inspection and trial operation during commissioning during operational acceptance 12. Price schedules (in the format attached) duly completed by the Bidder in the manner and detail indicated therein and following the requirements of ITB clause 12, 14.1 and 17. For ease of evaluation and reporting purposes price sheets shall also be submitted as editable EXCEL2003 or 2007 files. However, the ORIGINAL hardcopy will always take precedence over the electronic version in case of discrepancies.

Volume 2 13. Documentary evidence established in accordance with ITB 16.1 that the Plant and Installation Services offered by the Bidder conform to the Bidding Document. The documentary evidence of the conformity of the facilities to the bidding documents may be in the form of literature, drawings and data, and shall furnish a detailed description of the essential technical and performance characteristics of the facilities. 14. Recommended spare parts, equipment, tools and instruments a list giving full particulars, including available sources, storage and supply policy and current prices of all spare parts, special tools, etc. necessary for the proper and continuing functioning of the facilities for a period of 5 years. Detailed technical description and technical parameters of equipment, tools and instruments shall be submitted.

15. Method Statement Bidders shall submit proposals of work methods in sufficient detail to demonstrate their technical capability to meet the Employers requirements. Method Statements shall be submitted for the main activities such as concrete casting, tower erection, stringing, etc. they shall describe the procedure, the tools used, the qualification and quantity of the personnel employed, the test methods applied and the progress rates per day.

16. Technical Schedules (fully completed schedules with all required data properly filled in) If bidders offer data of goods/services from a subcontractor/supplier, authorization forms for these goods/services have to be submitted in an annex.
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Volume 3 17. Qualification Forms and Update of information provided in the PQ Application. In order to evidence the Bidder meets the project requirements and continues to meet the criteria used at the time of prequalification, according to Section III, item 2.1. The following forms shall be included in the bid in the format attached in Section IV: Historical Contract non Performance (Form CON-2) Financial Situation (Form FIN-3.1, FIN-3.2 & FIN-3.3) 18. Current Contract Commitments / Works in Progress as per the format included in Section IV (Form CCC) 19. Details of the proposed personnel and their experience records according to Section III item 2.3 in the format included in Section IV (From PER-1 & PER-2). 20. Subcontractors and manufacturers proposed by the Bidder. The Bidder shall include details of all major items of supply or services, according ITB 16.2 and Section III item 2.5, that he proposes purchasing or subcontracting, giving details of the proposed subcontractors, including vendors, for each of these items. Bidders are free to list up to three subcontractors/suppliers against each item of the facilities. The format attached in Section IV shall be used for the list of nominated subcontractors. The participation of the subcontractor/supplier shall be confirmed by an authorization form as included in the bidding forms. The Bidder shall be fully responsible to get approval by the Employer for any subcontractor to be involved in the Contract realization and that any plant, equipment or services to be provided by the contractor comply with the Bid documents, prior to conclusion of the Contract. 21. Equipment and machinery A list providing information about the equipment and machinery intended to be used by the Contractor for the Works, according to Section III item 2.4 in the format included in Section IV (From EQU). Separate lists shall be provided for the proposed subcontractors. In case the descriptions contain multiple equipment or machinery, those intended to be used for the project shall be clearly marked. 22. Covenant of Integrity (for Lot 3 only) according to ITB 3.1 Note: Bidders can combine three volumes into one with the same sequential order as in Volume 1, 2&3 described above.

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TANESCO Bidding Documents Section VI (Part B0)

B0
Employers Requirements General Technical Requirements

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Table of Contents
B0. General Technical Requirements B0.1 General Requirements B0.1.1 B0.1.2 B0.1.3 B0.1.4 B0.1.5 B0.1.6 B0.1.7 B0.1.8 B0.2.1 B0.2.2 B0.2.3 B0.2.4 B0.2.5 B0.3.1 B0.3.2 B0.3.3 B0.3.4 B0.3.5 B0.3.6 B0.3.7 B0.3.8 B0.3.9 Units of measurement Standards and codes Plant and equipment identification Marking, labeling and packing Transport and storage of material Standardization of makes Signs Pre-service cleaning and protection of plant General Steel structures Assembly material Excess Material Spare Parts Foundation design Design loads General requirements for the design and execution of all civil works Soil investigation Topographic survey Mobilization and site installation Earthworks Foundations works Concrete works 1 1 1 4 5 5 8 9 9 10 11 11 11 11 12 12 13 13 13 14 15 17 18 19 23 26 37 39 39 45 52 57

B0.2 Steel Structures and Assembly Material

B0.3 Civil Works

B0.3.10 Erosion protection B0.4 Inspection and Testing B0.4.1 B0.4.2 B0.4.3 General Inspections and tests during manufacture Inspections and tests during erection and commissioning

B0.5 Documentation and Drawing Approval

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B0.5.1 B0.5.2 B0.5.3 B0.5.4 B0.5.5 B0.5.6

General Specification stage Stages after contract award Design and manufacturing stage Erection stage Registration of drawings and lists

57 57 58 66 66 68

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B0. General Technical Requirements


The present clauses refer to the general technical requirements for EPC (Engineering Procurement Construction) contracts for electrical overhead lines. The following directions, information and technical requirements for design, engineering, layout, manufacturing, erection, installation and testing shall be observed as far as they are applicable for the material and equipment to be delivered. The requirements stated in this Section of General Technical Requirements are valid for all sections of the technical requirements, except where different, additional and/or special requirements are specified within the Particular Technical Requirements. Any changes on the design of any part of the Plant, which may become necessary after signing of the Contract, have to be submitted by the Contractor in writing to the Employer for approval, being sufficiently substantiated and justified. The Plant shall be brand new and designed, manufactured and arranged so that it will have a functional design and a pleasant appearance.

B0.1

General Requirements

B0.1.1

Units of measurement
The Contract shall be conducted in the SI (Systme International dUnits ) system of units in accordance with the provisions of ISO 31 and ISO 1000. In all correspondence, technical schedules, drawings and instrument scales, the following units or multiples thereof shall be used: Quantity Length Mass Time Temperature Temperature Difference Electric Current Luminous Intensity Area Volume Name of Unit Meter Kilogram Second Degree Celsius Kelvin Ampere Candela Square meter Cubic meter Liter Symbol m kg s C K A cd m2 m3 l

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Quantity Force Pressure (absolute) Pressure below 1 bar Stress Velocity Rotational speed Flow

Name of Unit Newton Bar Kilopascal Millibar Newton per square millimeter Meter per second Revolutions per minute Cubic meter per day Cubic meter per hour Kilogram per hour Liter per second metric ton per hour For gaseous substance: standard cubic meter per hour (referred to 0C and 1013 mbar) Kilogram per cubic meter Kilogram per standard cubic meter Newton meter Kilogram square meter Joule Joule per Kelvin Joule per cubic meter Joule per gram Watt Watt per square meter Watt per meter Kelvin Newton second per square meter Meter squared per second Newton per meter Parts per million Microsiemens per meter at 25C Hertz Coulomb Volt Volt per meter Farad Ohm Siemens

Symbol N bar kPa mbar N/mm2 m/s rpm m3/d m3/h kg/h l/s t/h Nm3/h

Density

kg/m3 Kg/Nm3 Nm kgm2 J J/K J/m3 J/g W W/m2 W/mK Ns/m2 m2/s N/m ppm S/m Hz C V V/m F S
2

Torque, moment of force Moment of inertia (mr2) Work, energy or heat Heat capacity, entropy Calorific value Power, radiant flux Heat release rate Thermal conductivity Dynamic viscosity Kinematic viscosity Surface tension Concentration Electrical conductivity Frequency Electric charge Electric potential Electric field strength Electric capacitance Electric resistance Conductance
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Quantity Magnetic flux Magnetic flux density Magnetic field strength Luminous flux Illuminance Thermal resistivity Energy

Name of Unit Weber Tesla Ampere per meter Lumen Lux Kelvin meter per Watt Kilowatt hour

Symbol Wb T A/m lm lx Km/W kWh

Materials All materials shall be new and of the best quality suitable for working under the conditions, variations in temperature and pressure encountered in service without undue distortion or deterioration or the setting up of undue stresses in any part, such as not to affect the efficiency and reliability of the plant. Either all materials shall conform to the approved standards and the respective code number, or exact analysis data and full information concerning properties, chemical and mechanical treatment shall be submitted. Only materials which have been tried and tested in similar plants shall be used. Steel castings shall not have any casting defects which could compromise the function of the component and affect the appearance. The materials employed shall serve their purpose, according to the operation conditions. The Contractor shall be responsible for selecting, working, treating and quality assurance of the materials to suit the intended purpose. Special attention shall be paid to the corrosion by galvanic effects or electrochemical corrosion. Design, selection of material and its combination as well as methods of erection shall be such as to exclude these effects. It is not permissible to use gray cast iron for components containing pressure, unless the Employer expressly agrees to this beforehand. Asbestos or materials containing asbestos for seals, expansion joints, etc. shall not be employed. Likewise it is not permissible to use mercury or oils containing Polychlorinated Biphenyl (PCB). No welding, fitting or plugging of defective parts will be permitted without permission in writing of the Employer.

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B0.1.1.1

Guaranteed values
The Contractor shall guarantee that the data mentioned on the name plate of the equipment and given in the data sheets will not deteriorate during the life of this equipment under the specified operating and maintenance conditions. The Contractor shall guarantee the values in the technical data schedule. The Employer reserves the right to reject any equipment that does not respect these values.

B0.1.2

Standards and codes


The work is to be performed according to the most recent relevant codes, standards, accident prevention regulations and legal regulations. The IEC international standards and recommended practices shall be fulfilled. All materials and equipment supplied and all work carried out as well as calculation sheets, drawings, quality and class of goods, methods of inspection, constructional peculiarities of equipment and parts and acceptance of partial plants, as far as these are beyond the special requirements of partial plants and as far as they are beyond the particular requirements of the technical requirements shall comply in every respect with the technical codes of the International Organization for Standardization (ISO). IEC recommendations apply to the electrical equipment. Goods and special guarantees beyond the scope of ISO and IEC, shall conform at least to the following standards and codes in the following priority: EN, DIN, BS, ASTM, IEEE; VDE Other internationally accepted standards which ensure a quality equal to or higher than the standards mentioned above, but only if these are submitted in the English language edition and accepted by the Employer. Contractor, subcontractors, sub-suppliers and shops are to be certified according to ISO 9001. It is the Contractors responsibility to provide sufficient evidence that any national or other standard the Contractor proposes (other than those mentioned above) will ensure an equivalent or higher standard. The Bidder shall clearly state in his proposal concerning the standards and codes, he intends to apply. In case of differences between the specification and relevant standard the more stringent condition shall be applied. In case of contradiction the specification shall prevail.

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B0.1.3

Plant and equipment identification


The Contractor shall apply a plant identification system showing the name and number of each item of plant and its respective arrangement drawing number and add any additional items necessary to fully identify the plant. There is to be only one description for any one item of plant and this must be used consistently for plant, electrical and instrumentation designations throughout. IEC-Publication 61346-1 shall be applied. The classification numbers shall appear in all drawings, lists, documents prepared by the Contractor for the project right from the initial stage of the contract execution. The Contractor shall supply all labels, nameplates, instruction and warning plates necessary for the identification and safe operation of the plant. Their inscriptions shall be in the national language of the Employers country if not otherwise mentioned. All labels, nameplates, instruction and warning plates shall be securely fixed to items of plant and equipment with stainless steel rivets, plated self tapping screws or other approved means. The use of adhesives will not be permitted. Nameplates for plant and equipment identification and record purposes shall be manufactured from stainless steel with a mat or satin finish, and engraved with black lettering of a size which is legible from the working position. Warning plates shall be manufactured from stainless steel engraved with white lettering on a red background and sited in the position where they afford maximum safety of personnel. All equipment within panels and desks shall be individually identified by satin or mat finish stainless steel labels, or laminated plastic labels where approved.

B0.1.4

Marking, labeling and packing


The Contractor shall prepare all equipment and materials for shipment in such a manner as to protect them from damage in transit, and shall be responsible for and make good any and all damage due to improper preparation or loading for shipment. Before being packed for shipment to the site, all items of the equipment shall be carefully numbered and marked so that they can be readily assembled and erected in the correct relative positions at the site. Wherever applicable, these numbers and markings shall be punched or painted so that they shall be clearly visible.

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Packing shall be done in convenient sections, so that the weight and size of sections are suitable for transport to the site and for handling at the site under the special conditions applicable there. All individual pieces shall be marked with the plant identification number and the correct designation shown on the Contractor's detailed drawings and on other documents like packing lists, spare parts lists, operation and maintenance instructions, etc. Marking shall be done identically on labels and by stamping the marks into the metal before painting, galvanizing, etc., and shall be clearly readable after painting, galvanizing, etc. All parts of the plant shall be packed at the place of manufacture. The packing shall be suitable for shipment by sea and for all special requirements of the transportation to the site. Where necessary, double packing shall be used in order to prevent damage and corrosion during transportation, unloading, reloading and during intermediate storage. All identical members shall be packed together, if reasonably possible, in a form convenient for shipment and handling. Small items shall be packed in boxes and large items shall be protected, where necessary, by timber, straw and sacking. All parts shall be suitably protected against corrosion, water, sand, heat, any adverse atmospheric conditions, shocks, impact, vibrations, etc. for later transport and storage. Tube ends and other similar open ends shall be protected against external damage and ingress of dirt and moisture during transit and while awaiting erection at site. Flanged pipes shall have their open ends protected by adhesive tape or jointing and then be covered with a wooden blind flange. Screws and not nails shall fix the lids and internal cross battens of all packing cases. The contents of the cases shall be bolted securely to the case or fastened in position with struts or cross battens, and not wedged in place with wooden shocks, unless these are fastened firmly in place. All struts or cross battens are preferably to be supported by cleats fixed to the case above and below to form ledges on which the batten may rest. Cases shall be up-ended after packing to prove that there is no movement of contents. Where parts are required to be bolted to the sides of the case, large washers shall be strengthened by means of a pad. Wood-shavings shall be avoided as far as possible for packing purposes. Tower members shall be packed for shipment in bundles of the same size and weight containing pieces of the same or similar identifications mark and length.
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The individual members may be stacked to bundles and plastic spacers shall be placed in between the individual members, reducing the formation of wet storage stains. All bolts, nuts, washers, step bolts and minor fittings shall be shipped in wooden cases of suitable size and weight, with pieces properly separated according to size and type. Bundles of steel angle sections shall be properly tied together by an approved method. The individual bundles shall be marked for identification by stamped metal labels. Particular care shall be taken by composing of bundles containing similar length of members and that the individual bundles do not have excessive weight for facilitate handling during shipment. Bundles may be as large as practicable to provide sufficient internal stiffness and resistance against excessive bending of deformation during lifting. Unless the Contractor can offer an equally acceptable method, bundles of angles shall be arranged in rectangular formation with notched outer stout wooden battens to locate the angles, the battens being located sufficiently close intervals to form a strong homogeneous element. Packing cases where used shall be strongly constructed and in no case is timer less than 25 mm in thickness to be used. The contents of packing cases shall be securely bolted or fastened in position with struts or cross battens. Cross battens supporting weight in any direction shall not rely for their support on nails or crews driven lengthwise into the grain of the wool, but shall be supported by cleats secured from the inside. Spare parts shall be packed for long duration storage. Individual steel members stacked in bundles as spare parts shall be spaced by plastic spacers. Wooden drums will not be accepted for the spare conductors, ground wires and OPGW. Each crate or package shall contain a packing list placed in a waterproof envelope. All items of the crate or package shall be clearly marked for easy identification against the packing list. All cases, packages, etc. shall be clearly marked on the outside to indicate the total weight, the position of the center of gravity and the correct position of the slings and shall bear an identification mark relating them to the appropriate shipping documents. All stencil marks on the outside of cases shall be either of a waterproof material or protected by shellac or varnish. All packing shall be included in the scope of delivery and the cost be included in the prices. The packing materials remain the property of the Employer.

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The Purchaser may require to inspect and approve the packing before the items are dispatched but the Contractor is to be entirely responsible for ensuring that the packing is suitable for transit and such inspection shall not exonerate the Contractor form any loss or damage due to faulty packing.

B0.1.5

Transport and storage of material


Shipment by sea freight shall be made to the designated port of destination. Airfreight shall be made to the destination airport, as agreed with the Employer. Shipments are to be made on a CIP basis according to Incoterms 2010 and explained in the commercial conditions. Prior to shipment the Contractor shall furnish by air mail, telefax, telex or otherwise, as agreed the shipping documents to the Employer. Details will be fixed during the Kick-Off Meeting. All cases and boxes shall be clearly and boldly marked and shall be sent to the Employer as per address details instructed by the Employer. When the actual transport has been completed, the Employer shall be notified accordingly. In order to facilitate custom examination, all packages and transport documents shall regardless of other markings be clearly and indelibly marked. It is the Contractors responsibility to ensure that the packing and handling is made in such a way that neither the steel nor the galvanizing shall be damaged in transit and storing. Transporting vehicles shall be clean and free from foreign material which could in any way injure the steel or zinc coating and painting. All necessary measures shall be taken to prevent structural deformation to members, or damage to galvanized or painted coatings. Members shall not be dragged on the ground, nor will the practice of throwing tower steel into piles on conveyances, or from conveyances onto the ground, and of skidding steel members over each other, be permitted. The Contractor shall ensure that adequate handling equipment is available to unload the heaviest piece of equipment. Tower material damaged shall be replaced by the Contractor at no cost to the Employer. Small accidental damages to galvanized surfaces may be repaired by application of an approved repair paint. Tower material damaged shall be replaced by the Contractor at no cost to the Employer. Larger damages to, or systematic defects of the galvanizing shall be repaired by hot-dip galvanizing only. The attempt to repair shall not bind the Employer to accept the repaired part when this is re-offered for inspection.

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Acceptance by the Employer of any repaired galvanized steel does not release the Contractor from his responsibility of supplying galvanized steel to give satisfactory service in the prevailing corrosive atmosphere. The Employer reserves the right to reject any galvanized steel found rusty, damaged, bent or other-wise defective, before final acceptance. Steel shall be stored on wooden supports of sufficient height, to avoid any ground contact or other contamination. Storage conditions shall be well ventilated, preventing the formation of wet storage stain form accumulation of humidity and sand. It shall be clearly understood, that white rust formation will lead to rejection of the affected material.

B0.1.6

Standardization of makes
The works shall be designed to facilitate inspection, cleaning, maintenance and repair. Continuity of supply is a prime concern. The design shall incorporate every reasonable precaution and provision for the safety of all those concerned in the operation and maintenance of the works. Corresponding parts throughout shall be made to gauge and be interchangeable wherever possible. All equipment performing similar functions shall be of the same type and manufacture, to limit the stock of spare parts required and maintain uniformity of plant and equipment to be installed. The Employer reserves the right to ask for coordination of standardization to the extent reasonably possible, and no price variation will be allowed for this procedure.

B0.1.7

Signs
Safety colors, safety symbols and safety signs must comply in construction, geometrical form, color and meaning with the ISO 7010 and ISO 3864 Signs for plant identification during the erection period shall be to Employer's approval. The signs should be of a material which is weather-resistant and of sufficient durability for the conditions prevailing on site. Mounting and installation The positions for the signs shall be chosen so that they are within the field of vision of the persons to whom they apply. The signs should be permanently attached. Temporarily dangerous areas (e.g. construction sites, assembly areas) may also be marked by movable signs. The safety signs must be mounted or installed in such a manner that there is no possibility of misunderstanding.

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Warning signs Warning signs should refer to the existence or possible existence of danger, e.g., general danger, high voltage and climbing prohibited. In addition to warning signs, appropriate black-yellow strip markings should also be used where necessary.

B0.1.8

Pre-service cleaning and protection of plant


This clause covers mechanical and pre-service cleaning and protection of the plant items and equipment at the Manufacturers workshop and at site that are not subsequently to be painted. Cleaning of fabricated component items shall be carried out after fabrication and final heat treatment or welding at manufacturers works or at site, as appropriate. In the event of the surfaces not being cleaned to the Employers satisfaction, such parts of the cleaning procedures or agreed alternatives as are deemed necessary to overcome the deficiencies shall be carried out at the Contractors sole expense. Mechanical cleaning as opposed to alternative chemical cleaning is the preferred method for workshop cleaning except where this is precluded by design or access considerations. Machined surfaces shall be protected during the cleaning operations. For recleaning small areas, hand cleaning by wire brushing may be permitted. Wire brushes used on austenitic materials shall have austenitic steel bristles. Austenitic stainless steels, copper and aluminum alloys, cast iron, bimetallic and metallic/plastic items, and components fabricated by spot welding or riveting shall not be chemically cleaned. All weld areas shall be suitably stress-relieved before chemical cleaning. All necessary equipment, provisions, chemicals etc. are to be provided by the Contractor. Besides this, the Contractor shall take over all responsibility for the treatment and disposal of wastes according to the local law and to the satisfaction of the Employer. The Contractor shall take all necessary precautions to ensure that the internal surfaces of all plant are kept clean and free from injurious matter during erection.

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B0.2

Steel Structures and Assembly Material

B0.2.1

General
Under steel structures are to be understood all overhead line towers with their body and leg extensions, additional crossarms if required, the foundation stubs, and stub setting templates. Under assembly material are to be understood all bolts, screws, rivets, nuts, washers, locking devices which are necessary for the assembly of the steel structures and their accessories as well as, for the assembling and mounting of the line equipment like insulator sets, conductor and earthwire / OPGW accessories.

B0.2.2

Steel structures
Generally, the design and stress calculation shall conform to a consecrated code or standard such as: EN 50341 Overhead electrical lines exceeding AC 45 kV DIN 1000 Steel Structures; Construction, DIN 4114 Stress Calculation of Steel Structures, DIN 18800 Steel Structures; Calculation and Construction The local climatic conditions, load calculation, description of loading cases, as well as the applicable design method and safety factors shall be as detailed in the Particular Technical Requirements. The material to be used for the structures is high tensile and mild steel sections and plates, according to internationally recognized standards (ISO 630, DIN 17100 or equivalent). All structural steel shall be protected against corrosion by hot dip galvanizing.

B0.2.3

Assembly material
All necessary bolts, screws, rivets, nuts, washers and locking washers shall be included in the scope of supply of the Contractor with sufficient spare to cover for losses. Members of lattice steel structures including stub setting templates shall be secured by means of bolts and nuts with approved spring washers. All bolts and nuts shall conform to ISO 898 respectively to DIN 267 and shall have metric screwed threads. Nuts and the heads of bolts shall be of the hexagonal type. Nuts except lock nuts shall be full bearing on one side.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Minimum size of bolts for all structural connections shall be 16 mm diameter in mild steel or 12 mm in high tensile steel. The quality of bolts shall not be less than 5.6 according to ISO 898 respectively DIN 267. All bolts and screwed rods shall be galvanized including the threaded portions. All nuts shall be galvanized with the exception of the threads, which shall be oiled. Where for any type of tower high tensile steel bolts are employed then bolts of this type shall be used for all connections for every type of tower on that line in order to avoid the use of mild steel bolts in error where high tensile type should be employed. High tensile steel bolts shall bear a mark on the head to allow identification of grades. The nuts of all bolts attaching insulator set droppers, U bolts and earth conductor clamps to the towers shall be locked in an approved manner. All washers shall be included under this contract, including locking devices and anti-vibration arrangements, which shall be subject to the approval of the Employer / Employers Representative. Taper washers shall be fitted where necessary. Nuts when finger tight or snug tight (about one-fourth turn from tight) on the bolt may be rejected if they are, in the opinion of the Employer / Employers Representative, considered to have an excessively loose or tight fit. Bolts with threads re-died after galvanizing will be rejected. Nuts and bolts of the same type shall be interchangeable and supplied from the same manufacturer.

B0.2.4

Excess Material
To ensure uninterrupted erection, the Contractor shall supply a two-pointfive (2.5) percent excess of bolts, nuts, washers, spring washer, step bolts, minor fittings and two (2) percent excess of bracings, gussets, plates of each item respective size, to cover losses or damages. For bracings only apply this for material size smaller than L 70. The cost for the excess material shall be included in the tower supply price. Note, the weight of the excess material shall not be included in the steel weight to be indicated in the data sheets of the bid documents. Any such assembly material which is surplus after the installation and final check of tower has been completed, shall be wrapped, marked and handed over to the Employer.

B0.2.5

Spare Parts
If required, spare parts for towers and accessories specified in the Price Schedule shall be supplied. As spare parts are commonly stored over a long period, particular care shall be made when packing these items. The Contractor will have to ensure that storage of all spare parts will be such that these are not affected by environmental influences such as rain, sun, etc.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Contractors storage proposal will have to be approved by Employer before implementation. The Purchaser reserves the right to cancel the requirement for supply of spare parts. The Contractor will not be entitled to any additional compensation by reason of eliminating the supply of the whole or a part of the specified spare part quantities. Accordingly the corresponding costs will be deducted from the total Contract Price.

B0.3

Civil Works

B0.3.1

Foundation design
All foundations shall be designed to withstand compression, uplift, settlement, overturning and sliding when subjected to the specified conditions of loading. Allowance shall be made in foundation design for hydrostatic pressure, effects of seasonal rain, drying out, cyclic loading and wind induced vibrations. All foundations have to be designed for adequate provision for horizontal shear forces in the region of ground line.

B0.3.2

Design loads
Loading cases may be separated into 3 categories of: Steady-state loads Steady state loads or dead loads are those loads imposed on a structure for a long or continuous time period. Transient loads Transient loads or live loads are those loads imposed on a structure for a short time duration or temporary time period. Construction loads Construction loads or erection loads are those loads imposed on a structure during erection or maintenance period. The following design loads shall be considered for the foundation structure: Dead load Dead load is defined as the weight of all permanent foundation construction and super structure as well as overburden soils vertical above of the foundation base. Soil load Horizontal soil load consists of lateral active and passive earth pressure which by pile foundation for example may be considered for lateral bedding. Hydrostatic load Hydrostatic load is the force acting on structures due to water pressure. The design of foundations shall include the buoyancy load due ground water which is equal to the weight of the volume of displaced water.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Highest water level under max. uplift load and lowest water level for compression load are to be considered as dead load. Wind load The wind load shall be considered as live load superimposed to the dead load with regard to conductor tension, member shape and structure height of tower. Earthquake load The earthquake load shall be considered as live load superimposed to the dead load and some wind load with regard to super structure elasticity and possible soil liquefaction. Erection load Erection/maintenance load is defined as live load superimposed to the dead load of structure but not permanently attached to it, i.e. loads imposed by lifting/temporary anchoring of pre-assembled structure parts, erection equipment places/anchored temporary on structure parts; personnel standing on structure members. Thermal load Thermal loads shall be defined as forces caused by changes in material temperature due to the expansion or contraction of the entire structure or individual structural/plant components, e.g. increase of conductor tension or differential line tension. Impact load Any live load that can produce dynamic action (such as a moving load or a short circuit impulse) shall be described by static models in which the dynamic effects are included, e.g. increase by an impact factor. Exceptional load Exceptional load is defined as live load superimposed to the dead load of structure but nor permanently acting, i.e. loads imposed during stringing operation or by broken wire condition or tower failure.

B0.3.3

General requirements for the design and execution of all civil works
1.) The design of all structures under this contract shall be such that differential and total settlements or other movements shall not exceed acceptable limits and full provision shall be made for all expansion and other joints. The design shall be to the approval of the Employer/Employer's Representative. Structural members subjected to flexure shall be designed to have adequate stiffness to limit deflections or any deformations that affect strength or serviceability of a structure adversely. The maximum allowable deflections of structural members shall be in accordance with the relevant design standards and as specified in the Particular Technical Requirements. Concerning the annex drawings which form part of these technical requirements they are to be considered minimum requirements in size and standard.
14

2.)

3.)

5413A08/FICHT-7269866-v5

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

4.)

The clearance from the conductor to ground and tower structure shall be such as to provide adequate space for the safe installation and proper operation, maintenance and repair of all plant and equipment of the transmission system. All materials used in the works shall be of the best quality of their respective kinds as specified herein, obtained from sources and suppliers approved by the Employer / Employers Representative. Samples of all materials proposed to be used in the works may be called for at any time by the Employer / Employers Representative. The work shall be carried out by competent personnel skilled in their various trades. Before commencing the works the Contractor shall ascertain the locations and nature of all existing overhead lines and underground services within the right of way corridor and shall take every possible precaution against any damage occurring to them or interference therewith, during the execution of the works. Live line interruptions and building permissions for construction works near or close to existing sub-ground or super structure shall be requested/obtained by the Contractor well ahead in due time of commencement the site activities Access pists, bush clearing and site leveling is the responsibility of the Contractor. Access roads which remain for maintenance shall be in good condition when handing over to the Employer. Before staring of design works, the Contractor shall submit to the Employer/Employers Representative for approval the proposed project design procedure containing the design data, standards and rules and the design criteria intended to be used for the civil works.

5.)

6.) 7.) 8.)

9.)

10.)

11.)

B0.3.4

Soil investigation

B0.3.4.1

General
The extent of the investigations shall be such as to permit the satisfactory determination of all necessary subsoil characteristics, to exclude any unacceptable settlement and to determine reliable type, size and execution of foundations. These investigations have to be completed before the works start.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

B0.3.4.2

Quality assurance
The following references have to be submitted to the Employer / Employers Representative for approval prior to start of any field work: experience in soil investigation work experience in laboratory testing experience in foundation engineering. applied soil drilling/penetration equipment The soil report containing the description of the soil conditions and the foundation engineering proposals is to be prepared by an expert and is to be signed by him. The expert shall supervise the boring works as well as the laboratory tests. Soil investigation report A report about the final soil investigations shall be worked out by the Contractor in such detail that recommendations for the individual foundation works and characteristic engineering properties of the specified soil classes are made. The report should include but not be limited to the following information: Penetration sounding log sheets Soil description and stratification Type and composition of soil State of consistency and relative density Ground water level max./min. Grain size curve Atterberg limit (plasticity) Natural/water content Density of soil Depth and position of borehole/pit/sounding and disturbed samples taken Summary of laboratory test results (table) Note: Estimation of the possible max. ground water level shall be made when the subsoil investigation is undertaken not at the end of wet season. Chemical analysis The groundwater and subsoil shall be chemically analyzed and classified with regard to its aggressive action against concrete. Earthing system The report shall contain sufficient information regarding the conductivity of the soils necessary for the design of earthing systems. Conclusions The investigation shall give accurate data about the level of the bearing layers and the depth of the groundwater table.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Clear recommendations for all foundations shall be derived from the laboratory tests and the in-situ investigations. These recommendations shall refer to the bearing capacity of the subsoil and the appertaining settlements in accordance with the type of foundation applied by the Contractor.

B0.3.5

Topographic survey
A topographical survey shall be made by the Contractor along the entire line route corridor. The work includes furnishing all labor, materials and equipment, and performing all work required for the survey at site, in accordance with the conditions at site and in accordance of the Particular Technical Requirements of the Contract Documents. The Contractor shall carry out all the necessary surveying works in order to: obtain topographic survey maps (plans and longitudinal profiles) ensure that the position and elevation of all works constructed by him are correct and required minimum clearance to live line parts is maintained at all times in any conditions. The existing benchmarks (if available), related to the national network, shall be used as basis for the surveying works. The new benchmarks are to be secured and marked in such a manner as to ensure that they can be found any time, that they will not be destroyed by construction activities. The surveying program and the list of equipment shall be submitted to the Employer / Employers Representative for approval. The results of the survey shall be reported as follows: description of the survey work, referring to the method applied, equipment used, work organization, field operation, data processing, interpretation and presentation of the results general line route maps containing access pists and line axis with angle and main suspension towers situation plan and longitudinal profiles along the entire line route corridor. For the final report, the Contractor shall also provide all the survey data in a digital format so as to permit reprocessing of any desired part or aspect of the survey.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

B0.3.6

Mobilization and site installation


The Contractor has to inform himself fully of the local conditions on site. Any claims for unknown obstacles or hindrances raised after contractsigning will not be accepted. For the implementation, construction, working conditions, maintenance of the site installation works, the Contractor can use the areas indicated for this purpose by the Employer. The Contractor shall provide: container type temporary site office buildings necessary for housing of the personnel of the Employer/ Employer's Representative buildings and containers necessary for the service in connection with the performance of the work construction plant necessary for the performance of the work miscellaneous facilities and installations for buildings and construction plant. After the completion of the work, the temporary service roads which will not be required for maintenance later on, buildings and relevant facilities built by the Contractor, shall be removed. All of the Contractor's facilities shall be provided with the services necessary for their operation, such as electrical energy, potable water supply, sewers, drainage system, fire extinguishing system, etc. The Contractor shall install an independent communication system to his, to the Employer's/ Employer's Representatives offices. The temporary site office buildings for the Employer/ Employer's Representative shall be structurally sound and compatible with the weather conditions on the site including the following rooms: office rooms for 2 engineers meeting room sanitary room storage room air conditioners refrigerator The Contractor has to submit for approval to the Employer all drawings and details for the buildings, services, equipment intended to be used before starting with the execution works on the site. If necessary, during the execution works, the Contractor can make modifications of site installation works, but without any claims for extension of the contractual execution time and additional costs.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

B0.3.7

Earthworks

B0.3.7.1

General
This section applies to all earth and rockwork required for the construction of buildings, structures, foundations and burying service lines in the ground. The Contractor shall satisfy himself as to the ground conditions on the site including the nature of the strata to be excavated, obstructions, possibilities of flooding and shall allow for all provisions necessary to carry out the work in the most suitable manner when submitting his Bid. Generally all buildings and structures must be founded on bearing strata which means that all excavation work for foundations shall meet the requirements of structural analysis based on the results obtained from the soil investigation and /or of the available information and instruction given by the Employer / Employers Representative. Furthermore this division applies to excavation works in connection with roadwork and access pists and landscaping. Excavation shall be done to the required dimensions and shall be finished according to the specified lines and slopes, in a way acceptable to the Employer / Employers Representative.

B0.3.7.2

Fill materials
The fill materials used are to be examined by the Contractor and approved by the Employer / Employers Representative. Select fill Select fill shall have the following properties: well graded, non-cohesive and nearly silt-free, salt free, soils free of organic matter. The material shall be of such nature and character that it can be compacted to the specified densities. It shall be free of plastic clays, of all materials subject to decay, decomposition or dissolution or other materials which will corrode piping or other metal. The intention is to use select fill below structures on foundation backfill and access pists used for maintenance if original soil is deemed to be not suitable. Ordinary fill Ordinary fill shall have the following properties: Natural inorganic soils: salt content not greater than 5%, organic matter less than 3%.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

The intention is to use ordinary fill for non-built areas and for backfill of tower foundations Special fill Special fill material shall be gravel or crushed rock. The intention is to use special fill e.g. as sub-base material where required.

B0.3.7.3

Execution of excavations
The works shall be excavated either by hand or by use of mechanical excavating equipment. Excavation by hand may be required for undercut / under-reamed foundations close to existing installations and/or underground services, but subject to special instruction of the Employer / Employers Representative . The Contractor shall carry out earth- and rockwork for the following works as defined hereafter: clearing and grubbing excavation of top soil open cut excavation backfilling ground water control and pumping measures safety precaution during earthwork underground excavation (if required) grading/leveling of tower site replacement of material trench excavation for earthing embankments and erosion protection walls Safety precaution The Contractor shall be responsible for all necessary safety measures. Proper strutting, sheeting and bracing, including re-arrangement of the installations when necessary, stabilization and protection of slopes, methods of excavation to reduce risks of slides, etc. shall be considered by the Contractor. Over excavation If somewhere, and for any reason, excavation are executed beyond the established lines and without the Employer / Employers Representative 's previous approval, the Contractor shall at his own expenses backfill with approved material (including required compaction) or with lean concrete to Employer / Employers Representative s approval, the volume corresponding to over-excavation. He shall not receive payment for over-excavation not ordered.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Stockpiles and disposal Excavated material from the Works selected by the Employer / Employers Representative for re-use shall be placed immediately in its final position, if possible, or otherwise may be stockpiled or deposited on Site as directed by the Employer / Employers Representative. The Contractor shall not have the right either to additional payment or to claim because of work involved in stockpiling materials, re-use of for carting to the waste disposal areas. Soil unfit for re-use shall be removed to sites approved by the Employer. Preparation of foundations All surfaces on which or against which concrete is to be poured shall be carefully cleaned and roughened to the Employer / Employers Representative 's satisfaction. The rock surface shall be free of oil, stagnant or running water, mud, loose rock, residue and impurities or any other improper material. Immediately before concrete placing, all rock surfaces shall be thoroughly cleaned. All earth surfaces against which concrete is to be poured, shall be clean and free of any detrimental impurities, organic matter or unsuitable material. Immediately after excavation, all such surfaces shall be moistened and treated as directed by the Employer / Employers Representative. Surface protection by means of a lean concrete layer, 5 cm thickness or plastic sheets might be required in circumstances where larger areas in the vicinity of the excavation is sensitive to water infiltration causing destabilization of the adjacent terrain.

B0.3.7.4

Backfilling
Foundations and structures shall be back-filled as shown on the drawings with approved material compacted in layers by suitable equipment until optimum stability has been obtained to the satisfaction of the Employer / Employers Representative. Compacting shall be carried out with special care by means of pneumatic or mechanical rollers or other compactors of a type previously approved by the Employer / Employers Representative. Density requirements shall be as follows by tests per modified AASHTO (American Association of State Highway and Transportation Officials) T180 Method D, at optimum moisture content Under structure foundations and slabs Embankment 97% 95%

The thickness of fill layers, number of passes and type of equipment to be used shall be proposed to the Employer / Employers Representative after compaction tests have been made. Surfaces receiving fill layers shall, if smooth, be previously scarified to obtain a good key between the new fill layer and the sub-grade.
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

B0.3.7.5

Soil replacement
The material to be used for replacement of soil shall not contain soluble or swelling components such as clays, or organic matters. Sand gravel mixtures of favorable grain size distribution shall be used in exchange. The fill material shall be placed in horizontal layers of no more than 15 cm in compacted thickness. The fill moisture content shall be controlled and adjusted in order to achieve a maximum of compaction. Fresh water shall be used for watering of soils. The foregoing shall be confirmed by tests. The fill material shall be compacted by vibratory roller (min. weight 20t). The minimum required degree of compaction shall be as defined under item "Tests and Properties" here in below.

B0.3.7.6

Protection of existing utilities and services


During construction the Contractor shall provide all protection for existing utilities and services as may be required by his construction operations. Permanent protection of certain items shall be as included under other sections or as instructed by the Employer / Employers Representative.

B0.3.7.7

Test and properties


The Control of working and tests operations shall be carried out by the Contractor in the presence of the Employer / Employers Representative. The Contractor shall prepare sheets for statistical analysis of the field and laboratory tests, and shall submit the sheets to the Employer / Employers Representative for approval. Controlling will consist of field and laboratory tests, such as compaction and density tests, grain-size distribution, and shear tests. If not otherwise specified under relevant items the following min. tests have to be carried out. one (1) test analyzing the ingredients of the water used for performance of the work three (3) tests for specific gravity of soil one (1) test for bearing capacity of soil for static load three (3) tests for grain size analysis of soils, if "Replacement of Material" is required three (3) tests for density of soil in place of sand-cone method for each second layer of "Backfilling and/or replacement of material and/or roadwork" Tests shall be performed for each 500m3 of fill and / or every 5th tower site.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

B0.3.7.8

Compaction equipment
The Contractor may use any compaction equipment or device which he finds convenient or economic. The thickness of the fill layers to be compacted depends on the chosen compaction equipment, but the compacted thickness of one layer shall not be more than 15 cm.

B0.3.8

Foundations works

B0.3.8.1

General
This clause describes all foundation works which are to be performed so as to ensure the bearing of all loads without detriment for and damage to the structures. The Contractor has to choose up-to-date methods and equipment to ensure this in accordance with relevant internationally recognized standards. The Contractor will be responsible for the suitability of the foundation applied for the existing underground conditions. Immediately prior to concreting any footing, the Contractor has to verify and assess the actual soil conditions between ground level and bottom excavation and below the foundation level.

B0.3.8.2

Work included
The works include furnishing of all labor, materials and equipment necessary for all foundation works and performance of all foundation works so as to ensure the bearing of all loads without detriment for and damage to the super structures. All works shall be performed in accordance with effective site conditions and the approved execution drawings. Checking of soil conditions/piling condition The soil conditions encountered during the foundation works, especially in the foundation level, shall be checked by the Contractor, recorded and compared with previous known and investigated results. Each single footing excavation must be verified by an experienced soil mechanic/civil expert of 10 years practice for assessing the actual in-situ soil condition present from ground level to bottom of pit. Rapid field test procedure by hand test method as shown in the table below in conjunction with pocket penetrometer, vane tester and granulation chart may be applied. If the encountered soil condition does not correspond to the preliminary approved foundation class, then the Contractor has to initiate, e.g. by site notes, the necessary foundation type change as to match the actual soil class.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Table Soil Assessment by Field Test Method

Fragment Rock Rock 50% Rocky, Type Boulders 20 cm Rock Class sedimentary cemented sandstone siltstone claystone breccia etc. Soil Cohesive Soil Type 35% Fines Comp. 0.06 mm

Compact Rock 90% Homogen. Blocks 600 cm

Degree of Hardness

Field Test / Hand Probe of Rock

Class 1 Hard Rock

Class 2 Soft Rock

igneous metamorphic granite andesite basalt gneiss etc. Granular Soil 65% Coarse Comp. 200 mm

very strong, tough, sound, durable

excavation requires chiseling or drilling and blasting hand held specimen can be broken by geological hammer can be scratched by knife or steel nail excavation can be done by pick axes sample edge crumbles by heavy hand pressure or breaks can be scratched by thumbnail Field Test / Hand Probe of Soil can be excavated by hand using spade wooden peg 5x5 cm hard to drive by sledge hammer steel bar 2 cm cannot be penetrated manually cannot be indented by thumbnail

medium tough, weak, fissured, friable

Soil Class

State of Consistency / Density

Class 3 Good Soil

Class 4 (5) Poor Soil

silt clay peat sandy silt clayey silt gravelly clay sandy clay silty clay etc.

cobbles gravel sand gravelly sand silty gravel clayey gravel clayey sand silty sand etc.

hard, compact, very dense, medium dense, very stiff, semi solid

firm, stiff, loose, very loose, medium firm, soft

can be excavated by hand using shovel wooden peg 5x5 cm easily to drive by sledge hammer steel bar 2cm can be penetrated manually with effort can be molded by hand, readily indented by thumb

Field identification of cohesive and granular soil components by settlement test in a scaled jar with water, ie. sand settles out in approx. 1 min., silt 5 min. and clay 10 min. Differentiation of relative quantities of dry samples by volume % estimation diagrams as particles of 0.06 mm are just visible to the naked eye. Depending on the state of consistency, density and hardness the corresponding soil (rock) class can be determined as outlined in above table. Soil classes and its allocated index / engineering properties are defined in the Particular Technical Requirements under the Chapter Soil Classification.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

If there is any doubt about the actual in-situ soil properties or if discrepancies appear with regard to the previous decisions or investigations as stated by the Employer / Employers Representative, then additional verification measures shall be undertaken to ascertain that the actual soil parameters are in compliance with the foundation design assumption after consulting the Employer / Employers Representative. Pile driving Pile driving operation must be supervised by an experienced civil engineer of 10 years practice. If the agreed pile criterion cannot be fulfilled according to the preliminary approved pile length, then the Contractor has to initiate, e.g. by site note, the necessary pile extension and/or increase the pile quantity per tower footing as to match the actual soil class. Dewatering During the foundation works the excavated areas, foundation levels and pits shall be kept free of water down to at least 0.5 to 1 m below the foundation level. Waterproofing The necessary measures shall be taken to protect the structure against water action Pitwall stability The excavated pit sides, walls or slopes have to be stable and comply with safety regulations. Foundations at different depths Foundations at different levels shall be based beyond a load spread angle of 30 (with respect to the horizontal). Safety against uplift For all parts of the structures extending into the groundwater, safety against uplift shall be guaranteed during the execution and final operation stages.

B0.3.8.3

Soil replacement
If unsuitable soils are encountered below the foundation level, these might be replaced by suitable layer-wise compacted material down to the bearing soil. Alternatively chimney/shaft extension down to the bearing soil can be executed. Materials and compaction method as well as quality control are described in Sub-Chapter "Earthworks". Select fill only shall be employed below all structure footings if soil replacement has to be executed.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

B0.3.9

Concrete works

B0.3.9.1

General
In general the concrete works shall be based on EUROCODE 1, 2 and 4, the provisions of the EN DIN standards or equivalent and the local rules, standards and regulations.

B0.3.9.2

Materials for concrete


All materials used for concrete and reinforced concrete structures shall be of the best quality, free from defects likely to undermine the strength and duration of service of the works. The materials furnished must at least comply with the agreed standards, and with all requirements described in these technical requirements. All materials shall be stored and handled in a manner that will prevent contamination and/or deterioration. Deteriorated and/or contaminated material shall not be used for the concrete and shall be removed from the site at the expense of the Contractor. Cement The cement used for concrete, reinforced concrete, mortar, grout and plaster works shall be a moderate sulfate resisting Portland Cement in accordance with DIN 1164 or EN 197 or equivalent. All deliveries of cement to the concrete supplier shall be accompanied by a certified mill test report and shall include all of the physical and chemical properties. The manufacturer's test certificate will normally be accepted as proof of compliance with the General Technical Requirements/Particular Technical Requirements. If required, confirmatory tests are to be conducted by a recognized quality control organization. The following information shall be provided for all cement shipments (either whole or part) which are intended for delivery to site: date of manufacture, date of original loading, destinations en-route, date of unloading, intended date of delivery to site. Cement which has been manufactured for longer than 6 months on the proposed date of delivery to the site shall be inspected, sampled and tested for approval purposes before delivery to the site. The Contractor shall obtain and provide to the Employer / Employers Representative the manufacturers Bulk Average Test Certificate for each consignment of cement to the works.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Samples shall be taken from each consignment of cement and tested as directed by the Employer / Employers Representative in an approved independent laboratory. All bagged cement shall be stored in a weatherproof building which shall be kept swept clean at all times. Cement shall be adequately protected against rain, humidity and dewfall, and all charging and discharging points shall be properly sealed. Water Water for preparing concrete and mortar shall be clean, fresh and free from organic and/or inorganic matter in solution or suspension in such amounts that may impair the strength or durability of the concrete. Water may be obtained from local sources, after comprehensive testing and analysis of samples. No seawater or water from excavations shall be used. Water shall be stored in clean containers. Aggregates Materials used as aggregate shall be obtained from a source known to produce aggregate satisfactory for concrete and shall be chemically inert, strong, hard, durable, of limited porosity and free from adhering coats, clay lumps, organic impurities that may impair the strength or durability of the concrete. Aggregate may comply with and be tested in accordance with the requirements of standards. Concrete additives Concrete additives approved by the Employer / Employers Representative shall be used to improve consistency, workability, quality and strength of the concrete. Unless otherwise agreed, an additive may comply with an approved standard. Plasticisers and air entrainers are intended to reduce bleeding of free water at the surface. It shall only be used after the written approval of the Employer / Employers Representative and in accordance with the manufacturer's instructions.

B0.3.9.3

Concrete mixes
General description and proportions and mixing The mix proportions are to be determined by proper mix design based on the requirements for strength, workability and the particular site in which the concrete is to be placed. The mix design shall be carried out by the Contractor's responsible specialist and approved by Employer / Employers Representative.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Concrete Classification
Concrete Class C8/10 C16/20 C30/37 Cube strength at 28 days N/mm 10 20 37 Maximum free water/cement ratio 0,70 0,60 0,55 Max. nominal aggregate size mm 30 25 20 Min. cement content CE 32.5 180 280 300

Classes of Concrete: C8/10 Plain concrete used for lean concrete, blinding, screeds, backfill etc. C16/20 Reinforced concrete for foundations, retaining walls C30/37 Reinforced concrete for piles Trial mixes Before concreting commences, the Contractor shall, at his own expense, make trial mixes to determine the mix proportions required to produce the strengths specified for each class of concrete and for each degree of workability required to allow placing, transporting and compacting of the concrete with the equipment he proposes to use in any particular situation. Only materials which the Contractor intends to use for concreting (including all admixtures) shall be used in the trial mixes. Test cubes from trial mixes shall be made and tested in accordance with approved standards. The appropriate strength requirements may be considered to be satisfied if none of the strengths of the cubes is below the required characteristic strength and if the average strength of the nine cubes is not less than recommended by the standards. Consistency of concrete The amount of water used in the concrete shall be adjusted as required but not exceeding the specified w/c ratio to ensure such a consistency that it can be readily transported placed and compacted without segregation of the materials or bleeding of free water at the surface. Addition of water to compensate for stiffening of the concrete before placing shall not be permitted. Consistency of the concrete shall be checked by slump tests. Mixing of concrete A weight batching would be desirable but an accurate volume batching (+/- 3%) of aggregates and cement might be acceptable rather for the lower concrete classes of C16/20 and C8/10 maintaining the specified concrete strength of the foundation structure. The actual mixing time shall be in the range of 1 minute by an efficient mixer with rotating drum and fixed arms.

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The water shall not be added until all the aggregate and cement are in the drum. Mixing shall continue until the concrete is uniform in color and for not less than 1 (one) minute after all the materials and water are in the drum. Partly set or excessively wet concrete shall not be used. No concrete shall be mixed by hand.

B0.3.9.4

Strength of concrete
Testing of fresh concrete by means of test cubes All test cubes shall be made and tested for compressive strength in accordance with - Method of testing concrete or DIN EN 12350-1, DIN EN 123506 and ISO 2736/ISO 4012 or equivalent - Test methods for concrete. Depending on the workmanship, foundation access and concrete volume, at each 2nd tower location on an average, a series of 3 test cubes shall be taken at random from different batches and at approx. equal intervals throughout the concreting operation at the day. The moulds shall be made of steel and shall have the following dimensions: Test cube 150 mm x 150 mm x 150 mm +/- 1mm Edge parallel, walls right-angled, flatness +/- 0.1 mm Test cylinder 150 mm +/- 1 mm, height 300 mm +/- 1 mm Flatness +/- 0.1 mm Freshly filled test moulds shall remain on site for 1 to 2 days protected from sun radiation and rain. For the remaining 26 to 27 days till crushing, they shall be stored fully submerged in water or in a room having a constant rel. humidity of > 95%. For foundation concrete class C 16/20 the concretes compressive strength is successfully proven if both criteria are fulfilled as follows: Criteria Each individual test specimen attains Average of the 3 test specimen attains Cylinder 15 N/mm 21 N/mm Cube 19/N/mm 25 N/mm

If the results are less than those specified above respective in the standards, the Employer / Employers Representative must suspend the concerned concrete works respective backfill operation and order further in-situ tests, for example core drilling. Any concrete found not to comply with the General Technical Requirements/Particular Technical Requirements shall be broken out and replaced or adequately reinforced to the satisfaction of the Employer / Employers Representative.
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The Contractor shall pay all costs incurred in making, curing, delivering and testing of concrete cubes/cylinders and core drilling.

B0.3.9.5

Transport of concrete
Immediately after mixing, the concrete shall be conveyed to the place of use as rapidly as possible using methods which will prevent the segregation, loss or contamination of materials. The concrete shall be placed and compacted within 30 minutes after batching operation was completed. Any concrete left unplaced after this time shall be rejected and removed from the site. Batching volume and consistency of concrete shall be selected that the fresh concrete batch can be placed without adding water after mixing. Longer transport distances requiring retarder additives for concrete set, is subject to prior testing and approval.

B0.3.9.6

Concreting operations
Inspection prior to concreting All concreting methods shall be subject to the approval of the Employer / Employers Representative. Concrete placing shall not be started until the Employer / Employers Representative has approved all preparation of forms, reinforcement, joints and all mixing, conveying, spreading, curing, finishing and protection equipment. Placing of concrete Concrete shall be placed in the forms as close as possible to its final position in a single operation to the full thickness of slabs and shafts/chimneys and shall be placed in horizontal layers, not exceeding 2.5 m height in a single pour of vertical shafts and chimneys with formworks and not exceeding 5 m when concreted direct to soil. The Contractor shall organize the pouring of concrete in such a manner that once concreting of a section has started the operation shall be continuous and each operation shall be completed prior to a stoppage. The temperature of concrete shall not exceed 30C measured at discharge into the formworks or foundation bottom works. Concrete shall not be placed when the ambient temperature is 40C or above, or is above 37C and is rising.

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Where specified on the drawings, construction, expansion or contraction joints shall be provided and the concrete shall be poured continuously between two adjacent joints. No other joints than shown on the drawings shall be permitted. Stoppage (cold) joints formed between two concreting operations separated by more than 6 hours time shall be subject to the same treatment as the construction joints. Concrete shall not be dropped into place from a height exceeding 2 meters. Trunking and chutes to Employer / Employers Representatives approval shall be used for any concrete to be deposited from a height exceeding 2 m. Concrete which has partially hardened shall not be exposed to injurious vibration or shock, except for controlled re-vibration where specified. When concreting of a certain large structural element is specified strictly as to be poured continuously, then the concreting operations shall be organized for day and night working, in long shifts, as necessary. Compaction and mechanical vibration of concrete As concrete is being placed it shall be compacted by mechanical vibrators, to obtain a dense material free from honeycombing, free from water and air holes. For compacting the concrete, internal vibrators shall be used operating within a range of 5,000 to 10,000 cycles per minute. The Contractor shall ensure that the vibrators are used in such a manner that the reinforcement is not displaced, the formwork not damaged and no segregation caused, but complete compaction of the concrete is achieved. Finish of concrete The concrete face shall have the finishes indicated on the drawings or as shown in the present General Technical Requirements/Particular Technical Requirements. The foundation top shall be monolithically casted that the finished surface of the concrete will be sound, solid and free from honeycombing, protuberances, air holes or exposed aggregate. No plastering, cement wash, mortar or paint shall be applied to cover defective concrete surfaces.

B0.3.9.7

Construction joints
The number of construction joints should be kept as low as possible consistent with reasonable precautions against shrinkage. Concreting should be carried out continuously up to construction joints. Where it is necessary to introduce construction joints, careful consideration should be given to their exact location, which should be indicated on the drawings. Alternatively, the location of joints should be subject to agreement between the Employer and the Contractor before any work commences. Construction joints should be at right angles to the general direction of the member and should take due account of shear and other stresses.
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Immediately prior to recommencement of concreting on a joint, the surface of the concrete against which new concrete will be cast should be free from laitance and should be roughened to the extent that the largest aggregate is exposed but not loosened. Care should be taken that the joint surface is clean immediately before the fresh concrete is placed against it. Particular care should be taken in the placing of the new concrete close to the joint. This concrete should be particularly well compacted and if possible a vibrator should be used. A record shall be kept on site of the time and date of placing the concrete in each section of the work.

B0.3.9.8

Expansion and contraction joints


The expansion joints, contraction joints and other permanent structure joints shall be provided in positions as shown in the drawings. Joints shall be straight and vertical, except where other specified, and concrete surfaces on both sides of the joint shall be flush. Where necessary, water stops of a type approved by the Employer / Employers Representative shall be embedded in the concrete. The water-stop should be made of high-quality material which must obtain its resilience through the service live of the structure for the double function of movement and sealing. To ensure a good tightness with or without movement of the joints the waterstop should be provided with anchor parts. The complete works of fixed and welded connections must be carried out strictly in accordance with the manufacturer's instructions.

B0.3.9.9

Concreting at night
When approval is given to carry out concreting operations (under control of the Employer / Employers Representative ) at night or in places where daylight is excluded, the Contractor has to provide adequate lighting at all points of mixing, transportation and placing of concrete.

B0.3.9.10

Concreting in high ambient temperature


The temperature of the mixed concrete shall not exceed 30 C. The Contractor shall take special measures in the mixing, placing and curing of concrete. These measures shall include the shading of aggregates, spraying of aggregates with water, cooling of the mix constituents (introduction of ice to the mixing water) and reduction of transportation time to the minimum. During placing suitable measures shall be provided to prevent premature setting of concrete placed in contact with hot surfaces. All concreting areas, formwork and reinforcement shall be shielded from the direct rays of the sun and sprayed with water when necessary.

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B0.3.9.11

Protective measures for concrete


The minimum clear concrete cover shall be as follows: concrete parts above ground (external surface) concrete exposed to underground and groundwater 35 mm 50 mm

Immediately after the compaction of the concrete has been finished, the Contractor shall ensure adequate protection from the weather. The concrete surface shall be covered with a layer of sacking, canvas, straw mats or similar absorbent material, special protection sprays kept constantly moist for at least 7 days. Curing compounds or other methods of preventing evaporation my be used if approved by the Employer / Employers Representative. Formworks may be removed within 1 to 2 days after placing the concrete. The formwork shall be kept shaded from the direct rays of the sun and shall be sprayed with water if required. Where large sections of concrete are poured, special precautions to the approval of the Employer / Employers Representative shall be taken to reduce and dissipate the heat generated by the setting and hardening of the concrete (e.g. built-in cooling water pipe system). The minimum amount of reinforcement shall be present to prevent shrinking cracks. No load of any kind shall be allowed on concrete which has not properly set and the Contractor shall prevent any load to be imposed on the concrete structures until it has been declared by the Employer / Employers Representative to be ready to carry loads.

B0.3.9.12

Repair of damaged or defective concrete


Concrete which has completed its final setting shall be inspected by the Employer / Employers Representative and any cracks, honeycomb areas, segregations, etc. shall be marked. No repairs shall be carried out until directed by the Employer / Employers Representative. Making good areas > 1m of extend and / or affected depth > 10% of the concerned structure thickness shall not more be patched by cement mortar and are subject to special repair procedure (epoxy based mortar) or structure reinforcement or partial reconstruction procedure. Cracks wider then 0.3 mm and/or deeper then 10 mm as well as air holes, surface offset or exposed/segregated gravel pockets deeper than 1 cm will also be subject to repair procedures.

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B0.3.9.13

Reinforcing steel
General Reinforcing steel used in reinforced concrete shall comply with EC 3 or equivalent: Reinforcement supports Reinforcement supports shall include all spacers, chairs, ties, slab bolster, clips, chair bars, and other devices for properly assembling, placing, spacing; supporting, and fastening the reinforcing bars. Spacers may be cast from concrete, but shall be of the same quality as that in which they will be embedded. Concrete block spacers shall be cast in metal moulds with an approved means of separating blocks and of ensuring that the blocks are of the proper size. Certificates Each consignment of steel reinforcement shall be accompanied by a test certificate from the manufacturer showing that the steel has been tested and analyzed and the date of such tests and analyses and that such tests and analyses comply in all respects with the standards. Test Reinforcing steel shall be tested as per EN 10080 in presence of the Employer/ Employers Representative. The costs for these tests are deemed to be included in the contract price. Rejection The Employer / Employers Representative will reject any reinforcement steel as the result of any failed test therefore not withstanding the manufacturer's certificates. Reinforcing bars having excessive corrosion, mill-scale deposits and out of diameter tolerance are also subject to rejection of the batch. Flash rust however might be acceptable to a degree were no impairment of the bonding property between steel surface and cement line may occur. Reinforcing bar position Reinforcement shall be installed and spaced as specified within the flexural tension, compression, thermal expansion and cracking zones. Individual reinforcing bars shall be positioned within the following allowance range: Clear cover of reinforcing bars: c c -0,5 cm +5,0 cm at clear covers C 3 cm 4 cm -1,0 cm +10 cm at clear covers C > 4 cm < 8 cm

C: clear cover means the specified distance between the outer most steel bar part (not center of stirup diameter) and the formwork or ground at 90 to the plane.
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Center spacing of reinforcing bars: s 0.25 S at center spacing S 20 cm S: center spacing means the specified distance between bar centre to bar centre (ccs) of two adjacent steel bars in parallel position. Overlapping length of reinforcing bars: l -5 cm (+10 cm) at overlap length L > 60 bar L: overlap length means the specified distance between the two cut-off ends of steel bars being continued in parallel position. Clear spacing of overlapping bars: p 3 bar at overlap length L > 60 bar P: clear spacing means the specified distance between the two outer most steel bar parts facing each other (not centers) of the two overlapping steel bars in parallel position.

B0.3.9.14

Finishing of concrete
All exterior corners (angles of 90 or less) of reinforced concrete shall be chamfered (25 mm x 25 mm). The top or final surface of all concrete works shall be finished monolithically and sloped by screeding, or floating, or troweling or grinding, or tooling as approved by the Employer / Employers Representative. Dry cement or cement and sand shall not be used to dry excess water on the concrete surface. Screeding: shall be executed by moving a straight edge or template by hand or by mechanical means immediately after compaction of the concrete. Floating: shall follow screeding, but shall not be started until some stiffening of the concrete has taken place. Troweling: Where specified as necessary, the floating shall be followed by finishing until a smooth surface free from defects is obtained. Grinding and tooling: Where specified, the methods to produce the desired surface shall be approved by the Employer / Employers Representative. The grinding and/or tooling shall not start until the concrete has hardened sufficiently to prevent dislodgment of the aggregate. Chiseling: Wherever possible all chiseling works shall be carried out with mechanical devices.

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B0.3.9.15

Formwork
Design and construction For stability and type of formwork and support framing used, DIN 4420 or equivalent are to be observed. The formwork and the supporting structure are to be so dimensioned as to be able to withstand all vertical and horizontal forces safely. Supporting structures shall be sufficiently rigid to maintain the forms in their correct position and to be true to shape and dimensions so that the final concrete is within the limits of the dimensional tolerances. Materials for formwork Forms shall be constructed from steel or from sound timber well seasoned and free from shakes. Plywood lining for forms shall be of timber which is resin-bonded and water repellent. Formwork surfaces in contact with concrete shall be free from adhering grout, projecting nails, splits or other defects. Joints shall be sufficiently tight to prevent the leakage of cement grout. Connections shall be constructed to permit easy removal of the shuttering and shall be either nailed, screwed, bolted, or otherwise secured so as to be strong enough to retain the correct shape during consolidation of the concrete. The fair faced concrete facades have to be to the satisfaction of the Employer / Employers Representative. The concrete surface for facades has to be absolutely stainless and all efforts have to be taken to achieve this. Preparation and inspection of formwork Before concrete is placed, all formwork shall be inspected to see if it is built according to the approved plans and to see if it has been cleaned and is free from sawdust, shavings, dust, mud, earth or other contamination and properly oiled. Contact surfaces of panels shall be treated with a suitable release agent (e.g. non staining mineral oil) where applicable. Surfaces which are not oiled shall be wetted thoroughly to prevent warping. Erection and placing of formwork All formwork shall be erected and placed in accordance with the construction drawings approved by the Employer / Employers Representative. Shuttering shall be true to line and braced and strutted to prevent deformation under weight and pressure of the wet concrete, live loads, wind and erection forces. The deflection shall not exceed 5mm and the casted structure dimensions shall be within 2 cm + 5 cm (to soil + 10 cm) observing the minimum reinforcement cover as specified above.

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Formwork for walls and elsewhere shall be arranged for a maximum concreting height of 2.5 m in a single pour. Where necessary panel openings are to be provided in the forms for cleaning, inspection, access of vibrators, etc.. All formwork will be inspected and approved by the Employer / Employers Representative before concrete placing commences but this shall not relieve the Contractor of any of his responsibilities under the contract. Striking of formwork Formwork shall not be removed until the concrete has sufficient strength to carry its own weight plus any constructional or designed loads likely to be applied with a normal factor of safety. It shall be removed in such a manner that no shock or injury shall result to the concrete. Before removal of the formwork the concrete shall be examined and removal shall proceed only on the instructions and under the supervision of a competent person.

B0.3.10 Erosion protection


General The scope covered by this section comprises the performance of all kind of masonry work in accordance with the static analysis and as shown on the approved working drawings. The requirements of EUROCODE 6 shall be observed. Material The material to be used for erosion protection comprises the following: clay bricks solid or hollow concrete blocks natural stones of granite, basalt or lime stone any other type of blocks and stone artificially produced binding agents metal accessories stone gabions reinforced concrete walls Execution Masonry work, arranging and bedding stones, etc. shall be executed in mortar to form a homogeneous mass and to bond them in such a manner that point or other loads and stresses are dispersed and distributed through the mass without the structure tending to disintegrate. Block work partitions less than 200 mm in thickness shall be solid block and strengthen around all openings by reinforced concrete frame of 200 mm width (as a minimum) and in the same thickness of the wall
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Block work more than 3 m in height shall be reinforced with reinforced concrete stiffening frame work comprising of 200 x 300 mm verticals at 4.00 meter centers and 200 x 300 mm horizontals at mid-height or at every 3.00 meters incase wall height is bigger than 6.00 meters. Construction during hot weather and cold weather The presence of water in mortar is necessary for the setting action to take place. Precaution shall therefore be taken to prevent the work drying too quickly, especially in hot weather. All bricks and blocks shall be saturated and natural stones wet before bedding to prevent them absorbing the moisture from the mortar, and also to remove all loose dust from the surface in contact with the mortar. Brickwork and/or block/stone work which has not been thoroughly wetted can be detected by a thin crack between the brick/block/board and the mortar joint. Such work shall be pulled down and rebuilt. All masonry work shall be suspended during extreme weather unless adequately protected. Block work under the ground slab, retaining walls and around foundations shall be min. 200 mm thick. Auxiliary work Unless specified otherwise, all and any kind of work, materials, services, safety measures, etc. as well as all tests and samples required for the completion of the work shall be included in the offer. Among others they also have to include the following services: a) b) c) d) e) provision and walling-up of al scaffolding holes and supports for beams and girders provision of slots, grooves, small drainage openings and the like drainage piper and gravel packages wire mesh galvanized for gabions design calculations and drawings as far as required

Tests and properties The minimum number of tests shall be as follows: a) b) c) two compressive test of soil block for load bearing walls per 200 m2 of bearing block walls three compressive tests of each type of material as mentioned above three compressive tests of each kind of mortar to be used

Quality assurance Blocks and stones shall be hard, of selected quality, reasonable in size and shape. The strength of the blocks and stones shall be according to the static requirements, but not less than: reinforced concrete class C16/20 as for foundations solid clay bricks > 10 N/mm compressive strength natural stones > 15 N/mm compressive strength
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Mortar Mortar for blockwork shall be cement mortar in the proportions 1:3 to 1:4 (Portland cement to sand). All mortar shall be mixed in a power-driven mixer and in addition, all materials shall be screened before mixing to remove lumps. Mortar whether with or without plasticiser shall be mixed only in sufficient quantity for the work immediately in hand and no partly set mortar shall be used. Reinforcement / fixing accessories for brick and blockwork Reinforcement Horizontal reinforcement to brick or blockwork is called for. It shall be in high tensile galvanized steel mesh 6 cm wide for 10 cm walls and 12 cm wide for 20 cm walls. The reinforcement shall be laid in as long lengths as practicable without laps. But where joints are necessary, the lengths shall be lapped not less than 30 cm, except at corners or junctions where the lap shall be equal to the width of the reinforcement and the reinforcement in one wall bent over that in the other. Application: every second layer.

B0.4

Inspection and Testing

B0.4.1

General

B0.4.1.1

Introduction
This section contains general requirements for inspections and tests of material, parts, equipment and workmanship of the plant during manufacture, assembling and erection and upon completion to demonstrate compliance with General Technical Requirements/Particular Technical Requirements, codes and standards to ensure overall reliability of plant operation and performance. The Employer, the Employers Representative and/or authorized agents shall, at all reasonable times, be allowed free and ready access to the Contractor's premises and those of his suppliers for the purpose of inspecting the specified equipment components, and obtaining information as to the progress of the work. Failure on the part of the Employer / Employers Representative , at this or any other time, to discover or reject materials or work which do not meet specified requirements shall not be deemed an acceptance thereof nor a waiver of defects therein. The approval of the Employer / Employers Representative will not prejudice the right of the Employer to reject equipment if it does not give complete satisfaction in service.

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The tests listed in the appropriate sections of these technical requirements are the minimum requirements. The Contractor shall, at the appropriate time, prove that his material and/or equipment comply with all the requirements of this section, such proof being the successful completion of tests and inspections.

B0.4.1.2

Scope, program, documentation


All main components and equipment offered for and supplied under this Contract shall be type tested. The Bidder shall enclose in his Bid Type Test Certificates separately for each such main component and equipment offered. Such Type Test Certificates shall be issued by internationally recognized testing organizations for type tests carried out on components and equipment which are, in the opinion of the Employer /Employers Representative, of identical type or identical in all essential respects to the equipment offered. If any of the Type Tests Certificates submitted is not applicable to the component or equipment offered, the Employer / Employers Representative reserves the right to require re-testing or the inclusion of additional tests in the routine test program. During manufacture, erection and after completion all materials, components and equipment supplied as well as works performed under this Contract may be subjected to inspection by the Employer/Employers Representative, should they so require. The works may also be subjected to inspection and tests by any approved agencies of insurance or inspection companies, approved by the Employer, in accordance with the requirements of these technical requirements. Quality assurance The Contractor shall provide and operate a quality assurance system both in his facilities and the facilities of his sub-Contractors and at site capable of producing objective evidence that the material and equipment meet the quality requirements of the technical requirements. The system shall be in accordance with ISO 9001. The Contractor shall include an outline inspection plan in his Bid. Before delivery a detailed inspection plan shall be submitted to the Employer/Employers Representative for approval. It shall describe the facilities and site inspection for each major component and for the finally assembled equipment and shall include the following: a schedule or flow chart indicating each inspection and the stages in the manufacturing and erection process where the Contractor proposes inspection shall be carried out a short written description of the method for each inspection standards of acceptance, with references to International Standards or Codes where applicable. Where the Contractor's acceptance standards are proposed, copies of such standards shall be provided.

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The Contractor has primary responsibility for ensuring the quality of items of equipment supplied under the Contract and remains accountable when manufacture or erection is subcontracted. It is therefore a requirement of the technical requirements that works are only subcontracted to companies with effective Quality Assurance (QA) organization and that the Contractor monitors the quality control by the attendance at tests of experienced inspectors employed by the Contractor. Adequate notice shall be given when the equipment is ready for inspection or test and every facility shall be provided by the Contractor and his subcontractors to enable the Employer/Employers Representative to carry out the necessary inspection of the plant. A detailed record of the results of all tests and inspection shall be maintained by the Contractor and copies provided to the Employer/Employers Representative within a reasonable time after the tests. Facilities for inspections and tests The tests shall be performed to the agreed inspection and test plan using acceptance criteria approved by the Employer/Employers Representative. The Contractor shall provide all the test equipment and test sets required for carrying out the inspection and tests. Equipment provided for testing at site shall remain the property of the Employer. All equipment shall have current calibration certification. The Contractor shall submit test programs for factory and site testing that is subject to approval by the Employer/Employers Representative. Test methods shall be based on IEC recommendations and standards. The Bidder shall state the applied standards and test methods. A tentative test program and a test procedure shall be supplied before each individual test. The test procedure shall specify in detail the tests to be performed, based on the specified requirements. Detailed documentation (e.g. circuit diagrams, flow charts) of the tested system/equipment shall also be available to the Employer / Employers Representative at the same time. Formats of the test report which are intended to be used shall be submitted for approval together with test program. The Contractor shall duly consider provisions specified in the Bidding Document Documents as minimum requirements when preparing the inspection and test plan with respect to type and extent of inspection and tests, to location, orientation and number of test samples, to frequency and amount of taking samples for statistical quality control and with respect to acceptance criteria for all QA measures.

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The Employer / Employers Representative will return a copy of the Contractor's proposed inspection program indicating those inspection stages for which notification is required. Notification shall be by fax and shall be sent at least 20 days prior to the intended test. If the Employer and/or the Employers Representative intends to be present at the test he will provide at least 24 hours notice and if his representative does not attend on the notified date the test may proceed unless an alternative date has been requested by the Employer / Employers Representative. Within thirty (30) calendar days of completion of each and every test copies of all test records, test certificates and performance curves shall be supplied for all tests carried out in accordance with the provision of the contract, whether or not the Employer / Employers Representative has witnessed them. Information given on such test certificates and curves shall be sufficient to identify the equipment and software to which the certificates refer and shall also bear the Contractors reference and heading. The test reports shall indicate the tests performed, contract references, the results obtained, instruments used, names of test personnel, and provide for witnesses' signatures. They shall also be numbered and dated.

B0.4.1.3

Rejection of elements
Any item of plant or component which fails to comply with the requirements of these technical requirements in any respect at whatever stage of manufacture, test, erection or on completion at site may be rejected by the Employer / Employers Representative either in whole or part as he considers necessary. After adjustment or modification if so directed by the Employer / Employers Representative; the Contractor shall submit the item for further inspection and/or tests. Plant or components with defects of such a nature that the requirements of the technical requirements cannot be met by adjustment or modification shall be replaced by the Contractor at his own expense and to the satisfaction of the Employer / Employers Representative.

B0.4.1.4

Codes and standards


All equipment shall be inspected and tested in accordance with the requirements of the relevant standards and codes and the present technical requirements. The type and extent of inspection shall generally be in accordance with that specified in the standard used for design and construction of the item of equipment supplemented or amended by the requirements of this section of the technical requirements. Additional design tests are also to be carried out as described in the other parts of this technical requirements.

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Reference to special codes and standards, where designated either directly or as "relevant", is intended to provide a measure of performance, safety, inshop and on-site testing, and methods of construction and/or installation which must be equaled or exceeded in order to be considered acceptable for use under these technical requirements. If more than a single degree of quality or accuracy is permitted within the scope of particular code or standard, the highest quality shall be applicable and the degree of accuracy commensurate with the intended function shall be selected but with the understanding in either case that the decision as to degree will be made finally along with procedures by the Employer / Employers Representative. In all instances, the finally accepted applicable code or standard shall be the version last published prior to the date of submission of the Bid selected as the basis for this Contract. Where no appropriate standard is available, tests shall be carried out in accordance with the manufacturer's standard practice, which needs the approval of the Employer / Employers Representative. In such cases the Contractor shall submit to the Employer / Employers Representative complete data and a suggested procedure for the testing to be performed before manufacture commences. If the proposed procedure is accepted, the Contractor shall provide the Employer / Employers Representative with four additional copies in English before any test is performed. The Contractor's attention is drawn to the climatic conditions in the site area. De-rating factors are to be in accordance with the relevant IEC codes and standards or an approved equivalent.

B0.4.1.5

Services prior to and during inspections and tests


In accordance with and in addition to agreed standards, the Contractor shall submit procedures for material testing, manufacture, quality control and performance testing as they apply from the procurement phase of raw materials to the finished product. No inspection will be made or deemed valid unless the Employer / Employers Representative's head offices, the Contractor and Sub-supplier are in possession of all relevant approved drawings and procedures for the item to be tested. The Contractor on request shall supply the Employer with a copy of drawings and procedures at the time of the test. All instruments and apparatus required for the inspection or used for the performance of tests shall be calibrated to an agreed standard at a laboratory of national standing. The cost of making such calibrations shall be borne by the Contractor in all cases.

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B0.4.1.6

Quality control of materials


General Materials shall be manufactured and tested in accordance with the specified standards and testing programs approved by the Employer / Employers Representative. If no standards are specified the equipment shall be tested in accordance with the relevant IEC regulations. All materials shall be suitably identified and traceable to supporting test certification. Material suppliers certificates of compliance will be acceptable for minor items only at the discretion of the Employer / Employers Representative. Materials for earthing and lightning protection The materials for the installation of earthing equipment and lightning protection shall be tested in accordance with the relevant IEC regulations.

B0.4.1.7

Workshop assembly
In addition to the quality and production control tests, the following shop assembly work and tests shall be made to check measurements, fitting and functioning. Equipment to be furnished shall be shop assembled to a status sufficient to prove that the design and workmanship have been executed in accordance with the technical requirements, that the delivery is complete, and that no work remains to be done at site which reasonably may or should be done in the workshop. Where applicable, each item of the equipment shall be assembled completely prior to delivery. Field joints shall be temporarily connected. All parts shall be properly match marked, identified and doweled to ensure and, where practicable, to facilitate correct and quick field assembly. If the assembly shows defects in the design or manufacture or unforeseen difficulties in assembling and dismantling, these must be eliminated. If required, design alterations or corrective machining may be executed provided that no sacrifice with respect to reliability of operation or interchangeability is made and provided that the agreement of the Employer / Employers Representative has been obtained. If the corrections cannot be carried out in accordance with the terms mentioned above, the components concerned would be rejected. The decision on possible subsequent corrections is reserved exclusively to the Employer / Employers Representative. Faulted equipment parts shall not be delivered.
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B0.4.1.8

Welding and surface coating tests


Welding For all major structural welded items the Contractor shall submit the following documented proposals prior to commencement of welding: welding procedure specifications with qualification records; post weld heat treatment procedures where applicable; inspection schedule including quality requirements; non-destructive testing procedures; standard weld repair procedures. All welders employed on items of plant for this Contract shall be qualified. All welds shall be visually examined and shall be of smooth contour, free from cracks, undercuts and other significant defects. Welds shall be nondestructively tested in accordance with the construction standard applicable to the item of plant. Where appropriate, the magnetic particle testing or the ultrasonic examination is to be applied. Galvanized zinc coatings Surfaces shall be visually inspected. Bare patches, lumps blisters or inclusions of foreign matter shall be cause for rejection. Zinc coating thickness shall be determined non-destructively in accordance with DIN EN ISO 2178 or coulometrically in accordance with DIN EN ISO 2177 or an equivalent standard.

B0.4.2

Inspections and tests during manufacture

B0.4.2.1

General
As far as practicable, quality of materials, workmanship and performance of all items of the equipment furnished under the present contract shall be inspected at the places of manufacture by the Contractor's QA inspectors. Equipment shall wherever practical be subject to tests on completion in the Manufacturer's work to prove that the reliability, operation and performance conform to the requirements of these technical requirements and the provisions of the appropriate standards. All facilities shall be provided by the Contractor to enable the Employer and to carry out the necessary inspection of the equipment components and the costs of all tests during manufacture and preparation of test records are to be borne by the Contractor.

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The Contractor shall submit for approval procedures describing the proposed test methods to be used. Type and layout of test facility, location of instrumentation, formula for calculation of results and correction to site conditions, etc. shall be included where appropriate. All measuring instruments used in tests shall be regularly calibrated at the expense of the Contractor and records shall be available for examinations by the Employer / Employers Representative. The passing of the inspection or test will not, however, prejudice the right of the Employer / Employers Representative to reject the equipment components if they do not comply with the technical requirements when erected, or give complete satisfaction in service. Where the Contractor desires to use stock material, not manufactured specially for the work, satisfactory evidence that such material conforms to the requirements of the Contract shall be submitted. In this case tests on these materials may be waived, but certificates are to be submitted. Arrangements shall be made for expediting the shop inspection by having all shop assemblies or pieces covering a single shipment ready at one time. Any packing work as well as transport to the site of the equipment concerned shall not be started before the approval of the Employer / Employers Representative has been obtained and all QA certificates due at this time for the equipment concerned have been received and reviewed by the Employer / Employers Representative.

B0.4.2.2

Transmission line equipment


a) Conductor and ground wire tests The conductors and ground wires shall be subjected to the sample tests at the Sub-suppliers workshop or in authorized laboratories according to standards IEC 61089, IEC 60888, IEC 60889, BS EN 50182: As a minimum, the following tests shall be carried out: 1. for wires diameter conductivity tensile breaking strength wrapping tensile stress at 1% elongation for steel wires galvanizing for steel wires 2. for the complete conductor appearance and finish constancy of shape overall diameter stranding and lay ratio quantity of wires

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tensile breaking strength weight 3. for grease grease weight per metro dropping point b) Tests of dampers Vibration dampers for conductors and earth wires shall be subjected to tests according to IEC 61897. The type tests of the vibration dampers refer to: dynamic characteristic test; fatigue test; clamp slip test; torque test. Dynamic characteristic test This test is intended to establish the dynamic characteristics of the dampers. The damper shall be vertically mounted on a shaker table and driven with a constant table velocity of both 0.10 m/s and 0.05 m/s. The frequency range shall be calculated with the formula: f = 0.2 with
V D

f = frequency (Hz) V = wind velocity (m/s) D = conductor diameter (m)

for a wind velocity range of 0.5 - 7 m/s. The sweep rate shall be 0.2 decades/minute. The reaction force and the phase angle between the reaction force and the velocity shall be measured and power and impedance shall be plotted against the frequency over the given frequency range. One half width value of the resonant peaks of the power curves provide good information about damping capabilities of a damper. This value shall be calculated for each resonant peak of the power curves. The values shall not be smaller than 0.3. Fatigue test This test is intended to demonstrate that the dampers have an acceptable fatigue limit.

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The damper shall be attached to a shaker and driven in a vertical direction for 100 million cycles. The frequency range shall be calculated as in "Dynamic characteristic test". After the fatigue test a new dynamic characteristic test shall be performed. There shall be no significant difference in the dynamic characteristics before and after the fatigue test. Clamp slip test This test is intended to verify the clamp slip force. The damper clamp shall be installed on the conductor using the following torque: 45 Nm for M10; 60 Nm for M12 or bigger threads. Then a force shall be applied to the clamp along the axis of the conductor. The minimum force required to cause the clamp to slip on the conductor shall be recorded. Torque test This test is intended to demonstrate that the dampers fulfill the requirements as per manufacturer's proposal and Employer / Employers Representative s approval. The clamp shall be attached to a section of the conductor. There shall be no failure of component parts. In addition to the type tests shown above, corona and radio interference tests have to be carried out. The sample tests of the vibration dampers refer to: verification of dimensions; check of dynamic characteristic (see type tests); check of clamp slip (see type tests); galvanizing. The sample tests shall be carried out to the Employer / Employers Representative 's requirements on an agreed basis. No routine tests are required. c) Tests of insulators and insulator sets The insulator units and the insulator sets used in this Contract will be subjected to type, sample and routine tests according to IEC 60383 and EN 50341. In addition, the following tests shall be carried out as type tests: radio interference tests, according to IEC 60437;
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artificial pollution tests, if applicable, according to IEC 60507; thermo-mechanical performance, according to IEC 60575. For the sampling rules and acceptance criteria the IEC Publication 60591 is also to be considered. The type tests (group 1) refer to: a1 - dry lightning impulse withstand voltage b1 - wet switching impulse withstand voltage c1 - wet power frequency withstand voltage For the insulator units only the tests under a1 and c1 have to be applied. In addition to the type test shown above, the overall dimensions of the insulator sets as designed and approved by the Employer / Employers Representative shall be verified. The sample tests (group 2) refer to: a2 - verification of the locking system b2 - verification of dimensions c2 - temperature cycle test d2 - electro-mechanical failing load test e2 - mechanical failing load test f2 - thermal shock test (glass only) g2 - puncture test h2 - porosity test (porcelain only) i2 - galvanizing test For the insulator sets only the tests under a2, b2 and e2 are to be applied. The routine tests (group 3) which refer to: a3 - visual examination b3 - mechanical routine test c3 - electrical routine test d3 - thermal shock routine test (glass only) have to be applied only to the insulator units. The performance requirements shall be in accordance with the relevant EN and IEC regulations. The tests referring to the insulator sets have to be carried out on completely equipped sets, with all clamp and fitting parts, installed in their characteristic working position and having attached also an agreed length of conductor. The tests shall be carried out only in approved testing laboratories, according to IEC recommendations and other regulations.
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d) Tests of clamps, fittings and accessories The line clamps and fittings used in the insulator and earth wire attachment to tower sets as well as for the conductor and earth wire assembling will be subjected to type, sample and routine tests according to IEC 61284, IEC 61854, IEC 61467, or equivalent test standards, as agreed with the Employer / Employers Representative . From time to time the Employer / Employers Representative may ask for further tests as required to ensure that the quality of the product is being maintained throughout the Contract. e) Tests of transmission towers The towers and tower members will be subjected to design and routine tests. Design tests The tests shall be executed in accordance with IEC Publication 60652 "Loading tests on overhead towers". The tests shall be carried out at the sub-suppliers workshop or at another approved place. Two test categories shall be applied: tests to ultimate design loads tests to destruction by applying the specified overload factors and, if applicable, by applying even higher loads up to destruction. The height of the towers to be tested shall be the tower with body extension and with leg extension as approved by the Employer / Employers Representative. The tests shall be carried out for all specified loading assumptions (load cases) which are decisive for rating of tower members. Steel towers submitted for test shall be galvanized. If the Contractor, in carrying out erection of supports on site, proposes to assemble the supports on the ground and subsequently raise them to the vertical position, the sample tower submitted for tests shall be so assembled and raised to the vertical position on the test foundation in the presence of the Employer / Employers Representative. Each tower shall then be subject to such test loads in such order as the Employer and/or Employers Representative may specify to prove compliance with the factors of safety. Loads for 100% load step shall be maintained for five minutes, during which time there shall be no slacking off or adjustments of loads.

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Should it become necessary to adjust the loading, the 5 minute period shall start after the loading is stabilized and constant. All test loads shall be removed completely before the loads for the next test are applied, unless previously agreed to by the Employer. All test loads shall be applied directly to the regular attachment details provided for these loads. The applied loads shall be measured right in front of the tower loading points and the reading of all measured loads shall be enabled at one central place. Any conspicuous yielding or any failure under any of the test loading or the use of an incorrect grade of steel shall be considered a defect. If a failure occurs, the Contractor shall correct the defect and repeat the loading test at his own expense, including any additional costs by the Employer and/or Employer's Representative for witnessing of the repeated test. Test samples shall be cut from members which fail in the destruction tests and from those members judged to be critical from the design calculations, and standard tensile tests shall be performed at the Contractor's expense. Results of the tests on these samples shall be used to correct the assembled tower test results for comparison with the design. Any tower or part thereof which has been overloaded during destruction tests shall not be used subsequently in the construction of the lines. Where tower tests to nominal design loads are satisfactorily completed, the corresponding towers shall be carefully inspected after dismantling to ensure that no parts have been damaged and shall be marked for use in the permanent works at positions to be indicated by the Employer / Employers Representative. A complete set of new bolts and nuts shall be supplied in such cases and their cost shall be deemed to be covered by the Contract Price. The Contractor shall furnish all test structures, complete testing facilities, as may be required and shall perform all work herein specified, or implied. All items not specifically mentioned shall be deemed incidental to testing. Routine tests Samples of the material for the towers - standard or procedure - shall be tested in accordance with the relevant standards, recommendations and codes of practice. The Employer / Employers Representative will inspect also as soon as available at the Contractor's works the first consignment of complete foundation steelworks and stub setting templates. To maintain fabrication standards, the Employer / Employers Representative may call for repeated erection checks of any tower type during the manufacturing period at no extra cost.

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B0.4.3

Inspections and tests during erection and commissioning

B0.4.3.1

General
The Contractor's scope of delivery includes all site test and inspection expenses, e.g. all labor, materials, water, electricity, consumables, chemicals and stores as well as the instruments and apparatus as may be required to perform such tests efficiently. The Contractor is responsible for and shall include in his delivery all safety measures such as barriers, warning signs etc. required for inspection and testing while erection is in progress and all interruption of work in this connection will be at his expense. All instruments and apparatus used for site inspection and testing shall be calibrated to an agreed standard at a laboratory of an international standing to be nominated by the Contractor. The cost of making such calibrations shall be borne by the Contractor in all cases. During the erection of all mechanical, electrical, control, monitoring and telecommunication equipment the Contractor shall make the plant item available at any reasonable time for inspection by the Employer /Employer's Representative, should either so require. To assist the Employer/Employers Representatives in their review of the quality of the work being performed, the Contractor shall provide the Employer / Employers Representative with a schedule of the specific areas and items of work that will be performed during each work week. The list shall be presented to the Employer / Employers Representative prior to the start of work on a day agreed by the Employer / Employers Representative . All work that is executed prior to such notification shall be done at the Contractors own risk and may, at the Employer / Employers Representative 's request, be subject to removal and replacement by the Contractor at his expense. In particular the Contractor has to mark on his implementation schedule all stages of erection or commissioning which are subject to the Employer / Employers Representative's acceptance and has to notify one week in advance when such acceptance becomes due. The stages subject to acceptance shall include but not be limited to the items indicated in the technical requirements. Before energizing certain checks need to be carried out. For start-up the Contractor will propose a program to be approved by the Employer / Employers Representative. The program should give a step by step guide for the start-up taking into account, but not limited to, the checking of each disconnector, circuit breaker, circuit identification, current, voltage and power indication, phase rotation and correct phasing (this start-up shall also include all the substation auxiliary supplies and air ventilation).
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Prior to placing each unit into commercial operation, commissioning tests shall be performed on the plant. These tests will be coordinated by the Employer but the Contractor shall assume full responsibility for the testing operation and safety of plant within his scope of work. The Contractor shall cooperate with the Employer and with the other Contractors to permit all necessary tests to be performed. The Contractor shall provide all necessary instruments to perform the tests on plant within his scope of work. The test instruments shall be new, of a current model and type, and with the precision required to conduct the specified tests. The Contractor shall follow operating procedures agreed by the Employer. Copies of all log sheets and test readings shall be given to the Employer as the tests proceed. After the conclusion of the tests, the Contractor shall compile a comprehensive test report to the approval of the Employer. This report shall include copies of all log and calculation sheets and all necessary tables and curves to record the results of the tests.

B0.4.3.2

Transmission line equipment


The following checks and tests measurements shall be made unless otherwise specified in these technical requirements (as appropriate) in accordance with agreed standards and testing program: Checks before start erection Check of completeness of delivery Check whether ratings are according to technical requirements Check and tests on completion After final erection the following checks shall be performed: visual check on equipment damage visual check of correct and neat installation check of critical minimal clearance distances check of bolt tightening check of completeness of earthing connections measurement of earth resistance check of correct phasing of transformer check of correct installation of instruction plates and safety signs a) Tower earthing resistance The tower earthing resistance shall be measured during initial installation and immediately before commissioning, but at least once during the dry season under reasonably dry soil conditions.

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The measurements are to be carried out by means of a high frequency earth resistance measuring instrument, according to EN 50341 or equivalent standard, in order to allow readings of the impulse resistance value of the earthing system connected or not connected to tower and by towers having earth wires installed or not. The measurements have to be clearly recorded. The schedules used for the recordings shall contain in addition to the measured ohmic values, details of the surface soil and under ground data at the time of tests as well as the soil resistivity values. If, in the opinion of the Employer / Employers Representative, it is necessary to reduce the tower earthing resistance by approved means such as the installation of earth rods or counterpoise, the Contractor shall make further tests after the additional measures have been carried out at no extra charge. b) Conductor and earth wire joints and clamps The electrical resistance of at least 10 (ten) completed clamps, joints and terminal fittings of each type shall be accurately measured by the Contractor in the presence of the Employer / Employers Representative. Should one clamp fail the test, another lot of 5 (five) clamps shall be tested. Where the joint consists of several parts bolted together (e.g. dead end clamp with bolted-on jumper terminal) the resistance to be measured is that of the complete assembly. The resistance of any such fittings shall not exceed 75% of the resistance of an equivalent length of conductor, measured adjacent to the fittings, and the current carrying capacity shall be at least equal to that of the conductor. The Contractor shall provide suitable equipment (such as the Chance Digital Micro Ohmmeter) in order to perform the above tests, and shall submit details of the proposed instruments to the Employer / Employers Representative for approval. Suitable clamps shall also be supplied for connecting the current leads of the measuring instrument to the test sample to provide adequate surface contact at the interfaces. Test probes as used for potential contacts are unsuitable for current connections. Stringing of conductor and earth wire shall not commence until the instruments are on site and ready for use. The center mark on the steel inner sleeve of joint shall be checked by the Employer / Employers Representative before completing the outer sleeve jointing. Details of the method shall be approved by the Employer / Employers Representative. The contact behavior of the conductor and earth wire joints and terminals shall be tested according to DIN VDE 0212 Part 52 A1 (type tests) or equivalent standard.

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c) Fiber-optic cable field acceptance test The Contractor shall perform field acceptance test and document the results of the installed cable to verify the cable's performance as required by this technical requirements. The Contractor shall notify the Employer and the Employer's Representative in advance so that the Employer and the Employer's Representative can witness these tests. If the cable does not pass the field acceptance test, the Contractor shall replace the cable at the Contractor's expense with cable that does meet these technical requirements. Attenuation per distance / uniformity The Contractor shall measure the attenuation-vs-distance and attenuation uniformity of the fibers while the cable is on the reel as well as of the installed cable using an Optical-Time-Domain-Reflectometer (OTDR). Measurements will be made at 1550 nm. The attenuation of the fiber-optic cable shall not exceed the requirements in these technical requirements. Attenuation with bending The Contractor shall perform attenuation with bending tests using a 260 mm diameter mandrel on the cable and a 75 mm and 25 mm mandrel on selected individual fibers. The attenuation due to bending shall not exceed the requirements in these specifications. Tensile strength of cable The Contractor shall extract a sample length of cable from each reel and subject it to a pulling tension of 550 kg force and inspect for cable damage due to stress. The Contractor shall measure before, during, and after the test pull. The attenuation increase due to tensile stress shall not exceed the requirements in these specifications. Fiber-optic equipment field acceptance test Operational tests shall be carried out in order to demonstrate correct system operation also in conjunction with other parts of the telecommunication system. The Contractor shall be responsible for the correct test procedures and testing shall be done in the presence of the Employer / Employers Representative. The tests shall include but not be limited to the following: check of optical continuity of the transmission path measurement of bit error rate measurement of jitter performance measurement of laser and receiver characteristics measurement of transmission times for protection and control signals individual checks of each transmitted signal check of safety measures (e.g. laser shutdown) and alarm systems (including alarm processing in the TMS and monitoring & SCADA system)

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measurements of optical parameters (attenuation, chromatic dispersion) shall be performed for each fiber on the completely installed sections of the transmission path. The results of these measurements shall be stored in a database for comparing them with subsequent check measurements. Documentation has not been met, the Contractor shall locate and correct all equipment faults, which have caused this shortfall in specified availability. d) White rust If evidence of white rust is apparent upon receipt at site of bundled steel sections, the Employer / Employers Representative shall order the Contractor to make such tests as he deems necessary to determine the extent of damage, if any, and the remedial measures necessary. e) Final erection checks Not later than 90 days before finishing the erection of the first line section the Contractor shall prepare and submit for approval the erection check documentation. The erection check documentation shall include check sheets for all transmission and shieldwire components for each line section. Immediately after finishing the erection of complete line sections final erection checks shall be performed. The final erection checks shall be conducted by the Contractor with the attendance of the Employers Representative or the Employer. The results of the final erection checks shall be recorded in the check sheets including the deficiencies to be rectified and shall be signed by the parties attending the checks. The deficiencies shall be rectified before energizing and in coordination with the requirements of the Employer. f) Tests on completion At least 90 days prior the completion of the first line section the Contractor shall submit a schedule of energizing. The schedule of energizing shall contain a sequence of how the Contractor intends to energize the different parts of the different line sections. Prior to the energizing of a complete line sections a visual inspection of this line section including the shieldwire system has to be performed and deficiencies which would affect the safety of the line and personnel are to be rectified immediately. The following tests shall be performed before energizing of the system: insulation measurement line impedance

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The line shall be energized at full working voltage before handing over and the arrangement for this, and such other tests as the Employer or the Employers Representative shall desire to make on the complete line, shall be assisted by the Contractor who shall provide such labor, transport and other assistance as is required without extra charge.

B0.5

Documentation and Drawing Approval

B0.5.1

General
All information, documentation, calculations, drawings, schedules etc. have to be submitted within such periods or at such dates which are required to guarantee a smooth handling of the project without any delays. The Contractor is responsible for submitting all documentation in accordance with a program to be prepared by him allowing all participants sufficient time to check, assess, comment and approve the documents. The quality of the submitted documents must be in accordance with acceptable international practice to allow a speedy checking procedure. Documents not fulfilling these requirements will be returned to the Contractor without comments for improvement and resubmission.

B0.5.2

Specification stage
The drawings issued by the Employer's representative with the Specification forming part of the documents for tendering purposes are intended to be descriptive of the character of the Works and used in conjunction with the requirements of the Specification and shall in no way limit the responsibility of the Contractor to supply all plant equipment, materials and services necessary to provide for a complete and functional complex. Any omission in both, drawings and the Specification, shall not relieve the Contractor of his responsibility to include such detail or work in his supply. The final sizes of equipment shown on the specification drawings have not been fixed by the Employer's representative since these are dependent on the size and shape of the tenderer's proposed equipment and materials forming the works and the space required for installation, maintenance, laydown, storage, access etc. They are however to be considered as minimum requirements. Any deviation has to be stated in the schedules "Departures From or Qualifications To the Specification". When measurements are affected by conditions already established, the Contractor shall take and be responsible for field measurements notwithstanding any information set forth on the specification drawings. The specification drawings portray the basic layout of the Scope of Works and the Tenderer shall incorporate these requirements in his tender drawings.

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The Tenderer has to ensure that the information provided within the Specification is sufficient to state his final Contract Price. No additional claims will be allowed for supplies and services for the interconnecting or other works to be performed by him. The Tenderer has the liberty to comment on any document and drawing issued with the Specification within the time specified in Section A0 'Instructions to Tenderer'. After the Tender has been submitted, the Tenderer is deemed to have checked all these documents and drawings and they are without any restriction accepted by him. No claim resulting out of omissions or discrepancies in this respect will be accepted by the Employer's representative/Employer.

B0.5.3

Stages after contract award

B0.5.3.1

Correspondence
All correspondence shall be addressed to the Employer and copied to the Employer's representative in accordance with the table shown below. In addition to the requirements of the Conditions of Contract, all meetings and discussions with the Employer's representative shall be in English and the Contractor shall engage English speaking supervisors only.

B0.5.3.2

Approval procedure for drawings and documents


For the purpose of this clause the term 'drawing' shall include diagrams, schedules, performance curves, etc. The Contractor shall distribute for approval two sets to the Employer and two sets to the Employer's representative simultaneously within the dates named in specifications such drawings, samples, patterns and models as may be called for therein or as the Employer's representative may reasonably require. Approval will be accorded by the Employer's representative four (4) weeks after receipt of the two documents. Copies of all drawings and other papers to be approved by the Employer's representative shall be provided as shown in the table below by the Contractor. The Contractor shall supply additional copies of approved drawings in accordance with the details set out in these conditions. The Contractor shall make available copies of detailed manufacturing drawings or calculations. Any such drawing or document and all other drawings or documents serving the purpose of information only will not be stamped. Drawings which need minor modifications only with no effect to the erection work will be limited approved, i.e. accepted for the construction phase. Such drawings will be checked again after completion (as-built drawings).

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One (1) copy of the drawings and other papers submitted will be returned to the Contractor with one of the following examination endorsements applied by the Employer's representative: -- NOT APPROVED -This drawing has been spot-checked for main dimensions and compliance with the overall layout, and is being returned for the necessary modifications. The revised documents shall be resubmitted to the Client for approval. Related activities on field works and/or manufacturing cannot commence. -- APPROVED ON CONDITION -This drawing has been spot-checked and limited approved with regard to the main dimensions and compliance with the overall arrangement. Provided that the necessary corrections will be considered and incorporated in the final design and project implementation, related activities on field works and/or manufacturing can commence. The revised documents shall be resubmitted for approval. The approval does not release the Contractor from his full contractual obligation on design liability and facility performance of the installed transmission system. -- APPROVED -This drawing has been spot-checked and approved with regard to the main dimensions and compliance with the overall arrangement. The related activities on field works and/or manufacturing can commence. The approved documents shall be resubmitted stamped by the Contractor For Construction. The approval does not release the Contractor from his full contractual obligation on design liability and facility performance of the installed transmission system. If the Contractor receives drawings and papers endorsed with the stamp N O T A P P R O V E D he shall without delay make all the necessary alterations and corrections and resubmit copies of these as shown below to the Employer's representative for approval. If the Contractor receives drawings and papers with the stamp APPROVED he shall without delay send copies as per table shown below stamped "FOR CONSTRUCTION". Generally, approved drawings shall not be changed except as stated below. If such a document is modified for any reason afterwards, it is understood that the previous notification of the Employer/Employers Representative is automatically null and void. The Contractor is hence obliged to immediately notify the Employer/Employers Representative of the existence of such further modification, to delete the pertinent remark Approved by the Employer/Employers Representative on from the original and such document shall undergo the above mentioned procedure again.
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Approved drawings and subsequent execution modification have to be recorded and incorporated into the concerned drawings as these will form an integral part of the As-Built Drawings. The drawing approval of spotted tower position on the profile/plan only does not guarantee the suitability of the pre-selected tower location with regard to foundation placement and adjacent slope stability. Clearance of the final tower position remains in the scope of the Contractors contract obligation as to be checked during tower pegging. The drawing approval is not the official building permit for the planned transmission lines and the concerned main crossing (roads, railways, aerials, etc.) The drawing approval of foundation classes on the basis of sounding results only does not guarantee the suitability of the pre-selected foundation type with regard to the actual encountered subsoil conditions. Clearance of the final foundation class remains in the scope of the Contractors contract obligation as to be checked during excavation. The Contractor shall ensure that drawings, calculations, designs etc. for approval are forwarded to the Employer's representative in sufficient time to allow enough time for examination of the drawings in the Employer's representative's office. In general this time period is 4 weeks from the date the documents were received by the Employers representative office. The Contractor shall also ensure that drawings are submitted early enough prior to the date required for approval to permit amendments to be made and the drawings re-submitted for approval without delaying the program deliveries or the guaranteed completion dates of the Works. If the Contractor has not received any notice within 5 weeks from the date of submission (reception date by the Employers Representative), then the documents and/or drawings shall be deemed of being approved. At monthly intervals the Contractor shall submit copies of the drawing schedule showing the actual status, i.e. preliminary, completed, modified or approved. If during the contract period, the Contractor is required to increase the size of any buildings, foundations etc. from that shown on his tender drawings to accommodate the finally approved arrangement of the works provided under the Contract (with due allowance for access, lay down, maintenance etc.), then such increases shall be deemed to be included in the Scope of the Contract. All drawings shall be black lines on a white background with all revisions clearly marked.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Logical and graphical symbols as well as abbreviations used in the drawings shall be identified in a legend. Abbreviations shall be described in their full text. All drawings shall bear the approved contract references and title block as agreed with the Employer's representative. At least the following information shall be included in the title block: the Contractor's name the Subcontractor's name, where applicable the Employer's name the Project name the name of the Employer's representative, when so advised brief description of the contents of drawings drawing and revision number first date and revision dates scale and scale bar (where applicable) location for the Employer's drawing number. The Contractor shall be responsible for any discrepancies, errors or omissions in the drawings and other particulars supplied by him, whether such drawings and particulars have been approved by the Employer's representative or not. Drawings and papers shall be submitted to the Employer's representative in such a sequence that the information required by the Employer's representative for examination purposes corresponds with the progress of the Works. All drawings and other papers which have to be submitted to the Employer's representative in accordance to these clauses, shall be composed in English. The design, dimensioning and the technical data in the drawings and other papers shall be based on the metric system only. All drawings and other documents submitted by the Contractor shall be of one of the following sizes which conform to the German Standards Specifications DIN 476: Size A0 A1 A2 A3 A4 Dimension in mm: of trimmed drawing and trimmed blue print (finished sheet) 1.189 x 841 maximum 841 x 594 594 x 420 420 x 297 297 x 210

Folded to size A 4 with margin for binding.


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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

The following scales shall be used: For reproduction : 1 : 2 / 1 : 5 / 1 : 10 / 1 : 20 / 1 : 50 / 1 : 100 / 1 : 200 / 1 : 1,000 / 1 : 2,000 / 1 : 1,500 / 1 : 10,000 / 1 : 25,000 1 : 50,000 / 1 : 100,000 / 1 : 500,000 / 1 : 1,000,000 For enlargements: 2 : 1 / 5 : 1 / 10 : 1

In addition to the sizes mentioned above, horizontally extended sizes are permissible, for example for route plans; these shall have the following dimensions: Height: 297 mm (A4-height) Length: x 210 mm, that is to say a multiple of A 4 length Continuous drawings which require several subsequent sheets for printing shall have sufficient overlapping zones to allow proper orientation without information losses. The quality of original drawings, master prints, blue-prints and of all other copies, irrespective of the method by which they have been produced, must be such that no damage whatsoever, such as partial or complete illegibility, can occur as a result of the tropical climate or other extreme climatic conditions. For drawings a paper grade weighing more than 80 grams per square meter shall be used throughout. The out-printing quality of topographical maps shall reach at least 300 dpi (dot per inch) and for satellite photos at least 600 dpi. The Employer reserves the right to ask for all drawings directly. The Employer's representative and the Employer shall have the right at all reasonable times to inspect at the factory of the Contractor all drawings of any portion of the Works. The Contractor shall submit design calculations and shop drawings. The Contractor shall, within the times named in the Specification, provide drawings showing the manner in which the Plant is to be assembled with all information relating, unless otherwise agreed, only to the Works, required for preparing suitable foundations, for providing suitable access for the Plant and any necessary equipment to the point on Site where the Plant is to be erected and for making all necessary connections to the Plant (whether such connections are to be made by the Contractor under the Contract or not). Any expenses resulting from an error or omission or from delay in delivery of the drawings and information shall be borne by the Contractor.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

B0.5.3.3

Progress of work and reports


The Contractor shall submit for the Employer's representative's approval, the details of proposed methods of reporting on all aspects of works throughout the duration of Project. The reporting system must meet the requirements of the Employer's standard reporting formats, and as a minimum, shall include: Weekly Summary Report Giving highlights of the week's activities, the actual progress planned in quantitative terms, and areas of concern if any, and work planned for the following week. This report is to be submitted by the second day of the following week. Monthly Project Progress Report As a minimum, the monthly progress report must include text, tabulations, charts, graphs and photographs as applicable thus providing appropriate information, both cumulative and for the past month on: overall, discipline wise and per section of works, status of progress on project and in comparison with planned progress current and future areas of concern and status of previously identified areas of concern remedial actions recommended to correct or reduce existing or potential problems and delays. Effectiveness of remedial action taken for earlier problems cost report and prospective cash flow schedule status, highlighting the status of milestones, status of critical activities, along with schedule trend analysis indicating the actions proposed to be taken to ensure timely completion of project progress, productivity and man-hour data to include budget, actual and forecast together with trend identification and analysis procurement progress, delivery details and forecasts including specific information on late deliveries likely to affect progress. The Contractor shall submit detailed progress reports. The reports shall show clearly and accurately the position of all activities associated with design, material procurement, manufacture, QA activities, works tests, shipping, mobilization, site erection, testing and commissioning with regard to the agreed contract program. The position on material procurement shall give the date and details of orders placed and indicate the delivery quoted by the manufacturer. If any delivery has an adverse effect on the contract program the contractor shall state the remedial action taken to ensure that delays do not occur.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

The portion on manufacture shall indicate the arrival of material, the progress of manufacture and date at which the equipment will be ready for transport. The information recorded shall also indicate all special occurrences (such as accidents, defects etc.), which will affect the date of completion in the manufacturer's Works. The site erection portion of the progress report shall be segregated into the main and ancillary items of civil, mechanical and electrical work and each item of work shall be monitored giving the percentage completion and the projected completion date of the Work in accordance with the agreed contract program. Any delay which will affect the completion, testing and commissioning dates of any item of Plant shall be detailed by the Contractor who shall state the action he is taking to effect completion to the contract program. The Contractor shall report in respect of the various groups of the Works the erection equipment in use or held in readiness, a return of labor and supervisory staff, and details of any matters arising which may generally affect the progress of site Work. The commencement of testing and commissioning, its duration details of any matters occurring during that period and the remedial action taken, the completion dates etc. shall be noted and segregated for each group of the Works. The progress reports shall be set out in a format to the approval of the Employer's representative. The progress report shall be forwarded within the first week of the following month so that on receipt the information contained therein is not out of date. Sufficient copies in English have to be submitted to the Employer's representative's offices and the Employer as may be requested by the Employer's representative during execution. Progress Review Meetings Progress review meetings shall be held at weekly and monthly intervals. Contractor's progress reports shall be reviewed in detail at these meetings. The dates shall be fixed well in advance on project calendar. Progress Review Meetings Records The Contractor shall record minutes of all progress review meetings with particular attention to actions agreed upon and the dates by which actions are required to be taken and the party responsible to carry them out.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Close Out Report The Contractor shall prepare a Final Report on the Project which shall be submitted to the Employer's representative not later than one month after the Certificate of Operational Acceptance for the entire installations has been issued. Format and content of the Close Out Report shall be agreed between the Contractor and the Employer's representative but shall, as a minimum, cover the following: project definition Contractor's Scope of Works (contract value) original and final overall Contract Value with major reasons for deviation original and final schedule with major reasons for deviations Contractor's organization charts commissioning report performance test calculations and results test certificates inspection certificates acceptance certificates all final engineering calculations bound in separate volumes.

B0.5.3.4

Documents, goods and materials to be handed over to the Employer


In addition to the requirements of the corresponding clauses of the Conditions of Contract on Completion, Commissioning and Operational Acceptance, the Contractor shall obtain a Operational Acceptance Certificate for each of the documents, goods, materials, maintenance equipment, spare parts, instruments etc., required by this specification to be handed over to the Employer. The Operational Acceptance Certificate shall state clearly that all items have been received in a satisfactory condition as required under the Contract. The Contractor shall as required be responsible for demonstrating the satisfactory condition of all items delivered to the Employer including the repacking for storage on site.

B0.5.3.5

Sub-contractors and sub-orders


As soon as practicable after entering into the Contract, the Contractor shall, having obtained the Employer's representative's consent in accordance with the Conditions of Contract, enter into the Sub-Contracts he considers necessary for the satisfactory completion of the Works. It is the responsibility of the Contractor that all information requested for the approval by the Employer's representative will be submitted in sufficient time to allow time enough for examination and approval.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

B0.5.4

Design and manufacturing stage


The Contractor has to submit drawings, diagrams, graphs, curves and all such information which are necessary to verify that the goods he intends to manufacture comply in every respect fully with the requirements of the Contract. All documents and information the Employer's representative/Employer deem necessary are to be submitted by the Contractor in a reasonable time.

B0.5.5

Erection stage
a) Operation and Maintenance Manuals The Contractor shall furnish to the Employer complete Operation and Maintenance Instructions and separately Operating Instructions in the following sequence: preliminary draft 4 (four) weeks prior to the commencement of precommissioning complete final issue accepted by the Employer's representative prior to the issue of Operational Acceptance Certificate. The Operation and Maintenance Instructions shall contain a detailed description of the equipment and components written in such a way as to enable the Employer to operate, maintain, dismantle, reassemble and adjust all parts. The instructions shall be accurate and easy to understand and shall be presented in such a manner that the contents can be used for instructing also untrained personnel in the operation, service, maintenance and repair of the installations and each individual equipment. Tables, lists, graphic presentations and explanatory diagrams should be used as far as possible for easy understanding. The instructions shall mention the inspection and maintenance intervals laid down separately for each individual equipment or part, the exact description of the operations to be carried out as well as the necessary spare parts and materials. The Contractor shall mention how and where additional spare parts can be ordered specifying for each part the ordering number. The Operating Instructions to be provided by the Contractor shall contain a detailed description of each individual plant written in such a way as to enable the Employer to operate all installations of the respective plant.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

The instructions must be accurate and easy to understand and shall be presented in such a manner that the contents can be used for instructing also untrained personnel in the operation of each individual plant. Tables, lists of operation sequence, graphic presentations should be used as far as possible for easy understanding. The instruction shall contain the detailed description of the operating principles for each system of the plant and how to operate them. The instruction shall contain indications how to use the earthing devices and other service and protective equipment the safety measures required, clearly presented and commented in detail. The Employer's representative reserves the right to specify a uniform cover (lose leaf folder) for all Operation and Maintenance Manuals (operation and Maintenance Instructions). The Contractor shall not be entitled to claim extra payment because of this requirement. The Contractor shall submit to the Employer/Employer's representative drafts of the Operation and Maintenance Instructions and Operating Instructions for approval. After having received approval and after all the necessary amendments and additions have been made, the Contractor shall send 7 (seven) filled copies of the Operation and Maintenance Manuals to the Employer's Representative in Tanzania who will transmit six (6) copies to the Employer, one (1) copy shall remain with him. One (1) filled copy shall be sent directly to the Employer's representative's home office. If it shall emerge during the erection, commissioning trial run or warranty period of the equipment that the Operation and Maintenance Instructions or Operating Instructions are inadequate or faulty and after obtaining such data only available after commissioning and proper setting the Contractor shall carry out and supply the necessary corrections and supplements. All amendments to documents shall be made by the Contractor free of charge. Drawings which have been modified shall be resubmitted.

B0.5.5.1

Record and as-built drawings


At a time to be agreed between the Employer's representative and the Contractor, but before handing over the spare parts and wear and tear parts and not later than the date on which the works are taken over by the Employer, the Contractor shall provide, free of charge in a quantity and to a destination as requested by the Employer's representative's office records, as-built drawings for all installations and constructions carried out by him. The Contractor shall prepare a Drafting and Numbering Procedure for approval of the Employer's representative/Employer.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

For extensions and/or modifications in substation as-built drawings shall include also the originally existing electrical equipment and originally existing building parts which were subject to extension and/or modification by the Contractor. The Contractor shall submit as-built drawings as fixed in distribution schedule. In addition, the Contractor shall submit all as-built drawings on floppy-disk in AutoCAD or compatible format, one copy to the Employer's representative and two copies to the Employer.

B0.5.5.2

Breakdown reports
From start of commissioning until the end of the guarantee period the Contractor is to prepare a special report as instructed by the Employer's representative/Employer for any failure of equipment or extraordinary case of disturbance indicating in detail the failure occurred, the reason for its occurrence and the operational consequences. The Contractor shall further describe the special activities carried out and his preventive measures to allow an undisturbed future operation. Additional investigations shall be carried out by the Contractor as instructed by the Employer's representative if necessary to define the reason for damage or reconcile contradictions. This report shall be subject to the Employer's representative's/Employer's approval.

B0.5.6

Registration of drawings and lists


The Contractor must maintain a register in which all drawings and lists prepared or used for the execution of the plant are to be enlisted. The register must be reproducible. The entries are to be typewritten or clearly hand-printed in English. Copies have to be submitted to the Employer's representative's head and site offices as well as to the Employer. Revision and Distribution: Here the last revision date, the revision index and the recipient of the drawings are to be entered. The recipients noted in the lists shall not include any internal work departments of the Contractor, with the exception of their local representatives or site managements in Mozambique. The recipients are already entered in the sample. Further recipients are to be entered in accordance with requirements. Letters are to be entered in the box separated by the vertical column with the Revision Date and Revision Index indicating whether the recipient has received prints or reproducible copies:

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

O = print C = reproducible copy Example: Revision and Distribution


Date of Distribution Index EDM Head Office O O O EDM Site Office C C C Contractor Contractor Head Office Site Office O O O C C C Fichtner / Fichtner / SwedPower SwedPower Head Office Site Office O/C C O/C C O/C C

a b

B0.5.6.1

Documentation after letter of acceptance


Prelim. Final (weeks)

Documentation after Letter of Acceptance

Following documentation and information shall be provided (weeks) to the Employer's representative/Employer within the specified time scale calculated in weeks after Letter of Acceptance: General: Detailed time schedule for the design, manufacture, delivery, erection and commissioning period with important intermediate dates Payment schedule Completed data sheets for the technical particulars of the scope of supply List of all drawings intended to be subject for approval List of all standards Monthly Progress Reports List of all valid drawings 3

updated every month 3 4 6 2 every month every month

4 -

Operation and maintenance instructions and operating instructions

8 before factory acceptance test

4 before start of Operational Acceptance

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B0)

Documentation after Letter of Acceptance As built drawings

Prelim.

Final before Operational Acceptance not later than one month after Operational Acceptance as instructed by the Employer's representative

Close out report

B0.5.6.2

Documents distribution
In addition to the number, type and distribution of documents called for under various clauses of this Specification the following document distribution shall be followed by the Contractor. For the Employer H. O. Correspondence Drawings for approval (and resubmission) for construction as built Insurance Certificates Progress report (incl. photos) Damage reports O + M manuals draft final List of spare parts Close out report Test Certificates * ** 2 2 3* 8** 2 5 5 1 6 2 2 2 Job Site 1 2 1 1 1 1 1 For the Total Employer's representative H. O. Job Site 1 2 1 1* 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 5 4 8 9 4 9 8 4 8 4 5 5

including one reproducible (for blue-printing) including two reproducible (for blue-printing)
70

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1
Employers Requirements Particular Technical Requirements for 400kV Overhead Line
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Table of Contents
B1. Particular Technical Requirements B1.1 General B1.2 Plant Description B1.2.1 B1.2.2 B1.2.3 B1.2.4 B1.2.5 B1.2.6 B1.2.7 B1.2.8 B1.2.9 Geography Topography Hydrology Geology Geomorphology Vegetation Wind Earthquake Summary 1 1 3 3 4 5 5 5 6 6 6 6 7 9 9 9 10 13 14 14 14 15 17 18 18 18 19 20 20 21 21 21 22
I

B1.3 Scope of Supply and Services B1.4 Technical Detail Requirements B1.4.1 B1.4.1.1 B1.4.1.2 B1.4.1.3 B1.4.2 B1.4.2.1 B1.4.2.2 B1.4.2.3 B1.4.2.4 B1.4.3 B1.4.3.1 B1.4.3.2 B1.4.3.3 B1.4.3.4 B1.4.3.5 B1.4.4 B1.4.4.1 B1.4.4.2 B1.4.4.3 Line Design General Codes and Standards Basic Design Data Line Routing, Survey, Profile Plans Preliminary line route Line routing and survey Profile plans Line route approval Environmental Protection General Protection of vegetation Protection of livestock Bird protection Monitoring of environmental impact Towers General instructions Materials Design

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.4.3.1 B1.4.4.3.2 B1.4.4.3.3 B1.4.4.3.4 B1.4.4.3.5 B1.4.4.3.6 B1.4.4.3.7 B1.4.4.3.8 B1.4.4.4 B1.4.4.4.1 B1.4.4.4.2 B1.4.4.4.3 B1.4.4.4.4 B1.4.4.4.5 B1.4.4.4.6 B1.4.4.4.7 B1.4.4.4.8 B1.4.4.5 B1.4.4.6 B1.4.4.7 B1.4.4.7.1 B1.4.4.7.2 B1.4.4.7.3 B1.4.4.7.4 B1.4.5 B1.4.5.1 B1.4.5.2 B1.4.5.2.1 B1.4.5.2.2 B1.4.5.2.3 B1.4.5.2.4 B1.4.5.2.5 B1.4.5.3 B1.4.5.3.1 B1.4.5.3.2

Design method Tower types / tower outlines Design spans Spacing and clearances Loads and load cases Partial Safety Factors Structural analysis Detailing Fabrication Workmanship Shearing and cutting Punching and drilling Bending Welding Tolerances of members Marking Corrosion protection Tower load test Packing Quality assurance General Sample testing Shop assembly Routine tests General Soil investigations General Standards Investigations Procedures Report Foundation design General Soil classification

22 23 25 25 28 32 32 36 40 40 41 41 42 42 43 43 43 46 48 50 50 51 51 52 52 52 53 53 53 54 56 57 58 58 59

Foundations

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.5.3.3 B1.4.5.3.4 B1.4.5.4 B1.4.6 B1.4.6.1 B1.4.6.1.1 B1.4.6.1.2 B1.4.6.2 B1.4.6.2.1 B1.4.6.2.2 B1.4.6.3 B1.4.6.3.1 B1.4.6.3.2 B1.4.6.3.3 B1.4.6.3.4 B1.4.6.3.5 B1.4.6.3.6 B1.4.6.4 B1.4.6.5 B1.4.6.5.1 B1.4.6.5.2 B1.4.6.5.3 B1.4.6.6 B1.4.6.7 B1.4.7 B1.4.7.1 B1.4.7.2 B1.4.7.3 B1.4.7.4 B1.4.7.4.1 B1.4.7.4.2 B1.4.7.4.3 B1.4.7.4.4 B1.4.7.4.5 B1.4.7.5

Foundation types Design principles Foundation tests

61 65 67 69 69 69 70 72 72 73 74 74 78 82 83 85 85 86 89 89 89 91 93 94 95 95 96 98 101 101 102 103 105 105 106

Conductor, Earthwire and ISWER Phase conductor Design Sag and tension requirements Earthwire or ISWER (ACSR) Design Sag and tension requirements OPGW or ISWER (OPPC) Design of conductor Design of optical fiber unit Sag and tension requirements Splicing and joint boxes of OPGW OPPC straight joint box OPPC termination box OPUG Tests General Conductors Optical fiber unit Spare parts Packing, shipping, transport Insulators and Fittings General Insulators and insulator sets Composite insulators Clamps and fittings for phase conductors General Suspension clamps Tension clamps, joints and repair sleeves Armor rods Guard rings Clamps and fittings for ISWER system

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III

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.7.5.1 B1.4.7.5.2 B1.4.7.5.3 B1.4.7.5.4 B1.4.7.5.5 B1.4.7.6 B1.4.7.6.1 B1.4.7.6.2 B1.4.7.6.3 B1.4.7.6.4 B1.4.7.7 B1.4.7.7.1 B1.4.7.7.2 B1.4.7.7.3 B1.4.7.7.4 B1.4.7.7.5 B1.4.7.7.6 B1.4.7.8 B1.4.8 B1.4.8.1 B1.4.8.1.1 B1.4.8.1.2 B1.4.8.2 B1.4.8.2.1 B1.4.8.2.2 B1.4.9 B1.4.9.1 B1.4.9.2 B1.4.9.3 B1.4.9.4 B1.4.10.1 B1.4.10.2 B1.4.10.3 B1.4.10.4

General Suspension assemblies Tension assemblies Mid span joints Arcing horns Clamps and fittings for Earthwire and OPGW General Suspension assemblies Tension assemblies Mid span joints Tests General Insulators and insulator sets Clamps and fittings for conductors and earthwires Clamps and fittings for OPGW and OPPC Particular tests Tests during erection Packing

106 107 108 108 108 109 109 110 111 111 111 111 112 113 113 114 116 117 117 117 117 119 120 120 121 122 122 122 122 124 125 125 126 127 128

Dampers Spacer dampers Requirements Tests Stockbridge dampers Requirements Tests Warning System Warning spheres Tower painting Warning lights General Type of earthing systems Material Final acceptance of tower earthing resistance

Aircraft Navigation

B1.4.10 Earthing

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IV

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.11 Construction, Stringing, Commissioning B1.4.11.1 B1.4.11.2 B1.4.11.3 B1.4.11.4 B1.4.11.5 B1.4.11.6 B1.4.11.7 B1.4.11.8 B1.4.11.8.1 B1.4.11.8.2 B1.4.11.8.3 B1.4.11.8.4 B1.4.11.9 B1.4.11.10 B1.4.11.11 B1.4.11.12 B1.4.11.13 B1.4.11.13.1 B1.4.11.13.2 B1.4.11.13.3 General Safety, infrastructure and supervision Route clearing Access roads Tower pegging Route modifications Site preparation and erosion protection Foundation works General Earthworks Leg/ Stub setting Concrete works Tower erection Earthing Conductor and earthwire stringing Line hardware and insulator string set installation Pre-Commissioning and Commissioning Final checking Commissioning Operational Acceptance

128 128 129 132 132 133 134 135 135 135 136 138 139 140 143 144 149 149 149 150 151 152

B1.5 Technical Schedules

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1. Particular Technical Requirements


The present clauses refer to the particular technical requirements for EPC (Engineering - Procurement - Construction) contracts for electrical overhead lines. The following directions, information and technical requirements for design, engineering, layout, manufacturing, transport, customs clearance, delivery, unloading, temporary storage, erection, installation and testing shall be observed as far as they are applicable for the individual material components and plant equipment to be delivered. The requirements stated in this section of Particular Technical Requirements are binding technical requirements and shall be interpreted and applied in conjunction with the General Technical Requirements. In case the contract specification and relevant standards show different requirements, the more stringent one shall be applied. The transmission system shall be brand new and designed, manufactured and arranged so that it will have a functional design and a pleasant appearance. The plant and its components shall meet the specified performance and required life time under safe operation conditions.

B1.1

General
Background The proposed new HV transmission line project is part of TANESCOs short-term strategy for National Grid transmission line reinforcement. This new 670 km long power line from Iringa to Shinyanga will link existing and future generating sources in the south and southwest of Tanzania to the load centers in the Mwanza and Arusha regions in the North. The power now being generated at Lower Kihansi, Kidatu and Mtera, and in future at Kiwira, Mpanga, Ruhuji, Mchuchuma and Rumakali, shall be transmitted to the load centers in the north and northwest of Tanzania by reinforcing the existing transmission grid. The planned energy expansion project shall boost the countrys central south-north power transmission capacity from Iringa to Shinyanga for improving electricity supply to the economically fast-growing north-western part of the country. Forming a part of TANESCOs national grid, the new high-voltage transmission line will also be a link of the future interconnected East-African High-Voltage Power Grid. In anticipation of future interconnections with neighboring countries of Kenya in the North and Zambia in the South, this strengthening of the grid is a key component of regional economic cooperation and development. It has to be pointed out that this proposed project is one of the high priority items in TANESCOs Capital Investment Plan (CIP). The project shall be implemented forming three lots and working in parallel.

5413A08/FICHT-7269867-v13

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Design and operation voltage level In a first stage, the new line will be operated with 220 kV in order to use the existing substations along the line and to facilitate the integration of the supplied power into the existing countrys electrical grid. However, the new transmission line shall be designed and equipped for the 400kV level completely. ISWER system The new 400kV transmission line shall be equipped with an ISWER system in Lot 3. The issue deals with the power supply to the villages located along the line route up to 126km distance from the high voltage transformer substation. It is planned to use the rated voltage of 36kV for subtransmission and distribution to the following fourteen villages with low load density: DISTRICT Iramba VILLAGE 1. Kizonzo 2. Mseko 3. Mgongoro 4. Makomero 5. Mbutu 6. Bukama 7. Imalanguzi 8. Mwanakoma 9. Igurubi 10. Kalitu 11. Kiloleli 12. Mwajiginya 13. Mwaweja 14. Ngunga

Igunga

Kishapu

The 36kV system is operated with the neutral solidly grounded transformer. The configuration is solely radial. The system consists of the insulation of the two shield wires of the 400kV transmission line (one normal earthwire and one OPGW), energizing the two shield wires in the nearest high voltage transformer substation as two phases of the 36kV system and establishing the third phase via a series resister reactor (R-L-block) and earth-return. At each point-off point, the current flows from the line through the primary coil of a step-down transformer to earth through an earth rod. From the earth stake, the current goes its way back to the main step-down transformer at the head feed of the line. The secondary winding of the local transformer will supply the customer with three phase (P-N-P, 2 x 240 V) power, with the N-Volt conductor connected to a safety earth point. The T-off points (normal design) consist of a special V-suspension string for the insulated shield wires in order to fix the conductor (or the jumper)
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

36kV post insulators for leading one conductor to the other tower side of the T-off direction two 36kV tension strings to be fixed at the crossarm peak for the Toff down-lead of the two phases or alternatively cable up-lead to the earthwire crossarm level and installation of cable end connector and surge arrester with jumper link to the earthwire on an auxiliary platform and the termination points (normal design) consist of a tension insulator set for the OPPC/ earthwire surge arresters separation unit for optical fibers of OPPC joint box to connect optical fibers of OPPC and OPGW but the equipment is not in the scope of this Contract (except insulator strings). The exact locations of these points are not known at the moment. However, all construction detail preparations shall be done to install the Toff or termination equipment at any tower. The ISWER components to be supplied within this Contract (conductors, insulator strings including fittings with arcing horns) are specified in the paragraphs below. Earthing of the towers equipped with ISWER is considered to be critical and needs special instructions.

B1.2

Plant Description

B1.2.1

Geography
The line route and associated substations are located in the central highlands of Tanzania between 35 and 36 east and extending in the latitudes from 4 to 8 south of equator as shown in the General Map of Project Area. The planned line of approximately 670 km will interconnect four substations at the cities of Shinyanga, Singida, Dodoma and Iringa. Accordingly, three line sections (lots) are resulting as shown below: Line section Iringa Dodoma Dodoma Singida Singida Shinyanga Total Lot 1 2 3 Angle points 38 pt. 30 pt. 36 pt. 104 pt. Line length 225 km 217 km 228 km 670 km

The following transport facilities are present in the project area: main harbour: Dar Es Salam for heavy duty goods international airport: Dar es Salam for large planes national airport: Dodoma for medium size planes primary road: Dar Es Salam to Dodoma asphalted
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

secondary road: Iringa to Shinyanga gravel and asphalt railway: Singida Dodoma Dar Es Salam NOTE for Lot 1, Iringa Dodoma, only: Lot 1 of the proposed Transmission line runs from Iringa to Dodoma, of which the government of Tanzania, through TANROADS, is upgrading the road structure adjoining the towns Iringa and Dodoma in the same stretch to a bituminous level. The road being upgraded (260km in length), has been sub divided into 3 lots as follows:Lot 1 of the road starts from Iringa to Migoli (95.2km), Lot 2 is from Migoli to Fufu (93.8km), Lot 3 is from Fufu to Dodoma (70.9km). Each lot is independent of one another, i.e, have different consultants and Contractors. Lot 2 from Migoli to Fufu, runs on both sides of the two regions of Iringa and Dodoma. The upgrading works of the road are already in progress for a duration of 36 months (3yrs) as from 16th March 2011. During that period of road construction, the EPC Contractor will be encountering diversions as well as restrictions to places whereby bridges and culverts are at construction stage, such that much corporation is required so that disruption of either side of the works is avoided or minimized during implementation of the construction of the transmission line of which will be using the road or its diversions as per time to time directives.

B1.2.2

Topography
Commencing from the south, the line passes from the Iringa Highlands to the north over the Kidunda Ranges at 1,650 m a.s.l. From the rocky, steep slopes, the highlands drop sharply within ~ 50 km nearly 1,000 m over a dissected scarp towards the Mtera Reservoir. The line bypasses the power plant Mtera in rolling hills over the Fufu Escarpments to Dodoma. Continuing to north-west along the Great North Road, the terrain is in general rather flat to gentle sloped. After Singida the line traverses moderately rising countryside with another sharp drop into the partly swampy Wembere Plains. Towards Shinyanga the terrain rises steadily from lightly hilly to undulating landscape. Location Kidunda Mtera Iringa Dodoma Singida Shinyanga Altitude above sea level 1,650 m 750 m 1,550 m 1,120 m 1,510 m 1,170 m Remarks highest elevation T/L lowest elevation T/L highest elevation S/S lowest elevation S/S -

5413A08/FICHT-7269867-v13

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.2.3

Hydrology
The predominantly tropical climate in these latitudes is characterized by frequent and intensive thunder showers during rainy season. The mountain ranges around Iringa and Dodoma are like cloud-bursting obstacles in the weather atmosphere. The annual rainfall of around 1m in the highlands to less than half a meter in the plains is concentrated on the wet months only from November to May, peaking in March and April. This pattern of rainfall in combination with sandy ground let rivers and marshy terrain dry up after rainy season. Only two rivers in the project area, the Great Ruaha and its largest tributary, the Little Ruaha, which feed the Mtera Reservoir, are perennial. The phenomenon of seasonal river and seasonal swamp allow great mobility across the countryside during dry season from June to October. Location Iringa, Dodoma Singida, Shinyanga Annual average rainfall approximately 1.0 m approximately 0.5 m

B1.2.4

Geology
Some parts of the line route are located in areas of outcropping metaigneous weather-rock basement. Differential continental plate drifts during the late tectonic phase of the Precambrium period pushed the rock partially to the surface. The fractured earth-crust underwent a medium-grade metamorphic transformation forming a rock basement in various hardness predominantly of granite accompanied by gneiss and sequences of intercalated metacalcerous crystalline rocks, quartzite and schist. Two major parallel faults of a highly sheared and down-thrown area between Fufu and Isimani are forming the plains of the Great Ruaha River. Composition of soil predominantly metamorphosed outcrop rock of weathering granites and gneiss on hills and alluvium in plains and residual soils in depressions

B1.2.5

Geomorphology
The low-grade metamorphosed outcropping sedimentary rock and granites are gradually weathering to partly gravelly sand with fines. The weathering product of predominantly coarse crystalline sand forms the slopes of the hilly terrain, whereas the large plains are of alluvial deposits and residual soils of clayey fine sand with some silt. Although the soil is in general of firm to dense compactness having good bearing properties, the low percentage of cohesive fine components makes the soil in exposed areas prone to erosion. Particular effort shall be made during the field investigation in locating and recording these areas for tower spotting and erosion protection measures.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

In some isolated parts and marshy terrain localized lateritic and black cotton soil have developed and is extending up to several meters depth. Property of soil predominantly red to yellow-brown and brown sandy earth of firm to dense compactness of fairly good bearing capacity

B1.2.6

Vegetation
The vegetation is depending on climate pattern, rainfall quantity, irrigation systems and soil fertility. The vicinity of the all-year well-watered banks from the Little and Great Ruaha is an important maize-growing area with some paddy fields and fruit plantations whereas the dryer zones cattle, crops and bushes are prevailing. Line section Iringa Dodoma Dodoma Singida Singida - Shinyanga Prevailing vegetation cultivation, trees scrub, bush cultivation, grass land

B1.2.7

Wind
Winds in the plains around Singida and Shinyanga are light to moderate throughout the year. Wind speeds are somewhat higher towards the end of dry season. Thunderstorms during the wet season can generate strong surface winds of mainly short duration.

B1.2.8

Earthquake
The East-African continental riff, an active fault line caused by differential plate movements is associated with earthquakes in the range of a local magnitude ML 6 to 7. This earthquake belt is located approx. 500 km to the west of the planned transmission line in the neighboring country Rwanda. Tanzania itself is situated in a stable area. In the event of an earthquake in Rwanda of say ML 6 to 7 and taking into account a perceptibility radius around the epicenter of between 400 to 700 km, the intensity 500 km away from the fault rupture would be reduced to under magnitude ML 5 or 0.1 g ground acceleration and subsequent impact on the line structure would be minor.

B1.2.9

Summary
The climatic conditions for the new 400kV line are summarized as following:

5413A08/FICHT-7269867-v13

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Altitude above sea level Relative average humidity Annual average rainfall Isokeronic level Maximum solar radiation Minimum ambient air temperature Maximum ambient air temperature Design temperatures: Minimum conductor temperature Maximum conductor temperature Maximum earthwire temperature for 1s Everyday temperature Temperature with maximum wind Design wind speed in 10m height VR (10 min mean value) Seismic acceleration coefficient

750-1700 m 80% 1000 mm 100 days/year 1035 W/m2 15 C 40 C 10 C 85 C 160 C 25 C 10 C 31 m/s 0.1 g

B1.3

Scope of Supply and Services


The project will be contracted and implemented as a turn-key contract. This section sets out the scope of design, supply and installation as well as requested services including all necessary components and services not mentioned, but deemed to be included in a turn-key type contract. Works shown in the approved drawings, but not explicitly mentioned in the specification and works described in the specification, but not shown in the approved drawings will nevertheless be considered as to be included in the signed turn-key contract. The Contractor is deemed to have obtained all necessary information on scope of work and site conditions, which may influence the agreed contract price. The Contractor is deemed to have satisfied himself as to the means of worksite access, the nature and extent of work and materials necessary for the entire completion of work in every respect as for a satisfactory operation of the transmission system being implemented. The Contractor shall assume at least the following works, duties and services as the contract scope: Lot 1, overhead line from Iringa S/S to Dodoma S/S, line length 225km including temporary outgoing for 220kV operation at Iringa S/S Lot 2, overhead line from Dodoma S/S to Singida S/S, line length 217km including temporary incoming/ outgoing for 220kV operation at Dodoma S/S Lot 3, overhead line from Singida S/S to Shinyanga S/S, line length 228km including temporary incoming/ outgoing for the 220kV operation at Singida S/S and temporary incoming for Shinyanga S/S Temporary incoming and outgoing for the 220kV operation mean surrounding of the future 400kV substation extension area with the help

5413A08/FICHT-7269867-v13

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

of a 400kV overhead line (see plans in the Annex). The new 400kV line shall end at the dead end towers in front of the future 400kV T/L bays of the S/S. The temporary line shall run from this dead end tower to the 220kV T/L bays of the S/S. 400 kV overhead line, double circuit, twin bundle ASCR Bluejay conductor, insulator strings, steel latticed towers, reinforced concrete foundations two earthwires, one as normal ACSR conductor plus one as OPGW in specified sections of Lot 3 ISWER system (one ACSR conductor plus one OPPC both insulated for 36kV) instead of normal earthwire/ OPGW all preparations for T-offs of the ISWER system termination of ISWER system after 126km distance from the substation and separation of the optical fibres for the OPPC/ OPGW special 400kV towers with horizontal phase conductor configuration for bird protection in Lot 3 The scope of line contract ends at the substation gantries, i.e. slack span of conductors, insulator strings and their attachment at the gantry and jumpers for the link to the substation conductors shall be included under this scope. The ISWER system ends at the gantry top including jumper link to the substation and separation of the optical fibre part of the OPCC. The optical fibre termination box shall be installed at the gantry base. The OPGW system ends at the gantry top including jumper link to the substation. The OPGW termination box shall be installed at the gantry base. engineering services for the planned transmission system to the necessary extent of a turn-key project detail design of the transmission line components to the necessary extent for manufacturing and construction mobilization, store yards, access roads, bush clearing survey of ground features, plotting of situation plan and longitudinal profiles with tower spotting soil investigation, penetration sounding, test pits, sampling and evaluation of the engineering properties procurement, manufacturing, testing, supply, insurance, shipping, customs clearance, unloading, transport, storage of line material and components testing of tower and foundation testing of conductors and insulator strings including their components installation and erection of foundations, earthing system, erosion protection, towers, insulators, conductors, ground wire, OPGW aircraft warning near airports by red/white structure painting and installation of orange cable spheres installation of step bolts, anti-climbing device, tower number and danger plates, landmarks for right of way tidy-up maintenance roads commissioning with final check and live test of transmission system as-built documentation and operation & maintenance manual supply of spare parts and maintenance tools
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

site office building with furnished rooms to accommodate the Employer vehicles as specified for the Employer factory Acceptance Tests training abroad for Employers staff on the training for Employers Staff conducted on site over the full project period Tower Spotting and Electromechanical Design Software preinstalled on laptop computers for Lot 2. Line route maps, typical foundation types, tower outline drawings, insulator and conductor configuration as well as earthing principles are annexed to this specification. All materials, designs, details, fabrication and tests shall be in compliance with the requirements described hereafter and the details on the drawings. However, these technical requirements do not limit the responsibility of the Contractor to perform all design and works and to supply all accessories within the scope, in order to render the Works complete and ready for operation. No omission or ambiguity on the drawings or in these technical requirements will relieve the Contractor from the responsibility for furnishing first class materials and workmanship. All designs and details shall be subject to approval by the Employer / Employers Representative. The Employer / Employers Representative reserves the right to ask the Contractor, without additional cost, for any changes in design and details, necessary to make the construction conform to the Contract requirements. The Contractor shall assume full responsibility for the adequacy and accuracy of the Work, which is required to be provided. He remains responsible for providing all necessary interface data. The Bidder shall offer quantities according to the price schedules. These quantities were estimated for bidding purpose, based on the preliminary line design. They are not valid for the Contractors material ordering. A verification and possible adjustment of the quantities will be done during the engineering stage and detail design and shall be subject to approval of the Employer / Employers Representative. The Contractor has to establish the necessary quantities based on his final, approved design.

B1.4

Technical Detail Requirements

B1.4.1 Line Design

B1.4.1.1

General
The new European Standard EN 50341 Overhead electrical lines exceeding AC 45kV, is in force since 2001 and was introduced officially in all

5413A08/FICHT-7269867-v13

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

CENELEC member countries on January 01, 2004. The approach of Part 1 General requirements Common specifications shall be applied for the design of all main components of the 400 kV overhead line taking into consideration the local conditions in Tanzania (ambient conditions like temperatures and wind velocities). The design method to be applied for dimensioning of the towers, foundations and line equipment is based on the limit state concept applied in conjunction with the partial safety factor approach as per EN 50341. This philosophy allows taking into consideration uncertainties regarding the external loads as well as dispersion of the resistances of the different line components and materials. However, within the method, due to lack of enough statistical data, the deterministic / empirical way of determination of loads shall be considered. Corresponding partial safety factors to be applied are specified in the following chapters. Based on the preliminary line route and the General and Particular Technical Requirements, the Contractor shall perform his own investigation, calculations and studies to check and optimize the line design. The Contractor shall be responsible for the complete and comprehensive design adapted to the actual project conditions.

B1.4.1.2

Codes and Standards


The transmission line design shall follow the recommendations of EN 50341-1. The following listed standards for the specification of the components (conductors, insulators, fittings, steel, steel structures, etc.), are preferably European, IEC and ISO standards, but equivalent standards such as ASTM, ASCE, JIS, etc. will be accepted provided that the requirements are equivalent: General EN 50341-1 (2010): Overhead electrical lines exceeding AC 45kV, Part 1 - General requirements - Common specifications IEC 60038 (1983): IEC standard voltages IEC 60060 (1989): High voltage test techniques IEC 60270 (2000): High voltage test techniques Partial discharge measurements Conductors EN 50182: Conductors for overhead lines - round wire concentric lay stranded conductors ASTM B 232/ B 232M: Specification for concentric-lay-stranded aluminum conductors, coated-steel reinforced (ACSR) EN 60889: Hard-drawn aluminum wires for overhead line conductors EN 50189: Conductors for overhead lines - Zinc-coated steel wires

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

EN 50326: Conductors for overhead lines - Characteristics of greases EN 10244: Steel wire and wire products - Non-ferrous metallic coatings on steel wire - Part 2: Zinc of zinc alloy coatings IEC TR 61597 (1995): Overhead electrical conductors - Calculation methods for stranded bare conductors IEC 60468: Method of measurement of resistivity of metallic materials ISO 7802: Metallic material - Wire - Wrapping test OPGW IEC 60793: Optical fibers - Part 1: Measurement methods and test procedures IEC 60794-1-1: Optical Fiber Cables - Generic Specification General (Materials, Construction, Measuring Methods) IEC 60794-1-2: Optical Fiber Cables - Generic Specification Basic Optical Cable Test Procedures ITU-T G.652: Transmission media characteristics Optical fiber cables - Characteristics of a single-mode optical fiber cable ITU-T G.655: Transmission media characteristics Optical fiber cables - Characteristics of a non-zero dispersion shifted single mode optical fiber cable Insulators/ Insulator Strings IEC 60071-1 (1993): Insulation co-ordination - Part 1: Definitions, principles and rules IEC 60071-2 (1996) : Insulation co-ordination - Part 2: Application guide IEC 60815 (1986): Guide for the selection of insulators in respect of polluted conditions IEC 61109 (1992): Composite insulators for AC overhead lines with nominal voltage greater than 1000 V definitions, test methods and acceptance criteria IEC 61466-1 (1997): Composite string insulator units for overhead lines with nominal voltage greater than 1000 V Part 1: Standard strength classes and end fittings IEC 61466-2 (1998): Composite string insulator units for overhead lines with nominal voltage greater than 1000 V Part 2: Dimensions and electrical characteristics IEC 60120 (1984): Dimensions of ball and socket couplings of string insulator units IEC 60372 (1984): Locking devices for ball and socket couplings of string insulator units: Dimensions and tests IEC 60437: Radio interference test on high-voltage insulators IEC 60507: Artificial pollution tests on high-voltage insulators to be used on A.C. systems IEC 61 467: Insulators for OHL >1kV - Power Arc Tests for Insulator Sets

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Fittings IEC 61284 (1997): Overhead Lines - Requirements and tests for fittings IEC 61854: Overhead Lines - Requirements and Tests for Spacers IEC 61897: Overhead Lines - Requirements and Tests Stockbrigde Type Aeolian Vibration Dampers Towers EN 1993-1-1: Design of steel structures - Part 1-1: General rules and rules for buildings EN 1993-1-8: Design of steel structures - Part 1-8: Design of joints EN 10025 (2004): Hot rolled products of structural steels EN 10029: Hot rolled steel plates 3mm thick and above EN 10056: Structural steel equal and unequal leg angles - Part 1: Dimensions, Part 2: Tolerances ISO 898 (1999): Mechanical properties of fasteners ISO 1461 (1999): Hot dip galvanized coatings on fabricated iron and steel articles IEC 60652 (2002): Loading tests on overhead line structures Paper 3B from IEE Effects of Interacting Construction Deviations on 500 kV Power Line Structures by F. Villa, Kuala Lumpur, Malaysia 1993 Foundations EN 1997-1-1: Geotechnical design - Part 1: General rules EN 197-1 (2000): Cement Composition, specification and conformity criteria BS EN 12620: Specification for aggregates from natural sources of concrete EN 206-1 (2000): Concrete Specification, performance, production and conformity EN 10080: Steel for the reinforcement of concrete - Weldable reinforcing steel - General EN 1992-1: Design of concrete structures - Part 1-1: General rules and rules for buildings EN 12350-1: Testing fresh concrete EN 12390-3: Testing hardened concrete IEC 61773: Overhead lines Testing of foundations for structures.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.1.3

Basic Design Data


The following table shows the minimum design requirements from the point of view of the electrical system. Nominal voltage Un Maximum operating voltage Us Nominal voltage for ISWER Power frequency Basic Insulation Level Design BIL (lightning impulse) Switching impulse withstand voltage phase - earth Ratio of switching overvoltage phase-to-phase and phase to ground System highest 3-phase short-circuit current level (1s) Short circuit current (1s) for thermal stability check of the earthwires and ISWER Design creepage distance for medium pollution as per IEC 60815 400 kV 420 kV 36 kV 50 Hz 1425 kVpeak 1050 kVpeak 1.5 40 kA 10 kA 25 mm/kV (Us)

In addition to the climatic and electrical design data, the following data shall be taken into consideration for the design. Number of 400kV circuits Conductor type Number of conductors per phase Transmission capacity of the line/ per circuit Number of earthwires or ISWER Earthwires consisting of Insulated shield wire earth return (ISWER) for rural electrification, consisting of Lightning protection angle for towers Type of towers Type of foundations 2 ACSR Bluejay 2 550 MVA for 220 kV 1000 MVA for 400 kV 2 1 ACSR 95/55 and 1 OPGW similar to ACSR 95/55 1 ACSR 185/30 and 1 OPPC similar to ACSR 185/30 15 Steel lattice structures In-situ casted reinforced concrete

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.2 Line Routing, Survey, Profile Plans

B1.4.2.1

Preliminary line route


It has to be pointed out that the proposed line route shown in the preliminary line routing drawings is based on the preliminary line survey by means of GPS. The route is presented in the Annex and is based on maps 1:50,000, which have been digitized and geo-referenced for easier handling with positioning instruments and design software. Final detail drawings of the final line route shall be submitted to the Employer for approval. The drawings form the basis for obtaining the building permit by the Employer. The Contract Price shall include provision for additional detail drawings as may be required by the Building Authority. On these maps, so called WGS 84 co-ordinates (World Geodetic System 1984) are used for the horizontal datum (X and Y) and Mean Sea Level of the Adriatic sea for the elevations (vertical datum Z) while the projection is Universal Transversal Mercator (UTM). The list of angle point co-ordinates expressed in the UTM/WGS84 system together with line length and tower deflection angles is presented in the Annex. The accuracy of the measurements and the precision of representation can be estimated at 10m. This is enough to locate every point on the map as it corresponds to 0.2 mm only at the scale 1:50,000. On the ground, the precision is sufficient to locate the proposed angle points as the angle point was pegged out by concrete pegs.

B1.4.2.2

Line routing and survey


The Contractor shall carry out his own final line survey based on the proposed line route under consideration of route modifications as requested by the Employer and on the Contractors own route optimization proposals approved by the Employer / Employers Representative. Within final precision survey and profile measurements, angle points may be shifted from the present preliminary route due to site constraints. All these works are deemed as within the scope of work and no extra cost for survey and preparation of all drawings as well as for changes of route will be paid to the Contractor.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

The line survey shall be performed by qualified and experienced surveyors. Not less than 15 days prior to the commencement of the work, the Contractor shall submit qualification records of the proposed personnel, the work program and a list of survey equipment for approval by the Employer / Employers Representative. The Contractor's Chief Surveyor of the individual line surveying crews shall in all cases announce himself to the occupier/landowner immediately before entering any private property for the purpose of survey. During the survey, the Contractor shall also check the presence of existing water or gas pipe lines, electrical signal lines within the vicinity of the line or telecommunication antennas and to ensure that there will be no hazardous, induced voltages or any other interference. In the event of complications within the proposed line route corridor of right of way the Contractor shall prepare a technical solution and submit it for approval by the Employer. Such services are deemed to be included in the Contract Price. Profiles shall be produced as a result of a precision ground or aerial survey The thedolites used and measuring techniques applied shall be state of the art, employing digital recording technique. The vertical tolerance of levels forming the profile and actual ground level shall not exceed 20 cm. The horizontal distances shall have an accuracy of 1 in 2000 and angle measurements of 1 minute accurate.

B1.4.2.3

Profile plans
The Contractor shall prepare profile plans with tower positions plotted thereon. All drawings are subject to approval by the Employer. Tower spotting shall be based on the ground profile drawings prepared by himself and design data specified. The following principles and conditions have to be taken into consideration: Where the slope of ground 90 to the line axis exceeds hillside + 5 %, a parallel profile in a distance of 15 m has to be surveyed. These levels shall be indicated on the profile as broken and/or chain lines and the distances stated. If the slope of ground at the pegged out tower locations 45 to the line axis exceed 5 % sloping, the diagonal profile has to be surveyed extending 15 m to each side from the center peg. Those separate drawings are the planning base for tower legs extension and check on foundations imbalanced inverted soil cone under uplift load. Within the right of way corridor of 90 m width all features such as hedges, fences, graves, ditches, roads, railways, rivers, buildings, canals, telecommunication and all power lines shall be shown. Road numbers or name of roads shall be stated or, if unclassified, the destination. Railways are to be given the destination, number of tracks, whether or not electrified and the level at the top of rail stated. The voltage level for power lines shall be indicated.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

All buildings or high obstructions within 45 m to each side of the center line shall be shown dotted at their measured height with the distance left or right of line indicated. Along the bottom of the profile sheet a route map shall be drawn, to the same scale as the horizontal scale of the profile showing all relevant details, within a distance of 45 m to each side of the route center line. The tower spotting shall be performed with a computer-plotting program where the conductor sagging data (tensions or parameters) are fed as input data. The checking shall be performed by conventional methods using sag templates or with the computer program, both to be provided by the Contractor. The sag template used shall be suitable for the respective climatic zone and for the ruling span of the section where the plotting is performed. Tower numbers, tower types, elevations, level differences, UTM (Universal Transverse Mercator) coordinates, horizontal and vertical coordinates of all features affecting the line construction shall be indicated on the profile plan. For all tower positions the specified maximum wind spans and the specified maximum and minimum weight spans shall be observed; the individual spans shall be less than the specified maximum spans. By adequate tower spotting the lengths of successive spans in one section shall be as close as possible. For suspension towers the minimum ratio of the weight span to wind span shall be such as to guarantee that the maximum insulator set deflection angles of I-type suspension sets is not exceeded and that both sub-strings of V-type suspension sets remain tensioned. The tower spotting shall take into consideration the specified minimum ground clearances as well as the minimum distances of the conductors to obstacles to be crossed such as power transmission lines, main roads, houses, etc. as specified in the Technical Schedules. The profile plans shall display the bottom conductor catenary, at 85oC, together with the ground or special clearance curves, as well as the minimum temperature catenary. The Contractor has to provide a clearance calculation for all crossings of all classifications of roads, railways, rivers and all power and telecommunication lines in order to proof that the required clearance is met under the worst conditions. Railways and main roads shall be crossed at an angle of 90 30 at maximum unless otherwise approved.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Special attention shall be observed near populated areas or close to the roads where the OHL is to be parallel with existing OHTLs. The towers shall be placed as aligned as possible to the existing ones and their positions shall be subject to the Employers / Employers Representatives approval. In this respect, the location of the existing OHTL towers shall be clearly marked on the drawings. The number of suspension towers in a straight line section (between two successive tension towers) shall be limited by the section length which should not exceed 5 km or approx. every 10th tower, subject to approval. Unless instructed otherwise, the longitudinal profile drawings shall be plotted in the following scale. 1:2000 horizontally and 1:500 vertically The profile shall be plotted with the direction of the line route left to right on the profile sheet. In general, individual profile sheets shall commence and finish at tension supports but where this is not practicable and continuation sheets are found to be necessary the ground line is to be drawn so that there is an overlap of at least 300 mm between adjacent sheets. Each section shall normally be started on a new sheet. The date of survey of each section shall be added.

B1.4.2.4

Line route approval


The Contractor has to submit the profile plans to the Employer for approval including calculations to proof that for all crossings the requirements are met. The detailed tower spotting shall indicate the tower locations exactly in order to identify the concerned landowners easily. Additionally, a map showing all access roads necessary for the construction works (existing ones and ones to be constructed) has to be submitted together with the profile plans to the Employer for approval. The negotiations with the landowners and authorities about the tower locations, the right of way, the access to the line for the construction works and the compensation for land acquisition, for crops, temporarily damages etc. shall be in the responsibility of the Employer. During approval procedure by the authorities and negotiations with landowners, tower locations may be shifted again or the line route may be relocated. The Contractor shall consider such changes after surveying the modified line route. No extra cost for survey and preparation of all drawings of such route changes will be paid to the Contractor.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.3 Environmental Protection

B1.4.3.1

General
The Contractor is urged to observance of the requirements of the national environment protection legislation. The Contractor shall take all precautions to avoid damage to public, land, property, crops, etc. and shall ensure that the work is adequately supervised so that damage is avoided. The Contractor shall adhere to the recommendation of the Environmental and Social Impact Assessment (ESIA) and Environmental and Social Mitigation Plan (ESMP), a copy of which can be obtained from the Employer. Where the Contractor considers that damage cannot be avoided, if the work is to proceed normally, he shall notify the Employer/ Employers Representative accordingly. If the Employer/ Employers Representative confirms that such unavoidable damage will occur, the Employer will be responsible for compensation in respect of the damage and the Contractor shall proceed with the works within the limits indicated by the Employer. All surplus material shall be removed after erection and the site shall be left in a clean and tidy condition. The following rules and procedures shall be adhered to by the Contractor with regard to protection of the environment: The Contractor pledged himself to treat the waste in accordance with the law of the United Republic of Tanzania The Contractor pledged himself the treatment of all hazardous waste, generated by his activities on site in accordance with the current law of environmental regulations of the local Authorities. The Contractor pledged himself to deposit all dismantled equipment containing hazardous substances to the Employers places, which are leak proof. In case, that hazardous substances leak into the surface water or ground water because of the Contractors activities, he is responsible and undertakes improvement action. He will ensure on his own costs liquidation of the incurred damages.

B1.4.3.2

Protection of vegetation
The Contractor shall limit the movement of his crews and equipment to the right-of-way and on approved access routes, so as to minimize damage to crops, orchards or property. No movement of machine and vehicles allowed outside approved access roads and construction platforms. Route clearing shall be executed in accordance with the requirements specified below. No tree may be felled without the express permission of the Employer. Selected route clearing staggered to the height of danger trees may become necessary. Roots and other plants shall not be removed to prevent excessive surface erosion. Wood has to be transported to location as

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

indicated by Employer. Burning on site is strictly prohibited. Access roads shall be kept as short as possible and preferably commencing from existing roads instead of continuous access roads along the line axis. Access roads shall always run below the platforms to reduce erosion impact and be constructed as specified below. Due to loose sands and silts in some parts of the line surface protection and erosion mitigation measures (drainage, small platforms, stone pitching, gabions, vertiver grass for hedges, etc.) may become necessary as specified below. Ruts and scars shall be obliterated, damage to ditches, terraces, roads and other features of the land shall be corrected, and the land shall be restored to its original condition. The Contractor shall be responsible to the occupants of the land which are crossed by the transmission line for any damage to personal property resulting from his fault or negligence, including damage caused by straying livestock, and he shall make prompt settlement of damages to personal property resulting from his negligence. The Contractor shall be responsible for notifying the Employer in writing of all instances of damage to crops plantation, livestock, etc. Where the Contractor causes damage beyond the indicated limits or to a degree, which the Employer/ Employers Representative considers excessive, the Contractor shall be responsible for reinstatement and/or compensation. If, in such circumstances, the Contractor fails to settle compensation to the extent that, in the Employers/ Employers Representatives opinion, the progress of the works is likely to suffer, the Employer shall negotiate and settle the matter and the cost shall be deducted from moneys due to the Contractor. The Contractor shall use all means necessary to control dust on roads, construction areas and borrow pits. Surfaces shall be regularly watered to prevent dust becoming a nuisance for the public and interfering with the proper execution of the works.

B1.4.3.3

Protection of livestock
Adequate provision shall be made by the Contractor to prevent the straying of or injury to livestock during the execution of the works and until the permanent reinstatement of fences, walls, hedges, gates and the like is completed. The Contractor shall not bring any dog on or near the site or suffer or permit any of his employees, representatives or agents or any Subcontractor to bring any dog on or near the site and shall cause the immediate removal of any dog which may be on or near the Site in breach of this provision.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

The Contractor shall be liable for any injury to or loss of livestock due in the opinion of the Employer/ Employers Representative to failure to comply with the above requirements. Means shall be provided on all lattice steel towers and tower extensions were required to avoid the risk of livestock being caught between tower members and being injured.

B1.4.3.4

Bird protection
The line crosses areas in Lot 3 over a total length of 35km (Wembere Plain and Lake Singida) where a special race of bird lives. In order to minimize the risk of collisions with the conductors, the bundle conductors shall be placed in one level. A special tower family has to be designed for the concerned line sections having one long horizontal crossarm for one line circuit (three phase conductors) on each side (see Annex 2.2). The top conductors (earthwires or ISWER system) shall be marked by accepted bird warning systems. An accepted system is e.g. a black and white warning flag system (see Annex 7) installed in a distance of 25m on each earthwire or ISWER. In case of earthwire peaks above the horizontal crossarms at anchor towers, the steel structures of the peaks shall be painted in black and white (see chapter for tower painting below). On the other hand, insulator strings shall be protected against pollution caused by birds. Tower members above insulator strings shall have bird guards. In all sections equipped with ISWER, the 36kV insulators shall have bird guards too which prevent resting of birds. The 36kV tension insulator strings are to be equipped with bird guards above the arcing horns.

B1.4.3.5

Monitoring of environmental impact


The Contractor shall monitor the implementation of the measures agreed in the Environmental and Social Impact Assessment (ESIA) Report for each lot of the line. One chapter in each monthly progress report is to be reserved for this subject. The monthly progress reports shall also focus on impacts during the construction on site. Problems like oil pollution of the ground air pollution caused by vehicles and mechanisms dust pollution during transportation especially close to populated areas noise pollution during construction and transportation especially close to populated areas excavation disposal of material which cannot be used for re-filling waste disposal

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

shall be investigated and measures (e.g. speed limits, maintenance of mechanism) proposed for an action list to be applied during construction.

B1.4.4 Towers

B1.4.4.1

General instructions
This technical requirements covers the design, shop detailing, manufacture, pre-assembly, fabrication, inspection and packing of self-supporting steel lattice towers. All materials, design, details, fabrication and tests shall be in compliance with the requirements described hereafter, with details shown on the drawings, with the minimum design data specified in the Technical Schedules and as approved during project implementation. The electrical and mechanical design and details shall conform to the requirements of EN 50341-1. The suspension insulator swing angles may also be calculated in accordance with EPRI publication Transmission Line Reference Book 345 kV and above, second edition 1987 and recommended by CIGRE SC22, WG 06 Appendix 11.1 Computation of swing angle distribution. Technical documentation (designs, detail drawings, calculations, etc.) and other documentation (instructions, testing programs, technical data, etc.) shall be subject to approval by the Employer/ Employers Representative. All necessary modifications in details for making the project conform to the Technical requirements, shall be carried out by the Contractor without additional cost to the Employer. Should any inaccuracy be found, all further work to be done in order to correct these discrepancies will be at the Contractor's expense. In case of existing tower designs are proposed, it has to be proven that the structures fulfill the minimum electrical and mechanical requirements as per Technical Schedules, or that suitable design adjustments are offered. Such design proving and shop detailing will be the responsibility of the Contractor but suitable design calculation shall be included in the offer to allow technical evaluation of the bid.

B1.4.4.2

Materials
All materials shall be brand-new and of the best quality for use in the conditions and the variations in temperature and pressure that will be encountered in service without undue distortion or deterioration or the setting up of undue strains in any part that might affect the efficiency and reliability of the plant. Any steel member with traces of hole filling shall not be used. Special attention shall be paid to eliminating the possibility of

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

corrosion resulting from galvanic electrochemical effects. Design, selection of materials and all methods of erection shall be such as to keep these effects to a minimum. Materials used for the design and construction of the steelwork shall comply with the codes and standards listed below. Unless the materials meet these codes and standards, they shall be subject to the Employer/ Employers Representative approval. The materials for steel tower construction shall be as follows: a) Rolled shapes and plates All materials shall be hot-rolled of mild steel and /or high-tensile steel and shall conform to the steel qualities S235JO and S235J2G3/G4 and S355JO and S355J2G3/G4 respectively according to EN 10025 or equivalent standards. The chemical composition and mechanical properties of the grades of steel used shall correspond to the EN 10025 and be suitable for working in the project area. Connection bolts, nuts and washers All tower steel connection bolts, nuts and washers shall conform to ISO 898-1 and 2 or equivalent. Only the bolt classes 5.6 and/or 8.8 shall be used. Locking devices All tower bolt connections shall be provided with one flat washer and one spring washer. Tower signs Signs, consisting of aerial patrol signs, phasing signs, circuit name signs, danger signs and number signs shall be made of mild steel covered with enamel on both sides, or of aluminum. The thickness shall not be less than 2 mm. Writings on signs shall be in the language of the Country

b)

c)

d)

B1.4.4.3

Design

B1.4.4.3.1

Design method
The design philosophy shall be based on the limit state concept applied in conjunction with the partial factor method. The deterministic (empirical) approach to tower design loads and the concept of differentiated partial material factors, shall be applied as recommended by EN 50341.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

According to this concept the weighted resistances of the components concerned shall be checked against the ultimate (factored) actions applied to the OHL components:

Ed Ed

FK)

Rd Rd = RK /

The directly calculated physical loads are increased by partial safety factors whereas the resistances are divided by material factors in order to consider uncertainties (see also Paragraph 4.4.3.6 below).

B1.4.4.3.2

Tower types / tower outlines


General The project comprises of two tower series (families) for the 400 kV double circuit overhead line: The tower family with vertical phase conductor arrangement shall be used in general, the tower family with horizontal phase conductor arrangement is to be applied in two sections in Lot 3 for bird protection only. Depending on the line route necessities in these special sections, a reduced tower family (i.e. NSh and LAh type) may be designed. Type of Towers The functional tower types of the tower families are selected based on the line angles of the line route. For fabrication, tower testing and erection but also for facilitate line maintenance and spare parts keeping, the following tower types are specified: NS, normal suspension tower, capable to be utilized for very small line angles of up to 2 HS, heavy suspension tower, capable to be utilized for increased wind spans, long spans, increased weight spans, small line angles up to 2 or for a combination of such conditions. An unfavorable weight to wind span ratio is assumed. LA, light angle tower for line angles of up to 30 HA/ DE, heavy angle tower for line angles of 30 to 70 and dead-end tower for 0 to 45 angle in line direction and 0 to 90 angle of the slack span to the gantry. TP, transposition tower at straight line 2. For the DE tower the indicated angles refer to one side of the tower while for angle towers the angles given are actual line angles (i.e. line deviation angle at both sides). The HA/DE tower will have to be designed for its utilization as angle tower as well as dead-end tower. Therefore it will have to be provided with two separate sets of crossarms. In addition, for the particular requirements of the dead-end tower having a line angle of 90 degrees to the substation gantry, detailed clearance and structural checks with consideration of necessary jumper suspension sets and additional crossarms have to be performed.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

The TP tower will have to be designed with auxiliary crossarms for transposition of the phases. For complete transposition cycle, three TP towers shall be installed in each of the 3 line sections over the 670 km long 400 kV line. Jumper and in-loop insulators shall be of composite type material to avoid excessive sagging of insulator string. Denomination of Tower Types The proposed tower denomination system comprises: the symbol for the tower functional type NS, HS, LA, HA/DE , TP which stand for light normal suspension, heavy suspension, light angle, heavy angle, dead-end and transposition respectively an index h added to the symbols for the tower family with horizontal phase conductor configuration in Lot 3 the respective tower height variant, i.e. the body extension used, if any. For example LA+3 is the light angle tower having 3 m body extension. Leg extensions are not included in the tower denomination. Tower Outlines The outlines of the suspension and angle towers shall comply with the general requirements as specified and shown in the Annex and shall be such as to provide the required minimum clearances between conductors, from live parts and tower steelwork, and to ground as specified hereafter. Tower body and leg extensions / reductions Each tower type shall consist of a common portion (Basic Body) to which typical trunks (body extensions, four tower legs and four stubs) shall be added for obtaining a complete tower structure. The basic tower height (standard tower height with body extension 0) shall be determined taking into account the maximum conductor sag for the nominal span (see the table below), the suspension insulator string length and the minimum ground clearance. In order to adapt the tower height to the terrain, to allow the crossing of obstacles and to use the towers as economical as possible towers shall be provided with body extensions and reductions. The towers shall be provided with the following tower body extensions/ reductions:
Tower type NS, NSh HS, HSh LA, LAh HA/DE, HAh TP Body extensions -4, 0, +4, +8, +12 -4, 0, +4, +8, +12, +16 -4, 0, +4, +8, +12 0, +4, +8 0, +4, +8

The hilly terrain over a part of the line requires leg extensions for the 400 kV towers. The leg extensions set to be designed for each tower type shall
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

be suitable for all body extensions of the respective tower type and shall be interchangeable. All structures have to allow a combination of different leg extensions as follows:
Structure type All tower types with any possible body extensions / reduction Leg extensions -3, -2, -1, 0, +1, +2, +3

B1.4.4.3.3

Design spans
The tables below show the specified span parameters for the defined double circuit tower families of 400 kV to be used for tower design analysis and tower spotting on the longitudinal profile. They are intended to enable the necessary degree of flexibility allowing an economic line design.

Tower type NS, NSh Normal Suspension HS, HSh Heavy Suspension LA, LAh Light Angle HA/DE, HAh Heavy Angle/ Terminal TP Transposition

Line angle

0 - 2

Conductor suspension Suspension I-string

Nominal span 400 m

Wind span 440 m reduced 1) 800 m reduced 1) 440 m

Weight span max 700 m min. 200 m max. 1100 m min. 300 m max. 700m min. -350m max 700 m min. -350 m

Phase span

650 m

2)

0 - 2 long span 0 - 30

Suspension 400 m I-string Tension string Tension string 400 m

950 m

2)

650 m

2)

0 - 70 0 - 90 3) 0 - 2

400 m

440 m

650 m

2)

Tension string

400 m

440 m

max. 700 m min. -350 m

650 m

1) wind span values for the line angle of 0; for line angles >0 the wind span has to be decreased accordingly 2) these are minimum values for the mid-span criterion; actual maximum spans may be higher in case mid-span phase-to-phase spacing will be determined by phase-to-tower steelwork clearances. 3) considering the slack span between terminal tower and S/S gantry

B1.4.4.3.4

Spacing and clearances


The positioning of the conductors and earthwires respectively ISWER system on the tower shall be determined considering the following minimum clearance conditions: a) the clearances between live parts and the earthed tower steelwork b) the clearances between phase conductors in mid-span, in still air c) the earthwire protection angle d) clearance to ground and obstacles

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

In detail: a) Clearance between live parts and earthed tower steelwork The basic data for the calculation of the inner clearances are to be used as per EN 50341-1, Table 5.2, 5.3 and 5.4. The correction for the altitude of 1700m above sea level is to be considered as per Annex E, Table E.4 as follows:
Dpp Del D50Hz_p_e

400 kV, Lightning 1450 kV 400 kV, Switching 1050 kV 400 kV, Maximum operation voltage 36kV, Lightning 200 kV

3.20 4.05 0.50

2.86 3.30 0.73 0.50

The clearances between live and earthed parts have to be considered in a different way for different clearance cases and swing angles corresponding to the three voltage stress types (lightning, switching and power frequency), as per the table above. The electrical clearances specified are to be considered as minimum dimensions to be provided between the outermost tower steel parts (outstanding web angles, step bolts) to the nearest point of the line conductor, insulator set live hardware or conductor accessory.
Formula Clearance in still air Clearance for swung insulator I string due to 58% of maximum wind on conductor I jumper suspension sets under 15 swing jumper loops under 15swing Clearance for swung insulator I string due to maximum wind on conductor I jumper suspension sets under 35 swing jumper loops under 35 swing Del 0.75 x Del Value 400kV 3.30 m 2.50 m Value 36kV 0.50 m 0.40 m

D50Hz_pe

0.75 m

0.20 m

The swing out angle determination for suspension insulator strings as per EN 50341-1, Chapter 5.4.2.2.3, uses a three years wind (wind pressure 58% of maximum pressure - QWc, QWi) for clearance calculations. The swing out angle of the insulator string shall be calculated with Q 0.5 QWi arctan Wc r QGc 0.5 QGi where: QWc QWi r - wind on conductor (according EN 50341-1, chapter 5.4.2.2.3) - wind on insulator string (according EN 50341-1, chapter 5.4.2.2.3) - ratio weight to wind span
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

QGc QGi

- weight of conductor - weight of insulator string

The ratio of weight span to wind span r is to be considered as shown in the Technical Schedules: 0.80 for the normal suspension towers 0.60 for the heavy suspension towers. The insulator set swing angle may be also determined according to EPRI Publication Transmission Line Reference Book 345 kV and above, second edition 1987 and recommended by CIGRE SC22, WG 06 Appendix 11.1 Computation of swing angle distribution, Diagram A11.1.3. b) Still air mid-span clearance between phase conductors The phase to phase distance for horizontal phase disposition is in [m] c k f max li 0.75 D pp 0.45 and for vertical phase disposition c k f max l i 0.75 D pp . The maximum sag for shall be used for the defined phase span (maximum span). Li is the insulator string length of the I string. The factors k are defined in EN 50341-3-4 for horizontal clearance 0.62 for vertical clearance 0.75 . The dimensions of the crossarms of the angle-tension towers shall be as to ensure that the horizontal spacing between conductors under normal conditions is not less than that at normal suspension towers. The ISWER support positions have to ensure the corresponding spacing as well as the assumed shielding angle. c) Earthwire protection angle The shielding angle of the earthwires or ISWER shall be 15 to the outer most phase conductor of the top conductor bundle. The sag of the earthwires or ISWER under every day temperature (25C) shall be 5 % less than the sag of conductor for the nominal span. d) Clearance to ground and obstacles The minimum vertical clearances to ground and within line crossings over different obstacles are specified in the Technical Schedules. The maximum and minimum conductor sags shall be calculated under still air condition, for the conductor maximum and minimum temperatures, as indicated in Technical Schedules.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

The Contractor shall indicate in his bid the total creep which he will consider after ten years operation and shall base his bid on the assumption that this creep will be compensated by increasing the initial conductor tension accordingly.

B1.4.4.3.5

Loads and load cases


Dead Loads The deadweight of soil, foundations (both under submerged conditions, if necessary), towers, conductors, insulator strings and all other equipment shall be considered in general. Regarding the conductors weight, the values of the specified weight spans, either maximum or minimum, whichever is most critical, are to be taken into account. Wind Loads The wind loads on the line equipment and tower shall be calculated based on the reference wind speed factored for the respective height above ground in accordance to EN 50341-1, chapter 4.2.2.1.6: Reference wind speed VR for Tanzania VR = 31 m/s Design wind speed Vh for height h 10 m Vh = VR Design wind speed Vh for height h > 10 m Vh = 0,19 ln (h/0,05) VR Terrain category II Actual height above ground for conductors h average altitude of attachment points for insulator strings h maximum altitude of attachment point for tower sections h altitude of the midpoint of each section Wind pressure as per EN 50341-1, chapter 4.2.2.2: qh = 0.5 1.225 Vh2 Wind on conductor as per EN 50341-1, chapter 4.2.2.4.1: QWc = qh Gq GL Cc d (L1 + L2)/2 cos2 Gq - gust factor (Chapter 4.2.2.3) Gq = (1 + 2.28 / ln (h / 0.05))2 GL - span factor (Chapter 4.2.2.4.1) GL = 1.3 0.082 ln (L) CC - force coefficient (Chapter 4.2.2.4.1) CC = 1.0 d - conductor diameter L - wind span L1,2 - length of the adjacent spans = angle of incidence for wind direction but unequal 0.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Wind on insulator string as per EN 50341-1, chapter 4.2.2.4.2: QWins = qh Gq Gins Cins Ains Gins - reaction factor (Chapter 4.2.2.4.2) Gins = 1.05 Cins - force coefficient (Chapter 4.2.2.4.2) Cins = 1.2 Ains = projected area of insulator string. Wind on tower as per EN 50341-1, chapter 4.2.2.4.3: QWt = qh Gq Gt (1+0.2 sin2 2 ) (Ct1 At1 cos2 ) + Ct2 At2 sin2

Gt - reaction factor (Chapter 4.2.2.4.3) Gt = 1.05 Ct1,2 - drag factor for tower faces depending on solidity ratio (see EN 50341-1, figure 4.2.2 and 4.2.3) At1 - effective area of the elements of face 1 At2 - effective area of the elements of face 2 - angle of incidence for wind direction. Conductor Tension Loads The conductor and ISWER tensions have to be determined by the Contractor. The calculation of tensions shall consider the following assumptions: a) the everyday stress of the conductors and earthwires is based on: no wind (0 m/sec) everyday temperature (+25C) the maximum working stress of the conductors and ISWER based on: the maximum design wind pressure condition or the minimum design temperature condition

b)

The tensions in the ISWER shall be such that the sag at everyday stress is 5 % less than that of the conductors calculated for the basic span. The conductor / ISWER tension shall not exceed 18% of the ultimate conductor tension for every day conditions. Erection and Maintenance Loads The Contractor shall submit for approval his proposals to be applied to the towers during stringing (including back stays), and shall comply with the safety factors as per Technical Schedules for towers and foundations under the following conditions: a) Conductor and earthwire tension components based on minimum temperature without wind for the sequence of stringing (including all conductor installation stages)

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

b) Conductor and earthwire tension components based on wind loads of 50 % of specified maximum wind pressures plus wind load on conductors, insulators, tower, etc. for the sequence of stringing (including all conductor installation stages) c) Vertical loads for normal working condition, plus 3.0kN acting vertically anywhere on any one crossarm bottom chord member d) Any member in the tower which slopes less steeply than 30 to the horizontal shall be designed to have the specified safety factors when subjected to the maintenance loading described in this clause, together with a vertical load of 1.5kN acting midway along its greatest unsupported length. Load Cases The loading cases to be considered for the design of the line supports and of their foundations are normal working cases and exceptional cases, as follows: Normal Working Loads (N1 and N2) The load assumptions as specified below shall take into consideration the maximum transverse wind hypothesis and the maximum oblique (45) wind hypothesis. Normal Working Loads (N3) This load case is a combined load hypothesis for making the angle towers stronger in longitudinal direction to resist cascading. Broken Wire Loads (E1) Design spans for the broken phase conductor or the broken OPGW as well as for the other intact conductors apply the design spans specified. The one sided reduced conductor tension refers to the complete bundle conductor. Cascading Loads (E2) Suspension tower capability is controlled by exceptional load cases E2 in order to prevent extended cascading in case of tower failures. Such unequal conductor tensions may result from unequal spans in the line sections. Erection and Maintenance Loads (E3) All stages during conductor installation shall be described. The configuration of the back stays has to be taken into account (see explanation above).

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Table - Tower Load Cases


Structure Type Suspension Normal Loading Cases Deadweight, Wind Cascading N1, N2 N3 Deadweights Wind on tower, accessories and conductors Broken Wires E1 Deadweights One sided reduction of conductor or earthwire/ ISWER tension under wind load condition by 25 % for phase conductor bundle and 65 % for earthwire/ ISWER acting at any one attachment point Deadweights One sided reduction of conductor or earthwire/ ISWER tension under wind load condition by 100 % for phase conductor bundle and earthwire/ ISWER acting at any one attachment point Exceptional Loading Cases Cascading Erection and Maintenance E2 E3 Deadweights Deadweights One sided reduction of Erection and maintenance loads including conductor and earthwire/ structure anchoring loads due stringing operaISWER tensions under wind tion load condition by 15 % for a) No wind phase conductors bundle and b) 50 % of max. wind on tower, accessories 40 % for earthwire/ ISWER and conductors, without man-load acting at all attachment points simultaneously

Angle Tension Transposition

Deadweights Wind on tower, accessories and conductors Conductor tensions under wind load condition

Deadweights One sided reduction of conductor and earthwire/ ISWER tension under wind load condition by 66 % for phase conductor bundle and earthwire/ ISWER acting at all attachment points simultaneously

Deadweights Erection and maintenance loads including structure anchoring loads due stringing operation a) No wind, conductor tension for min. temperature b) 50 % of max. wind on tower, accessories and conductors, conductor tensions accordingly, without man-load

Dead End Special Branch Off

Deadweights Wind on tower, accessories and conductors Conductor tensions under wind load condition acting on one side

Deadweights Reduction of conductor or earthwire/ ISWER tension under wind condition by 100 % acting at any one attachment point

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.4.3.6

Partial Safety Factors


Load Factors The following partial factors (F) for actions shall be applied to the different loads within the respective load cases:
Effect Deadweight Wind Conductor tension Construction/ maintenance Safety factor
G W C

Load cases (N1 ... N3) Comp.1.1/ uplift 0,9 1.3 1.3 -

Load cases (E1 ... E3) Comp.1.1/ uplift 0,9 1.0 1.0 1.5

For compression loading cases, the partial safety factor for the tower dead weight is to be considered G = 1,1. In case of uplift loads for crossarms and foundations, this factor shall be taken as G = 0,9. Strength Factors Based on the recommended failure sequence of structure components, the following structure partial factors (M) for material strength are to be applied: steel member of suspension tower steel member of angle tower steel bolts of tower connection factor 1.10 factor 1.25 factor 1.25

B1.4.4.3.7

Structural analysis
General For the structural tower design the Contractor is to use the threedimensional indeterminate stiffness design method. However, the Contractor may propose for approval the use of another recognized design method proven to be accurate. The computer program to be used shall be developed and tested by a recognized institute, acceptable to the Employer/ Employers Representative. The correctness of the design method, the accuracy of the computer software used as well as the practicability of the structure detailing have to be confirmed by full scale tower loading tests. The input data shall indicate all loads and their manners of application including the determination of wind load on tower. Wind load on towers shall be applied at each panel point along the height of the towers.

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The Contractor shall submit the following data: Name and version of the computer software and standards applied for the structural analysis Detail calculation of loads Loading tree schemes Outline drawing of tower model for the structural analysis, showing the individual modeling elements (e.g. beams, trusses, stabilizers) including joints (nodes) Label and joint degree of freedom Tower outline drawings of all 4 faces showing the joint labels (AutoCAD.dwg) Three-dimensional coordinates of all tower joints in electronic format. The results of the structural analysis shall show in a table: Total stresses in each member for each load case and the critical case The effective slenderness ratio, calculated capacity and ratio of maximum total stress to calculated capacity for each member and connection Size and type of steel for each member and number of bolts required for its connection The calculated weight of the complete galvanized tower The compression and uplift reactions and corresponding horizontal shears at each leg of all towers for all loading cases, for foundation calculation Identifying the corresponding maximum load value decisive for designing the foundation and outlining what partial load factor is included or excluded and on a drawing the scaled outline of the tower with all redundant, bracing members and their sizes completely dimensioned in compliance with all clearance requirements (clearance diagram). The ultimate stresses for the different stress categories shall be taken from EN 50341-1, Annex J (Lattice Steel Supports):

Component/Action Members: Compression Tension on net section Bolted Connections: Bolts in shear Bolts in bearing

Characteristic Resistance see ENV 1993-1-1 0.9 Fy Anet

0.6 Fub A Fu d t

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TANESCO Bidding Documents Section VI (Part B1)

Remarks:

Fy Fub Fu

= = =

Yield stress Ultimate tensile stress of bolt material Ultimate tensile stress

In computing the net section for tension members, the diameter of the bolt hole shall be taken as 2.0mm greater than the nominal diameter of the bolt. The determination of the net section area shall be as specified in the EN 50341-1, Annex J (Lattice Steel Supports). Limit of effective slenderness ratio Slenderness ratio for members shall be limited as shown in the Technical Schedules. Built-up members composed of two or more rolled shapes shall be connected with stitch bolts such that the slenderness ratio of either shape, between bolts, does not exceed 75 % of the governing slenderness ratio of the builtup member as a whole. Minimum thickness and size of steel members The minimum thickness (t) and size of steel members of towers shall be as follows: Leg, stub and main compression members in crossarm All other members having computed stresses Redundant members without computed stresses Gusset plates Equal angle sections Unequal angle sections Remark: 6 mm 5 mm 5 mm 6 mm L 45x45xt L 45x30xt

The minimum connected leg of the angle section shall be such that the bolt head or nut does not bear on the fillet.

Tower structures The tower structure shall be modeled as a fully triangulated system. The same goes for the secondary bracing. As a part of the line route is hilly, it is recommended to adopt a slim tower structure in order to keep the horizontal spacing of tower legs and the leg extensions in reasonable limits and/ or to reduce the size of the tower platforms also with regard to erosion hazard. In order to ensure an acceptable fit of the bracing members to the leg member, the slope of the tower body is limited. It shall not exceed 360mm/m. Stubs suitable for the foundation types and for legs of the tower types are part of the scope and templates for the alignment of the stubs shall be provided.

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In order to facilitate transportation and handling, the length of any structural member shall not exceed 9 meters. Redundant members shall be capable of supporting an axial tensile or compressive load of at least 2.5 % of the maximum computed compressive load in the supported main member applied perpendicular to the axis of the main member. For the HA/DE towers having line deviation angles of 60 and more, rectangular crossarms may be used so that live metal clearances are maintained with or without the use of jumper suspension insulator strings. The crossarms of suspension towers shall be designed to allow the attachment of double insulator strings. Additionally for the Employer's use during maintenance, each suspension cross arm tip shall incorporate two attachment points of equal strength at approved positions: one for the suspension insulator set and the other for maintenance equipment. The crossarms of tension towers shall be designed to allow the attachment of double insulator strings and an additional attachment with two holes for maintenance purpose. It shall be possible to apply full conductor tension safely to either additional hole. The insulator string attachment points of angle towers shall be so designed to have the two strings of double insulator sets in parallel position for the average line angle. Connections The tower structures shall be of the bolted type. Due to the danger of embrittlement, welding shall be avoided as far as possible and have to be approved by the Employer/ Employers Representative. Bolted connections shall consist of metric threaded bolts together with a flat washer, a spring washer and the nut. Rivets shall not be used. The bolt length and washer thickness shall accommodate, that no threads shall be located within the shear plane of the members/ plates being connected maintaining the following bolt end projection after tightening the nut: minimum projection of 2 treads and maximal 10 mm from the end of nut. The Contractor shall supply the net quantities plus 5 % of all permanent tower bolts, nuts and other similar items and materials required for installation of the works at the site. Quantities of such bolts, nuts, etc., which are surplus after the installation of the equipment has been completed shall become spare parts and shall be wrapped, marked and handed over to the Employer.

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For structural connections, one bolt size is preferred. The minimum diameter and number of bolts at each connection for stressed members shall be as follows: Diameter: Number of bolts: 16 mm 1

All nuts, washers and bolts shall be hot dip galvanized. Threads before galvanizing shall be coarse threads. There shall be no excess of galvanizing at the root of the thread and nuts shall turn easily on the complete bolts without excessive looseness. Bolts and nuts shall be hexagonal and dimensioned adequate to develop full strength. The bearing faces shall be perpendicular to the axis of threads, free of burns and projections and shall have chamfered corners. Bolts will be rejected if they are considered by the Employer/ Employers Representative to have an excessive loose or tight fit. The number of splices shall be practically the minimum. Splices shall be capable of developing the computed stress in the member. No credit shall be allowed for bearing on a butting area of butt splices.

B1.4.4.3.8

Detailing
General Tower dimensions, framing, member sizes and length, number, size and length of bolts, thickness of each filler, detailed dimensions of gusset plates and other necessary details to fabricate each piece shall be shown on the approved detailed drawings. No change shall be made without the written approval of the Employer/ Employers Representative. The tower structure shall be braced-out and bolted to a rigid degree as to limit residual head deflection and diaphragms sagging under operational conditions taking into account bolt slippage and stub setting allowance. Calculated horizontal deflection of the tower head under ultimate design load including bolt slippage shall not exceed 1.5 % of the structures overall height. The one-sided transverse load effect on angle towers can be off-set by raising vertically the stubs of compression legs relative to the uplift leg level. Deflection tolerances are shown under the section Leg/Stub Setting. All bracing members shall be in one piece where practicable. All double diagonal bracing members shall be connected at their point of intersection by at least one bolt. Plan bracing of towers at the levels of crossarms shall be such a type to prevent the cross section of the towers from deforming from the original form under torsion loads. The angle included between any two connecting stressed members shall not be less than 15.

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TANESCO Bidding Documents Section VI (Part B1)

The angle included between diagonal members and main members for the HA/DE and TP towers shall not be less than 25. Stubs shall be provided with suitable holes for connection to the standard grounding system. The lowest bolt hole in the stub for connection of the main bracing member shall be 50mm above the foundation concrete level. Drawings All members and plates shall be designed on drawings, the Contractor shall endeavor to use as few designations as possible, and each member of identical size and detail shall have the same designation, regardless of its position in the structure. The member and plate designation shall be successively grouped on individual drawing. The groups of designations shall be indicated on the drawings. A proper cross-index shall be furnished, correlating the tower part numbers with the tower types and drawing number. A bill of materials shall be submitted containing the size, length and galvanized weight of each member and the total weights of body, body extension and foundation stub conforming to the detailed drawings approved. It shall also include the number of bolts, nuts, washers and attachment devices per structure. Joints All joints shall be such that eccentricities are kept as small as practicable. Profile thickness variation resulting in gapes 2 mm between members at connecting points or composed members or bolted diagonal intersecting points shall be filled by galvanized or stainless steel made packing or shims of appropriate thickness. For all bolts in tapered flanges beveled washers shall be furnished. Gusset plates, where used, shall be designed by the Contractor and shall be in accordance with the relevant standards. Bolt spacing and edge distance from the centre of bolt hole, in mm, for double circuit towers shall be as follows:
Nominal Bolt Diameter Min. M12 M16 M20 M24
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Bolt Spacing Max. 120 mm 160 mm 200 mm 240 mm

Minimum Edge Distance Rolled Edge 16 mm 22 mm 27 mm 32 mm Sheared Edge 20 mm 25 mm 30 mm 40 mm 37

30 mm 40 mm 50 mm 60 mm

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Tolerances within the bolt group well as distances between holes.

1 mm for the end and edge distances as

Bolt securing system All bolt connections in all tower types up to a height of 10m above ground level shall be secured against theft by an adequate securing system. The Contractor shall describe his offered system and verify the effectiveness of the anti-theft device as well as mechanical strength capacity, bolt geometry and corrosion resistance in comparison with an ordinary bolt connection. The system shall be submitted for approval. Step bolts Each tower shall be provided with step bolts of an approved type on two diagonally opposite legs spaced alternately on the angle flanges at not more than 380 mm between centers, starting immediately above the anti-climbing device and continuing to each earthwire. The minimum diameter of the step bolts shall be 16 mm. Step bolts shall not be used as connection bolts. Holes for removable step bolts below the anti-climbing guards shall be provided at not more than 380 mm between centers on the legs to which the permanent step bolts are fitted. Attachment devices Attachment devices shall be suitably furnished on all crossarms to suspend and to terminate insulator strings or earthwire assemblies. Provisions shall be made to fix the OPPC-joint units at the earthwire crossarms of towers used in Lot 3. The attachment points shall be designed in accordance with the requirements of this technical requirements and the calculation shall be submitted together with the structural analysis of the tower. ISWER T-off points Any earthwire crossarm of Lot 3 towers shall allow the installation of an ISWER T-off point. Provisions shall be made for the installation of Vsuspension strings at suspension towers (and anchor towers where necessary) to fix the earthwire (or the jumper). Holes are to be foreseen on the top of the crossarm in order to fix post insulators for leading one earthwire to the other side of the tower. Additionally, each crossarm peak shall have connection holes for the attachment of a special down-lead structure of the ISWER system (see Annex). Alternatively, appropriate holes shall be foreseen in each earthwire crossarm structure for assembly of auxiliary platforms for installation of cable end connection equipment (see Annex). ISWER termination point Appropriate holes shall be foreseen in each earthwire crossarm structure for fixing the ISWER termination equipment (OPPC termination unit, separation and joining of optical fibers, surge arresters - see Annex). Tower signs
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The Contractor shall furnish all materials for tower signs including all bolts, nuts, washers, brass eyelets fitted with the holes and supporting structures, if required, for attaching signs to the structure as per the structure list. The colors of figures and background shall be as described below or as will be indicated later by the Employer and shall be of corrosion resistant aluminum with embossed letters and painted, or of enameled mild steel. The Contractor is required to make provision in the tower members for attaching signs at the locations described hereunder. a) Airborne plates On each tension and every tenth suspension tower an airborne observation number plate shall be provided. The tower number shall be cut from the sheet metal in black coating, with a letter height of min. 450 mm. The plate background shall be yellow. The plates shall be installed, either on the top crossarm or on the earthwire peak, in a position that is easily recognizable from the air. b) Circuit number sub-plate Circuit plates shall show the circuit number in orange letters, on a white background. The figures height shall be 200 mm. Circuit plates shall be installed at each circuit at the bottom of first cross arm and shall be provided at every tower. Termination gantries shall be equipped with circuit plates showing the circuit name in full length. c) Phase plates Phase plates shall show the letters R, Y and B, in black color, on red, yellow and blue background, respectively. One set of three phase plates shall be installed above the anti-climbing guards at every tower.

d) Danger plates Danger plates shall feature black symbols on a white background. They shall comprise a skull with crossed bones, as well as lightning arrows. The text DANGER shall be boldly written in both English and local languages. The voltage shall be shown, as well. Danger plates shall be attached above the anti-climbing guards at every tower. e) Number plate The tower number plate (1 No.) shall show the tower number in black letters, on a white background. The figures height shall be 150 mm. The number plate shall be attached above the anti-climbing guards at every tower.

Anti-climbing devices Each tower shall be fitted with an approved anti-climbing device with gates which shall provide climbing facilities for use by authorized personnel. The height of the anti-climbing device above heighest ground level of tower

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

footings shall be approximately 3,0 m. The anti-climbing devices could be of the "spikes" type or barbed wire t ype. Spikes shall be of a solid design, have a sharp end, a minimum length of 250mm and shall be pointed downwards. The maximum distance between the strings of barbed wire shall not be more than 100mm. The horizontal separation of the strings of barbed wire shall be maintained by the provision of spacers at a maximum distance of not more than 2 m. Gates should be provided and secured with an approved brass or galvanized steel padlock. Landmarks for the right of way After tower erection, landmarks shall be positioned in order to mark the right of way of the line. Two landmarks on both sides (in totally four) shall be placed between two adjacent towers. The landmarks shall be of concrete type with a red painted head, and of sufficient length in order to avoid easily displacements. Bird guards Tower members positioned above or near insulator strings shall be fitted with galvanized steel needle strips, effectively preventing birds from sitting in these locations. The strips shall extend horizontally enough beyond the protected location and shall be applied to all surfaces a bird can sit on. The bird guard measures have particularly to be applied on the insulator strings of the ISWER. Where needles are projecting from cross arm contour towards live parts, the tower clearance diagram shall consider the height of the needles.

B1.4.4.4

Fabrication

B1.4.4.4.1

Workmanship
Fabrication of materials shall be in accordance with the state of art and as specified. Fabrication shall not commence until approval of drawings and completion of successful tower tests, unless otherwise directed by the Employer/ Employers Representative. Workmanship shall be first class throughout. All pieces shall be straight, true to detailed drawings and free from lamination flaws and other defects. All clipping, back-cuts, grindings, bends etc. must be true to the detailed drawings and free of burrs. All identical pieces bearing the same erection number must be exactly interchangeable with each other and interchangeable in their relative position in all structures of which they form a part. The Contractor shall be responsible for the correct fitting of all parts. He shall replace, free of charge, any defective material discovered during

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

erection, and pay all costs of field corrections for such replacement. All parts of the structure shall be neatly finished and free from kinks, twists or bends. The fabrication shall be in strict accordance with the shop drawings prepared by the Contractor and approved by the Employer/ Employers Representative.

B1.4.4.4.2

Shearing and cutting


Materials may be sheared to length, but the ends, unless otherwise noted, must be square with length and free of burrs so that difficulty of assembly caused by interference of end section with other members at the time of assembling the steel tower may not occur. The use of a burning torch is permissible for cutting members provided all irregular edges are trimmed smoothly before galvanizing. Stresses shall not be transmitted into the metal through a burned surface. The material adjacent to a burned surface for a distance equal to the thickness of the material shall not be considered a part of the net section for tension members. The use of a burning torch for cutting bolt holes will not be allowed.

B1.4.4.4.3

Punching and drilling


All bolts holes in steel members shall be punched, sub punched, reamed or drilled before galvanizing. Holes for conductor attachment shall not be punched but only drilled. All members shall be cut to jig and all holes shall be punched or drilled to jig. Holes are to be punched with racks and jigs employed to ensure accuracy throughout. The punches and dies for this work must be maintained sufficiently sharp so as to produce clean round holes normal to the plane of material. Holes shall be free of burrs, folds and depressed, upset, or ragged edges. Bolt holes shall be drilled full size and at right angles to the surface of the steel, accurately spaced and true to line, pitch gauge and edge distance. Any member having holes or cut more than 1 mm from correct position will be subject to rejection. No welding, filling or plugging will be permitted unless otherwise approved by the Employer/ Employers Representative. Holes may be punched subject to the following limitations. In the cases listed below, holes shall be drilled full size or sub-punched to a diameter of not less than 4mm smaller than the required diameter and reamed to the required diameter: a) Structural steel more or equal to 14mm thick;
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TANESCO Bidding Documents Section VI (Part B1)

b) c) d)

High strength structural steel more or equal to 10mm thick; Holes in the vicinity of bends in members or gusset plates; Holes in crossarm members normally loaded in tension for both steel qualities S235 and S355 according to EN-10025 or equivalent.

Holes which are elongated or otherwise distorted by bending will not be accepted. The diameter of bolt holes shall be 13.5, 17.5, 21.5 and 26 mm for 12, 16, 20 and 24 mm bolt diameter respectively, or for larger sizes not greater than 2.0mm greater than the bolt diameter. All parts shall be carefully cut and holes accurately located so that when the members are in position the holes will be truly opposite each other before being bolted up. Drifting of holes will not be allowed. Bolts shall pass freely through matching holes in a direction at 90 to the member being connected. Threaded (tapped) holes shall comply with the requirements of relevant standards.

B1.4.4.4.4

Bending
All bending of high-strength structural steel must be done hot. Bends of a difficult nature on structural steel shall be done hot, but otherwise cold bending can be employed. Members bent hot shall be heated in a non-oxidizing flame over a sufficient area to prevent excessive deformation. Hot bends shall be left for slow cooling in air. Where bends are near splices, the upset metal shall be forged smoothly for full bearing on the contact surface. All bends shall be finished, free from waves, folds, or localized reduction in sectional area shall not exceed 3 % of the nominal area. Member length variation shall not exceed the tolerances shown below to its projected straight length. A member bent in error with respect to the location of a bend line shall be rejected.

B1.4.4.4.5

Welding
All welding shall be performed in accordance with the Standard EN 1993-11 or equivalent. A shielded arc-welding process shall be used. All welds shall be made in such a manner that residual shrinkage stresses will be reduced to a minimum. If not previously qualified, the welding process and the welders employed in performing the work covered by the Contract

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Documents shall be qualified in accordance with the requirements of the mentioned standard EN 1993-1- 1, or DIN 18800-7 or equivalent. No field welding will be allowed unless otherwise approved by the Employer/ Employers Representative. The structural steel, the welding process, electrodes and treatment shall be such as to avoid embrittlement of the steel and safe operation shall be assured at low temperatures. No welding to compose individual tower members will be permitted. All tower member profiles shall be formed by hot rolled steel over its entire design nominal length.

B1.4.4.4.6

Tolerances of members
Tolerances of finished members shall be as follows: Finished members shall not have a lateral deflection (bendings) greater than 1/1000 of the members nominal design/length. Cut members without ends finished for contact bearing shall have a tolerance 1.5mm for members up to 3m in length. For members over 3m long, an additional 1mm for every 3m length may be allowed, but in no case will a tolerance of more than 3mm allowed for any member.

B1.4.4.4.7

Marking
All individual pieces shall be marked with the correct designations shown on the detailed drawings approved and shall indicate the type of towers also. Markings shall be done by stamping the marks into the metal before galvanizing and details shall be clearly legible after galvanizing. The figures and letters shall be minimum 12mm in height. Marking of bolts shall be made on bolt heads to identify manufacturer, grade, size and length. Markings may be raised or depressed.

B1.4.4.4.8

Corrosion protection
General All steel structures shall be protected against corrosion by hot dip galvanizing. Painting will be required for application on some galvanized tower structures for aircraft warning purpose only. Detail specification for tower structure painting is shown below. Galvanizing a) Cleaning After fabrication has been completed and accepted, all materials shall be clear of rust, loose scale, dirt, oil, grease and other foreign substances that may affect the uniformity of the coating.

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TANESCO Bidding Documents Section VI (Part B1)

Structural steel items shall be initially grit blasted to BS 4232, second quality, (Sa 2 ) or by pickling in a bath. Careful cleaning of welds is necessary before welded assemblies are dipped. The welds and the surrounding metal should be cleaned separately, preferably by sand blasting. Excess spelter shall be removed by appropriate means acceptable to the Employer/ Employers Representative. b) Galvanizing All defects of the steel surface including cracks, surface laminations, laps and folds shall be removed. All drilling, cutting, welding, forming and final fabrication of unit members and assemblies shall be completed before the structures are galvanized. All steelwork shall be hot dip galvanized in accordance with internationally recognized standards such as EN ISO 1461, or equivalent, providing a smooth, clean and uniform zinc coating of min 85 micrometers thickness for bars and plates and 55 micrometers for bolts and nuts. The ingot zinc used for galvanizing shall comply with the requirements of BS EN 1179. The preparation for galvanizing and the galvanizing itself shall not adversely affect the mechanical properties of the coated materials. It is essential that the shape of steel members and assemblies which are to be hot-dip galvanized shall conform to the requirements of the process. Vent-holes and drain-holes should be provided to avoid high internal pressures and air-locks during immersion, which may cause explosions, and to ensure that molten zinc is not retained in pockets during withdrawal. On removal from the galvanizing bath, the resultant coating shall be smooth, continuous, free from gross surface imperfections such as bare spots, lumps, blisters and inclusions of flux, ash or dross. Excessively thick or brittle coatings due to high levels of silicon or phosphorus in the steel, which may result in an increased risk of coating damage and/or other features that make the final product non-fit-for-purpose shall be cause for rejection. Bolts, nuts and washers including the threaded portions shall be hot-dip galvanized and subsequently centrifuged. The threads shall be cleaned of all surpluses on packing, clear of the ground and stored away from all materials that might stain or corrode the galvanizing. Dies shall not be used for cleaning threads other than on nuts. Nuts shall be galvanized and tapped 0.4 mm oversize and threads shall be oiled after galvanization to permit the nuts to be finger-turned on the bolt for the full depth of the nut.

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TANESCO Bidding Documents Section VI (Part B1)

Finished materials shall be dipped into a solution of dichromate or be otherwise treated after galvanizing for white rust protection during sea transportation and storage. Protected slings shall be used for off-loading and erection. Galvanized work to be stored at the works or on site shall be stacked so as to provide adequate ventilation to all surfaces to avoid wet storage staining (white rust). Spacers between individual members or plates being stacked shall be used. Small areas of the galvanized coating damaged in any way shall be restored by: Cleaning the area of any weld slag and thorough wire brushing to give a metallic clean surface. The application of two coats of zinc powder-rich paint, or the application of a low melting point zinc alloy repair rod or powder to the damaged area, which is heated to 300C. c) Minor repair Under this Contract minor repairs are defined as permitted repairs undertaken at site or outside the contractual manufacturing plant at galvanized (finished) steel parts. All finished steel parts which exceeds the criteria shown below shall be replaced by new, correct components as per approved drawings free of charge. Drilling of one mismatched hole at anyone individual steel part permitted provided that the minimum edge clearance and minimum distance to the mismatched and other holes is maintained. Filling of mismatched holes is not permitted. Cutting of one side at anyone individual steel part permitted provided that the minimum edge clearance to holes is maintained. Maximum 5 holes and 5 cuts per tower permitted and maximum 5 affected towers per 10 km line. Drilling and cutting on tower stub parts encased in concrete is permitted and will not count to above criteria as it might be required for adaption of foundation depth. Materials on which galvanizing has been damaged shall be re-dipped unless in the opinion of the Employer/ Employers Representative, the damage is local and can be repaired by applying a coating of galvanizing repair paint. Where such repair is authorized, the damaged area shall be cleaned by wiping with clean rags saturated with mineral spirits of xylene, followed by wire brushing. After wire brushing, the area shall be re-cleaned with solvent to remove residue, and shall be given one heavy brush coat of galvanizing repair paint. The percentage of pure zinc by weight in dry film of galvanizing repair paint shall not be less than 85.
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TANESCO Bidding Documents Section VI (Part B1)

The repair procedure of damage galvanizing is specified under section Tower Erection.

B1.4.4.5

Tower load test


Type test reports of the existing tower designs if proposed by the Bidder shall be submitted with the Bid. The suspension towers shall be tested to destruction as described below. The tension towers shall be tested to destruction too, but at least to ultimate design loads depending on the test stations load capacity, as described below. The test loads shall be the design loads multiplied by the corresponding partial safety factors and by the material factor for steel member sections. The Employer/ Employers Representative is entitled to attend tests and inspections, and the Contractor shall bear all costs and expenses of tests and attendance as per price schedules. The Contractor shall give the Employer/ Employers Representative notification in writing, not less than 45 days in advance, of the date when towers will be ready for test. Test program shall demonstrate procedures of test in order to proof the specified technical requirements and be subject to approval by the Employer prior testing starts. Additional tests may be called by the Employer/ Employers Representative to ensure that the required quality is met. The Contractor shall supply all necessary labor, material, equipment and competent and authorized test personnel. Calibration of equipment is deemed to be included. Six (6) copies of test reports and/ or certificates are to be provided showing all results and information necessary. If the Employer/ Employers Representative waive to attend the test, it will neither relieve the Contractor of his full liability to meet the required quality and to complete the works nor prejudice or affect the rights of the Employer/ Employers Representative set forth under this contract. The test shall be performed with the Employer/ Employers Representative in attendance and in accordance to IEC 60652 "Loading tests on overhead towers" and complying with the following requirements: a) Tower The tower shall be fabricated according to the detailed drawings approved in a manner as close to final production procedures as practicable. The tower shall be complete in every detail. Markings for test tower members shall be prefixed with the letter "T". b) Erection The tower shall be erected on a rigid foundation using the specified tower bolts and nuts tightened to the specified torque.

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TANESCO Bidding Documents Section VI (Part B1)

c)

Rigging The Contractor shall submit for approval diagrams showing the proposed methods of applying loads and deflection measuring.

d) Loading Test loads shall be the design working loads multiplied by corresponding partial safety factors for loads and materials. All test loads corresponding to conductor and earthwire loading shall be applied directly to the regular attachment details provided for those loads. Test wind loads equivalent to wind loads on the tower shall be applied where convenient and in such a manner that the locations and the summations of applied load and overturning moment are as close as possible to the actual conditions, as designed. An extra compressible member is not allowed for use in applying wind loads on tower. To ensure application of full-test loads to the tower, friction losses in rigging shall be computed and added to the rigging loads. The first load case in a Heavy Angle tower testing program should be the one that produces the largest leg force. If subsequent load cases also give sufficiently high leg force, tower bolts at major joints must be loosened and re-tightened prior to the test to minimize residual loads. e) Loading program The Contractor shall program the tests for the decisive load cases in order to most favorably demonstrate that the towers will carry all design loads and conditions specified in the loading diagrams. Deflection measurements Deflections shall be recorded at the beginning and end of each loading period to provide longitudinal and transverse deflections at the tower top, at the elevation of the crossarms and at least at one intermediate point of tower body.

f)

g) Load tests The initially applied loads and the increment of loading shall be 25% of the working loads given in the loading diagrams. However, the increments of load shall be in accordance with IEC 60652. Each load increment shall be maintained for not less than two minutes except that under full design load, the period of five minutes shall be maintained and during this time there shall be no slacking off or adjustment of the loads. Should it become necessary to adjust the loading, the two or five minutes period shall start after the loading is stabilized and constant. All test loads shall be removed completely before the loads for testing under different loading conditions are applied. The ultimate normal conditions or the most critical load case shall be the last test to be carried out in the presence of the Employer/ Employers Representative.

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Load Cell Calibration shall be carried out before and after each test or series of tests in the presence of the Employer/ Employers Representative. h) Destruction test After the successful completion of the ultimate load tests, the tower shall be further tested to destruction by increasing the loads for a given loading case, as specified/approved by the Employer/ Employers Representative. The load increments shall not exceed 5 % of the ultimate design load. Each load increment shall be held at least five minutes while deflections are being recorded. The maximum test load may be limited to 1.3 times the ultimate design load or the test stations load capacity. i) Modification of tower components Any conspicuous yielding or permanent deformation or any failure of any part of the tower under any of the tests specified shall be considered a defect. If a defect develops, the Contractor shall modify the design of the tower and submit it to the Employer/ Employers Representative for approval. The modified tower shall then be re-tested. The expenses associated with re-design and re-test due to a defect in the Contractor's work shall be borne by the Contractor. j) Material tests Steel materials used for test towers shall be subject to tension or bend test in accordance with the relevant material standard. Tests shall be performed by the Contractor at no additional cost to the Employer. The test specimens shall be selected as follows: i) Four sets selected from the destruction members of each test tower. ii) Four sets selected from the undisturbed members of each test tower. iii) Two sets of bolts and nuts selected from the adjoining destruction members of each test tower. iv) Two sets of bolts and nuts selected at random from each test tower. k) Reports The Contractor shall furnish certified copies of full reports of all tower and material tests, the calibration of the dynamometers or gauges, including clear photographs of the test set-ups and nature of all failures, diagrams showing deflection of towers at each interval of loading, detailed diagrams showing the manner in which all the loads were applied and deflection records.

B1.4.4.6

Packing
The whole of the goods shall be packed where necessary in non-returnable cases or on non-returnable drums or otherwise prepared for overseas shipment in a manner suitable to withstand rough handling without sustain-

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ing damage. All packing materials shall remain the property of the Employer. Bundles of steel angle sections shall be properly tied together by an approved method and care taken to ensure that they are robust and not of excessive length for handling during shipment. All labels shall be of stamped metal. Unless the Contractor can bid an equally acceptable method, bundles of angles shall be arranged in rectangular formation with notched outer stout wooden battens to locate the angles, the battens being compressed on the bundles by outside tie bolts - the above binders being located at sufficiently close intervals to form a strong and homogeneous element. Provision shall be made by placing of plastic spacers between the individual members for the circulation of air and draining of water minimize white rust formation. Bundles shall be as large as practicable to provide stiffness and resistance to careless handling. Packing cases where used shall be strongly constructed and in no case is timber less than 25mm in thickness to be used. The contents of packing cases shall be securely bolted or fastened in position with struts or cross battens. Cross battens supporting weight in any direction shall not rely for their support on nails or screws driven lengthwise into the grain of the wood, but shall be supported by cleats secured from the inside. Bolts and nuts shall be crated for shipment. Crating together of components of dissimilar metals is unacceptable. Particular attention shall be given to strutting before packing cases are fastened down. Cases shall be up-ended after packing to prove that there is no movement of the contents. Timber wedges or chocks shall be firmly fastened in place to prevent their displacement when the timber shrinks. If light parts are fastened to the sides of a case, hoop iron straps secured by screws shall be used for the purpose. Nails driven in and bent over shall not be permitted. Where bolts are used, large washers shall be fitted under the head and nut to distribute the pressure and the timber shall be strengthened by means of a pad. The Contractor's attention is drawn to the provisions for galvanizing wherein the Contractor shall be required to protect all steelwork before shipment to prevent damage by white rust to galvanized surfaces. Considering the stability of the bundles, natural air ventilation shall be ensured e.g. by using plastic fillers in order to avoid a permanent accumulation of wetness or moisture.

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All stencil marks on the outside of casings shall be either of a waterproof material or protected by shellac or varnish to prevent obliteration in transit. The use of excelsior as a packing material shall be avoided at all times. Waterproof paper and felt linings shall overlap at seams at least 13mm and the seams secured together in an approved manner, but the enclosure shall be provided with screened openings to obtain ventilation. Each crate or package shall contain a packing list in a waterproof envelope and copies in triplicate shall be forwarded to the Employer/ Employers Representative prior to dispatch. All items of material shall be clearly marked for easy identification against the packing list. All cases, packages, etc., shall be clearly marked on the outside to indicate the total weight, to show where the weight is bearing and the correct position of the slings and shall bear an identification mark relating them to the appropriate shipping documents. The Employer/ Employers Representative may require inspection and approval of the packing before the items are dispatched but the Contractor is to be entirely responsible for ensuring that the packing is suitable for transit and such inspection shall not exonerate the Contractor from any loss or damage due to faulty packing.

B1.4.4.7

Quality assurance

B1.4.4.7.1

General
The Contractor shall supply a detailed Quality Assurance Procedure including an Inspection and Test Plan (ITP) which shall be submitted to the Employer for approval. The Contractor shall be responsible for performing all tests and inspections required during the production of the towers. The Employer/ Employers Representative is entitled to attend tests and inspections, and the Contractor shall bear all costs and expenses of tests and attendance as per price schedules. The Contractor shall give the Employer/ Employers Representative notification in writing, not less than 45 days in advance, of the date of material testing. Test program shall demonstrate procedures of test in order to proof the specified technical requirements and be subject to approval by the Employer prior testing starts. Additional tests may be called by the Employer/ Employers Representative to ensure that the required quality is met. The Contractor shall supply all necessary labor, material, equipment and competent and authorized test personnel. Calibration of equipment is deemed to be included. Six (6) copies of test reports and/ or certificates are to be provided showing all results and information necessary. If the Employer/ Employers Representative waive to attend the test, it will neither relieve the Contractor of his full liability to meet the

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required quality and to complete the works nor prejudice or affect the rights of the Employer/ Employers Representative set forth under this contract. The Contractor shall identify all materials, including bolts and nuts used in the project on the appropriate mill test reports and/or material certificates, and shall furnish the mill test reports and/or certificates to the Employer/ Employers Representative for approval. The Contractor shall make dimensional checks of all materials for conformity to the relevant material standard. The Contractor shall make a visual inspection of all materials before and after galvanizing. Size of test "lot" and number of tests shall be in accordance with appropriate standards.

B1.4.4.7.2

Sample testing
In addition to the above inspection and tests, the Contractor is required to perform the following tests at his own expense on samples selected at random by and in the presence of the Employer/ Employers Representative or of his representatives. a) Physical tests on samples of structural steel sections The tests to be carried out shall include yield strength, ultimate tensile strength and percentage elongation. One set of tests shall be carried out for each 50 tons of steel passing through the fabrication plant. b) Galvanizing tests on samples of structural steel sections The tests to be carried out shall include determination of thickness of zinc coating, adherence of zinc coating and surface appearance. One set of tests shall be carried out for each 50 tons of steel passing through the fabrication plant. c) Mechanical and galvanizing tests on bolts and nuts Mechanical property and galvanizing tests on samples of bolts and nuts shall be carried out in accordance with the requirements.

B1.4.4.7.3

Shop assembly
One tower of each type and height, including every combination of body extensions, shall be assembled in the shop to such an extent as to ensure proper field erection. The test shall be performed with the Employer/ Employers Representative in attendance. Any member distorted, twisted or bent due to incorrectness of detailed drawing shall be corrected. Reaming of mismatched holes will not be permitted. A reasonable amount of drifting will be allowed in assembling. Assembly may be vertical or horizontal. If the assembly is horizontal, blocking and adequate support shall be provided to prevent distortion and overstressing of members to ensure proper fit. In assembling, only sufficient

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number of bolts need be used to hold members in their true position one to another. If any errors on the drawings or fabrication are discovered, all incorrect drawings shall be revised and the corrected part shall be re-fabricated and re-assembled at the Contractor's expenses. All revised drawings shall be resubmitted for approval.

B1.4.4.7.4

Routine tests
The Employer/ Employers Representative will inspect as soon as available at the Contractor's works the first consignment of complete foundation steelwork and stub setting templates. Thereafter inspection of galvanized steelwork will be limited to complete structures, with or without foundation steelwork, the weight of steel to be inspected for each inspection visit has to be agreed by the Employer/ Employers Representative. Where additional inspection visits are required to be made due to shortcomings or deficiencies, the cost of travel, subsistence and accommodation of the Employer will be borne by the Contractor.

B1.4.5 Foundations

B1.4.5.1

General
The Contractor has to choose up-to-date methods and equipment to ensure that the design and erection of foundations will be in accordance with relevant internationally recognized standards. The construction work referred hereto shall be performed in such a manner that the high standards of quality and function required in detail below are achieved. Special attention shall be paid not only to the question of basic design and construction, but also to the aspects which are specific to the route of the overhead line, its local climate and specific geology. The works shall be designed and executed with due regard to the need for inspection, cleaning and repair works, and service for prolonged periods of operation requiring minimum of inspection, adjustment and repair works. All materials shall be new and of the best quality, suitable for working under the climatic conditions without undue distortion or deterioration or the occurrence of undue stresses in any part, such as to affect stability safety as well as the efficiency and reliability of the works. The Contractor shall assume full responsibility for: the use of the most suitable materials appropriate design

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competent workmanship full serviceability in unrestricted continuous operation observance of the technical requirements.

B1.4.5.2

Soil investigations

B1.4.5.2.1

General
The Contractor shall be responsible at his own cost for ascertaining that the foundations to be employed are suitable for the sub-soils encountered at each tower and support site at an early stage of the Contract. Detailed soil investigations shall be carried out by the Contractor along the line route as a prerequisite for planning of the foundations. The extent of the investigations shall be such as to permit the satisfactory determination of all necessary sub-soil characteristics, to exclude any unacceptable settlement and to determine reliable type, size and execution of foundations. For classifying the soil, the Contractor shall carry out investigations by test pits or auger borings and penetration tests at all line angle point locations and additionally, at sufficient locations between the angle points depending on the terrain and geology, but not more than 4 km apart. These investigations have to be completed before the design works start. The soil investigation report shall also contain details about the soils earthing resistivity. After the tower locations have been pegged out, each tower location shall be investigated by penetration test except where soundings have been undertaken during the initial investigations by the Contractor. Reference is also made to the General Technical Requirements.

B1.4.5.2.2

Standards
The tests are to be carried out in conformity with international standards EN, DIN, BS, IEEE or equivalent by a well experienced and reputable Institute to be named by the Contractor and approved by the Employer/ Employers Representative. Other standards are subject to the approval prior to the performance of the laboratory tests. The following standards are important and acceptable but the list is considered to be incomplete: BS 1377 BS 5930 DIN 4021 Method of test for soil civil engineering purposes Code of Practice for site investigation Subsoil; exploration by trial pits and borings as well as sampling; investigations in soils

Part 1 (1971)

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DIN 4022

Part 2 (1976) Part 3 (1976) Part 1 (1969)

Part 2 (1977)

DIN 4023 DIN 4094

(1975) Part 1 (1974)

Part 2 (1980) DIN 18196 (1970)

IEEE 691 (2001)

As above, investigations in rock As above; investigations of groundwater Subsoil and groundwater; designation and description of soil types and rocky soil; list of soil courses for testing and boring without continuous gaining of core samples As above; list of soil courses for investigations and boring in rocky soil (circulating as draft) Subsoil and water drilling; graphical presentation of results Subsoil; equipment for dynamic and static subsoil soundings; dimensions of apparatus and process Subsoil; dynamic and static penetrometer; application and evaluation of results Earthworks; soil classification for civil engineering purposes and methods for identification of soil groups Guide for Transmission Structure Foundation Design and Testing

B1.4.5.2.3

Investigations
The geotechnical investigation shall be based on in-situ testing for the determination of the soil strength and visual tactile examination of disturbed samples for the determination of soil classification. In-situ testing shall comply with the following requirements: granular soil - standard penetration tests (SPTs or DPLs), cone penetration tests (CPTs), or in presence of large gravel content pressure meter tests (PMTs). cohesive soil - as for granular soils except that use of SPTs is subject to the Employer's approval. Vane shear tests (VSTs) may also be used in fairly uniform, fully saturated soils. rock - weak rock SPTs, medium to hard rock PMTs. rock solid rock drilling. Penetration sounding equipment shall comply with the relevant standard and as summarized below:
Main Characteristic Of Equipment Applicable standard Penetration force Data reading Cone diameter Sectional area SPT Standard Penetration Test ASTM 1586 dynamic blows/30cm 49-51mm hollow 20cm DPL Dynamic Probing Light DIN 4094 dynamic blows/10cm 34-36mm solid 10cm CPT Dutch Cone Penetrometer BS 5930 static pressure/20cm 35-36mm solid 10cm 54

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Point angle Drop weight Fall height Penetration rate Drill rod deviation

40/180 90 60 63-64 kg 9.9-10.1 kg accuracy 5 % of reading 74-78cm 49-51cm 20-40 blows/min. 15-30 blows/min. 1,5-2,5 cm/sec. bend 0,1 % and plumb 2 % of drill rod length

Other then above shown penetration equipment is subject to approval and provision of the penetrometers characteristic data, correlation charts to one of the above specified equipment and relation/interpretation to the various soil engineering properties. The index parameters for soil classification and its correlation to the specified engineering properties shall be based on the in-situ test results. The SPT provide soil samples for classification beside of the penetration resistance for correlation with the soil properties. These correlations are generally more reliable for compact granular soil than for soft cohesive soils. The DPL provides dynamic penetration resistance only which are generally more reliable for semi-solid to loose fine soils than for hard or very soft soils. The CPT provides static penetration resistance and local friction only which are generally more reliable for medium stiff to very soft cohesive soils than for compact granular soils. Accordingly requires the DPL and CPT test complementary auger borings or test pits for obtaining subsoil samples and its classification. For all soil investigation locations, the contractor shall give clear information, in addition to boring results for the following local conditions: surface condition and inclination of the ground in the area of the future foundations inclination of cracks and fissures in the rock and their stratification and judgment about the global stability relevant inclination of the ground surface in the vicinity of the future tower foundations if sliding or rock fall hazard is expected possible flooding or scour (wash out) action possible around foundations during periods of heavy water flow data about the maximum groundwater level for all tower sites. Consequently, the investigations shall preferably be undertaken towards the end of rainy season. Otherwise inquiries and assumptions on the max. subsoil water level shall be made. At all soil investigation locations the in-situ testing shall be advanced to the following limits: Test pits up to -4 m or reaching rock prior 4 m depth Auger borings and rock drillings up to -6 m depth SPT up to -8 m or reaching 30 blows per 30 cm prior 8 m depth DPL up to -8 m or reaching 60 blows per 10 cm prior 8 m depth CPT up to -8 m or reaching 8 MN/m per 20 cm prior 8 m depth In soft, very loose soil up to -12m -15m to advance penetration

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Every test pit or auger boring or SPT sampling at -1m, -3m, -5m (for test pits -4m) depth to take each one disturbed soil sample. In-situ measurements of soil resistivity shall be undertaken preferably in accordance with the Wenner method (ASTM G57-78). Four electrodes are to be set out at straight line in intervals of 10 to 20 m apart and driven 0,5 to 1,0 m into the ground maintaining a ratio depth to distance of 1/20. A portable Megger Earth Tester or a similar four terminal type instrument shall be applied for measuring the in-situ resistance evaluating the corresponding soil resistivity. The Contractor shall order Laboratory Tests to determine the necessary soil mechanic parameters for the foundation design of towers. The index properties to be determined and observations to be provided are:
Cohesive soil Granular soil Rock

State of consistency Degree of compactness Degree of hardness Atterberg limits Grain size Metamorphic grade Unit weight Unit weight Weathering state Water content Saturation degree Rock defects CPT/DPL resistance SPT/DPL resistance RQD core recovery Subsoil description, texture and stratigraphic sequence Ground water and flood water level 2 Aggressiveness of ground water and subsoil (SO 4 , Mg, pH) Position and depth of pit, borehole, sounding and samples taken Electrical ground resistance (conductivity of in-situ soil)

The Contractor shall name a professional soil mechanics expert and foundation engineering expert. The expert shall supervise the boring works.

B1.4.5.2.4

Procedures
a) Execution of Borings For the drilling in non-cohesive soil, the Contractor shall supply a bore equipment with a diameter of at least 150mm. The equipment shall allow the additional execution of Standard Penetration Test (SPT) and disturbed sampling for instance by using piston samplers. During boring, in case hard rock is encountered, it shall be continued with rock drilling to establish continuity of rock strata. For drilling work in hard rocky soils a double tube core barrel of between 7,5 cm to 12,5 cm inside diameter shall be used exclusively, provided that this kind of boring can be continued to the final bottom of the bore hole in question. Depending on the rock quality a core sample recovery rate of 90 % should be achieved. Beyond this, the Contractor may choose for his own convenience the type of equipment and accessories to be used at each individual bore hole and depth, provided that in the Employers/ Employers Representatives opinion the equipment chosen is suitable for the drilling. The Contractor may also choose the initial and intermediate diameters of each bore hole for

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his own convenience, provided that he will secure the before mentioned minimum acceptable size of core. Adequate casing has to be used to ensure the stability of the bore hole. The Contractor will not be entitled to any compensation or additional payment for casing. b) Sampling Undisturbed samples if required shall be of 100mm diameter and 450mm length. Samples shall be collected in such a manner that the structure of the soil and its moisture content are not changed. Disturbed soil samples shall be collected in bore holes and test pits at regular intervals. Jar samples weighing approximately 1kg shall be collected in bore holes and test pits and SPT at 1m intervals starting from a depth of 1m below ground level and at every identifiable change of strata to supplement the boring records. c) Bore Logs Detailed bore logs/field books must be kept for all borings. They shall include all pertinent data and results and all observations, measurements or tests as may be directed by the Employer/ Employers Representative.

B1.4.5.2.5

Report
Field reports have to be handed over to the Employer/ Employers Representative at site including bore-logs protocols with all pertinent data, SPT, DPL, CPT sounding diagrams, ground water locations, core drilling diagrams, test pit logs as well as readings within the agreed time after completion of the corresponding work. Weekly Progress Reports on approved forms shall be submitted to the Employer/ Employers Representative at Site. On completion of all field laboratory work, the Contractor shall submit to the Employer/ Employers Representative a Geotechnical Investigation report containing the equipments technical data and method applied during the investigation, field test results, photos, laboratory observations and test results both in tabular and graphical form, practical and theoretical considerations for the interpretation of the test results, supporting calculations for the conclusions drawn etc. The report shall contain theoretical as well as practical considerations for the design and construction of the foundations for different types of structures and any proposals which the Contractor may consider necessary to make with regard to the parameters and dimensions for the design of standard foundations and of special foundations. The report shall contain sufficient information regarding the conductivity of soils necessary for the design of earthing system. The report has to be signed by the named geotechnical expert.

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The Contractors qualified geotechnical engineer shall visit the Employers/ Employers Representatives office for a detailed discussion on the draft report. During the discussions, it shall be decided on the amendments that need to be made in the draft report. Thereafter, the Contractor shall incorporate in the report the agreed modifications, and after the Employer/ Employers Representative approves the report, the Contractor shall submit ten (10) copies of the final report along with a reproducible set of all tables, graphs, etc. The Contractor shall prepare a schedule for construction purposes, which clearly indicates the type of foundations to be installed at each site and records of the soil investigation data on which the choice has been made. A field test procedure (hand test method) shall be established and included in the report about assessment and classification of actual soil conditions once the foundation excavation is open to verify compliance with the defined foundation design parameter. The Schedule will be subject to the approval of the Employer/ Employers Representative prior to commencement of foundation construction.

B1.4.5.3

Foundation design

B1.4.5.3.1

General
The foundations shall be designed by the Contractor on the basis of accepted codes of practice, the relevant literature or methods which have been used with satisfactory practical experience by the Contractor, and agreed by the Employer/ Employers Representative. General the design approach shall follow the recommendations of EN 1997-1-1 (Geotechnical Design, Part1: General Rules), EN 1992-1-1 and EN 1992-3 (Design of Concrete Structures, Part3: Concrete Foundations). But also other accepted standards may be applied like EN 50341-3-4 (German National Normative Aspects), clause 8 or BS 8004 and BS 8110. An overview on foundation design practice and most common tower footing types used in practice are presented in CIGRE Recommendation 206 of August 2002. All foundations shall be designed to withstand uplift, settlement and overturning (as appropriate) when subjected to the applied system loading. Allowances shall be made in the foundation design for hydrostatic pressure where this may occur and the effects of seasonal rains, drying out or other cyclic loading. During design of towers, the tower reactions on the foundation shall be calculated considering appropriate maximum simultaneous loading on the towers. Foundation design loads will be calculated on the basis of the maximum axial and horizontal tower reactions. Maximum foundation shear force from any load combination for the download leg will be assumed to act simultaneously with the maximum foundation compression force.

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Similarly, maximum foundation shear force from any load combination for the uplift leg will be assumed to act simultaneously with the maximum foundation uplift force. If a limit state method is used the obtained tower reactions forces shall include the partial safety factors for the loads and the resultant reactions shall be used for foundation design. The partial safety factors for material and soil are given in the Technical Schedules. Foundation type design shall be economized by applying the max. foundation load obtained from the structural analysis of max. tower body and leg extension of the individual tower types allocated to the different soil classes of foundation design i.e. only one foundation design per tower type and soil class. Further simplification might be achieved by cross-grouping to establish the same dimension, for example a good soil light angle tower with that of a poor soil heavy suspension tower. Out of all the load cases the maximum tower footing reaction forces shall be applied for designing the foundations taking into account possible liquefaction effects of loose fine uniform graded sands in ground water. Transition zones of variable ground water table shall be assumed of being completely submerged. The Contractor will be responsible for the suitability of the foundation types applied for the existing underground conditions. Any information given in these technical requirements in relation to the foundation design is for bidding purpose only. For the final foundation design the Contractor has to perform the required soil investigations and has to base his design calculations on the detailed information obtained. The Contractor is requested to quote firm unit rates for the different types of foundations and towers as set out in the Price Schedules. These unit rates will be considered as flat rates covering all foundation costs for any type of soil encountered along the line and no adjustment of the rates will be permitted.

B1.4.5.3.2

Soil classification
The geotechnical parameters for bidding purposes are provided below. The Contractor shall however perform the geotechnical investigation during execution of the Contract at each location as specified in this bidding document in order to confirm the specified values and correlations or justify its changes. Index parameter changes and its correlation to the engineering properties is subject to foundation loading tests to destruction and approval by the Employer/Employers Representative. No extra payment will be made if the actual soil condition is found to be worse than the soil parameter and excavation condition shown in the table below and outlined in these technical requirements. The requirements for in-situ soil assessment corresponding to the defined soil classes below are outlined in the General Technical Requirements of section Work Included under paragraph Checking of Soil Conditions in table Soil Assessment by Field Test Method.

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Excavation Condition 90 % rocky, rock mass 6 m, top layer rock debris, drilling pneumatic hammer chiseling restricted blasting Foundation Type rock anchor

Soil Class 1 Hard Rock

Index Properties very strong strong tough sound homogenous durable no penetration advance RQD > 0.6 and uniaxial strength > 5 MN/m weak medium tough very weak fractured fissured weathered SPT > 50 N/30 DPL > 100 N/10 CPT > 10 MN/m RQD < 0.5 compact very dense medium dense hard very stiff semi solid SPT 18 5 N/30 DPL 30 10 N/10 CPT 5 1 MN/m loose firm stiff SPT 10 3 N/30 DPL 15 5 N/10 CPT 3.0 0.7 MN/m

Engineering Properties compact rock mass bearing pressure perm. 1000 kN/m ult. 2000 kN/m uplift capacity shear friction resistance ult. 200 kN/m comp. backfill 18 KN/m rock density 25 kN/m fractured rock large boulders very hard and cemented soil bearing pressure perm. 500 kN/m ult. 1000 kN/m uplift capacity ult. frustum angle 30 comp. backfill 18 kN/m granular and cohesive soil rel. density Dr 0.5 consistency lc 1.0 bearing pressure perm. 250 kN/m ult. 400 kN/m uplift capacity ult. frustum angle 20 comp. backfill 16 kN/m

2 Soft Rock

50 % blocks 1.0 m and boulders 0.2 m, rock debris, pickaxe chiseling pneumatic hammer restricted blasting

reduced reinforced concrete pad and chimney with undercut

3 Good Soil

4 Poor Soil No Water

5 Poor Soil With Water

very loose medium firm soft subsoil water SPT 5 2 N/30 DPL 8 3 N/10 CPT 1.5 0.5 MN/m

6 Very Poor Soil With Water

extremely loose very soft subsoil water SPT 2 1 N/30 DPL 3 2 N/10 CPT 0.5 0.3 MN/m

< 50 % blocks< 1.0 m and cobbles < 0.2 m, rock debris, gravel and sand, silt and clay, water below foundation bottom, pick spade auger excavator core part only granular and occasional boulders, cohesive soil rock debris, rel. density Dr 0.4 gravel and sand, consistency lc 0.8 silt and clay, bearing pressure water below perm. 150 kN/m foundation bottom, ult. 250 kN/m formwork at pad, uplift capacity strutting of excavation, ult. frustum angle 10 spade comp. backfill 16 kN/m shovel excavator granular and occasional boulders, cohesive soil gravel and sand, rel. density Dr 0.3 silt and clay, consistency lc 0.6 water above bearing pressure foundation bottom, perm. 100 kN/m water pumping, ult. 150 kN/m formwork at pad, uplift capacity strutting of excavation, ult. frustum angle 5 shovel comp. backfill 10 kN/m excavator granular and gravel and sand, cohesive soil silt and clay, rel. density Dr 0.2 pit and organic soil, consistency Ic 0.5 water above bearing pressure foundation bottom, perm. 50 kN/m water pumping, ult. 80 kN/m formwork at pad, uplift capacity strutting of excavation, ult. frustum angle 0 shovel comp. backfill 10 kN/m excavator

reduced reinforced concrete pad and chimney with undercut

standard reinforced concrete pad and chimney no undercut

extended reinforced concrete pad and chimney or bore piles if required with tie beams

reinforced concrete raft foundation or steel mortar composite piles or precast piles if required with tie beams for spread footings

The specified range of penetration counts respective cone bearing value obtained from the different penetration tests varies in relation to the soil composition and variability of soil deposits. The above shown mean value is for mixed soil types having a wide scatter whereas the ( + ) range is rather for cohesive fine soils and the ( - ) range for granular coarse (non-cohesive)
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soils. The equipments characteristic data and its reliability of results are outlined in the previous section of Soil Investigation. Hard rock is defined to consist of hard material (mineral composition) of high geological age, which is only slightly weathered. It can contain joints and fissures but shall attain an uniaxial compressive strength > 5 MN/m as well as an RQD > 0.6 at the same time (Rock Quality Designation > 60 %, i.e. the total length of recovered core consisting of pieces of at least 10 cm length shall be more than 60 % of the drill run length). Further engineering properties such as density weight of compacted backfill, submerged soil and frustum angle of inverted earth cone allocated to the individual soil classes are also specified in the Technical Schedules.

B1.4.5.3.3

Foundation types
Corresponding to the defined soil classes the following foundation types shall be designed: A Rock anchor foundations comprise of rock anchors and a reinforced concrete block of at least 1.5m depth directly cast against rock for soil class 1. The length of the anchor bolts or anchor profiles shall be calculated with the consideration of the following mechanical characteristics: the bearing capacity of the anchoring bolts or profiles the rupture of the adhesive power between the steel anchor and grouting material the rupture of the adhesive power between the grout and rock the failure-rupture of the rock due to shear forces. In all cases the length of anchors shall be at least 1,2 m or 50 x d (d the diameter of the anchor bars.)

C Pad and chimney foundations comprise of a reinforced concrete base mat with a secondary upper pad and a square or round pier (chimney) of depth T 2,0m depth for soil classes 3,4 and 5. The following dimensional ratio shall be maintained: width B/depth T between 0,5 to 1,0 D Raft foundation comprise of a reinforced concrete pad interconnecting the 4 tower footings as a slab at shallow depth of T 1,5m depth for soil class 6 E Pile foundations comprise of a group of piles or special piles (micro piles, etc.) interconnected by a reinforced pile cap per tower leg for soil class 6. Foundation types A, C and E are spread footing foundations. In case of
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narrow base tower, sufficient spacing between the individual foundation edges shall be maintained avoiding excessive superposition of spreaded stress in the adjacent soil. Foundation type D is a raft foundation extending over the 4 tower footings. Integrated concrete beams onto the slab intersecting at the 4 tower stubs may increase rigidity of the raft. The pad, raft and slab thickness shall be d 0,1 times the foundation base width (d 0,1B) but not smaller than the minimum thickness of d 0,3 m by vertical edge and of d 0,4 m by undercut edge. The spacing between piles within one group of foundation type E must be sufficiently large, so that no damaging or displacing should occur. Driven piles orientated in the same direction shall have a minimum axis distance of e = 3 times max. a (where max. a = maximum side dimension or diameter or pile). The clear distance should, however, be not less than 1.0 m, for driven piles. For bored piles the above is only valid inside the bearing horizon. The work includes all work for the execution of piles as well as the work required for test piles, pile load tests and working piles (including logs and reports). The pile bearing capacity and settlement behavior shall be checked by quality control tests (preferably by pulling tests): up to 10 piles up to 30 piles more than 30 piles 1 test 2 tests 1 more test for every further 30 piles

Undercut and underream are unreinforced concrete base enlargements at the foundation bottom casted directly to the excavation sides. The pyramidal shaped projection shall be 0,2 m and maintaining a height 2 times the projection width (2:1). Individual tower footing at different depths shall be based beyond a load spread angle of 60 form the vertical commencing from the higher located foundation bottom edge. Reinforced concrete tie beams are connecting the 4 foundation chimneys at shallow depth below ground level for evenly distributing horizontal footing forces, e.g. spread footing foundations in steep terrain or by long span tower foundations or chimney extension. Foundation with water (GW level above foundation bottom) might be subject to seasonal variation of flooding level and ground water table. The effect of buoyancy for the uplift resistance and its affect on the geotechnical parameters shall be taken into account for the foundation design assuming the water level raises to the surface. Provision in the different foundation type design shall be made as follow:
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Chimney extension above ground to lift the steel structure (by 0,5 m and 1,0 m) when the flood level exceeds 0,2 m above terrain around the tower location Chimney extension below ground to increase the foundation depth (by 0,5 m and 1,0 m) when the terrain slope exceeds 1:4 within a radius of 0,5 B + 1,5T (B foundation base, T foundation depth) around the tower footing Connection (tie) beams below ground when the tower span exceeds 500m and/or the terrain slope of tower location exceeds 1:2 Minimum lateral soil zone shall extend two times the depth (2T) horizontally from the outer most foundation edge to steep embankments or cliffs. If the adjacent area to the footings is prone to erosion or slope instability or have insufficient clearance, protective measures shall be put in place such as installation of stone gabions or retaining walls or shifting the tower location. The cost for the specified secondary upper pad and edge undercut shall be included in the unit price of the respective foundation class. No pre-cast elements are accepted, except pre-cast concrete piles. Grillage foundations shall explicitly not be applied in this project due to the partly aggressive soil conditions and the large foundation uplift loads which cannot be transferred safely and economically into the subsoil. As a result of the soil investigation undertaken by the Contractor at the tower locations, it might be necessary to use different types of foundations as those described in this section. No claims will be accepted for the necessary other type of foundations. The Contractor shall ascertain from the geotechnical investigation that the ground conditions are suitable for each foundation. The type of foundations specified above and shown in the attached drawings are for tender purpose and may be altered for construction by the Contractor subject to correlation results obtained from ultimate load foundation tests. It can be select also other type and alternative solutions for the foundations which are considered more economical or more adequate for the effective soil and topographical conditions of the OHL. The different - alternative - solutions proposed by the Contractor must guarantee the following conditions and criteria: no extra cost for changes compared to the agreed contract unit price of the respective soil class identical or higher safety in all aspects for the proposed foundation type(s)
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maintaining minimum foundation structure dimensions as shown above the experience of the Contractor with similar foundations of the new proposal executed in the same conditions for 400kV/330kV Transmission Lines availability and applicability of his equipment for the execution of foundations in the difficult project area. testing methods for the alternative proposal. The Contractor shall submit to the Employer/ Employers Representative the calculation of each typical foundation type with clear information about the: maximum compression and uplift as well as horizontal loads without safety factors or what safety factor is included. the stability of the foundations with respect to uplift, compression and horizontal loading calculated according to the safety factors. The effective pressure of the soil shall not exceed the limits calculated by the Contractor on the basis of the data of the soil investigation report. All relevant calculations and checks are to be established with the following as minimum: permissible or ultimate soil pressure, effective pile load, effective anchoring, settlements (compatibility with structure above to be proved) sliding shear failure (including slope stability if applicable) uplift safety permissible concrete/ steel stresses protection against aggressive soil conditions by appropriate measures. All foundations on slopes greater than 1:4 shall be checked for stability against rotation where appropriate. Due consideration shall be given to the increased uphill lateral loading of the soil and the decrease in downhill resistance provided by the soil, when compared to foundations installed on level ground. Due consideration shall also be taken of any decrease in the uplift resistance of the foundation. Where appropriate decrease in soil bearing resistance shall also be considered. The calculations are subject to the approval of the Employer/ Employers Representative. A selection of the foundation type shall be made for each tower to suit its particular site conditions, and the final tower list prepared there-from. The tower foundation list shall be submitted for approval to the Employer/ Employers Representative. The decision of the Employer/ Employers Representative which type of foundation shall be employed at a given location shall then be final without change of Contract Price.

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B1.4.5.3.4

Design principles
General Unless otherwise directed (e.g. for raft) all tower foundations shall be designed as individual leg foundations, four foundations per tower. Unless specified to the contrary, foundations for angle/terminal towers shall not have different designs for compression and tension footings, but shall be satisfactory for the most adverse condition of maximum and minimum angles of deviation/entry and with the wind blowing from the most onerous direction. Only one foundation type applying the maximum loads resulting from the maximum body (+8/+12/+16 m), leg (+3 m) and cap (+1 m) extension shall be designed for each soil class and tower type. For the resistance to uplift loads, the concrete foundation shall be assumed to mobilize the frustum of an inverted earth cone having an angle of not more than 35 to the vertical from the foundation base. The net weight of the soil shall be taken as specified or when confirmed from the soil investigation report. Alternative methods of design can be adopted, subject to approval of the Employer/ Employers Representative. The utilization of standard concrete (mixed in-situ, quality not higher than C20/25 according to EN 206-1) is preferable since higher concrete classes often fail to reach the specified design strength under power line site conditions. In the calculations and drawings, the Contractor has to state clearly whether the calculations for pad & chimney foundations are made for "undercut conditions" and pouring the concrete directly against the soil surface or for "no undercut conditions" and pouring the concrete inside formwork. Design method The design philosophy shall principally be based on the limit state concept applied in conjunction with the partial factor method. The concept of differentiated partial material factors of foundation structure and foundation geotechnic shall be applied as recommended by EN 50341-1. Strength factors Based on the recommended failure sequence of structure components, the following structure partial factors (M) for material strength are to be applied for the foundation design: reinforcing steel for concrete foundations foundation in-situ cast concrete structure soil property at suspension towers soil property at angle towers factor 1.20 factor 1.50 factor 1.90 factor 2.15

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The foundation structures of the individual soil classes shall be designed to a rigid degree as to limit residual foundation displacement under operational conditions when mobilizing max. soil resistance. The allowable foundation differential deflection of spread footings vertically and horizontally under working load shall not exceed the following range: 5 to 7 mm at ratio hw 8 to 6 at double , triple lattice (rather cohesive soil ) 8 to 12 mm at ratio hw 5 to 3 at K, lozenge bracing (rather granular soil ) hw being the ratio of tower height to base width. Foundations for different ground conditions Where special ground conditions exist, which do not allow any of the above types in an original or modified form, special types of foundation have to be proposed, and - after Employer/ Employers Representative approval - to be used. Stubs Stubs for tower body and leg extensions shall be of the same design as that for a standard height tower. Only one design of stub shall be permitted for each type of tower, and shall not be bent or cranked. The thickness of the stub legs shall not be less than the corresponding tower leg member. In addition to stubs of normal length, short stubs may be used, provided that provision is made for the attachment of bolted cleats. Cleats shall be capable of transferring 100 % of the design uplift and compression load by shearing, bonding and compressive resistance. Chimney Reinforced concrete chimneys shall be designed to withstand the maximum resultant horizontal residual shear component, with due allowance given where appropriate to resultant lateral (passive) earth pressure of the backfill (assumed to increase linearly with depth). No allowance shall be made of the nominal strength of concrete in tension and the stub shall not be considered as providing any part of the tensile area of reinforcing bars. To eliminate the need of muff concrete, the lowest bracing leg connection shall not be less than 400 mm above nominal ground level. The top of chimney of tower foundation shall be at least 300 mm above nominal ground level. Foundations for lattice steel tower legs with high hillside shear force, due to certain combinations of unequal leg extensions may however differ from those designed for level ground by the addition of extra reinforcement in the chimney, and/or tie beams connecting the individual legs.
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Stub and Chimney Extension In addition to the universal legs extension, stub and chimney (concrete) extension shall be provided with a minimum length of 1.5 m in order to have an optimized adjustment to the ground in hilly areas (0,5 m intervals of either above or below ground level). Caps All concrete foundations shall be sloped off around the steel leg section and smoothly finished to ensure water drainage away from the tower steel. The foundation cap shall be monolithically casted having optimal bond with the chimney part of the foundation. No concreting shall be commenced in any portion of the work until the designed portion has been approved by the Employer/ Employers Representative. Concrete Cover All structural steelwork and reinforcing including links and stirrups below ground level shall be completely encased in concrete to ensure a minimum cover of 50 mm. Such cover shall exist from the point of entry into the concrete base to either 300 mm above final ground level, or to the top of the concrete leg extension.

B1.4.5.4

Foundation tests
General The Employer/ Employers Representative is entitled to attend tests and inspections, and the Contractor shall bear all costs and expenses of tests and attendance as per price schedules. The Contractor shall give the Employer/ Employers Representative notification in writing, not less than 45 days in advance, of the date of material testing. Test program shall demonstrate procedures of test in order to proof the specified technical requirements and be subject to approval by the Employer prior testing starts. Additional tests may be called by the Employer/ Employers Representative to ensure that the required quality is met. The Contractor shall supply all necessary labor, material, equipment and competent and authorized test personnel. Calibration of equipment is deemed to be included. Six (6) copies of test reports and/ or certificates are to be provided showing all results and information necessary. If the Employer/ Employers Representative waive to attend the test, it will neither relieve the Contractor of his full liability to meet the required quality and to complete the works nor prejudice or affect the rights of the Employer/ Employers Representative set forth under this contract. Routine tests on foundation material The Contractor shall obtain from material suppliers Certificates of Test, proof sheets, mill sheets, etc., required by the relevant applicable standard, showing that the materials have been manufactured in accordance with the requirements of this technical specification. But the production of the manufacturer's certificates of test as aforesaid shall affect the liberty of the Employer/ Employers Representative to reject after delivery, materials found not to be suitable, or not in accordance with this requirements.
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Additionally, reinforcing steel shall be tested as per EN 10080 in presence of the Employer/ Employers Representative. The costs for these tests are deemed to be included in the contract price. Routine tests on foundations Routine tests on construction works and foundations (1.2 times working load) shall be carried out or caused to be carried out by the Contractor without extra cost. The Contractor shall incorporate the necessary samples and specimen testing and the provision of equipment for all tests without extra payment. The results of the tests shall be notified immediately to the Employer/ Employers Representative in writing. No work may be back-filled or otherwise covered without an instruction from the Employer/ Employers Representative, respectively without being tested or checked. Where materials or workmanship are rejected by the Employer/ Employers Representative the objected part must be immediately removed from the site at the Contractor's cost. Proof tests on foundation The Contractor shall carry out successful foundation load tests up to design ultimate load or destruction ( 1.3 times ultimate design load ) in order to prove the suitability of the foundation selected with particular type of soil. The Contractor may be required to carry out uplift tests on concrete block foundations within the line easement and at positions decided by the Employer/ Employers Representative for the particular foundation types specified. The contractor will cast a separate single leg foundation to the appropriate design and subject the leg to an uplift test. The Contractor shall provide all labor materials, equipment and apparatus for performing the load tests. The tests shall not be started until 14 days after pouring concrete. The tests shall be carried out and the results shall be submitted in a format in accordance to IEC 61773 and Cigre Brochure No. 81. The particular rates entered in the Price Schedules shall include the excavation, pouring concrete and backfill for the foundation, the test operation, the supply and removal of the testing equipment and any ancillary works which are necessary for the test to be carried out. The Contractor should also include in his testing rates the cost of breaking out the concrete and cutting off the stub to a depth of not less than 700 mm below ground level after the test has been concluded.

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B1.4.6 Conductor, Earthwire and ISWER

B1.4.6.1

Phase conductor

B1.4.6.1.1

Design
The Contractor shall carry out all works in skilled manner in compliance with modern methods of engineering. In addition, the Contractor shall conform to all applicable regulations regarding the manufacture and delivery of the goods and shall follow all instructions issued by the Employer/ Employers Representative. The conductor to be supplied shall be twin bundle of aluminum conductor steel reinforced (ACSR) of type BLUEJAY as per ASTM B232. The distance between the sub-conductors of the bundle shall be 450mm. Basic Standards for the complete conductors for the component wires aluminum wires steel wires grease for conductor creep ASTM B232 EN 60889 EN 50189 EN 50326 IEC 61395

If the Contractor wishes to base his bid on standards or codes other than those specified e.g. such authoritative standards appropriate to the country of manufacture, he may do so provided that he submits with his bid complete data about the standards or codes applied and confirms in his bid that such standards or codes meet, as a minimum, the requirements of the designated standards. The Contractor shall submit with and as a part of his bid a tabulated list of the differences between the standards or codes applied and those designated herein. Alternative standards or codes are subject to approval by the Employer/ Employers Representative. The conductors shall be suitable for service in the specific climate with the main characteristics as specified in the Technical Schedules. The conductors shall be of design and construction as to ensure long service with high economy and low maintenance costs. They shall be suitable in every respect for continuous operation at nominal parameters as well as in transient operating conditions. All materials used under this contract shall be of the best quality and workmanship shall be of the highest class throughout with the designs and dimensions of all parts such that the stresses to which the conductors are

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subjected shall not render them liable to distortion or damage under the most severe conditions encountered during installation as well as in service. Special attention shall be paid to the conductor stranding process to ensure the necessary tightness between different layers in order to avoid slippage or relative movement of strands or cage formation during stringing. The conductor shall be manufactured according to the requirements of EN 50182 (tolerances of diameter, stranding, joints/ welds). When the wire breaks during stranding, the weld shall be marked by a band of red paint each side of the weld on the finished conductor. In addition, the outside of the drum shall be marked with a letter "W". Drum number and notice of existence of the weld is to be communicated to the Employer/ Employers Representative by letter before delivery of the goods. In the event of any machinery used for conductor manufacture being used for materials, other than aluminum, galvanized or aluminum clad steel, the manufacturers shall furnish the Employer with a certificate stating that the machinery has been thoroughly cleaned before use on aluminum, aluminum alloy, galvanized or aluminum clad steel wire and that the conductor is free from contamination. The main design data and performances of the conductors are to be entered by the bidders in the Technical Schedules and become part of the Contract. All these data shall be proven by means of calculations and tests as specified. If the guaranteed values are not achieved, the Employer/ Employers Representative may reject the said part of the goods at the Contractor's expense. The Contractor shall submit certificates of analysis giving the percentage and nature of aluminum impurities. The copper content shall not exceed 0.04 %. If the electrical resistance per kilometer of conductor on any drum exceeds the guaranteed resistance, the Employer/ Employers Representative may then reject any drum found faulty in this respect.

B1.4.6.1.2

Sag and tension requirements


The conductor shall be strung with consideration of the following maximum tension/ stress criteria: every day tension condition: At the yearly average temperature (25C), with no wind, the final horizontal tension/ stress shall not exceed 18 % of the calculated breaking load/ stress or of the minimum guaranteed breaking load/ stress indicated by the manufacturer. maximum load condition: At the minimum temperature (10C) with maximum design wind load, the final horizontal tension/stress shall not exceed 50 % of the calculated breaking load/stress or of the minimum guaranteed breaking load/stress indicated by the manufacturer.

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The conductor shall have, within the adopted limit state design method, the following partial safety factors: partial safety factor for actions F: partial material safety factor M: 1.30 1.55

This is equivalent to a limitation to 50 % of the breaking load within the classical global safety factor method. The Bidder shall supply for the conductor stringing data (initial and final) calculated for different line spans in a chart or tabular form, sag and tensions for the temperatures between 10 - 85 C.

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B1.4.6.2

Earthwire or ISWER (ACSR)

B1.4.6.2.1

Design
The 400 kV OHTL line will be equipped with two (2) earthwires. Both earthwires are to be implemented either as normal earthwires (one a classical ACSR conductor, the other one a similar OPGW) or as Insulated Shield Wire Earth Return (ISWER - one a classical ACSR conductor, the other one a OPtical Phase Conductor (OPPC)) in Lot 3. For the classical non-insulated earthwire, the ACSR 97-AL1/56-ST1A type according to EN 50182 shall be applied, for the 36kV insulated one (ISWER) the ACSR 184-AL/30-ST1A type according to EN 50182 shall be applied. Basic Standards for the complete conductors for the component wires aluminum wires steel wires grease for conductor creep EN 50182 EN 60889 EN 50189 EN 50326 IEC 61395

If the Contractor wishes to base his bid on standards or codes other than those specified e.g. such authoritative standards appropriate to the country of manufacture, he may do so provided that he submits with his bid complete data about the standards or codes applied and confirms in his bid that such standards or codes meet, as a minimum, the requirements of the designated standards. The Contractor shall submit with and as a part of his bid a tabulated list of the differences between the standards or codes applied and those designated herein. Alternative standards or codes are subject to approval by the Employer/ Employers Representative. The conductors shall be suitable for service in the specific climate with the main characteristics as specified in the Technical Schedules. The conductors shall be of design and construction as to ensure long service with high economy and low maintenance costs. They shall be suitable in every respect for continuous operation at nominal parameters as well as in transient operating conditions. All materials used under this contract shall be of the best quality and workmanship shall be of the highest class throughout with the designs and dimensions of all parts such that the stresses to which the conductors are subjected shall not render them liable to distortion or damage under the most severe conditions encountered during installation as well as in service.
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Special attention shall be paid to the conductor stranding process to ensure the necessary tightness between different layers in order to avoid slippage or relative movement of strands or cage formation during stringing. The conductor shall be manufactured according to the requirements of EN 50182 (tolerances of diameter, stranding, joints/ welds). When the wire breaks during stranding, the weld shall be marked by a band of red paint each side of the weld on the finished conductor. In addition, the outside of the drum shall be marked with a letter "W". Drum number and notice of existence of the weld is to be communicated to the Employer/ Employers Representative by letter before delivery of the goods. In the event of any machinery used for conductor manufacture being used for materials, other than aluminum, galvanized or aluminum clad steel, the manufacturers shall furnish the Employer with a certificate stating that the machinery has been thoroughly cleaned before use on aluminum, aluminum alloy, galvanized or aluminum clad steel wire and that the conductor is free from contamination. The main design data and performances of the conductors are to be entered by the bidders in the Technical Schedules and become part of the Contract.. All these data shall be proven by means of calculations and tests as specified. If the guaranteed values are not achieved, the Employer/ Employers Representative may reject the said part of the goods at the Contractor's expense. The Contractor shall submit certificates of analysis giving the percentage and nature of aluminum impurities. The copper content shall not exceed 0.04 %. If the electrical resistance per kilometer of conductor on any drum exceeds the guaranteed resistance, the Employer/ Employers Representative may then reject any drum found faulty in this respect. The earthwire/ ISWER will also be installed to protect the line against lightning strikes and shall withstand the specified fault current without suffering damage. It shall have the characteristics shown in the Technical Schedule.

B1.4.6.2.2

Sag and tension requirements


The earthwire/ ISWER (normal ACSR) shall be strung with consideration of the following maximum tension/ stress criteria: every day condition: At the yearly average temperature (25C), with no wind, the final horizontal tension/ stress shall not exceed 18 % of the calculated breaking load/ stress or of the minimum guaranteed breaking load/ stress indicated by the manufacturer.

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maximum load condition: At the minimum temperature (10C) with maximum design wind load, the final horizontal tension/stress shall not exceed 50 % of the calculated breaking load/stress of the minimum guaranteed breaking load/stress indicated by the manufacturer. Line sections equipped with warning spheres on the earthwire / ISWER, the nominal tension in the earthwire / ISWER and conductor as well as the actual spans might be reduced as to offset the additional load imposed by the warning balls achieving similar differential load conditions at the angle towers compared to sections without warning spheres. The earthwire / ISWER shall have, within the adopted limit state design method, the following partial safety factors: partial safety factor for actions F: partial material safety factor M: 1.30 1.55

This is equivalent to a limitation to 50 % of the breaking load within the classical global safety factor method. The earthwire / ISWER (normal ACSR) shall be suitable for stringing on spans up to 950 m in length, with sags coordinated to those of the conductor. The following sag condition has to be observed: For the nominal span under every day condition, the final earthwire / ISWER (normal ACSR) sag shall not exceed 95 % of the phase conductors sag. The Contractor shall supply for the earthwire / ISWER (normal ACSR) stringing data (initial and final) calculated for different line spans in a chart or tabular form, sag and tensions for the temperatures between 10 to 85 C.

B1.4.6.3

OPGW or ISWER (OPPC)

B1.4.6.3.1

Design of conductor
The 400 kV OHTL line will be equipped with two (2) earthwires. Both earthwires are to be implemented either as normal earthwires (one a classical ACSR conductor, the other one a similar OPGW) or as Insulated Shield Wire Earth Return (ISWER - one a classical ACSR conductor, the other one a Optical Phase Conductor (OPPC)) in Lot 3. For the non-insulated OPGW, a design similar to a ACSR 97-AL1/56A20SA type according to EN 50182 shall be applied. For the 36kV insulated OPPC (ISWER), the design shall be similar to a ACSR 184-AL/30A20SA type according to EN 50182.

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The OPGW/ OPPC shall be based on an a composite construction of aluminum (AL) wires with aluminum clad steel (ACS) wires reinforcement - in order to fulfill the requirements regarding mechanical strength, conductivity for lightning discharge and short circuit current resistance, corrosion resistance and protection of the optical fibers. The OPGW/ OPPC shall be composed of stranded metallic wires over a central fiber optical core or shall include optical fiber containing tubes in one of the inner wire layers of the conductor. The construction of the OPGW/ OPPC shall be so that the optical fiber shall not be firmly constrained against other fibers, strength members, moisture barrier compound or any other components in order that the fiber strain is de-coupled from the strain in other components when the OPGW/ OPPC is under tension. The Bidder shall fully detail the composition of the optical fiber unit including heat shielding material and maximum temperature rating of the materials. Moisture ingress is not permitted into the optical fiber unit and Bidders are to provide details as to how this is achieved. Regarding the optical fibers, the OPGW/ OPPC shall have 48 fibers (24 fibers as per ITU-T G.652 plus 24 fibers as per ITU-T G.655). Ordering of OPGW/ OPPC lengths on drums is recommended to be done considering the line lengths between designated and approved joint box positions for minimizing OPGW/ OPPC waste. As usually the drum length is around 4.5 5.0 km, tension towers shall be used accordingly. The radius of the tightest curve into which the stressed and unstressed cable may be bent during installation without having any adverse effect upon the specified properties shall be less than twenty times the outer diameter of the cable. Electrical and Mechanical Requirements The Contractor shall carry out all works in skilled manner in compliance with modern methods of engineering. In addition, the Contractor shall conform to all applicable regulations regarding the manufacture and delivery of the goods and shall follow all instructions issued by the Employer/ Employers Representative. The OPGW/ OPPC shall possess a good electric conductivity allowing to support the single phase short circuit currents a good conductivity for an effective screening and reduction of induced voltages into nearby telecommunication lines and other conductive objects (pipes, fences, etc.), a good mechanical performance allowing proper sag co-relation with the phase conductor, a good corrosion resistance efficient protection of the optical fibers a long lifetime.
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TANESCO Bidding Documents Section VI (Part B1)

The OPGW/ OPPC shall be suitable for service in the specific climate with the main characteristics as specified in the Technical Schedules. The main design data and performances of the conductors are to be entered by the bidders in the Technical Schedules and become part of the Contract. All these data shall be proven by means of calculations and tests as specified. If the guaranteed values are not achieved, the Employer/ Employers Representative may reject the said part of the goods at the Contractor's expense. The Contractor shall submit certificates of analysis giving the percentage and nature of aluminum impurities. The copper content shall not exceed 0.04 %. If the electrical resistance per kilometer of conductor on any drum exceeds the guaranteed resistance, the Employer/ Employers Representative may then reject any drum found faulty in this respect. Short circuit and lightning resistance The OPGW/ OPPC shall be able to withstand electrical loads due to short duration short-circuit loads and lightning discharges. The short circuit parameters are similar to that defined for earthwires. These shall not cause breakage or deformation of any component of the cable. The attenuation coefficient shall not rise to more than 0,05 dB/km above that of the unloaded cable at a normal ambient temperature. Any increase in attenuation shall be temporary and shall return to its original level within 15 minutes. The lightning discharge is defined as: 10 Coulomb; duration 5 ms. 100 Coulomb; duration 500 ms. In the event of a one-off lightning discharge (lightning test), the residual breaking strength shall be at least 50 % RTS. The water screen and any loose tube shall be unaffected by such discharge. None of the optical fibers' transmission properties shall be affected by lightning strikes. The maximum allowable attenuation increase at the point of the strike shall be less than 0,01 dB. Any attenuation increase shall be temporary and shall return to its original level within 15 minutes. Resistance to fatigue and installation loads The OPGW/ OPPC shall be able to withstand the high-frequency (>1 Hz) and low-frequency (<1 Hz) vibrations occurring in the high-voltage line. The fatigue strength of the OPGW/ OPPC and all OPGW/ OPPC parts, at the fatigue load specified in IEEE 1138, shall be sufficient to enable it to remain in service for hundred (100) years while the optical core remaining without any visual damage.

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TANESCO Bidding Documents Section VI (Part B1)

Any increase in the attenuation coefficient resulting from high-frequency or low-frequency vibrations according to (fatigue tests) and installation loads according to (sheave test) during the course of the cable's service life or mechanical loads due to installation shall be less than 0,01 dB/km. Basic Standards optical fibers

IEC 60793 ITU-T Recommendation G. 652 IEEE Std 1138 EN 50182 IEC 61232 IEC 60794 IEC 61395 IEC 61089 IEEE Std 1138 EIA/TIA-455-81A EIA/TIA-455-82B IEC 60811 EIA-455-113;122;124

optical phase conductor construction

tests

If the Contractor wishes to base his bid on standards or codes other than those specified e.g. such authoritative standards appropriate to the country of manufacture, he may do so provided that he submits with his bid complete data about the standards or codes applied and confirms in his bid that such standards or codes meet, as a minimum, the requirements of the designated standards. The Contractor shall submit with and as a part of his bid a tabulated list of the differences between the standards or codes applied and those designated herein. Alternative standards or codes are subject to approval by the Employer/ Employers Representative. Manufacture All materials used under this contract shall be of the best quality and workmanship shall be of the highest class throughout with the designs and dimensions of all parts such that the stresses to which the conductors are subjected shall not render them liable to distortion or damage under the most severe conditions encountered during installation as well as in service. Special attention shall be paid to the conductor stranding process to ensure the necessary tightness between different layers in order to avoid slippage or relative movement of strands or cage formation during stringing. The conductor shall be manufactured according to the requirements of EN 50182 (tolerances of diameter, stranding, joints/ welds). When the wire breaks during stranding, the weld shall be marked by a band of red paint each side of the weld on the finished conductor. In addition, the outside of the drum shall be marked with a letter "W".

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Drum number and notice of existence of the weld is to be communicated to the Employer/ Employers Representative by letter before delivery of the goods. In the event of any machinery used for conductor manufacture being used for materials, other than aluminum, galvanized or aluminum clad steel, the manufacturers shall furnish the Employer with a certificate stating that the machinery has been thoroughly cleaned before use on aluminum, aluminum alloy, galvanized or aluminum clad steel wire and that the conductor is free from contamination.

B1.4.6.3.2

Design of optical fiber unit


Optical Core Design a) Construction The optical core design shall be based upon the loose tube principles. This means that the cable design shall provide a strain margin. Elongation of the stainless steel tube caused by cable elongation shall be in proportion to such cable elongation. The optical core design shall prevent longitudinal fiber transport in the loose tubes. A clear water-blocking compound shall be used around the optical fiber to prevent the ingress of moisture and other impurities to the optical core and individual tubes. The water-blocking compound shall retain its characteristics up to the rated fault current temperature. The requirements of the waterblocking compound are as follows: shall not inhibit movement of the fiber within the tubes be compatible with other materials used remain pliable and maintain its water resistance over the operating temperature range and over the OPGW/ OPPC service life be free of air entrapment shall not cause H2 gas generation over the operating temperature range and service life be dermatological safe. The stainless steel tube shall consist of a welded or extruded metallic tube. The inside of the tube shall be smooth. Stainless steel tubes: If the tube has a welded seam, no welding debris shall be left inside the tube. Lengths of tube shall not be welded together; i.e. there must be no transverse welds. If transverse welds are to be accepted (only in agreement with the Engineer) the location of the weld in the tube and its position in the actually delivered cable should be indicated. The tube shall be free of pinholes.

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TANESCO Bidding Documents Section VI (Part B1)

The tube shall not deform and shall continue to fulfill its function when subjected to the following: The electrical, thermal and mechanical loads stated in this generic specification The high-frequency (>1 Hz) and low-frequency (<1 Hz) vibrations occurring in the high-voltage line Use with the prescribed suspension and tensioning equipment and vibration dampers All regular and permissible conductor assembly processes Non-circularity of the tube shall be 5%. b) Transmission properties of cabled fibers The optical fibers shall be incorporated without splicing. All the cabled fibers shall be of the same type and technology. Back-scatter pattern: The optical fibers in any length of cable shall not be spliced and shall be homogeneous in quality. The back-scatter pattern shall therefore not display any reflections or irregularities of more than 0,10 dB, before or after cable installation, whereby the maximum detected pulse length shall be 50 ns at the -10 dB pulse level and a resolution of 1 meter. Local attenuation coefficient: The local attenuation coefficient, calculated from the two way optical fiber back-scatter patterns, may vary from the average slope within 0,1 dB/km per 1000 m in the 1550 nm window. c) Cut-off wavelength The cut-off wavelength (cc) of the processed optical fiber shall be less than 1260 nm (cabled fiber deployment). d) Filling compound The filling compound shall: be a silicone-free, electrically non-conductive, homogeneous gel prevent formation of gaseous hydrogen within the loose tube not be harmful to any component of the cable be dermatological safe shall not inhibit movement of the fiber within the tubes be free of air entrapments remain pliable and maintain its water resistance over the operating temperature range and over the OPGW/ OPPC service life.

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TANESCO Bidding Documents Section VI (Part B1)

e) Strain margin The optical core design shall be such that the specified load combinations will never result in an excess of the strain margin. The strain margin shall be greater than the sum of: the cable elongation due to the load combination (the withstand short circuit current, at 200 oC with the OPGW/ OPPC stressed at EDS), or the cable elongation at 50 % RTS and 20 oC. OPGW/ OPPC creep determined for duration of 10 years, in acc. to IEC 61395. residual cable elongations determined while applying the EDS tensile load. for the stranded loose tube design, a reserve of at least 0,2 % shall be applied. Fiber Design a) General The optical fiber phase conductor (OPGW/ OPPC) and the optical fiber underground cable (OPUG - see paragraph below) shall have 48 fibers (24 fibers as per ITU-T G.652 plus 24 fibers as per ITU-T G.655).The following characteristics of each optical fiber are preferred for both OPGW/ OPPC and OPUG: Transmission rate: Transmission wavelength: Mode field diameter: including tolerances Optical cladding diameter: Cable Attenuation: 2.0 to 155.0 Mbit / sec. 1310 nm and 1550 nm 9.0 to 11.5 micrometers (m), 125 m 2.4 % not greater than 0.36 dB/km for every fibre in every drum at optical wavelength of 1310 nm; and not greater than 0.21 dB/km for every fibre in every drum at optical wavelength of 1550 nm; The quality of the optical fibers shall be such that the splice attenuation between two optical fibers of the same type shall on average over 60 % of the splices be less than 0,06 dB and in no case be more than 0,15 dB above the cut-off wavelength range. not greater than 3.5 ps/km.nm at optical wavelength of 1310 nm; and not greater than 19.0 ps/km.nm at optical wavelength of 1550 nm; less than 0.23 greater than 30 years

Joint Attenuation:

Total Dispersion:

Core numerical aperture: Life span:

The Tenderer is required to supply a graph of attenuation versus wavelength over the range of 1200 nm to 1600 nm.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

No joints shall be allowed in any fibre in any drum length. Discontinuities will be acceptable if: less than 0.10 dB in magnitude measured at 1310 nm and OTDR traces from both ends of the cable at 1310 nm amd 1550 nm wavelength shows a difference of less than 0.05 dB/km for every drum The Tenderer shall state the refractive index of the optical fibres at 1310 nm and 1550 nm. b) Fibre Coating The optical fibre are to be coated with a tight outer UV-hardened acrylate protective coating; diameter 250m 15m. Alternatives may be proposed to the Employer for approval. The coating shall be mechanically easily removed over a length of up to 50 mm for the purpose of cleaning, cleaving and fusion splicing. The optical fibre coating material shall not generate H2 gas around the optical fibres that will increase the optical loss as specified above over the designed life span of the optical fibre. The Tenderer shall supply details of the methods employed to minimise the generation of H2 gas. The Tenderer is to provide details of the coating material, dimensions and minimum radius of the coated. All coatings/colours are to be compatible with fusion splicers utilising the light inject detect (LID) method and profile alignment method. c) Color coding of optical fibers Each fiber is to be color coded in order to facilitate fiber identification. These coatings shall be color-coded as specified in IEC 60304 and shall not degrade the optical cladding/core either mechanically or optically. The coloring including marking shall be unambiguous using different colors. It shall be possible to identify all the optical fibers within each loose tube in a 30 cm length of optical cable core, provided that each loose tube is coded. The coloring shall be permanent; it shall only be possible to remove the coloring by stripping off the coating or by using special solvents. The colors shall not fade inside the cable or as a result of exposure in the joint box or at the terminals. Coloring shall not prejudice any of the properties of the optical fiber or the cable. d) Stripping coating from optical fibers The removal of surplus buffers shall be a straightforward mechanical operation. No residues shall be left on the surface of the fiber.

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TANESCO Bidding Documents Section VI (Part B1)

Any extra hermetic coating applied to the optical fiber to impart mechanical strength or provide protection against dirt shall only remain on the fiber if it does not unnecessarily complicate splicing. e) Reliability of supplied fibers Prior to incorporation, all optical fibers shall undergo an exaggerated tensile strength test to guarantee that the risk of breakage is suitably low. The fiber Manufacturer shall perform the proof test: Test level: 0,7 GPa, maintained for at least 1 second (real time) with a minimum elongation of 1.1 %. Only the fibers which pass this strain level will be accepted. The Tenderer shall supply details of the test method and references to any standards used, including a copy of the applied standards. f) Tractability of fibers Subcontractors shall apply certified fibers. The identification of each optical fiber shall be guaranteed from the moment it is drawn.

B1.4.6.3.3

Sag and tension requirements


The OPGW/ ISWER (OPPC) shall be strung with consideration of the following maximum tension/ stress criteria: every day condition: At the yearly average temperature (25C), with no wind, the final horizontal tension/ stress shall not exceed 18 % of the calculated breaking load/ stress or of the minimum guaranteed breaking load/ stress indicated by the manufacturer. maximum load condition: At the minimum temperature (10) with maximum design wind load, the final horizontal tension/ stress shall not exceed 50 % of the calculated breaking load/ stress or of the minimum guaranteed breaking load/stress indicated by the manufacturer. Line sections equipped with warning spheres on the OPGW/ ISWER (OPPC), the nominal tension in the OPGW/ ISWER (OPPC) and conductor as well as the actual spans might be reduced as to offset the additional load imposed by the warning balls achieving similar differential load conditions at the angle towers compared to sections without warning spheres. The OPGW/ ISWER (OPPC) shall have, within the adopted limit state design method, the following partial safety factors: partial safety factor for actions F: partial material safety factor M: 1.30 1.55

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TANESCO Bidding Documents Section VI (Part B1)

This is equivalent to a limitation to 50 % of the breaking load within the classical global safety factor method. The OPGW/ ISWER (OPPC) shall be suitable for stringing on spans up to 950 m in length, with sags co-ordinate to those of the conductor. The following sag correlation condition has to be observed: For the nominal span under every day condition the final OPGW/ ISWER (OPPC) sag shall not exceed 95 % of the phase conductor sag. The Contractor shall supply for the OPGW/ ISWER (OPPC) stringing data (initial and final) calculated for different line spans in a chart or tabular form, sag and tensions for the temperatures between 10 to 85C. Before starting the delivery of the goods, the Contractor shall submit the detailed OPGW/ ISWER (OPPC) length calculation for the line, according to the actual sections, spans and dislevelments. The Bidder is required to state the maximum tension to which the OPGW/ ISWER (OPPC) may be strung without affecting the optical properties of the fibers and to retain efficient operation of the communication link. The Bidder is to provide details on the handling and installation techniques of the OPGW/ ISWER (OPPC), in particular, the precautions and methods to be taken in order to prevent damage to the optical fibers. Any special equipment or techniques required shall also be given, particularly with respect to: stringing sheave minimum diameter anti-twist requirements bull wheel diameter for stringing tensioner.

B1.4.6.3.4

Splicing and joint boxes of OPGW


On the Substation gantries and at every 3 5 km on tension towers, connections between OPGWs and between the OPGW and the OPUG (optical fiber underground cable) shall be realized by means of joints in joint boxes. At the tension towers not provided with joint boxes, the Contractor shall provide suitable attachment fittings to by-pass the tower without any additional joint. At all angle points the prescribed minimum bending radius shall be observed. If necessary, special tandem or multiple stringing blocks have to be used for stringing the OPGW at angle points. The joint boxes shall be of the 'hood' type with encapsulated cable entry and they shall be mounted within the framework of the transmission towers above the anti-climbing device. The OPGW access to the casing should be via entry ports in the base, properly sealed to prevent moisture ingress. Same joint casing shall be suitable for jointing OPGW with OPUG by substitution of appropriate glands in entry ports.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

The Bidder shall present in his bid by means of detailed description and drawings, the OPGW/ OPGW and OPGW/ OPUG jointing procedure and devices and is responsible for the operational continuity of the optical fiber system considering that the interface point between line and underground cable is the joint casing at the gantry. The Contractor shall provide detailed drawings showing the location of all joints. Each joint shall be uniquely numbered. All documents supplied by the Contractor shall be submitted to the Employer/ Employers Representative for approval before starting of the manufacture in the workshop. Weatherproof units shall be provided for the joint boxes (casings). The joint boxes shall include all necessary hardware to terminate, protect and fix the spliced fibers. Optical losses shall be no more than 0.08 dB at average per splice and no single splice loss shall exceed 0.10 dB. Each splice shall have a spare length of fiber of approximately 1m or more. A finished splice shall be supported within the joint box by suitable clips or restraints. It shall be possible to remove and replace the splice in the support device without risk of damage to the splice or fiber. The inlets of the joint boxes shall be sealed with thermofit plastics. These inlets shall be possible to match necessary branches. The outer material of the box shall be oil resistant and metallic, preferably aluminum. The enclosure is to be re-enterable and re-sealable without detriment to the integrity of the enclosure and optical fibers. Enclosure re-entering and sealing shall not require power tools and use a minimum number of special tools. Bidders shall provide detailed specification for mechanical and optical aspects of all joints, splices and end sealing arrangement for the individual parts and/or complete system. The Bidder shall submit with his bid a calculation of the total attenuation (overall losses) for the complete telecommunication link considering all splices, fiber aging, etc. The total alternation shall be a guaranteed value. The quality and performance of all joints shall be consistent with achieving the mechanical requirements over its design life. As part of the jointing procedure the Contractor shall monitor the optical performance of each joint using an Optical Time Domain Reflectometer. Upon completion of jointing and prior to sealing the joint casing an estimate of joint loss and measurement of the total fiber attenuation shall be made. If the total fiber loss is projected to exceed the designed installation loss then the joint shall be broken and rejoined until the specified performance is achieved. If local injection and detection techniques are used to measure the attenuation then any fiber bends necessary shall not affect the physical properties of the fiber and shall not shorten its life span.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

The fusion splice tray shall not have any sharp edges or protrusions which may damage the optical fiber. Number tags for fiber and tube identification are to be included.

B1.4.6.3.5

OPPC straight joint box


At every 3 5 km on tension towers, connections between OPPCs shall be realized by means of straight joint boxes. The straight joint box is to be positioned in the OPPC jumper and fixed by an auxiliary suspension string (see sketch in the Annex). The Bidder shall present in his bid by means of detailed description and drawings, the OPPC/ OPPC jointing procedure and devices and is responsible for the operational continuity of the optical fiber system. The Contractor shall provide detailed drawings showing the location of all joints. Each joint shall be uniquely numbered. All documents supplied by the Contractor shall be submitted to the Employer/ Employers Representative for approval before starting of the manufacture in the workshop. Requirements regarding mechanical properties, sealing to prevent moisture ingress, optical splice losses, spare length in the box, life time, monitoring of joining procedure and fiber identification are similar to the requirements for joint boxes specified above.

B1.4.6.3.6

OPPC termination box


On the Substation gantries and at the termination point of the ISWER system within the line in Lot 3, OPPC termination boxes are to be provided in order to decouple the optical fibers from the medium voltage level of the conductor (see sketch in the Annex). After separation of the optical unit, connections between OPPC and OPGW and between the OPPC and the OPUG (optical fiber underground cable) shall be realized by means of joints in joint boxes as described above. The Bidder shall present in his bid by means of detailed description and drawings, the OPPC/ OPGW and OPPC/ OPUG jointing procedure and devices and is responsible for the operational continuity of the optical fiber system considering that the interface point between line and underground cable is the joint casing at the gantry. All documents supplied by the Contractor shall be submitted to the Employer/ Employers Representative for approval before starting of the manufacture in the workshop. Requirements regarding mechanical properties, sealing to prevent moisture ingress, optical splice losses, spare length in the box, life time, monitoring of joining procedure and fiber identification are similar to the requirements for joint boxes specified above.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

B1.4.6.4

OPUG
The OPUG will be used to connect the OPGW/ OPPC from the overhead line termination gantry or special structure into the Substation buildings a) Cable construction and Mechanical Performance Cable construction The cable shall not use metallic strength members or (semi) conductive elements and particles and armoring. The optical fibers shall not constrain firmly against other fibers, loose tubes, strength members, moisture barrier compound, binding type or any other cable components in order that the fiber strain is de-coupled from the strain in other components is under tension. The permissible tensile load Qp shall be greater than 2,0 kN or otherwise as motivated and proven by the Contractor and approved by the Employer. The corresponding maximum cable elongation shall not exceed 0,2 % plus the strain margin. If the cable is stressed with a load equal to Qp the cable shall be fully elastic and protective layers shall not abrade. The maximum impulse resistance Ri shall be greater than 4,0 kN or otherwise as motivated and proven by the Contractor and approved by the Employer. The corresponding maximum cable elongation shall not exceed 0,4 % plus the strain margin. Mechanical strength The mechanical strength shall be derived entirely from its constituent loadbearing layers. Any reinforcing elements in the optical cable core shall be ignored. The breaking strength of the cable shall be greater than the permissible tensile resistance (QP). Bending radius The minimum bending radius of the cable, during installation as well as after installation, without having any adverse effect upon the specified properties shall be less than fifteen times the outer diameter of the cable within the temperature range TL and TH. This bending shall not cause any significant fiber strain and no attenuation increase greater than 0.02 dB of bent fiber. Resistance against compression The cable shall be able to withstand compression loads due to extreme mechanical loads during installation. No deformations of the optical cable core due to occurring compression loads are allowed. The cable shall be able to withstand the pressure due to cable freezing. The average increase in attenuation shall be less than 0.05 dB and the cable jacket shall not show cracks or other pressure damage when examined under tentime magnification.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Resistance against torsion The cable shall be able to withstand combined torsion and pulling loads. The following conditions are applied for determining the torsion resistance of the cable: rotation 180 /m length of the sample: 10 m load: 20 % of Qp number of cycles: at least 10 no fiber breakage attenuation increase 0.02 dB per fiber per 10 sample length b) Cable Sheath and Jacket The cable shall be made up of a central optical fiber unit being able to accommodate 48 fibers, over which a cable sheath is applied. This cable sheath shall be of low density polyethylene with 5 % butyl rubber and 2.5 % carbon black. Finally, a close-fitting hard nylon cable jacked shall be uniformly extruded over the cable sheath. The jacket shall consist of material suitable for the hauling of cable through ducts and in addition, the overall jacket shall be suitably treated to protect the cable against vermin, insect and termite attacks and chemical corrosion. The minimum thickness shall be 0.3 mm. The cable jacket shall be marked with the inscription OPTICAL FIBER CABLE at a spacing not exceeding two meters as well as the distance markings in meters in order to assist possible future fault location. The markings are to be legible and indelible even after the installation process and shall not reduce the effectiveness of the cable to protect itself against outer damaging factors. The outer cable diameter shall be constant within 1 %. Since the cable will be installed in buildings, fire retardancy shall be provided. c) Installation of OPUG in Ducts: Selection, Requirements. The cable shall be suitable for installation in a duct with a suitable diameter to be selected by the Contractor. The Contractor shall provide suitable or preferred installation techniques and instructions. The cable will be installed in a plastic duct. The main purposes of using the plastic tubes are: easy installation of the OPUG cable straight in the digging or in the existing sewage; cable mechanical protection; stand-by capacity for the second cable installation

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Ducts shall be prelubricated in order to enable safe OPUG installation when either applying an air blasting system, a pumping system or a pulling system. Selection of ducts The selection of a particular basic design (smooth, corrugated or ribbed) depends on the need for a specific pulling strength, flexibility and the coefficient of friction. Pre-lubricated inner ducts shall be either permanently impregnated with antifriction compounds or coated with liquid lubricant during manufacture. When using supplementary lubricant with pre-lubricant, the Contractor shall check the compatibility of the lubricant with pre-lubricant in order to prevent an increase of the friction coefficient instead of a decrease. The following duct types are to be distinguished: Direct buried inner duct. Buried, in conduit. If any aerial sections are required, the inner duct shall be attached to a steel carrier. In building. The use of PE without fire retardant additives instead of FRPE (fire retardant polyethylene) and PVC is required. For the selection of inner ducts, the following applies except if the Contractor submits a selection to the Employer for approval otherwise. The selection guide is based upon the ratio of outer duct diameter and wall thickness of the duct (SDR). When selecting a decreasing SDR number, this indicates a more robust inner duct capable of withstanding more severe mechanical stresses. Requirements The inner duct shall have a maximum permanent ovality of 6% (at 50C). This is to be inspected on the last two layers on the drum. The compression resistance shall be greater than 1350 N (at 50C). This load shall not cause a permanent reduction of the outer diameter greater than 4 %. When subjected to an impact of 136 J at -20 C non-corrugated inner ducts must remain free from cracks or tears. Corrugated inner ducts must remain free from cracks and tears when subjected to impact loads of 68 J. The conductivity of the duct must be greater than 10 M per meter duct. Ducts shall be made of HDPE material. Inner ducts shall be detectable at any buried depth up to 1 meter. The horizontal location shall be measurable within 10 % of the inner duct depth. Applied lubricants shall comply with inner ducts pre-lubricated impregnated or antifriction compound coatings. This matter of compatibility counts for all installation methods. Any pulling pilot strings in the duct shall be non-conductive. The color (black; orange or green) shall be resistant to staining in the presence of sulphides. Identification marks to be printed on the ducts will be indicated by the Employer after contract award. The markings must be permanently extruded into the inner duct and easy to distinguish.
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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Black ducts shall not contain more than 10 % of reworked material. Colored ducts shall not contain any reworked material. The inner ducts shall be capable of being bent 180 and then straightened at temperatures down to -20 C. The bending may then not cause any buckling, kinking or permanent deformation. The gantry-side of the ducts shall be linked to a steel tube, which provides a protective channel from the duct, along the gantry foundation up to the joint box. At the exit of cable and tube, applying a heat-shrinkable sleeve shall prevent water penetration.

B1.4.6.5

Tests

B1.4.6.5.1

General
The Employer/ Employers Representative is entitled to attend tests and inspections, and the Contractor shall bear all costs and expenses of tests and attendance as per price schedules. The Contractor shall give the Employer/ Employers Representative notification in writing, not less than 45 days in advance, of the date of material testing. Test program shall demonstrate procedures of test in order to proof the specified technical requirements and be subject to approval by the Employer prior testing starts. Additional tests may be called by the Employer/ Employers Representative to ensure that the required quality is met. The Contractor shall supply all necessary labor, material, equipment and competent and authorized test personnel. Calibration of equipment is deemed to be included. Six (6) copies of test reports and/ or certificates are to be provided showing all results and information necessary. If the Employer/ Employers Representative waive to attend the test, it will neither relieve the Contractor of his full liability to meet the required quality and to complete the works nor prejudice or affect the rights of the Employer/ Employers Representative set forth under this contract.

B1.4.6.5.2

Conductors
General The Contractor shall supply a detailed Quality Assurance Procedure including an Inspection and Test Plan (ITP) for all conductors (phase conductor, earthwire, OPGW and both ISWER conductors) which shall be submitted to the Employer for approval. The Contractor shall be responsible for performing all tests and inspections required during the production of the conductors. All materials used in the manufacture of conductors shall be covered by test certificates stating their mechanical and chemical properties to prove compliance with this technical requirements and EN 50182 or IEC as appropriate. The following certificates/ test records shall be submitted for approval: metallic material test certificate conductor stranding equipment non contamination certificate

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TANESCO Bidding Documents Section VI (Part B1)

galvanization test records. Conductors The following tests shall be applied for all conductors (phase conductor, earthwire, OPGW and both ISWER conductors as normal ACSR and OPPC). Tests shall be undertaken in accordance with the requirements of EN 50182 and referred standards: EN 60889 EN 50189 EN 50326 EN 10244 IEC 60468 ISO 7802 Hard-drawn aluminum wires Zinc-coated steel wires Conductor grease Galvanization thickness Measurements of resistivity Wrapping test

Existing type test certificates may be submitted for the appropriate conductor type and are acceptable provided that they are not older than 8 years and show Tensile strength as per EN 50182, Chapter 6.4.8 Stress strain curves as per EN 50182, Chapter 6.4.7 Stringing test as per EN 50182, Chapter 6.4.9. Reference lists are also accepted for the proof of stringing capability. In case such type test certificates and reference lists cannot be provided, the type tests have to be carried out in presence of the Employer/ Employers Representative, and the costs are deemed to be included in the contract price. Routine/ Sample tests shall be performed as per EN 50182, Table 5. In the event of the sample from any length not passing the mechanical or resistance tests, a second and third sample shall be undertaken from the same length, and if one of these also fails under test, the length of conductor (i.e. drum) from which it has been taken shall be rejected. Details of the test results shall be made available to the Employer/ Employers Representative upon request for approval. Grease The manufacturer's type test certificates for proving compliance with the technical requirements as per EN 50326 with regard to the following grease properties shall be submitted to the Employer/ Employers Representative for approval: dropping point tests thermal history test reversibility oxidation
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TANESCO Bidding Documents Section VI (Part B1)

corrosive substances in grease anti-corrosion properties. Sample tests on grease as per EN 50326 shall be undertaken at the same time as sample tests on the conductor. Grease for the dropping test shall be removed without heating.

B1.4.6.5.3

Optical fiber unit


General Test programs shall be prepared and submitted to the Employer/ Employers Representative for approval. The date of tests shall be announced in time in order to allow participation of the Employer/ Employers Representative if requested. A test report has to be submitted to the Employer/ Employers Representative for approval within two weeks after test performance. Type Test Tests shall be performed in accordance with IEC 60794-4 and IEC 607942. Existing type tests certificates may be accepted provided that tested OPGW/ OPPC structure corresponds to the offered one and the certificates are not older than 8 years. Stress-strain A sample of OPGW/ OPPC not less than 10m length, complete with the proposed end fittings shall be subject to a stress-strain test. The test shall be undertaken in accordance with IEC 61089, Annex B and the measuring techniques in accordance with IEC 60794-1-1. There shall be no visual change to the OPGW/ OPPC strands after the test and that the fiber strain must be less than 0.05 % at 85% of the UTS of the cable. Tensile Performance The test shall be undertaken in accordance with the load conditions specified in IEC 61089, Annex B and the measuring techniques in accordance with IEC 60794-1-2. There shall be no permanent change in the fiber attenuation at the specified wavelength after the test, while the change in attenuation during the test shall be less than 0.05db/km from zero load to 85 % of the UTS of the cable. Crush and Impact The tests shall be undertaken in accordance with the recommendations of IEC-60794-4 and IEC 60794-1-2. The crush test shall be undertaken by applying a 10kN load for 1min to the OPGW/ OPPC via a 100 x 100 mm movable flat plate. There shall be no measurable permanent change in the fiber attenuation at the specified wavelength, while any temporary change in attenuation shall be less than 0.1db.

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The impact test shall be undertaken by dropping a 4kg weight from a height of 150mm onto the end of a 20 mm diameter steel mandrel placed on the OPGW/ OPPC. After 20 repeated applications, there shall be no measurable change in fiber attenuation at the specified wavelength, while any temporary change in attenuation shall be less than 0.1db. Temperature Cycling The optical performance under temperature cycling shall be tested in accordance with IEC 60794-1-2, with TA and TB as stated in the Technical Schedules and the duration of 4 hours. The test should be undertaken twice. Water Ingress The optical sub-unit shall be tested for water ingress in accordance with IEC 60794-1-2. Short Circuit Current One sample of OPGW/ OPPC not less than 10 m in length shall be subject to a short circuit current pulse. The short circuit current pulse specified in the Technical Schedules shall be supplied in less than 1s after the conductor has been raised to the specified initial temperature. During the test the temperature of the optical sub-unit shall be measured, the temperature immediately after the current pulse shall be less than the specified temperatures. The test shall be performed three times with an interval of 30min between tests. Optical alternation of the test fibers shall be monitored continuously. After the third impulse the OPGW/ OPPC shall be dismantled and the optical cable examined throughout its length for any signs of deterioration. Lightning Strike The test shall consider both an initial stroke and a power follow through. The test conditions shall be Class 0 according to IEC 60794-1-2. The test shall be carried out on a sample of OPGW/ OPPC not less than 2m long. The acceptance criteria shall be that OPGW/ OPPCs calculated residual strength is not less than 90 % of the original stated ultimate tensile strength. Any damaged strands shall be assumed to be broken. Sample Tests Tests for aluminum clad steel wires/aluminum alloy wires shall be carried out in accordance with the requirements of IEC 61232/ IEC 60889. Samples taken on random sampling basis from the OPGW/ OPPC drums ready for shipment against each batch shall be tested for overall diameter, the lay length and lay ratio of layers, lay directions and DC resistance in accordance with IEC 61089 or EN 50182 at the factory by the manufacturer which may be witnessed by the Employer/ Employers Representative. In addition, attenuation shall also be measured on each fiber of above mentioned sample drums of OPGW/ OPPC with OTDR.

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Routine Tests OPGW/ OPPC on all drums shall be tested for mechanical tests including measurement of overall diameter of OPGW/ OPPC, measurements of thickness of Al and ACS wires, diameter of tube, wrapping test of Al and ACS wires, check of surface quality and OPGW/ OPPC weight, checking of lay length and lay ratio of layers, checking of lay directions, breaking load test of OPGW/ OPPC and DC resistance measurement in accordance with IEC 61232/ IEC 60889/ IEC 61089 or EN 50182 at the factory by the manufacturer as routine tests. In addition, attenuation shall be measured on each fiber of all OPGW/ OPPC with OTDR at the factory by the manufacturer as routine test. Optical Fibers Optical fibers shall be type tested in accordance with the requirements of ITU-T Recommendations G655/G652D and IEC 60793 as appropriate. Routine tests regarding attenuation OTDR shall be carried out according to IEC 60793-1 at the factory by the manufacturer. Joint Boxes, Termination Boxes The hard ware for OPGW/ OPGW, OPPC/ OPPC, OPPC/ OPGW, OPGW/ OPUG and OPPC/ OPUG joints used in this Contract shall be subjected to type tests. The Bidder shall nominate in the Technical Schedules the type tests he proposes for these joints. Joint box and termination box type tests shall include a water immersion test for proving the joint water tightness and seals, with measuring of attenuation variation of the splice and loss characteristic in an assembled joint at the start and end of a seven (7) days immersion period. Type test certificates may be submitted to the Employer/ Employers Representative for approval. The costs for these tests are deemed to be included in the Bid Price.

B1.4.6.6

Spare parts
Mandatory spare parts Spare conductors (phase conductor, earthwire, OPGW and both ISWER conductors), as per the price schedule No. 1&2 shall be delivered together with the last scheduled dispatch and are to be provided in continuous lengths on non-returnable steel drums as specified. The quantities of the spare conductors are shown in the Price Schedules. Corresponding prices shall be entered by the Bidder in this price list. If any additional quantities should be ordered after the date of the Taking-over Certificate, the prices may be subject to adjustment. The spare conductor have to be adequately protected against humidity, corrosion, etc. and packed and treated in such a manner as to be suitable for storage in the climatic conditions at the site, for an indefinite period. They shall be delivered on steel drums provided with identification labels stating

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also quantities. The spare conductor shall be delivered to the Employers stores and delivery will not be deemed to be completed until the packing material has been checked by the Employer/ Employers Representative. The Taking-Over will only take place if all spare parts have been delivered to the Employers store. Mandatory spare parts, as per price schedules, shall be provided. Recommended spare parts The Bidder shall supply a list of recommended spares for maintaining the fiber optic link over its expected lifetime. The spare parts shall be separately itemized in the price schedule No. 6. The list shall not be binding and the Employer may purchase all or part of these recommended spares.

Tools Any special tools and test equipment needed to maintain the fiber optic link over its expected lifetime shall be included. The type and quantity of tools is given in the price sheets. The test equipment and other special tools proposed shall be of the same type as used by the Contractor for erection and commissioning. The test equipment and tools included in the Contract shall, however, not be made available to the Contractor during erection and commissioning. All test equipment and electrically operated tools shall be suitable for operation from 50Hz, 230V AC mains supply. In addition, the Fusion Splicer and Optical Time Domain Reflectometer (OTDR) shall be fitted with batteries for operation in the field. The Bidder shall provide relevant manufacturer's technical data / pamphlets for all items. All test equipment shall be supplied completely with Operator's Manuals and Repair & Maintenance Handbooks. All test equipment shall be provided with weatherproof, foam-lined transport cases suitable for transporting the equipment in the back of a four-wheel-drive vehicle. The transport cases shall be lockable and shall accommodate all necessary accessories and cables plus the Operator's Manual.

B1.4.6.7

Packing, shipping, transport


The conductors (phase conductor, earthwire, OPGW and both ISWER conductors) shall be delivered and shipped on stoutly constructed timber or steel drums as specified, and lapped with protective covering across the whole width of the drum. The packing for the corresponding spare parts shall comply with the requirements specified for long time storing. The OPGW/ OPPC shall be shipped in continuous lengths clearly marked by the manufacturer.
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All drums with conductors shall have a layer of waterproof wax paper or plastic sheet which must be safe against chemical reactions laid around the barrel under the conductors and another one laid over them and under the lapping. Drums shall be securely fastened around the perimeter and shall be suitable for rolling on the flanges without causing damage to the conductor. The disposal of all empty drums shall be the responsibility of the Contractor. The following information shall be clearly written in indelible paint on both flanges of each drum: contract title and reference number; manufacturer's name; lifting instructions and limitations; direction of rolling. An aluminum or painted metallic marking plate shall be fixed to each drum clearly showing the following data: type and size; length; gross and net weight; batch and drum numbers; stranding date; main dimensions of the drum; correct direction of rolling. Contractor shall submit a sketch or drawing showing the full details of drum design and the details of the proposed method of impregnation and lagging the inner drum surfaces with approved tarred paper or equivalent material. The minimum length of the conductors on drums is subject to the Employers/ Employers Representatives approval.

B1.4.7 Insulators and Fittings

B1.4.7.1

General
Complete insulator sets consisting of long-rod composite insulator units and assembling fittings as well as fittings for phase conductor, earthwire, OPGW and ISWER system are required as described below and in the Technical Schedules. The Contractor shall provide detailed assembly drawings for each type of assembly required. Insulator sets shall generally be in compliance with the typical assembly shown in the Annex. Alternative designs will be acceptable provided that they are functionally similar and meet the performance specifications.

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B1.4.7.2

Insulators and insulator sets


All insulator sets including their clamps and fittings shall be in fair weather free from visible corona discharges. In particularly, the live part of all insulator sets shall be conceived and shielded in a way to avoid visible corona under fair weather condition The freedom from corona shall be proven by design tests in the workshop or laboratories in accordance with the tests recommended in the standards or described below. An extinction corona voltage of at least 10 % higher than the phase-to-earth value of the specified highest voltage for equipment shall be obtained. All insulator sets shall be provided with the necessary guarding devices in order to keep their radio and television noise as low as possible. A noise level less than 46 dB above 1 microvolt shall be ensured under standard laboratory conditions. This is to be proven by tests as per the mentioned standards. By means of adequate fittings (guarding rings), an optimized and more uniform potential distribution along the insulator strings shall be assured. All insulator sets shall be provided with arcing / grading fittings located at the conductor side of string end for assuring the necessary corona radiation level and to protect the insulators from the effects of the electric arc. All insulator sets shall be designed to withstand the single-phase fault currents. This performance shall be proven by design tests in the workshop or laboratories in accordance with the tests described below. The upper and lower horns and guard rings shall be installed on the insulator assemblies as recommended by the fittings manufacturer and confirmed by electrical tests. Locking devices for the insulator units themselves and for associated ball and socket fittings shall be of stainless steel and shall comply with IEC 60372. The design shall be such as to allow easy removal for replacing of insulator units or fittings without the necessity to remove the insulator set from the crossarms. Locking devices shall be incapable of rotating when in position. For the dimensioning of the insulator sets from the mechanical point of view, the loads and loading conditions shown below along with partial safety factors for loads, as well as the material safety factor have to be considered: the weight of the conductors and of the insulator set the wind loading on conductors the maximum working tension of the conductors partial load safety factors as specified above partial material safety factor for intact insulator string M = 2.50 partial material safety factor for broken insulator string M = 1.25 . The electromechanical failing load for the insulator units and the nominal loading capacity for the insulator string fittings shall be referred to.

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The insulator string shall be of sufficient length to provide the required electrical performance as regards the specific leakage path and minimum required withstand voltages. This has to be determined as per catalogue data, but has to be finally proven by tests on complete sets because the insulator set fittings have a not negligible influence. The electrical and mechanical performance requirements for insulator sets are shown in the Technical Schedules. The suspension towers will be equipped with suspension insulator sets. The tension towers (angle-tension and dead-end towers) and gantries will be equipped with tension insulator sets. The 400kV insulator sets shall be designed for horizontal twin bundle of the ACSR BLUEJAY type conductor, spaced at 450 mm. Spacing between double strings shall be sufficient to assure good behavior of insulators and good performance of guarding rings. The double suspension insulator set shall be used for crossings of buildings, main roads, overhead transmission lines 110kV, railways and for HS tower types in general. Double suspension insulator sets shall have the two strings in a plane parallel to the line and be fixed in two points to the crossarm. Double tension sets will be installed on all tension and terminal towers. The insulator set attachments to the tower crossarms are of special importance. Therefore two independent fixing points to the tower are specified for double insulator sets. Attachments to the tower are to be of secure connection such as with swivels. Hooks are not acceptable. Suitable adjustment, in case of tension sets, has to be done for the different line angles in order to assure equal repartition of the loads to the two insulator strings of the set. Special attention has to be paid to ensure that by breakage of an insulator string of a double set, the remaining string shall withstand the resulting static and dynamic stress by applying the specified partial safety factors shown in the Technical Schedules. Between the terminal towers and gantries (in the slack span), low duty tension sets shall be installed in conductor direction and down droppers. The 36kV insulator sets for the ISWER shall be designed for ACSR 184AL/30-ST1A respectively ACSR 184-AL/30-A20SA (OPPC). The single I suspension insulator set shall be used as standard set on suspension towers and as jumper suspension set on the tension and terminal towers, where clearance requirements so demand. Single tension sets are to be used at
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all tension and terminal towers. In case of ISWER T-off solutions, the swinging out of the conductor shall be restricted. A V-suspension insulator string is to be used therefore instead of a normal I-string at suspension towers and for fixing the jumper at anchor towers if necessary (see Annex).

B1.4.7.3

Composite insulators
Composite insulators shall be offered in order to utilize their positive effect regarding a more compact tower design. The insulator units are to be of composite long-rod type featuring a glassfiber reinforcing epoxy rod core with high temperature vulcanized silicone rubber housing and clevis caps. The housing is the external insulation part of the insulator and provides the necessary creepage distance and protection of the load bearing core. The design shall be in accordance with IEC 61466. Standards and Recommendations The composite insulator must be designed, manufactured and tested according to the following standards and recommendations: IEC 61109 Ed. 2.0 (2008) : Composite suspension and tension insulators for a.c. systems with a nominal voltage greater than 1000V . Definitions, test methods and acceptance criteria. IEC 61466-1 (1997) : Composite string insulator units for overhead lines with a nominal voltage greater than 1000 V . Part 1 : Standard strength classes and end fittings. IEC 61466-2 (1998) : Composite string insulator units for overhead lines with a nominal voltage greater than 1000 V. Part 2 : Dimensional and electrical characteristics. IEC TS 60815 (2008), Guide for selection of insulators in respect of polluted conditions. IEC Standard 60471, Dimensions of clevis and tongue couplings of string insulator units IEC Standard 60120, Ball and socket coupling of string insulator units IEC TR 62039 (2007): Polymeric Materials for Outdoor Use under HV Stress IEC TR 62662 (2010) Guidance for production, testing and diagnostics of polymer insulators with respect to brittle fracture of core materials IEEE Std 987-1985, Guide for Application of Composite Insulators CAN 411.4 (1998), Composite suspension insulators for transmission applications

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CIGRE - Paper 33-204 Session 2000, Considerations on the Design of Composite Suspension Insulators Based on Experience From Natural Ageing Testing and Electric Field Calculations CIGRE 22.03, Technical Brochure 184, Composite Insulator Handling Guide CIGRE B2.21, Technical Brochure 365, Use of power arc protection devices for composite insulators on transmission lines CIGRE B2.21, Technical Brochure 284, Use of corona rings to control the electrical field along transmission line composite insulators CIGRE D1.27, Technical Brochure 255, Material properties for nonceramic outdoor insulation. Design of components The insulators shall be of sufficient length to provide the required electrical performance in one single unit. In-line coupling of two or more units is not acceptable. The core shall be an epoxy resin rod with axial glass fiber reinforcement of high strength (fiber reinforced plastic rod). The rod shall be resistant against hydrolysis under service conditions. Therefore, E-CR-glass fibers embedded in an epoxy matrix shall be used for the core. The FRP core shall be assembled by means of modern Statistic Process Controlled (SPC) and Acoustic Emission (AE) monitored crimping technology. Temperature certificate issued by the manufacturer shall indicate an application range of the core material and the core / end fitting assembly of -50+100C. All other core material properties shall be in accordance with CIGRE Technical Brochure No. 255. The core of the composite insulator shall be protected against environmental influences by a silicone rubber housing. The thickness of the silicone rubber covering the rod shall be at least 3 mm. The interface formed between rod and housing shall be of a quality to prevent stress corrosion and brittle fracture phenomena, i.e. high electrical strength and equivalent acid resistance are required. The housing shall be perfectly (vulcanization chemically) bonded to the core. An injection or compression molding process applied to form the complete housing is not acceptable. Only extruded / modular housing technology is accepted. The chemical bond between the core and the housing must be stronger than the tear strength of the housing material. The manufacturer shall prove that he masters non destructive technique (N.D.T.) to check the quality of the core to housing interface. The housing shall be designed in such a way that the end fittings are not covered with housing material in order to avoid electrical punctures and electrical overstress of the housing. The preferred design of the interconnection between rod and end fitting is of type a according to CIGRE Paris Session 2000 Paper 33-204 figure 2. The housing shall be fully coaxial at the shank in order to avoid punctures and flashunders. In order to achieve an excellent pollution performance and tracking performance (minimum class 1A 3.5 according to IEC 60587), the application of
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high temperature vulcanizing (HTV) silicon rubber filled with an appropriate amount of aluminum tri hydrate (ATH) shall be applied. The material shall be of blue/gray color and be resistant against the ultra-violet radiation being present in the solar spectrum at ground level. For the design of shed profiles, IEC 60815 shall be applied. Under-rib sheds are preferred for high creepage designs. They shall also be preferred if severe handling and transportation conditions are expected on-site. Due to their higher mechanical stability against deformation, under-rib sheds are being at an advantage over regular smooth sheds. Additionally, pollution performance calculations shall be provided for the offered housing profiles. The performance curves shall be compared to those of conventional insulators made of glass/ porcelain. The maximum admissible ESDD / NSDD parameters shall be defined. All other housing material properties shall be in accordance with IEC TR 62039. The metal end fittings should be made of forged steel and hot dip galvanized according to ISO 1461. The fittings shall be attached onto the rod by a compression method process which does not damage the individual fibers of the rod in any way. Fittings configuration shall be defined by the actual need (e.g. ball and socket or clevis and tongue connection) and shall comply to the standard requirements. The gap between fitting and core housing shall be sealed permanently against the ingress of moisture. Sealing by compression only is not regarded to be permanently waterproof. Covering the gap, even partly, with housing material or sealing in form of over-molding the end fittings are unacceptable due to electrical reasons. Sealing of the interface by application of a metastable silicone elastomere with permanent elasticity is considered an acceptable solution. The material shall adhere to the surface of the metal cap, as well as to the housing. The sealing shall be hidden in a special gap and not be subjected to critical electrical field stresses. Design of string Suitable electrical field grading devices in accordance with CIGRE Technical Brochure TB 284 shall be applied in order to protect the composite insulator against premature failure and electrical field stress induced ageing. If the supplier is not responsible for the complete insulator string design, then written recommendation for the grading / corona ring setup has to be given to the main contractor. The effectiveness of the grading / corona protection devices shall be proven by 3D electrical field calculations where the complete insulator strings and the entire tower configuration shall be simulated for 3 phase voltage stress. The results of these calculations shall be part of the project documentation. Manufacture All parts of the insulator shall be free from any defects which may impair the mechanical or electrical properties of the insulator.

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The permitted tolerances shall meet the requirements according to IEC 61109: (0.040 x L + 1.5) when L 300 mm (0.025 x L + 6.0) when L > 300 mm, limited to 50 mm. Each insulator shall be marked with the following information: Manufacturer's name or logo, Year of manufacturer, Specified mechanical load S.M.L., Identification code providing traceability. The long-term stability of the marking shall be proven by means of the UV weathering test as per IEC 62217. The manufacture shall have an adequate experience in the production of composite insulators. Only insulator manufacturers with long term experience with the manufacturing of composite insulators using silicon rubber technology for a minimum of 25 years shall be considered with successful service experience and without change of the offered design and material. As proof, the manufacturer shall submit a supply-list for the last 25 years indicating type of insulator, quantity supplied, name and address of client, system voltage (400kV and above) and year of delivery. A company research and design department, a quality assurance system and a co-operation with research and investigation institutes or universities are considered to be essential. In addition, the manufacturer shall have the engineering, electrical / chemical / mechanical test and quality facilities to provide information and advice for after sales service. The manufacturer shall have established and maintain a quality system which fulfils the requirements of DIN ISO 9001:2008. This shall be proven by a certificate issued by a recognized Certification Company. The Quality Management System (QMS) and all manufacturing process steps shall be open for customer or third party (consultant) audits.

B1.4.7.4

Clamps and fittings for phase conductors

B1.4.7.4.1

General
All clamps and fittings shall be suitable for the above specified phase conductor type ASCR BLUEJAY twin bundle. They shall comply with the requirements of this Bidding Document and must be approved by the Employer/ Employers Representative. The Contractor shall ensure close and continuous liaison between the manufacturers of conductors, clamps, insulators and fittings so that the equipment will be perfectly adapted.

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All clamps and fittings except for spacer dampers and vibration dampers shall be supplied by the same manufacturer. Splitting up of the supply of clamps and fittings will not be permitted. For the dimensioning of the fittings from the mechanical point of view, the loads and loading conditions shown below along with partial safety factors have to be considered: the weight of the conductors and of the insulator set the wind loading on conductors the maximum working tension of the conductors partial load safety factors as specified above partial material safety factor for fittings M = 2.50 partial material safety factor for fittings in case one part of insulator string is broken M = 1.25 . In order to maintain low corona and low radio interference, the design of all clamps and fittings shall avoid sharp corners or projections, which would produce high electrical stress. The design of adjacent metal parts and mating surfaces shall be such as to prevent corrosion of the contact surfaces and to maintain good electrical contact under service conditions. Particular care shall be taken during manufacture of clamps and fittings and during subsequent handling to ensure smooth surfaces free from burrs and sharp edges. All line fittings concerned shall be dimensioned and designed to withstand the single-phase fault current shown in the Technical Schedules. Each insulator set shall withstand such a short-circuit without the temperature exceeding 200C in the fittings and without welding between the component parts. The Employer/ Employers Representative may require tests to be carried out to demonstrate the short circuit characteristics of each type of insulator set. The cost of such tests shall be borne by the Contractor. Adequate bearing area shall be provided between different fittings. Point contacts shall be avoided. All ferrous parts of the assemblies component elements and of the accessories for conductors shall be hot dip galvanized according to ISO 1461. The split pins of all clamps and fittings shall be of stainless steel.

B1.4.7.4.2

Suspension clamps
The conductor suspension clamps shall be of high-tensile corrosion-resistant aluminum alloy, suitable for a working temperature of 85C. The clamping components shall be forged or cast. In case of casting additional reinforcing strap is foreseen.

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The suspension clamps shall be as light as possible and of a vibration proof cover type. They shall be such as to form a fully articulated support for the conductors. The clamp bodies shall be centrally pivoted and the rotational axis of the clamp shall be preferably at same level as the conductor center line or below but not above. The clamp body shall be able to pivot at least 45 above and below the horizontal line. Special attention shall be paid to the mass moment of inertia of the clamp in order to avoid resonance of the clamp plus conductor system by wind induced vibrations. The Contractor shall ensure by appropriate calculations and design a suitable suspension clamp for the specified conditions also from this point of view. The phase conductors shall be protected within the suspension clamps by means of armor rods and the dimensions of clamps shall allow for this requirement. The armor rods shall be designed in such a way as to strengthen the conductor in the suspension points and to reduce the static and dynamic bending strains in the strand wires of the outer conductor layer. The suspension clamp components shall be dimensioned and shaped in such a way that no undue crushing or bending stresses are imposed upon the conductors and armor rods. The conductor supporting groove shall be curved at its ends in the vertical plan to an appropriate radius to permit the conductor to leave the clamp at the maximum angle of inclination (20). The mouth of the supporting groove shall be slightly flared in plan. The grooves in the clamping piece shall be bell-mouthed at each end and all conductor grooves and bell-mouths shall be smooth and free from waves, ridges or other irregularities. The bolts used in the suspension clamps shall be hexagonal hot-dip galvanized or stainless steel bolts. The washers underneath the bolt head shall be made from stainless steel only. Subsequent to tightening of bolts to the torque as recommended by the manufacturer, the clamp shall be capable of withstanding the maximum working tension of the conductor without any conductor slippage. They shall permit the conductor to slip at a load lower than the conductor breaking load. The clamp bolts and the clamping force shall be chosen to satisfy also the electrical requirements. The phase conductor clamps must be capable of withstanding the three-phase and the single-phase fault currents shown in the Technical Schedules without any damage. Attention must be paid to the elimination of fair weather corona emission from all parts of conductor suspension clamps under the specific site conditions.

B1.4.7.4.3

Tension clamps, joints and repair sleeves


Tension clamps and joints

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Conductor tension clamps and joints shall be of the compression type, suitable to withstand a working temperature of 85C. The conductor tension clamps shall be supplied with a jumper terminal which may be bolted at 0 or 30. The coupling element of the tension clamps to the string shall be clevis-type, hot dip galvanized. The electrical conductivity and current carrying capacity of the tension clamps, joints and jumper terminals shall be not less than those of the equivalent length of conductor. The tension clamps and joints of the phase conductors must be capable to withstand also the three phase short-circuit current shown in the Technical Schedules without damage. Attention must be paid to avoid fair weather corona emission from the conductor tension clamps and joints. Compression-type clamps and joints shall be tested by the Contractor to ensure that they will stand up to at least 95 % of the rated ultimate strength of the conductor. Joints and tension clamps shall be made of aluminum alloy-steel. Joints and tension clamps shall be supplied with filler compounds, to protect the assembly clamp-conductor against corrosion. The split pins used shall be of stainless steel. The design of the joints and tension clamps shall be such that only one pair of dies is necessary for the compression of the conductor. Mid-span joints shall not be less than 30m from the nearest conductor clamp. Unless the Employer/ Employers Representative agrees mid-span joints shall not be used under the following circumstances: in spans crossing power lines, buildings and main roads. in single span sections. Joint and repair sleeves Conductor repair sleeves shall not be used without the permission of the Employer/ Employers Representative which will be granted only in exceptional circumstances. Joint sleeves and repair sleeves for the conductors shall be of compression type. The joint sleeves shall consist of steel compression sleeve for the steel core of conductor, and aluminum compression sleeve for the complete of conductor. The aluminum compression sleeves shall be of aluminum alloy conforming to the specification in IEC 60889 standard or equivalent, and
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the steel compression sleeves shall be of carbon steel conforming to the specification in BS 970 part 1 respectively EN 10084, 10085, 10087, 10095, 10250-4 and BS PD 970. After compressed, the electrical resistance of the joint sleeve must be less than that of the jointed conductor with the same length as the sleeve, and the ultimate tensile strength of the joint sleeve must not less than 95 % of the ultimate tensile strength of the conductor.

B1.4.7.4.4

Armor rods
Preformed armor rods shall be used to protect the phase conductors in suspension assemblies. The direction of the armor rod lay shall be equal to the direction of the outermost wire lay of the conductor. The suspension clamps offered for the phase conductors shall accommodate the increased diameter resulting from armor rods. The ends of the armor rod wires shall be well rounded, without sharp edges, to avoid an increase in corona level.

B1.4.7.4.5

Guard rings
The guard rings of the insulator sets must fulfill simultaneously the functions of arcing rings, corona shield and potential distribution devices. As arcing device, the guard rings shall be designed to protect insulators and conductors when flashover occurs. The arcing fittings shall be made of hot dip galvanized steel and must have the capability to withstand a three-phase short circuit current as per Technical Schedules. The arcing fittings must be designed so that in case of flashover the arc will be led to the end burning spot. They may reach a final temperature not exceeding 600C during the shortcircuit. The function of arcing protection must not be greatly altered by the power arc. As corona shield devices, the guard rings shall be designed to ensure under fair weather and under the specific site conditions a corona-free insulator set line end as well as the specified insulator set radio noise performance. As potential distribution devices, the guard rings must be designed to insure a uniform distribution of the potential along the insulator string. The design of the guard rings shall consider and optimize simultaneously all the functions required.

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The rings shall be strong enough to support a weight of 100kg without permanent deformation. The ring attachment shall be via bolted connections to the hardware assembly. Standard tubular field grading rings made of alumina or steel directly attached to the insulator end fitting may withstand power arc / short circuit currents of maximum 20 kA / 0.5 sec. If higher power arc currents are specified then the combination of grading rings with special power arc protection devices shall be applied in accordance with CIGRE Technical Brochure No. 365. Also combined field grading / arcing devices such as tandem rings are suitable for currents up to 63.5kA / 1sec. The function of such devices shall be proven by tests in accordance with IEC 61467.

B1.4.7.5

Clamps and fittings for ISWER system

B1.4.7.5.1

General
All clamps and fittings shall comply with the requirements of this Bidding Document and must be approved by the Employer/ Employers Representative. They shall be suitable for the insulated ACSR earthwire/ OPPC types specified. The Contractor shall ensure close and continuous liaison between the manufacturers of earthwire/ OPPC, clamps and fittings so that the equipment will be perfectly adapted. The detailed design of OPPC suspension and tension hardware shall be coordinated with the manufacturer of the OPPC. The installation techniques and procedures shall be submitted to the OPPC manufacturer and his written approval for the complete design and materials intended to be used with the approved OPPC type will be presented to the Employer/ Employers Representative before the final approval for the hardware and OPPC will be granted. All clamps and fittings except for vibration dampers shall be supplied by the same manufacturer. Splitting up of the supply of clamps and fittings will not be permitted. Besides, the Contractor shall assure perfect fitting of the earthwire/ OPPC set attachment armatures (connecting hardware) to the tower steel construction. The design of adjacent metal parts and mating surfaces shall be such as to prevent corrosion of the contact surfaces and to maintain good electrical contact under service conditions. The attachment sets shall withstand lightning strokes and fault currents as specified in the Technical Schedules without suffering damage, and this performance must be checked in accordance with the requirements. The Employer/ Employers Representative may require tests to be carried out to demonstrate the short circuit characteristics of each type of connection-to-tower set. The cost of such tests shall be borne by the Contractor.

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All ferrous parts of the assemblies component elements and of the accessories for conductors and earthwire/ OPPC shall be hot dip galvanized according to ISO 1461. The split pins of all clamps and fittings shall be of stainless steel. The suspension towers will be equipped with suspension sets and the tension towers with tension sets. All sets shall be designed for the specified earthwire/ OPPC selected type and for the mechanical loads and loading conditions shown below as well as the safety factors given in the Technical Schedules: earthwire/ OPPC dead weight the wind loading on earthwire/ OPPC maximum working tension of the earthwire/ OPPC partial load safety factors as specified above partial material safety factor for fittings

M = 2.50 .

Particular care shall be taken during manufacture of clamps and fittings and during subsequent handling to ensure smooth surfaces free from burrs and sharp edges.

B1.4.7.5.2

Suspension assemblies
Armor grip suspension clamps shall be used for earthwire/ OPPC. The clamp body shall be of high-tensile strength corrosion-resistant aluminum alloy and shall be preferably forged or cast. In the case of cast ones an additional reinforcement shall be foreseen. The spiral rods shall also be of aluminum alloy and shall not have diameters less than 4 mm. The material of the clamps should satisfy the norms EN 1559 for aluminum alloy castings and EN 1562 for malleable cast iron. The neoprene or other non-metallic material shall have good resistance to aging and be capable of withstanding temperatures between + 10C and +40C without changing of essential properties. The material shall have adequate resistance to the effects of ultra-violet radiation, ozone or pollution factors. The rotational axis of the clamp shall be in the longitudinal axis of the earthwire/ OPPC to avoid unacceptable distortion of the earthwire/ OPPC due to unbalanced longitudinal loads. The Contractor shall ensure by appropriate design a suitable performance of the clamp-conductor assembly by wind induced vibration. Connecting hardware is required for a suitable connection to the tower and the Contractor is responsible to supply the complete set of the suspension assembly.

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B1.4.7.5.3

Tension assemblies
The earthwire/ OPPC attachments to tower shall be of helical grip type consisting of two helical parts (fittings), one for earthwire/ OPPC protection and the other one as actual dead-end fitting. Preformed helical dead-ends shall have "cabled loop" eyes. The material of the spiral rods shall be high-tensile strength aluminum clad steel. The material of the clamps should satisfy the norms EN 1559 for aluminum alloy castings and EN 1562 for malleable cast iron. The protection part is defined to protect the earthwire/ OPPC against radial forces produced by the high longitudinal tensions during operation. The protection part must be laid in the opposite direction of the outer layer of the earthwire/ OPPC and the dead-end part must be laid in opposite direction to the protection part. The grip strength shall be at least 95 % of the ultimate tensile strength of the earthwire/ OPPC. The tension attachment devices must correspond to the earthwire/ OPPC type and dimensions. The protection part must be longer than the tension (deadend) part and the length must be sufficient to install vibration dampers. The number and diameter of the spiral rods of the two parts are generally different but must be coordinated to meet the operational requirements.

B1.4.7.5.4

Mid span joints


Regarding insulated ACSR earthwires, mid-span joints shall not be less than 30m from the nearest earthwire clamp. Unless the Employer/ Employers Representative agrees mid-span joints shall not be used under the following circumstances: in spans crossing power lines, buildings and main roads. in single span sections. The OPPC shall not be jointed in the spans.

B1.4.7.5.5

Arcing horns
As arcing device, the arcing shall be designed to protect insulators and conductors when flashover occurs. The arcing fittings shall be made of hot dip galvanized steel and must have the capability to withstand a lightning strike and a short circuit current as per Technical Schedules. The arcing fittings must be designed so that in case of flashover the arc will be led to the end burning spot. The gap between the horns shall be in a range so as to be suitable to guarantee a maximum operation voltage for the ISWER system of 36/3 kV. Proof has to be given that the rod gap has sufficient self-extinction capacity (horizontal and vertical arrangement).

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They may reach a final temperature not exceeding 600C during the shortcircuit. The function of arcing protection must not be greatly altered by the power arc.

B1.4.7.6

Clamps and fittings for Earthwire and OPGW

B1.4.7.6.1

General
All clamps and fittings shall comply with the requirements of this Biding Document and must be approved by the Employer/ Employers Representative. They shall be suitable for the earthwire/ OPGW types specified. The Contractor shall ensure close and continuous liaison between the manufacturers of earthwire/ OPGW, clamps and fittings so that the equipment will be perfectly adapted. The detailed design of OPGW suspension and tension hardware shall be coordinated with the manufacturer of the OPGW. The installation techniques and procedures shall be submitted to the OPGW manufacturer and his written approval for the complete design and materials intended to be used with the approved OPGW type will be presented to the Employer/ Employers Representative before the final approval for the hardware and OPGW will be granted. All clamps and fittings except for vibration dampers shall be supplied by the same manufacturer. Splitting up of the supply of clamps and fittings will not be permitted. Besides, the Contractor shall assure perfect fitting of the earthwire/ OPGW set attachment armatures (connecting hardware) to the tower steel construction. The design of adjacent metal parts and mating surfaces shall be such as to prevent corrosion of the contact surfaces and to maintain good electrical contact under service conditions. At all suspension, tension towers and substation gantries, the earthwire/ OPGW shall be electrically connected to the steelwork by means of jumpers of the same size and material as the earthwire/ OPGW as well as by means of suitable fittings. The earthwire connections to the towers (connecting hardware, earthing connections) shall withstand the lightning stroke and fault current shown in the Technical Schedules without suffering damage and this performance must be checked in accordance with the requirements. The Employer/ Employers Representative may require tests to be carried out to demonstrate the short circuit characteristics of each type of connection-to-tower set. The cost of such tests shall be borne by the Contractor.

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All ferrous parts of the assemblies component elements and of the accessories for conductors and earthwire/ OPGW shall be hot dip galvanized according to ISO 1461. The split pins of all clamps and fittings shall be of stainless steel. The suspension towers will be equipped with suspension sets and the tension towers with tension sets. All sets shall be designed for the specified earthwire/ OPGW selected type and for the mechanical loads and loading conditions shown below as well as the safety factors given in the Technical Schedules: earthwire/ OPGW dead weight the wind loading on earthwire/ OPGW maximum working tension of the earthwire/ OPGW partial load safety factors as specified above partial material safety factor for fittings

M = 2.50 .

Particular care shall be taken during manufacture of clamps and fittings and during subsequent handling to ensure smooth surfaces free from burrs and sharp edges.

B1.4.7.6.2

Suspension assemblies
Armor grip suspension clamps shall be used for earthwire/ OPGW. The clamp body shall be of high-tensile strength corrosion-resistant aluminum alloy and shall be preferably forged or cast. In the case of cast ones an additional reinforcement shall be foreseen. The spiral rods shall also be of aluminum alloy and shall not have diameters less than 4 mm. The material of the clamps should satisfy the norms EN 1559 for aluminum alloy castings and EN 1562 for malleable cast iron. The neoprene or other non-metallic material shall have good resistance to aging and be capable of withstanding temperatures between + 10C and +40C without changing of essential properties. The material shall have adequate resistance to the effects of ultra-violet radiation, ozone or pollution factors. The rotational axis of the clamp shall be in the longitudinal axis of the earthwire/ OPGW to avoid unacceptable distortion of the earthwire/ OPGW due to unbalanced longitudinal loads. The Contractor shall ensure by appropriate design a suitable performance of the clamp-conductor assembly by wind induced vibration. Connecting hardware is required for a suitable mechanical and electrical connection to the tower and the Contractor is responsible to supply the complete set of the suspension assembly.

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B1.4.7.6.3

Tension assemblies
The earthwire/ OPGW attachments to tower shall be of helical grip type consisting of two helical parts (fittings), one for earthwire/ OPGW protection and the other one as actual dead-end fitting. Preformed helical dead-ends shall have "cabled loop" eyes. The material of the spiral rods shall be high-tensile strength aluminum clad steel. The material of the clamps should satisfy the norms EN 1559 for aluminum alloy castings and EN 1562 for malleable cast iron. The protection part is defined to protect the earthwire/ OPGW against radial forces produced by the high longitudinal tensions during operation. The protection part must be laid in the opposite direction of the outer layer of the earthwire/ OPGW and the dead-end part must be laid in opposite direction to the protection part. The grip strength shall be at least 95 % of the ultimate tensile strength of the earthwire/ OPGW. The tension attachment devices must correspond to the earthwire/ OPGW type and dimensions. The protection part must be longer than the tension (dead-end) part and the length must be sufficient to install vibration dampers. The number and diameter of the spiral rods of the two parts are generally different but must be coordinated to meet the operational requirements.

B1.4.7.6.4

Mid span joints


Regarding earthwires, mid-span joints shall not be less than 30m from the nearest earthwire clamp. Unless the Employer/ Employers Representative agrees mid-span joints shall not be used under the following circumstances: in spans crossing power lines, buildings and main roads. in single span sections. The OPGW shall not be jointed in the spans.

B1.4.7.7

Tests

B1.4.7.7.1

General
The Employer/ Employers Representative is entitled to attend tests and inspections, and the Contractor shall bear all costs and expenses of tests and attendance as per price schedules. The Contractor shall give the Employer/ Employers Representative notification in writing, not less than 45 days in advance, of the date of material testing. Test program shall demonstrate procedures of test in order to proof the specified technical requirements and be subject to approval by the Employer prior testing starts. Additional tests may be called by the Employer/ Employers Representative to ensure that the required quality is met. The Contractor shall supply all necessary labor,

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material, equipment and competent and authorized test personnel. Calibration of equipment is deemed to be included. Six (6) copies of test reports and/ or certificates are to be provided showing all results and information necessary. If the Employer/ Employers Representative waive to attend the test, it will neither relieve the Contractor of his full liability to meet the required quality and to complete the works nor prejudice or affect the rights of the Employer/ Employers Representative set forth under this contract.

B1.4.7.7.2

Insulators and insulator sets


The insulator units and the insulator sets used in this Contract will be subjected to type, sample and routine tests according to IEC 61109 Composite insulators for AC overhead lines with a nominalvoltage greater than 1000V, Definitions, test methods and acceptance criteria IEC 60437 Radio Interference Test IEC 61467 Insulators for overhead lines, insulator strings and sets for lines with nominal voltage greater than 1000 V, a.c. power arc tests IEC 60507 Pollution Test IEC 60587 Test methods for evaluating resistance to tracking and erosion IEC 60591 Sampling rules and acceptance criteria. Type, sample and routine tests shall be performed. The costs for these tests are deemed to be included in the Bid Price. Regarding composite insulators, the following sample tests shall be carried out in addition to IEC 61109 in order to guarantee first class quality and long service, and the costs are deemed to be included in the Bid Price: The quality of crimping of the core shall be proven by dynamic / cyclic load-time tests. The derived load-time curves shall show a withstand extrapolation of 50 years for 50% static combined with 6% dynamic (7 Hz vibration frequency) loading related to the SML. 96h acid resistance test of the loaded rod as per IEC TR 62039, Clause 3.8 performed in ambient temperature, in order to evaluate whether the specified glass material is used 96h tensile test (60% of UTL or 70% of SML as per IEC 61109) with determination of UTL subsequently, in order to verify compliance with type test certificates 3000h UV test in addition to UV weathering test as per IEC 62217 Tracking and erosion test as per IEC 60587 applied for specimen of housing material, in order to prove the housing material Aging resistance certified for 5000h multi-stress test according to IEC 61109 Annex C. Sealing test as per CEA/ LWIG procedure (CAN 411.4, Clause 4.7.3) Coaxiality of the housing at the shank shall be proven by cutting sample insulators taken from the production at least for 5 pieces for evaluation

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Housing and core materials applied for delivery shall be recorded by fingerprinting methods as presently defined in CIGRE WG D1.27 (FTIR, TGA/DSC and gravimetric analysis shall be applied in order to fingerprint type, design tested and delivered materials). The fingerprints shall be documented for at least 15 years in a report by the manufacturer. The composite insulator manufacturer shall provide existing test reports of similar insulators manufactured by him in proof of his capability to perform the above required additional tests and the high quality of his materials and products. Regarding visual examination, the surface of each insulator shall be examined in order to reject insulators with defective surfaces. Defective insulators are those which are not in accordance with the following details: The mounting of the metal fitting on the insulating parts shall be in accordance with the drawings. The color of the insulator shall be approximately as specified in the drawings. Cracks at the shank and on the shed surface are not allowed. Individual superficial defects shall not exceed 25 mm and the total defective area shall not exceed 0,2% of the total insulator surface. The depth of the cavities on the insulator surface shall not exceed 1 mm. Scaly crumblings are allowed at the edges of a shed only. However, the total amount of crumblings shall not exceed a volume of approx. 100 mm per 1000 mm of insulating length and an individual crumbling shall not exceed 50 mm. Individual protrusion up to 2 mm at the rim of the sheds are admitted, protrusion at the shank is not admitted. Burrs derived from molding process which are aligned with the insulator's axis shall be removed completely in order to avoid electrical long term failure of the insulator.

B1.4.7.7.3

Clamps and fittings for conductors and earthwires


The clamps and fittings used in the insulator sets and for attachment to tower as well as for the conductor assembling will be submitted to type, sample and routine tests according to IEC 61284 as agreed with the Employer/ Employers Representative. Galvanizing tests, if applicable, are included. The costs for these tests are deemed to be included in the Bid Price.

B1.4.7.7.4

Clamps and fittings for OPGW and OPPC


The OPGW/ OPPC suspension and tension attachment-to-tower sets shall be tested for mechanical and thermal performance. These are in particular: tensile load test clamp bolt tightening test

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unbalanced load test aeolian vibration test fault current test. The Joints for OPGW/ OPPC (joint enclosure and splices) are subject to the requirements of IEC 61073, IEC 61300 and shall be tested as specified in the documents. The mechanical tests specified in IEC 61073-1, par. 4.5, shall be performed. The test procedures shall follow the recommendations of CIGRE, TF 22.11.03, Guide for Fittings for Optical Cables on Transmission Lines, Part 2A, Testing Procedures (published in ELECTRA No. 188, February 2000). The tensile test shall be agreed with the OPGW/ OPPC manufacturer and the optical attenuation shall be measured. The clamp bolts have to be tightened according to the recommended moments and the OPGW/ OPPC shall be checked afterwards visually. The vibration test shall be coordinated with IEC 60794. The Bidder shall demonstrate the adequacy of the grounding connection to the fault current by test date, field experience or calculation. The costs for these tests are deemed to be included in the Bid Price.

B1.4.7.7.5

Particular tests
In addition to these tests mentioned above, particular tests of the insulator sets and insulator units have to be carried out: corona test; radio interference test; thermal stability test (OPGW/ OPPC). The tests referring to the insulator sets have to be carried out on completely equipped sets, with all clamp and fitting parts, installed in their characteristic working position and having attached also an agreed length of conductor bundle. The costs for these tests are deemed to be included in the Bid Price. Corona Tests The corona tests shall be carried out as design tests in the manufacturer's works or in specialized laboratories. The line components to be corona tested are all insulator set types as well as the conductor accessories like joints and repair sleeves.

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Each type of insulator set has to be completely equipped with all clamp and fitting parts and installed in its characteristic working position, having attached also agreed length of conductor bundle. The suspension sets will be provided with armor rods and, if applicable, with counterweights also. The conductor accessories can be installed as separate test object or inserted in the insulator set test arrangement. For the corona tests, the optical detection method with pre-stressing according to IEC 60270 (1981) shall be applied. The test object has to be energized for 5min at minimum 267kV (r.m.s) phase-to-ground. Then the voltage shall be continuously decreased in order to establish the voltage value of which visible discharges disappear (corona extinction voltage = Ve). After this, the voltage shall be continuously increased in order to establish the voltage value at which visible discharges appear (corona inception voltage = Vs). Five (5) successive tests have to be performed according to this procedure. The average value of the resulting corona extinction voltages Ve shall be considered as test result. Pictures shall be taken during the test at several voltage levels in order to demonstrate optically the corona performance of the test object. The following has to be agreed with the Employer/ Employers Representative: the arrangement of the test object; the optical equipment and its characteristics; the relative position of the optical equipment to the test object; the simulated atmospheric conditions. The results must confirm an extinction voltage of at least 267kV phase-toground. Radio Interference Tests The radio interference (RI) tests shall be carried out as type test in the manufacturer's works or in specialized laboratories. Same line components like for corona tests (see above) shall be tested for radio interference or radio noise. Same requirements and recommendations regarding the completeness and arrangements of the test objects like for corona tests (see above) are applied also for RI tests. Additionally, each insulator unit type shall also be tested.

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The RI tests will be based on the IEC 60437. The test voltage will be 267 kV. The radio noise limits (across 300 ohm at 1 MHz) is 46 dB above 1 microvolt. The arrangement of the considered objects for tests, the measuring circuit as well as the simulated atmospheric conditions shall be subject to agreement between Employer/ Employers Representative and Contractor. Thermal Stability Tests Thermal stability of the OPGW/ OPPC suspension and tension attachments to tower shall be verified according to the procedures recommended in IEC 61854. If requested by the Employer/ Employers Representative a thermal stability tests shall be carried out as type tests in the manufacturer's works or in specialized laboratories on the OPGW/ OPPC suspension and tension attachments to tower. Each attachment set type shall be completely installed in its typical working position together with a sufficient OPGW/ OPPC wire length in order to allow for a simultaneous test (OPGW/ OPPC and attachment set). Each set type will be submitted to a cycle of three (3) tests with different test parameters as shown below:
Test 1 2 3 Short-Circuit Current 7 kA 10 kA 22 kA Duration 1.0 sec. 0.5 sec. 0.1 sec.

Oscillograms of the short-circuit currents and voltages applied during tests shall be recorded. Photographs shall also be taken from the tested object before and after test. The tests shall be considered as successful if no damage of the OPGW/ OPPC or of the attachment sets occurs. The fault current supply circuit and the arrangement of the tested object shall be subject of the Employers/ Employers Representatives approval.

B1.4.7.7.6

Tests during erection


Galvanizing Thickness The galvanizing thickness shall be randomly tested on site after receiving the galvanized components as well as during erection. The zinc coatings must comply with the thickness requirements for each component. The Contractor shall have available on site for the Employers/ Employers Representatives use an instrument suitable for the accurate checking of galvanizing thickness. The measuring instrument shall be available from the

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time of arrival of the first consignment of material until the issue of the operational acceptance certificate. The cost of the gauge and other operating expenses are deemed to be included in the Contract price. Test for Splicing After installation of the OPGW/ OPGW, OPPC/ OPPC but before splicing the optical fibers shall be tested regarding attenuation. Furthermore, OPGW/ OPPC, OPGW/ OPUG and OPPC/ OPUG joints shall be tested to prove compliance with the specified performances (attenuation), including OTDR tests.

B1.4.7.8

Packing
The insulators shall be packed and carried out in suitable boxes. Each package of insulators shall be marked with the type designation used by the manufacturer. A handling guide shall be attached to each crate. The guide shall reflect the best practice documented in CIGRE Technical Brochure No. 184. Fittings shall be packaged in non returnable timber crates in a manner that prevents damage during transport and handling. Small items may be packed in jute bags up to a gross weight of 25kg within larger containers. Containers over 25kg shall be delivered on pallets suitable for handling by forklifts. Components of dead ends, mid-span joints, armor rods etc., shall be packaged as complete sets. Cardboard containers and metal drums are not acceptable.

B1.4.8 Dampers

B1.4.8.1

Spacer dampers

B1.4.8.1.1

Requirements
Phase conductors arranged in twin bundle shall be fitted with spacer dampers in order to maintain a distance of 450 mm between the sub-conductors under all working conditions and to protect the conductors under aeolian vibrations. The number of spacer dampers shall be determined by a Damping Study which is deemed to be included in the scope of work. The Contractor shall submit all data and calculations regarding the characteristics, number and placement of the spacer dampers to be used for the various ranges of spans. The calculations shall cover the range of 1 to 7 m/s wind velocity and typical conductor tensions (EDS) and the range of span lengths. The Contractor will guarantee by means of corresponding calculations that the bending stress of the conductor will be restricted to maximum 150 m/m. All

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data for the calculations shall be performed under the responsibility of the Contractor and shall be subject for approval of the Employer/ Employers Representative. The spacer dampers shall be efficaciously distributed along the spans at approved unequal intervals, but at minimum 2 m away from any mid span joint or repair sleeve or any other fitting attachment to the conductor. The following requirements shall be observed: Sub-conductor contacts under normal service conditions are excluded. The conductor bundle must have satisfactory torsion stability. Damage of sub-conductors and of spacer dampers themselves by shortcircuit is excluded. For bolted clamps, all bolts of the spacer dampers shall be captive. The shape of the clamp shall provide a large radius around the conductor in order to guarantee a corona-free level similar to that of the conductor bundle. The clamp shells and the spacer himself shall be made of corrosion-resistant high-strength aluminum alloy. For bolted clamps, the bolts and nuts used in the spacer clamps shall be galvanized or of stainless steel. The washers underneath the bolt head shall be made from stainless steel only. The clamping bolts shall be of steel having a minimum tensile strength of 800 N/mm2. The tightening torque shall be defined for conditions of friction for bolt head, thread and washer and shall consider a setting of the connection. Nuts shall only need slackening, not removal, in order to fit the spacer to the conductors. The nuts or bolts shall be locked in an approved manner against vibration loosening. Spacer clamps shall incorporate an approved arrangement to ensure that the correct clamping pressure is maintained when conductor strands move due to bedding down, creep and tension or temperature variation. Clamps shall not damage the conductor at any time. Elastomers or other non-metallic materials shall have good resistance to aging and be capable of withstanding temperatures between +10C and +85C without change of essential properties. The materials shall have adequate resistance to the effects of ozone, ultra-violet radiation and air pollution over the entire temperature range. The spacer dampers shall be capable of the movements shown below without damaging the conductors: longitudinal movement parallel to the conductor vertical movement at right angle to the conductor torsional and axial on horizontal plane max. 25 mm max. 15 mm max. 2

The spacer dampers shall be designed and manufactured by an approved company which can show that similar spacer dampers have been supplied
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by them for overhead transmission lines with horizontal twin bundle conductors and can also show that the equipment supplied has provided several years of trouble free service. The Contractor shall provide evidence by end users certificates and show details which include a full and complete specification of the materials, manufacture and guaranteed performance of the spacer dampers. The Employer/ Employers Representative will accept only the spacer dampers which are guaranteed by the Contractor to meet satisfactorily the test requirements specified below: working temperature: +85C corona: no visible fair weather corona discharges under the specific site conditions. Therefore, under standard laboratory conditions and according to the recommendations in IEC 61854 the corona extinguishing voltage shall be not less than 267kV r.m.s. phase-to-earth radio interference (RI): 46 dB above 1 microvolt at 420 x 1.1/ 3 = 267 kV r.m.s. voltage value phase-to-earth static compression and tensile performance: 5kN for 1min and the separation of the clamps before and after the test shall not differ by more than 5 % impulse compression performance by short-circuit: 40kA peak with one clamp offset longitudinally by 35 mm (spacing 450 mm), conductors at everyday tension compression and tensile fatigue performance: 10 million cycles at 1Hz each clamp loaded to 500N (fatigue test sub-span oscillation) vertical fatigue performance: 100 million cycles at 20Hz with a relative displacement of the clamp of 15 mm torsion fatigue performance: 100 million cycles at 20Hz with a relative displacement of the clamp up to 2 for bolted clamps, a clamp slip: max. 1mm by a load of 6kN applied for 10min. Alternatively and verified by a Damping Study, rigid spacers together with stockbridge dampers for each sub-conductor may be offered.

B1.4.8.1.2

Tests
The Employer/ Employers Representative is entitled to attend tests and inspections, and the Contractor shall bear all costs and expenses of tests and attendance as per price schedules. The Contractor shall give the Employer/ Employers Representative notification in writing, not less than 45 days in advance, of the date of material testing. Test program shall demonstrate procedures of test in order to proof the specified technical requirements and be subject to approval by the Employer prior testing starts. Additional tests may be called by the Employer/ Employers Representative to ensure that

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the required quality is met. The Contractor shall supply all necessary labor, material, equipment and competent and authorized test personnel. Calibration of equipment is deemed to be included. Six (6) copies of test reports and/ or certificates are to be provided showing all results and information necessary. If the Employer/ Employers Representative waive to attend the test, it will neither relieve the Contractor of his full liability to meet the required quality and to complete the works nor prejudice or affect the rights of the Employer/ Employers Representative set forth under this contract. Spacer dampers shall be type and sample tested in accordance with IEC 61854 (Requirements and Tests for Spacers). All tests shall not cause damage to the conductors to which the test spacers were applied. For short-circuit tests, the peak and r.m.s. values as well as the method is described above. Tests of the electrical and mechanical characteristics of the spacer dampers shall be deemed to be covered in the Price Schedules.

B1.4.8.2

Stockbridge dampers

B1.4.8.2.1

Requirements
Vibration dampers of Stockbridge type shall be installed at all earthwire suspension and tension points and shall be mounted on armor rods. The expression earthwire is to be understood as either non-insulated ACSR conductor and OPGW or insulated ACSR conductor and OPPC (ISWER system). Minimum two dampers per span shall be provided; one damper per span is not permitted. The exact number of dampers shall be determined by a Damping Study which is deemed to be included in the scope of work. The Contractor shall submit all data and calculations regarding the characteristics, number and placement of the vibration dampers to be used for the various ranges of spans. The calculations shall cover the range of 1 to 7 m/s wind velocity and typical earthwire tensions (EDS) and the range of span lengths. All data for the calculations shall be performed under the responsibility of the Contractor and shall be subject for approval of the Employer/ Employers Representative. Regarding the damping characteristics of the vibration damper, the Contractor shall guarantee that close to the suspension clamps as well as to the damper own clamp, the conductor stains due to the wind induced vibrations are kept within acceptable limits over the entire range of possible frequencies. The Contractor shall guarantee by means of corresponding calculations that the bending strain of the conductor will be restricted to maximum of 150 m/m and the damper clamp velocity will not exceed 0,1m/s.

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The damper clamps shall be of forged aluminum alloy or cast and shall be designed to ensure that dampers do not cause damage to the earthwire type for which they are used. As function of the necessary distance between the first vibration damper and the mouth of the suspension clamp on earthwire, the damper clamp shall be dimensioned taking into account the installation on the earthwire or on the armor rods.

For bolted clamps, the clamping bolts shall be of steel having a minimum tensile strength of 800 N/mm2 and shall be designed to facilitate an easy damper mounting. The screws shall be locked in an approved manner. The washers shall be made of stainless steel. Elastomers or other non-metallic materials if used shall have good resistance to aging and be capable of withstanding temperatures between +10C and +40C without change of essential properties. The materials shall have adequate resistance to the effects of ozone, ultra-violet radiation and air pollution over the entire temperature range. The damper shall be designed to exclude water collection. If this is not possible, they shall have drainage holes with a minimum diameter of 6mm. All ferrous parts of the damper component elements shall be corrosion protected.

B1.4.8.2.2

Tests
The Employer/ Employers Representative is entitled to attend tests and inspections, and the Contractor shall bear all costs and expenses of tests and attendance as per price schedules. The Contractor shall give the Employer/ Employers Representative notification in writing, not less than 45 days in advance, of the date of material testing. Test program shall demonstrate procedures of test in order to proof the specified technical requirements and be subject to approval by the Employer prior testing starts. Additional tests may be called by the Employer/ Employers Representative to ensure that the required quality is met. The Contractor shall supply all necessary labor, material, equipment and competent and authorized test personnel. Calibration of equipment is deemed to be included. Six (6) copies of test reports and/ or certificates are to be provided showing all results and information necessary. If the Employer/ Employers Representative waive to attend the test, it will neither relieve the Contractor of his full liability to meet the required quality and to complete the works nor prejudice or affect the rights of the Employer/ Employers Representative set forth under this contract. Stockbridge dampers shall be type and sample tested in accordance with IEC 61897 (Requirements and Tests for Stockbridge Dampers). All tests shall not cause damage to the earthwire to which the test dampers were applied. Tests of sliding forces shall be applied for bolted damper clamps only.
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Tests of the electrical and mechanical characteristics of the Stockbridge dampers shall be deemed to be covered in the Price Schedules.

B1.4.9 Aircraft Navigation

B1.4.9.1

Warning System
If required by the Employer/Local Authorities selected line sections shall be provided with aircraft warning spheres for denoting obstacles, conforming to the Convention on International Civil Aviation. The warning aids may comprise of one, two or all three measures detailed hereunder.

B1.4.9.2

Warning spheres
The warning spheres shall be 600 mm diameter and manufactured from fiberglass. The spheres shall be colored and will not fade when subjected to the direct rays of the sun. They shall be manufactured in two halves and designed such that assembly and attachment to the conductor is simple. Provision for drainage of water (humidity) within the ball shell shall be provided. All metal parts used for holding the spheres in position (no twisting or slipping) shall be of mild steel and galvanized. The spheres shall be fitted to both earthwires on the 400kV transmission line. The expression earthwire is to be understood as either non-insulated ACSR conductor and OPGW or insulated ACSR conductor and OPPC (ISWER system). The position of spheres shall meet the following requirements: The system shall comprise white spheres (RAL 9010), alternating with red ones (RAL 3000) The spheres on two earthwires for any span shall be so staggered that the maximum distance between any two spheres is not greater than 30 m The first and the last spheres in any span shall be approximately 15 m from the towers defining the span The fixing clamps of the spheres shall match the preformed armor rods to be supplied for each sphere, to be mounted between sphere shell and earthwire The type and details of the spheres shall be closely coordinated with the OPGW/ OPPC manufacturer in order to avoid any excessive stress on the OPGW/ OPPC.

B1.4.9.3

Tower painting
If required by the Employer/ Local Authorities tower or tower peaks of selected line sections shall be painted in red and white for denoting obsta-

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cles, conforming to the Convention on International Civil Aviation or in black and white for bird protection in the specified sections of Lot 3. Tower painting is subjected to approval of the Employer/ Employers Representative. Cleaning Prior to chemical treatment/ surface preparation, the galvanized surfaces shall be carefully cleaned by brushing with fresh water to remove all foreign substances such as salt, white rust and zinc corrosion products, dust sand and dirt. Chemical treatment procedure of galvanized steel surfaces shall be subject to the approval of the Employer/ Employers Representative. Prior to painting, the galvanized surfaces shall be carefully checked for damages, defects and impurities. In case of persistent white rust, and corrosion products it is necessary to remove these by sweep-blasting or mechanical brushes. However, tarnishing of surfaces must be avoided. In specific cases where damages are severe, re-galvanizing shall be required. Such prepared surfaces must be approved by the Employer/ Employers Representative prior to paint application. Painting For better adhesion and corrosion protection priming coats shall be applied by brush or by airless spray only. The other coats of paint are to be applied by brush roller or spray and in accordance with the paint manufacturers recommendations: first layer of primer second layer of intermediate coat final layer of red or black or white color. All surfaces to be painted must be moisture-free and paintings shall not take place when: the surface temperature is above 50C the relative humidity is above 85 % or the surface temperature is closer than 3C or below the dew point it is raining. All finishes shall be clean and in good sound conditions. Each coat shall completely and uniformly cover the coat underneath it. Depending on the authorities requirements, epoxy based multi layer coatings may be applied. There must be no delay between application of successive coats but each coat must by thoroughly dry or as directed in the paint instructions before next coat is applied. Before additional coats are applied to painted surfaces, the existing paint shall be cleaned of all foreign matters and suitably sanded if necessary.
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Excessive coat thickness shall not exceed the maximum specified by the paint manufacturer.

B1.4.9.4

Warning lights
If required by the Employer/ Local Authorities selected line sections shall be provided with aircraft warning lights for denoting obstacles, conforming to the Convention on International Civil Aviation. The aircraft obstruction lights shall have the following general features: A solar powered LED (Light Emitting Diode) clustered lighting system. Two bulbs per tower peak, of which only one may be lit at a time (switchover-relay). Having a minimum light intensity of 100 candelas for cable fed- and 10 candelas for solar powered systems, steady aviation red light. Having a minimum bulb life time of 20 000 hours. All components to be corrosion proof in marine environment (stainless steel grade A4 only). System performance shall be understood as the reliable automatic illumination during all hours of darkness with a visible light intensity as stipulated in ICAO document. The system offered shall be comprehensive and complete in every respect. If the Bidder proposes a system fed by cables, it shall be designed to withstand the high voltage, induced in case of line earth fault. It shall consist of constant current regulator, high voltage cable, dimmer switch, protection equipment, insulating transformers, lightning arresters, etc. The connection and cabling to the nearest available safe mains supply is deemed to be included, too. In case the Bidder offers solar powered lights, a battery maintenance interval of minimum 5 years shall be guaranteed, as well as the luminous flux as above under the condition of dusted solar cells. Photovoltaic panel output shall be rated, over and above age rating, by 40 %, on account of dust accumulation on the panel surface. The upper edges of the solar panels shall be fitted with stainless steel needle strips, effectively preventing birds from sitting in these locations. It shall be noted that the supply of equipment shall include the necessary spare parts as per manufacturers recommendation, for a service period of five years. Expenditure incurred is deemed to be included in the price quoted in the price tabulation sheet.

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B1.4.10 Earthing

B1.4.10.1

General
The line route is located for a part in hilly terrain with predominantly firm to compact silty clay and sand and localized outcropping rock a condition which is unfavorable for the tower earthing. Therefore the natural earthing of the foundation steel in combination with artificial earthing system is specified. The earthing material shall be supplied in advance before other line material will be shipped to enable foundation works to be carried out. Each tower shall be connected to ground by means of an earthing system as shown in Annex. The design and tests shall generally follow EN 50341 and IEEE 80-1986. The tower earthing system will be composed of: the natural earthing system of foundation reinforcing steel the artificial earthing system around the four tower footings earthing pits with Ground Enhancing Material (GEM) if required. Connection of the earthing devices to the tower steel shall be made approx. 10 cm above the foundation concrete cap and connected by bolts to two diagonally opposite located tower legs. The ground earthing wire shall be embedded in suitable plastic hoses from the foundation cap top down to 1.0 m below ground level as shown in the Annex. At each tower, a proper earthing system shall be installed, consisting of an earthing conductor ring around the complete tower foundation at a minimum of 1.0 m below the surface and at 1.0 m distance from the tower foundations. The earthing conductor will be connected to the tower legs on two diagonally opposite stubs. Each connection of the earthing conductor to the tower stubs as well as other earthing connections to towers shall be made with two bolts with nuts, wahshers and spring washers of appropriate material. The minimum diameter of the bolts will be 10 mm. Whenever different materials are to be joined, the necessary bimetallic transition plates are to be inserted as required to make sure that electrolytic action (corrosion) is avoided. The individual tower earthing resistance measured without the earthwire connected, in dry season is specified as maximum 20 Ohms for line sections without ISWER system. In line sections with ISWER system installed, due to the relatively low BIL of 36kV standard isolator, the earthing resistance of the 400kV towers shall be (as normal case) less than 7 Ohms.

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Earthing materials to be furnished shall be as specified in the Technical Schedules and summarized below. All materials shall be standard commercial quality suitable for the intended use. After installation of the earthing system but before stringing of conductors or earthwires, the Contractor shall measure the earth resistance at each tower structure and, provided that the specified values could not be met, improve it by: using earthing rods connected to the earth conductor ring installation of a second earthing conductor ring extending the grounding wire in diagonal direction execution of earthing pits with GEM grading rings for tower locations with free and frequent access of people (residential areas, camping places, playing grounds, etc.), where touch and step voltages are to be checked. The stringing of the OPGWs may commence after final approval of the resistance value by the Employer/ Employers Representative.

B1.4.10.2

Type of earthing systems


Natural Earthing To include the foundation steel into the tower earthing, inside the concrete the vertical reinforcing bars will be connected electrically by a steel tape loop which shall be also welded/screwed to the stub angle. Further earthing connections shall be provided to include also the horizontal reinforcing mesh net at the bottom of the foundation. Artificial Earthing The earthing system provided shall be adapted to the soil conditions existing along the line route. If the measured resistance is higher than the specified limit values at the line and approximately 2 km before the substations 10 Ohms, the Contractor shall propose measures for improvement. These measures can be but are not limited to: deep earthing rods Second earthing ring earthing conductors diagonal running from the tower legs. Any additional earthing electrodes shall be routed 1.0 m underground to the respective foundation and connected underground by compression type clamps to the primary earthing system. After application of additional earthing, the Contractor shall repeat the resistance measurement in all concerned locations. Ground Enhancing Material (GEM)

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If the measured resistance is higher than the limit values after installation of artificial earthing extension, earthing pits of minimum 1.5 m depth shall be provided and filled with Ground Enhancing Material. An earthing rod shall be driven in the filled pit and connected to the extended artificial earthing system by an additional grounding wire. After application of additional earthing, the Contractor shall repeat the resistance measurement in all concerned locations. Grading Rings At tower locations subject to special requirements of safety of public, a closed earthing ring has to be buried around the tower leg, to a depth of 0.6 m at a distance of 1 m to the tower steelworks. The ring is to be connected to counterpoise tower leg earthing. If found necessary, a second grading ring shall be installed at a depth of 0.8m in a distance of 5 m to the first grading ring. For tower locations where the Contractor is advised by the Employer/ Employers Representative to install an earthing ring he shall perform calculations proving the safety limits of step and touch voltages. These calculations shall be carried out in accordance with approved standards and shall be subject to approval by the Employer/ Employers Representative. After application of additional earthing grading rings, the Contractor shall repeat the resistance measurement in all concerned locations.

B1.4.10.3

Material
Earthing conductor The tower grounding wire or the grounding tape (earthing strap) shall be at least 11.5mm diameter galvanized steel wire 40x6mm galvanized steel band. The earthing conductor shall be connected to the tower steel structure (stub) by using connectors and/ or bolts. Connectors The connection of the basic and additional earthing system to the tower stubs inside the concrete or above the foundation shall be made by means of a flat connector compressed on the steel wire and bolted to the stub. In case of using an earthing tape, the tape may be connected directly to the stub by two bolts. The bolts shall be of sufficient length to suit the steel connecting angle/ plate thickness and provide for the nut and washer. A compression type connector may be used for the grounding connection of steel wire to steel wire/ to reinforcement bars. The connector shall be made of steel. The current carrying capacity of the connector shall not be less than that

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of ground wire. The effective length of the clamp shall be sufficient to grip the connecting wires firmly under normal service conditions. Alternatively bolted clamp connectors can be proposed. Grounding Rod The ground rods shall be of galvanized steel type, delivered in modules and provided with connectors. The minimum length may not be smaller than 2.0m and the diameter not smaller than 15mm. The earth electrode shall be connected to the tower steel by using ground wires/ tapes and connectors.

B1.4.10.4

Final acceptance of tower earthing resistance


The line route is partly traversing areas of sandy and rocky terrain, which are unfavourable subsoil conditions for tower earthing. When the 20 Ohms limit respectively 7 Ohms for ISWER system are still exceeded after all afore specified enhancement measurer for lower earthing resistance were put in place, special acceptance limits may apply which in each case are subject to approval by the Employer/ Employers Representative. The individual tower earthing resistance measured in dry season shall depending on the natural soil resistivity not exceed the ultimate earthing resistance value shown below:
Soil resistivity [m] Earthing resistance [] <100 10 100-500 15 500-1000 20 1000-2000 25 >2000 30

B1.4.11 Construction, Stringing, Commissioning

B1.4.11.1

General
The following Bidding Document part contains the requirements and conditions for the work on site like preparation of access roads, route clearing, tower pegging, preparation of tower locations, foundation works and erosion protection, tower erection, conductor and OPGW stringing and sagging works as well as final commissioning. The requirements and conditions for the work are described in the following chapters. Methods of the works and qualification of specialists shall conform to high quality standards. Generally accepted practice requirements and practice of high-skill work shall be observed. The Contractor has to develop a suitable planning and has to split the line length suitably into several transmission line sections, which have to be treated separately and simultaneously in order to meet the target completion

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date. The necessary number of teams for each sub-process shall be determined. The Contractor shall have available competent and experienced supervisors on site at all times during construction/erection works, so that the required quality will be met.

B1.4.11.2

Safety, infrastructure and supervision


Safety of Personnel The maximum safety, consistent with good construction and erection practice must be applied to the personnel engaged for the works under this Contract. Particular care shall be taken for the following activities: Preparing ditches for foundations Tower erection/ lifting operations Road crossings in the places of traffic the conductors and wire cables shall be runout at a height of 6 m at least at the moment of conductors stringing care shall be taken to keep people away Electrified railroad crossings temporary towers shall be installed at least 20 m high with horizontal arms and installed in 15 m from the permanent railroad when performing the works, the railroad contact conductors and 10 kV OHTL conductors shall be de-energized Communication line crossings Stringing of conductor only after approved protection system against operational disturbance of the crossed communication line is in place. Operating transmission line crossings all installed towers shall be grounded stringing of conductors only after disconnection and reliable grounding of the energized span of the operating transmission line. Working near electrical equipment under operation recommendations of IEC 61936 recommendations of IEC 61472 recommendations of EN 50110 Compliance with Rules and Regulations All equipment and materials supplied and all works (civil, mechanical, electrical) carried out shall comply in all respects with the requirements of the Rules and Regulations as well as of Acts in force in the country of the Employer and applicable to the Contract works.

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All working methods employed and all plant and equipment supplied under this Contract shall be approved by the Employer and applied by the Contractor accordingly. Living Accommodation The Contractor shall make his own arrangements with regard to accommodation for his expatriate and locally recruited staff during the construction period. All dwellings and buildings existing or erected shall comply with local regulations with regard to construction, water supply, sanitation and other requirements. Temporary construction camps shall be provided with proper sanitation and other necessary facilities. All accommodation shall be removed by the Contractor when no longer required. After the removal of accommodation the ground shall be left in a clean and tidy condition. Medical Services The Contractor shall make his own arrangements where medical services may be required for his repatriate and locally engaged staff. Staff Transport The Contractor shall provide at his own expense all necessary transport for his personnel and materials. Transport for Employers site supervision The Contractor shall provide vehicles as specified in the Technical Schedules and Price Sheets. Office Accommodation The Contractor shall provide for his own such buildings as may be necessary for office accommodation for site staff during the construction period. The cost of these shall be deemed to be included in the Contract Price. Site Office for Employer The Contractor for each lot shall provide for the entire duration of the contract, site offices for the sole use of the Employers representatives and Supervisory Engineer (OISF) at localized areas as directed by the Employers and as specified in the Technical Schedules and Price Sheets. Fully furnished air conditioned, sound and weatherproof Site Office complete with electrical fittings, plumping and sanitary systems clean and provided with widows to give a sufficient supply of natural light. The contractor shall provide two (2) offices at two different locations with at least 25m of floor area each at the beginning and at the end of the lot. In addition, adequate toilets and shower/washrooms shall be provided. The offices can be 40ft long or more containerized or buildings capable of accommodating four (4) persons each working at conducive environment. Storage Facilities The Contractor shall make his own arrangements for storage area and shall obtain the approval of the Employer for the places along the line route. The
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Contractor shall provide any necessary protection and safeguarding of the materials in the areas. The site storage area shall be prepared with an adequately compacted base coarse for ordinary storage of conductor drums, tower steel, insulators and fittings so that the material will not be damaged by in-transit re-loading operations and effects of adverse weather during storage. Materials and equipment packed in flammable crates or drums shall be stored in such a manner as to avoid any damage arising from fire. Lifting Facilities The Contractor shall make his own arrangements to purchase or provide lifting facilities required for materials and equipment handling and transport on the site. Supervision, Erection and Checking of Work on Site The execution of all work on the Site shall be supervised throughout by a sufficient number of qualified representatives of the Contractor who have thorough experience of the erection and commissioning. The Contractor shall allow the Employer/ Employers Representative site inspections, but such checking shall not relieve the Contractor from the liability to complete the works in accordance with the Contract or exonerate him from any of his guarantees. If the Employer detects defects in the works, the Contractor shall provide enough staff for a sufficient period of time to remedy the defects. If the Employer finds the Contractor will be unable to complete the works in the agreed time schedule, then the Contractor shall work overtime but shall not make any claims for any extra expenses thereby incurred. Responsibility of Contractor Until each section of the works has been taken over or deemed to have been taken over under the Conditions of Contract, the Contractor shall be entirely responsible for such section of the works under construction and during test. During the period of maintenance the Contractor shall ensure that a competent representative is available at the Site for the purpose of carrying out any work of maintenance for which the Contractor is responsible. The Contractor shall be responsible for the behavior on site of all personnel employed by him. The Contractor shall be responsible for specifying the quality assurance requirements applicable to subcontractors and suppliers, for reviewing the implementation of subcontractors quality assurance arrangements and for ensuring compliance with the requirements.

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The Contractor shall ensure that all appropriate technical information is provided to subcontractors and suppliers. The Contractor shall, for the supply of items, plant and equipment (including those subcontracted) arrange for suitable protection for the product at all stages including delivery and installation at the site.

B1.4.11.3

Route clearing
Wayleave for the line (subject to the negotiations between Employer and authorities/landowners) will be provided by the Employer to enable the Contractor to carry out the Contract works. Before the Contractor commences work on any property he will obtain from the Employer expressed permission and if applicable a Wayleave Schedule giving details of any special requirements of the owners concerned. The Contractor shall give adequate notice of commencement of work to the landowners. Removal of Obstacles Where clearing is necessary, the following requirements shall be observed: Other trees and tall scrub shall be cleared to a distance of 45 m on either side of the centerline of the route. Trees and bushes shall be cut down to a height of not more than 0.5m above ground level and not removed by bulldozer. Tall trees outside the cleared area, of such height that they could fall within 2 m of conductors, shall be trimmed by the Contractor. No tree may be felled without the express permission of the Employer. The necessary permission for the removal of obstructions e.g. fences, buildings, telecommunication and power lines will be in the responsibility of the Employer. No obstruction may be removed without the express permission of the Employer. Re-Clearing Before the issue of the Operational Acceptance Certificate or at the time agreed by the Employer, the Contractor shall have re-cleared the vegetation within the easement of the specified line corridor.

B1.4.11.4

Access roads
General Access roads/routes shall be identified by the Contractor themselves as and where necessary, and shall be constructed by them at their own expense. A map showing all access roads (existing ones and ones to be constructed) has to be prepared and submitted to the Employer for approval. All new access roads required over reasonably good shall be located as far as possible within the easement, and the number of new access routes between existing roads and the easement shall be kept to a minimum. Finger roads are preferable instead of a continuous access along the line. The Employer will negotiate with the landowners about permission and compen-

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sation. The Contractor shall give adequate notice of commencement of work to the landowners. No unauthorized access route shall be taken by the Contractor. Construction The Contractor shall (after getting permission for the routes) do what is necessary to make the access suitable for his use and shall take all reasonable precautions to avoid damage, including, if required the erection of temporary fences or gates where permanent fences, hedges or gates have been removed. The Contractor shall not be entitled to any additional payment in the event of a particular access being difficult. New earth access tracks shall be 4 m suitably compacted. The final surface level shall be at least 0.5 m above the existing ground level and shall be constructed in such a way as to be adequately drained to prevent washouts. Occasional drain ducts laid into the road bed may become necessary to control drainage run off. Junctions between new tracks and existing roads shall not impede or damage neither the latter nor any associated drainage channels, etc. The bearing capacity of the terrain and its suitability for vehicles shall be checked before transporting the materials to the designed location. Maintenance and Handing Over The Contractor shall be responsible for maintaining all agreed access routes, without undue widening, in a usable condition for the duration of the Contract and the landowner shall not be put to any inconvenience in gaining access to his land or buildings. All necessary measures connected with the access, transport and maintenance are in the responsibility of the Contractor.

B1.4.11.5

Tower pegging
It will be the Contractor's responsibility that the final tower positions within the line sections will be correctly aligned, that the spans and relative levels of all proposed tower center pegs correspond with the profile, that the ground line is such that clearances to conductors are maintained in accordance with the profile drawings. Due precautions shall be taken to ensure that wind and weight span limitations (maximum or minimum) are not infringed. Angle (terminal) and suspension towers shall be placed within the following survey accuracy limits relative to their specified position on the profile plan: Closing error for distance between angle tower positions: d 3 D d: permissible absolute horizontal deviation, in (cm). D : horizontal distance between the involved angle points, in (m).

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Closing error for elevation of angle tower positions: h 1 D h : permissible absolute vertical deviation, in (cm). D: horizontal distance between the involved angle points, in (m) Accuracy of centre line angle at angle tower positions: r 0,02 or 1' r permissible absolute horizontal angle deviation, in degree (), or in minutes ('). Accuracy of suspension tower position in longitudinal direction at at straight line: x 8 Sa Sb x: permissible horizontal deviation in direction of the transmission centre line, in (cm) Sa: horizontal distance of forward-span of concerned suspension tower, in (m). Sb: horizontal distance of backward-span of concerned suspension tower, in (m). Accuracy of suspension tower position in transverse direction at straight line: y 1 Sa Sb y: permissible horizontal deviation at right angle to the transmission centre line, in (cm). Sa, Sb: as shown above. Accuracy of suspension tower position in vertical direction at straight line: z 20 cm z: permissible absolute vertical deviation, in (cm); this value is predetermined by the specified profile survey tolerance. Line route pegs are to be provided at an inter-visible distance of 150 m along the center line of the transmission line. The Contractor shall verify and provide adequate protection for these pegs to prevent disturbance during easement clearing, site preparation and construction.

B1.4.11.6

Route modifications
The contractor shall confirm all towers at the positions shown on the approved profile plans and drawings. If during the construction the site of any tower as spotted in the plan and drawings is not suitable by reasons of topographical, geological or any other affecting conditions, the Contractor shall be required to recommend alternative locations of the towers to the Employer/Employers Representative for consideration. The Contractor shall carry out the work in accordance with the Employers decision.

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For route modifications agreed with the Employer/Employers Representative, the Contractor shall carry out a complete line survey, elaboration of the longitudinal profile drawings including the necessary uphill side slope information, plotting of the towers, pegging the tower positions in site and surveying diagonal profiles for determination of leg extensions complete as required for the project. All these works caused by route modifications during construction are deemed to be included in the scope of Contract work and no extra payment will be done to the Contractor.

B1.4.11.7

Site preparation and erosion protection


Prevention and control of soil erosion at sites is of prime importance for the stability of the tower location. Leveling of tower locations shall be minimized in sloped terrain therefore. The tower sites themselves shall also be sloped as necessary to protect against erosion due to water flow. If there is a natural flow of water across the site, the water flow shall be diverted around the site or the site shall be suitably protected against erosion by grading and/or placing of rip-rap or other erosion barriers, vertiver grass, or construction of drainage. Prior commissioning of the OHL all tower location susceptible to erosion shall be inspected in presence of the Employer/ Employers Representative to check the effectiveness of the applied erosion protection. Indications of erosion have to be rectified by the Contractor and improvements of erosion protection provided as approved with the Employer/ Employers Representative. All measures against erosion protection executed in the beginning of works and/ or prior commissioning are deemed to be included in the Contract price.

B1.4.11.8

Foundation works

B1.4.11.8.1

General
The execution of tower foundations shall be done in accordance with IEEE Standard 977 1991 (R1997) as well as CIGRE Recommendation 308 (Foundation Installation) May 2006 and shall include the following main activities: Excavation works execution of the necessary preliminary works before pouring concrete of the foundations (anchors, groutings, coned shapes, soil exchange, compaction, reinforcement laying, placing of formwork, stub setting, etc.)

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concreting of foundation backfill works cleaning of site and transport of all superfluous materials protection of the interface between steel tower leg and top section of concrete function

B1.4.11.8.2

Earthworks
General Detailed procedures are specified in the part of General Technical Requirements. Particular attention is drawn to the requirements of verifying and assessing of the actual soil condition at each tower footing by an experienced soil mechanic/civil expert. Excavation In soil class 1 to 4 the pad concrete is directly placed against the natural soil. The excavation dimension shall be within 2 cm + 10 cm on the specified nominal dimension observing the minimum reinforcement cover and allowable concrete pad eccentricity not exceeding 15 % of the foundation base width. If loose soil pockets or mismatched excavation position exceed the tolerances, symmetrical enlargement and reinforcing bar extension shall be made to achieve a throughout reinforced centric concrete footing structure. The horizontal angular distortion of spread footing shall not exceed 3 relative to the diagonal axis and the overall horizontal angular distortion of the foundations (tower structure) shall not exceed 3 relative to the center line or bisector line. Test of select fill Place select fill in approximately 250 mm layers (compacted thickness) and compact to 97 % of maximum dry density (BS 1377: - Test 13). Quality control shall establish all of the following values: unit dry weight heavy dynamic sounding, to DIN 4094: 20 blows per 10 cm penetration or alternatively for dutch cone test, DIN 4094, 200 bar point resistance plate load test EV2 not less than 1200 kg/cm2 = 120 MN/m2 EV2/EV1 smaller than 2.2, where: EV1 being the modules of deformation of the first loading process and EV2 being the modules of deformation of the second loading process (reloading after relieving once). Test of ordinary fill Ordinary fill is required for all fill and backfill where special fill or select fill have not been specified on the drawings. Place ordinary fill and compact to 93 percent of maximum dry density (60 % relative density).

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Quality control shall establish all of the following values: Unit dry weight Heavy dynamic sounding, to DIN 4094: 16 blows per 10cm penetration or alternatively for dutch cone test, DIN 4094, 160 bar point resistance. These values are valid only for non-cohesive soils with silt content lower than 15 %. Plate load test EV2 not less than 600 kg/cm2 = 60 MN/m2 for non cohesive soils (silt content lower than 15 %) EV2 not less than 450 kg/cm2 = 45 MN/m2 for cohesive soils. EV2/EV1 smaller than 2.2 for non-cohesive soils EV2/EV1 smaller than 2.5 for cohesive soils Tests shall be performed for each 500m3 of fill but not less than once per shift. Blasting The Contractor shall not obtain or make use of any explosives without the express permission in writing by the local authorities. The Contractor shall comply strictly with the regulation as required by the authorities regarding purchase, storage, issuance and use of explosives and transport of same to and from site, and shall be deemed to have included in his bid all costs arising from the use, storage and transport of explosives as well as from supervision of blasting by security forces. Blasting shall furthermore be strictly and in every case subject to Employers/ Employers Representatives permission. All blasting shall be carried out by approved experts only and the Contractor shall be fully liable for any claims arising from damage or alleged damage, injury to the public etc. due to blasting. The Contractor shall be insured with an approved insurance company against all claims with respect to damage and injury arising from blasting. Fuses, detonators or blasting caps shall not be transported or stored together with dynamite or other explosives. The location and design of the storage places, the transportation methods and the precautions that shall be taken to prevent accidents shall be subject to the Employers/ Employers Representatives approval, but it is understood that this approval does not exempt the Contractor of his responsibility with regard to the handling of dynamite or other explosives. Drilling and blasting plans shall be submitted well in advance for the Employers/ Employers Representatives approval prior to commencement of any blasting work.

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When blasting is carried out, trees, structures etc. in exposed position shall be adequately protected from damage. Drilling and blasting shall be arranged and, where necessary, the rock being blasted shall be protected so as to prevent any scattering of the rock liable to cause injury to the public or damage to dwellings, buildings and other property and the works. Blasting shall be carried out carefully to avoid the loosening of rock surfaces that are to remain intact, particularly in those cases where concrete is to be placed directly against these rock surfaces. Backfill Unless otherwise directed, all filling shall be approved selected material and shall be deposited and compacted using approved material in layers not exceeding 150 mm thick for hand compaction and 250 mm for mechanical compaction. In presence of ground water, dewatering of the foundation pit shall be maintained during backfilling as to guarantee proper compaction of the subsequent fill material layers. The Contractor shall be responsible for making good all settlements of filling due to any cause whatever which may occur up to the end of the period of maintenance.

B1.4.11.8.3

Leg/ Stub setting


The maximum permitted leg/stub tolerances measured at the cross diagonals of anchor bolts or at the top of the stubs shall be as detailed below and are applicable prior to erecting the tower structure. Face, diagonal dimension: 0,1 % of distance Stub level difference: 0,05 % of diagonal distance Stub rake (batter axis): 0,5 % of stub length Stub twist (angular distortion): 0,5 to diagonal axis The stub setting and positioning will require the application of theodolites, mm-graduated steel tapes, templates or lower tower base assembly, rigid stub fixing frames and control measurements during the concreting operation. Final control measurement shall be recorded in the foundation installation sheet. If these tolerances are exceeded at the completed footings, the Contractor shall submit details of his proposed remedial measures to the Employer/ Employers Representative for approval.

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The final plumb of angle towers is also affected by a transverse deflection of the tower head due to conductor load and one-sided utilized bolt clearance (allowance of shank to hole 2,0 mm). To compensate this additional deviation, the compression stubs should be raised vertically. The amount they are raised will depend on the ratio of tower height to base width, angle of line deviation and lattice system of superstructure. Typically adjustments range from cm to 10 cm or 0,1 % to 0,5 % of base width. The stub level setting tolerance in this case will be applied to the Contractors calculated offset value added to the nominal dimension. After clamped-in conductors the tower structure deformation shall not exceed the following allowance: horizontal deflection of complete tower plumb 0,4 % of tower height by both circuits installed plumb 0,6 % of tower height by one circuit installed In plane deflection of tower sections sag 0,2 % of reference length by one or both circuits installed Records of the foundation setting out measurements shall be made available for approval by the Employer/ Employers Representative.

B1.4.11.8.4

Concrete works
General Concrete material requirements and concrete testing procedure are specified in the part of General Technical Requirements. Placing of concrete Concrete shall not be dropped into place from a height exceeding 2 m. Trunks and chutes to Employers Representatives approval shall be used for any concrete to be deposited from a height exceeding 2 m. Concreting in high ambient temperatures The temperature of the mixed concrete shall not exceed 30C. The Contractor shall take special measures in the mixing, placing and curing of concrete. These measures shall include the shading of aggregates, spraying of aggregates with water, cooling of the mix constituents and reduction of transportation time to the minimum. During placing suitable measures shall be provided to prevent premature setting of concrete placed in contact with hot surfaces. All concreting areas, formwork and reinforcement shall be shielded from the direct rays of the sun and sprayed with water when necessary.

Protective measures for concrete Immediately after the compaction of the concrete has been finished, the Contractor shall ensure adequate protection from the weather. The concrete surface shall be covered with a layer of sacking, canvas, straw mats or
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similar absorbent material, a permanent water layer or special protection sprays kept constantly moist for at least 7 days. Repair of defective concrete Repair of defective concrete shall be performed by skilled workmen. The Contractor shall keep the Employer/ Employers Representative advised when repair of defective concrete will be performed. Unless inspection is waived in each specific case, repair of defective concrete shall be performed only in the presence of the Employer/ Employers Representative. Unless otherwise approved, repair of imperfections in formed concrete shall be completed within 24 hours after removal of forms. Concrete that is damaged from any cause such as fractured and honeycombed shall be cut out to a depth at which sound concrete is exposed and filled within dry pack, mortar or concrete matching the structure. All concrete used for patching shall be bonded tightly to the surface of the sound concrete and shall be sound and free from shrinkage cracks and rough areas after curing and drying. All areas to be patched shall be coated with an approved concrete bonding agent in accordance with the manufacturer's printed instructions. Acceptance criteria of defective concrete are specified in the General Technical Requirements. Eccentricity of the final concrete structure relative to the stub axis shall not exceed 10 % of cross sectional dimension of the encasing concrete (chimney side or pile cap part). Offsetting of formwork to meet minimum concrete cover at all times and corresponding form enlargement up to +10 cm on the nominal dimension may be permitted to achieve final centricity of concrete footing.

B1.4.11.9

Tower erection
General The Contractor shall erect the towers and tower accessories in accordance with the approved detailed drawings. No steel tower shall be installed until at least seven days after the last placing of concrete in the foundation, and back-filling has been completed The execution of material delivery, assembly and erection of tower structures shall be done in accordance with IEEE Standard 951 1997. In addition, the following requirements shall be observed. Bolt tightening In general, the towers shall be assembled and erected with bolts finger-tight only. Finger-tight or snug-tight is about one-fourth turn from tight. Final tightening of bolts shall only take place when all members are in place. Bolts installed with spring washers shall be tightened to an approved torque range and as indicated in the following table:

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Size of Bolts (mm) Bolt cl. 5. 6 12 16 20 24

Tightening Torque (Nm) Non-oiled, non-MoS2 greased 30 50 70100 130...170 270...320

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Damaged members Members that are bent, twisted or otherwise deformed in storage, transportation, handling or erecting operations shall be straightened or replaced by the Contractor. Straightening shall be done only by the use of methods that will not damage the zinc coating. Tolerances for lateral variations of straightened members shall be as follows:
Member Type Compression Members Tension-only Members Tolerances 2 mm/1000 mm 6 mm/1000 mm

Members that are damaged in a manner causing reduction in their strength shall be replaced at the Contractor's expense. Site testing of zinc coat The galvanizing thickness shall be tested on site after receiving the galvanized steel members as well as during their erection. The zinc coatings must comply with the thickness requirements as per standards. The Contractor shall have available on site for the Employers/ Employers Representatives use an instrument suitable for the accurate checking of galvanizing thickness on site. The measuring instrument shall apply an electronic measuring method and be available from the time of arrival of the first consignment of material until the issue of the operational acceptance certificate. The cost of the gauge and other operating expenses are deemed to be included in the Contract price. Wet storage stain or bulky white deposits, flux stains or bar spots of an area > 2 cm and resisting by rubbing finger tips shall be removed by an approved procedure till sound coating reveals and shall be subject to the application of a repair coat as outlined below. Damaged galvanizing Tower members arriving on site with damaged galvanizing due to mishandling or formation of white rust shall be repaired by an approved means and submitted to the Employer/ Employers Representative for approval before erection commences. Members rejected by the Employer/ Employers Representative shall be reworked until the Employer/ Employers Representative is satisfied that the repaired coating will provide protection to the member similar to an undamaged galvanized coating. The Contractor shall have ready a sufficient quantity of appropriate repair zinc paint on site. Painting of towers For sites liable to be flooded, the tower body (all types) shall be painted with two coats of coal tar epoxy to a height of 1 m above ground level.

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The first coat of coal tar epoxy shall be spray applied to the clean, dry steel to give a dry film thickness of not less than 150 m. The coating shall be checked for thickness using a magnetic coating thickness gauge and for pinholes using a spark tester. Any deficiencies shall be repaired immediately. A second coat of coal tar epoxy shall be applied after a minimum of four hours after the application of the first coat but not later than five days after the application of the first coat to give a total dry film thickness of not less than 300 m. Coal tar epoxy shall not be applied when relative humidity exceeds 85 %.

B1.4.11.10 Earthing
General Earthing continuity from the earthwire/ OPGW to support fittings to the earthing system is provided by surface contact of bolted members (except ISWER system). The use of the natural earthing consisting of the structural foundation steel is essential. Welded connections shall be provided to include the vertical reinforcement bars of the chimney as well as the horizontal ones of the foundation base (pad) into the earthing system. These weld connections shall be inspected by the Employer/ Employers Representative before concreting. Standard earthing and extension of standard earthing has to be installed as described in the previous chapter. Before commencement of stringing, footing resistance measurements to be approved by the Employer/ Employers Representative shall be made at each tower site. Earthing of structures under the transmission line Where the line crosses metal roofs, pipelines or other objects which may have induced voltages by the energized line, the object concerned shall be earthed in accordance with the Employers/ Employers Representatives requirements. All metallic fences both new and existing, which cross under, or which are located in the proximity of and parallel to the transmission line shall be grounded. The metallic fence gates within the right-of-way shall be electrically bounded to the fences. After installation of the earthing system, the earthing resistance test shall be carried out.

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B1.4.11.11 Conductor and earthwire stringing


General At least one month before stringing commences, the Contractor shall submit a fully detailed stringing schedule to the Employer/ Employers Representative for approval. This schedule shall indicate locations of conductor and earthwire drums and pullers, the proposed position of mid-span joints, together with temporary staying of towers and all other relevant information required for the stringing operations including the maximum tensions to be used during running out of pilot wires, conductors and earthwires. The special instructions for stringing of the OPGW/ OPPC advised by the OPGW/ OPPC manufacturer shall be followed. The Contractor shall engage the manufacturer erection supervisor for the duration of the entire stringing works. The tension stringing method as well as the selection of equipment and tools shall be done in accordance with IEEE Standard 524 2003. Special attention is to be paid to the chapters regarding grounding of equipment and protection of personnel. In addition, the following requirements shall be observed. Crossing of roads, power lines, etc. Scaffolding shall be provided over roads, power and communication lines, houses etc. The cost of all scaffolding shall be included in the stringing price. The scaffolding which is used to cross specified low, medium and high voltage power lines shall be of such dimensions to allow clearances that the power lines being crossed may remain in operation during construction of the new transmission line. Shut-downs on the lines to be crossed may be given for construction of new line but shall not be given continuously for longer periods. Such restrictions in building and use of the scaffolds shall not be grounds for claiming additional costs. Design and construction of the live line scaffold shall not be inferior to the minimum standards outlined in the following clause. The scaffold shall be designed to withstand the maximum design wind speed, except that a reduced return period will be accepted. Consideration shall also be given due to impact loading by dropping of the upper phase conductor. The scaffold shall consist of square mesh nylon nets attached to steel wire ropes running perpendicular to the lower line route, carried by metal scaffolding at 3m intervals. The nets shall be attached to the catenary wires by means that do not require the presence of any persons on the net or the catenary wires whilst the lower line is alive. The scaffold shall extend at least 5 m either side of the outermost conductors of the upper line. a maximum of 2 m of this distance may be provided by means of catchers. Catchers shall be provided at each end of each scaffold support. The catchers may be vertical or inclined to a maximum angle of 45 from the vertical.

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Where possible the resistance to earth of the scaffold shall be less than 10 ohms. Special consideration by the Employer and the lower line operator shall be given in cases where this is not attainable with a reasonable number of driven earth rods. Bonding the scaffold to the earthing systems of either the life-line or the line under construction is not normally acceptable. Drawings of the scaffold, complete with details of the clearance plates and earthing arrangement, together with supporting, calculations shall be submitted to the Employer/ Employers Representative for approval. Repair of damaged conductors and earthwires Any damage caused to a conductor or earthwire shall immediately be reported to the Employer/ Employers Representative whose decision to replace or repair will be final.

Repair of the damage shall be carried out in the manner indicated or approved by the Employer/ Employers Representative at the expense of the Contractor. Damage is any deformity on the surface of the conductor which can be detected by eye or by feel. Damage includes, but is not limited to, nicks, scratches, abrasions, kinks, basketing, popped-out strands and broken strands. Where, in the opinion of the Employer/ Employers Representative, repairs can satisfactorily be effected, repairs shall be made by careful smoothing with fine emery paper, covering with repair rods or by cutting and jointing. When damage to the conductor does not exceed two aluminum strands, either broken or nicked deeper than one-third of their diameter to the earthwire does not exceed two AL strands, nicked deeper than onethird of their diameter repair sleeves may be installed. When more than two strands are broken, abraded or nicked deeper than onethird of their diameter, or two AL strands, nicked deeper than one-third of their diameter, the damaged section of the conductor shall be cut out and jointed and the OPGW/ OPPC shall be replaced. When there is repeated damage on the same span or in consecutive spans, all the conductors and earthwires affected in these spans shall be replaced. Kinked, basketed or severely damaged sections shall be cut out. All damage caused by come-alongs and other gripping devices shall be repaired or cut out before final sagging.
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Conductor and earthwire repair sleeves shall not be used without the permission of the Employer/ Employers Representative and will be granted only in exceptional circumstances. Re-drumming because of damage by the Contractor shall be at the expense of the Contractor. Jointing of conductors, earthwires and OPGW/ OPPC Joints in the conductors shall be of the compression type. Conductors shall be terminated at tension towers by means of compression type dead-end assemblies. Jointing of all conductors shall be performed as nearly as practicable at the same position. All compression joints shall be filled and finished with emery cloth to produce a smooth surface, free of flash and sharp points, which might be a source of corona or radio interference. The Contractor shall furnish all necessary tools, including compression tools required. At joints and terminations, the contact surface of conductors, dead-ends, midspan joints and jumper terminals, including the faces of contact palms, shall be bright and clean and shall be liberally coated with an approved jointing compound before compression and bolting operations are carried out. The Contractor shall ensure that no bird-caging, over-tensioning of individual wires or layers or other deformation or damage to the conductor or earthwire occurs. Cutting of layers of conductors and earthwire shall be carried out with tools designed to prevent damage to underlying strands or optical fiber tubes. The Contractor shall keep a record of each compression fitting showing its location, date of assembly, and the name of the linesman responsible for the assembly. All conductor joints shall be located in the span at least 30m away from a suspension clamp or tension clamp or compression dead-end. There shall be not more than one such joint per conductor in any one span. Sagging The conductors and earthwires shall be sagged in accordance with tension/sag tables calculated by the Contractor and approved by the Employer/Employers Representative. The Contractor shall at an early stage submit for the Employer/Employers Representatives approval his proposals for a system of initial tensioning which shall ensure that the conductors and earthwires are so erected as to arrive at the required final tensions after 10 years in service.

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The system shall be such that other components of the line are not overloaded during stringing operations and conductors and earthwires are not unduly exposed to Aeolian vibration damage in the period following the erection. The creep calculation shall consider that the conductors hang in the stringing blocks 48h before being pulled to the specified sag. Final tension shall mean the horizontal tension in a conductor or earthwire after a time period of approx. 10 years in service, which is considered the final stage of the conductors/ earthwires, under a given loading and temperature condition. Final tension corresponds to final sag where the permanent conductor elongation (creep) at maximum conductor temperature the specified minimum ground clearance is maintained. Initial tension shall mean the horizontal tension in conductor/ earthwire at the time of clamping-in, which is considered the initial stage of the conductor/ earthwire under a given loading and temperature condition. Initial tension corresponds to initial sag where the immediate conductor stretch has been consolidated prior clamping-in of conductor/ earthwire. Control measurements of sags within 2 weeks after clamping-in shall be within the following tolerances: Accuracy of sags of clamped-in conductors/ earthwire at any span length > 150 m and < 600 m: z 1 0,5 S S: horizontal span length, in (m) z: vertical deviation in (cm) relative to the initial sag Accuracy phase vertical spacing clearance: c 15 cm on nominal vertical distance Accuracy phase horizontal level difference: f 15 cm level difference relative to each other phase Bundle twist of spaced phase conductors: p 2 conductor to horizontal level Accuracy of cable temperature for sagging: t 2 C on actual temperature > +10C t: permissible deviation, in degrees Celsius, on the actual average temperature of conductor material. The specified tolerance requires the reference measurement of the actual conductor temperature to be obtained from a ~ 1 m long conductor sample. The thermometer shall be inserted into the cable core and suspended > 1 hour at the suspension level of the conductor in the respective sagging section prior to any readings of the temperature.
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Control measurements of sags > 2 weeks after clamping in should be done after giving due regard to the effects of creep on tensioned conductors (as a guide, ~ 50 % up to 80 % of the total creep resp. measurable sag increase arise within the first half year after erection). The spans adjacent to gantries of substations shall be slack spans. Clearances between conductors and ground and between jumpers and all structures are to be checked during erection and before handing over the line. Control measurements of conductor ground clearance > 2 weeks < 10 years after clamped-in conductors shall take into account the initial sag stage at a given temperature. The in-situ measured vertical clearance at initial stage shall be bigger than the specified minimum ground clearance plus allowance at the final stage by the amount of not yet consolidated conductor creep. The allowable difference between the measured vertical distance and the calculated ground clearance at any line point shall not exceed -0,50m. When exceeding the specified clearance tolerance, the Contractor shall undertake corrective measures being approved by the Employer/Employers Representative on his own expenses. The Contractor shall keep a schedule recording all sagging operations showing details of the section, the sagging and checking spans, ambient temperature, pre-stress (where appropriate) initial and final sags, the date of sagging, clipping-in offsets and conductor ground clearance measurements. This record schedule along with the record of compression fittings shall form a part of the final records for the line and shall be handed over for approval to the Employer/Employers Representative. The records shall be available for inspection at any time. Clipping in All conductors and earthwires shall be accurately marked for clipping-in at all towers on the same day following final sagging. Clipping-in offsets shall be calculated by the Contractor and marked using a method approved by the Employer/Employers Representative that will not damage the conductors and earthwires. Preformed armor rods shall be installed at all points of conductor and earthwire suspension. Armor rods shall be carefully centered in the suspension clamp. Suspension clamps shall be installed and adjusted such that the insulator string in its final position hangs in a vertical plane through the axis of the structure. If it becomes necessary to change the point of attachment of suspension clamp by more than 10 cm either way from the mid-point of the armor rods after they are installed, the rods shall be removed and reinstalled so as to

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center on the point of attachment. Under such circumstances the armor rods may be reused if not damaged. The Contractor will not be allowed any additional compensation for such removal, re-installation, or replacement of armor rods where required. The final suspension insulators shall hang plumb after clamped-in conductor by a tolerance to the vertical of 2 % of the insulator set length. The final mid-point position of sag adjuster links after clamped in conductors shall be within of l from the centre of adjustable range length (l). The final jumper loop clearance radial from the most bottom projecting steel part of crossarm shall be within 10 cm on the nominal dimension of the vertical distance in the loop bend.

B1.4.11.12 Line hardware and insulator string set installation


Insulators and fittings shall remain in their crates and shall be removed only just prior to erection and shall be handled carefully to avoid damage. Insulator with porcelain or glass insulating parts shall have no fissures or cracks and no surface defects such as folds, blow-holes, bubbles in the glass > 5 mm in diameter. Insulators shall be cleaned immediately prior to lifting onto structures with a soft cloth to remove all dust and deposits. Abrasives or wire brushes shall not be used. The execution of line hardware and insulator string set installation shall be done in accordance with IEEE Standard 951 1996 (chapter 10 insulators and hardware) as well as with IEEE Standard 524 2003 (chapter 10.8 damper and chapter 10.9 spacer and spacer damper).

B1.4.11.13 Pre-Commissioning and Commissioning

B1.4.11.13.1 Final checking


Subsequent to the completion of the transmission line construction, the Contractor shall carry out pre-commissioning and commissioning works. The Employer/ Employers Representative is entitled to attend final checking and commissioning tests, and the Contractor shall bear all costs and expenses of tests and attendance as per price schedules. The Contractor shall give the Employer/ Employers Representative notification in writing, not less than 45 days in advance, of the date of testing. Test program shall demonstrate procedures of test in order to proof the specified technical requirements and be subject to approval by the Employer prior testing starts. Additional tests may be called by the Employer/ Employers Representative
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to ensure that the required quality is met. The Contractor shall supply all necessary labor, material, equipment and competent and authorized test personnel. Calibration of equipment is deemed to be included. Six (6) copies of test reports and/ or certificates are to be provided showing all results and information necessary within two weeks after test performance. The pre-commissioning shall include but not be limited to: tightening of bolts and fixing of missing members to towers; remove all scaffolds and equipment and clear all debris and other rubbish from the site; restore surface damage, foundation subsidence and carry out erosion control measures, where directed by the Employer/ Employers Representative or as required by local authorities or regulations; remove all left-over materials at winch yards, drum yards and store yards; complete danger tree clearing and tree re-clearing on the easement; re-conditioning and handing over of access roads which shall be used for maintenance purposes; check phase sequence plates on both sides of all points of the line; measurement of the OHTLs and communication parameters.

B1.4.11.13.2 Commissioning
The Contractor shall be responsible for satisfying the Employer/ Employers Representative when the lines are ready to be commissioned and shall conduct the commissioning/tests in the presence of and as instructed by the Employer/ Employers Representative. The Contractor shall provide labor, transport and other assistance as required for Commissioning without extra charge. If any failure is detected, the Contractor shall locate and determine the cause of the failure and shall make any replacement or repair necessary or correct any errors in the installation to the satisfaction of the Employer/ Employers Representative and at no extra cost. Prior to the energizing, the Contractor shall provide the Employer/ Employers Representative with a written statement that all personnel and all temporary erection earthing points are withdrawn and the line is ready for energizing. The line shall be energized at full working voltage. Prior to the operational acceptance of the completed line, the following (as a minimum) tests shall be carried out: For power line conductor electrical continuity proving tests for each phase, by telephone connection or an alternative method approved and witnessed by the Employer/ Employers Representative; insulation megger tests for each phase, witnessed by the Employer/ Employers Representative;
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tower earthing system electrical resistance measurements by means of a high frequency instrument supplied by the Contractor and approved by the Employer/ Employers Representative; measurement of the OHTLs electrical parameters (line impedance, resistance, etc.). For OPGW/ OPPC The OPGW/ OPPC performances shall be measured between the joint boxes installed on the terminal gantries. The link attenuation shall be measured for each fiber. The total dispersion at 1550 nm shall not be greater than: Ns x 0.08 + L x 0.25 on each fiber, where Ns = total number of splices in line; L = length of the OPGW measured between the joint boxes mounted on the terminal gantries (including the excess in length due to sags and joints). Telecommunication The Contractor shall be responsible for the testing of the telecommunication link between NDC telecommunication rooms of the substations. The corresponding program shall be included in the test program.

B1.4.11.13.3 Operational Acceptance


On completion of the final checking and testing, the Contractor shall deliver to the Employer/ Employers Representative a written statement certifying that the line is complete in every respect and that all earths placed by the Contractor have been removed and that every member of the Contractor's staff has been informed that nobody is allowed to work on the line unless a working permit as been issued signed by the Employer/ Employers Representative. Tools, appliances and spare materials required for maintenance of the transmission line shall be handed over as detailed in the price schedules. All outstanding drawings and documentation are to be provided as per Contract.

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B1.5

Technical Schedules

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Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Unit

Bidder / Contractor

Data required

Data offered

1. General System highest voltage for equipment /power frequency Nominal voltage Rated lightning impulse withstand voltage (peak) Rated switching impulse withstand voltage Rated short duration power frequency withstand voltage System neutral System highest 3-phase short-circuit current level (1s) Short circuit current for thermal stability check of the OPGW (1s) Specific insulation creepage distance based on system highest phase to phase voltage for equipment (420 kV) min.: Radio noise limit for radio interference testing of insulator sets, fittings, etc. Corrosion protection measures: Hot-dip galvanizing for steel sections, fittings, etc Hot-dip galvanizing of bolts, nuts & washers Conductors phase conductor earthwire OPGW insulated earthwire (ISWER) OPPC (ISWER) m m 85 55

kV/Hz kV kV, peak kV kV, r.m.s. kA kA

420 / 50 400 1425 1050 630 Solidly earthed 40 10 25

mm/kV dB above 1 V

46

type type type

ACSR BLUEJAY ACSR 95/55 similar to AL/ACS 95/55 ACSR 185/30 similar to AL/ACS 185/30

type type

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Design Temperatures Maximum ambient temperature Minimum conductor temperature Maximum conductor temperature Every day temperature Temperature with maximum wind Reference wind speed VR at 10 m above ground Line Data Number of circuits Number of conductors per phase Number of OPGWs or OPPCs (ISWER) Number of EWs or insulated EWs (ISWER) Total approximate length of lines - Lot 1 - Lot 2 - Lot 3 Tower Types NS and NSh (normal suspension) Angle of deviation Type of insulator sets HS and HSh (heavy suspension) Angle deviation Type of insulator sets angle cap & pin angle cap & pin quantity quantity quantity quantity km km km C C C C C m/s Unit

Bidder / Contractor

Data required

Data offered

+40 +10 +85 +25 +10 31

2 2 1 1 225 217 228

0 2 Isuspension

0 - 2 I suspension

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description LA and LAh (light angle) Angle of deviation Type of insulator sets HA/DE and HAh (heavy angle/terminal) Angle Deviation for HA Angle of deviation for DE: Line side Substation Side Type of insulator sets TP (transposition) Angle of deviation Type of insulator sets angle cap & pin angle angle cap & pin angle angle cap & pin Unit

Bidder / Contractor

Data required

Data offered

0 - 30

tension

30-70

0-45 0-45 tension

0 - 2 tension

2. Minimum partial factors Partial factors for load actions ( F) For permanent actions (dead weight of conductors, earthwires, insulator sets, tower) For variable actions (wind, conductor tension) in normal loading cases For accidental actions in exceptional loading cases For construction and maintenance loads 1.1 (when stress increasing) and 0,9 (when stress decreasing) 1.3 1.0 1.5

factor

factor factor factor

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Partial factors for material strength ( M) Structural steel sections, plates, etc for suspension towers Structural steel sections, plates etc for angle towers Bolts Concrete Reinforcing steel Conductors and earthwires under maximum load condition Soil property at suspension towers Soil property at angle towers Insulators, all substrings intact Insulators, with one substring broken Insulator set fittings, all substrings intact Insulator set fittings, with one substring broken factor factor factor factor factor factor factor factor factor factor factor factor Unit

Bidder / Contractor

Data required

Data offered

1.1 1.25 1.25 1.5 1.2 1.55 1.9 2.15 2.5 1.25 2.5 1.25

3. Clearances Minimum clearance between phase conductors Dpp Minimum clearance to earthed parts Del Minimum Vertical Clearances Minimum vertical clearances from the line conductors at maximum sag to ground or for various crossings: Normal ground Ground in populated areas Roads and streets Grown trees Residential or other buildings Power lines (above) Telecommunication lines Railways
5413A08/FICHT-7269868-v8

m m

4.1 3.3

m m m m m m m m

10.00 12.00 11.00 4.70 7.20 3.90 3.90 11.00


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Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Rivers (no ships) Minimum Horizontal Clearance Highway Main roads Angle of crossing highways, main roads and railways Minimum horizontal clearances between the line conductors at maximum sag under calculated conductor swing and objects close to the line Mid-span wire clearances 400 kV Mid-span phase to phase clearance for horizontal phase arrangement Mid-span phase to phase clearance for quasi-vertical phase arrangement Mid-span phase to OPGW clearance for quasi-vertical wire phase arrangement Minimum clearances between conductors/live fittings and tower steel structure 400 kV: Under still air for the lateral phases of double circuit line towers For suspension insulator set calculated swing under moderate wind (58% of maximum wind pressure) jumper suspension sets and free jumpers under 15 swing For suspension set maximum calculated swing jumper suspension sets and free jumpers under 35 Minimum clearances between conductors/live fittings and tower steel structure 36 kV: Under still air for the lateral phases of double circuit line towers For suspension insulator set calculated swing under moderate wind (58% of maximum wind pressure) jumper suspension sets and free jumpers under 15 swing For suspension set maximum calculated swing jumper suspension sets and free jumpers under 35 Clearance condition for the earthwires m m m m m
c

Bidder / Contractor

Unit

Data required

Data offered

11.00

m m () m

22.5 22.5 90 30

5.20

0,62 f max

li

3.08

0,75 f max

li
li
b

3.08

0.75 f max

2.5

3.30

2.50

0.75

0.50

0.40 0.20

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description earthwire sag, compared to the conductor sag at 25 for the nominal span OPGW shielding angle () Unit

Bidder / Contractor

Data required

Data offered

5% less 15

4. Foundation and soil data The reference concrete volume of the tower foundation shall be calculated taking into account: All four footings per tower and soil class, horizontal terrain level, factored loads from max. tower body and leg extension, nominal volume excluding excess concrete, soil parameters as shown below and dimensional conditions as specified in the Technical Requirements, Foundation Design. Soil investigation Penetration equipment in accordance with the characteristic data as specified in the Technical Requirements, Soil Investigations; If other types, specify characteristic data. Foundation material Concrete class (nominal cube strength 20 N/mm ) according to Reinforcing grade (ripped bars fy 420 N/mm ) according to Cement grade (standard Portland cement) according to Supporting documents Outline drawing of each type of foundation Foundation Class 1 Hard Rock yes
2 2

type

SPT or DPL or CPT or other

class standard grade standard grade standard

C20/25 EN 206-1 BSt 420 EN 10080 CE 32.5 EN 197

Principal foundation category Ultimate bearing pressure Ultimate shear friction resistance

type kN/m kN/m

Rock anchor 2000 200

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Reinforced concrete density Homogeneous rock density Foundation anchor length Concrete reinforcing content Reinforced concrete volume incl. anchor mortar NS tower Reinforced concrete volume incl. anchor mortar LA tower Foundation Class 2 Soft Rocks kN/m kN/m m kg/m m m
3 3

Bidder / Contractor

Unit

Data required

Data offered

24 25

Principal foundation category Ultimate bearing pressure Ultimate shear friction resistance or Ultimate frustum angle Reinforced concrete density Compacted backfill density Foundation structure depth Concrete reinforcing content Reinforced concrete volume NS tower Reinforced concrete volume LA tower Foundation Class 3 Good Soil

type kN/m kN/m2 () kN/m


3

Standard pad & chimney no undercut

1000 100 30 24 18

kN/m m kg/m m m
3

Principal foundation category

type
2

Reduced pad & chimney with undercut 400 20

Ultimate bearing pressure Ultimate frustum angle

kN/m ()

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Reinforced concrete density Compacted backfill density Foundation structure depth Concrete reinforcing content Reinforced concrete volume NS tower Reinforced concrete volume LA tower Foundation Class 4 Poor Soil, No Water Principal foundation category Ultimate bearing pressure Ultimate frustum angle Reinforced concrete density Compacted backfill density Foundation structure depth Concrete reinforcing content Reinforced concrete volume NS tower Reinforced concrete volume LA tower Foundation Class 5 Poor Soil, With Water type kN/m () kN/m kN/m m kg/m m m
3 3 3 2

Bidder / Contractor

Unit

Data required

Data offered

kN/m

24 16

kN/m m kg/m m m
3

Standard pad & chimney no undercut

250 10 24 16

Principal Foundation category

type
2

Extended pad & chimney submerged 150 5

Ultimate bearing pressure Ultimate frustum angle

kN/m ()

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Reinforced concrete density Compacted backfill density Foundation structure depth Concrete reinforcing content Reinforced concrete volume NS tower Reinforced concrete volume LA tower Foundation Class 6 Very Poor Soil, With Water Principal Foundation category Ultimate bearing pressure Ultimate frustum angle Reinforced concrete density Compacted backfill density Foundation structure depth Concrete reinforcing content Reinforced concrete volume NS tower Reinforced concrete volume LA tower type kN/m () kN/m
3 2

Bidder / Contractor

Unit

Data required

Data offered

kN/m kN/m m kg/m m m


3

14 10

Shallow raft submerged or piles 80 0 14 10

kN/m m kg/m m m
3

5. Lattice Steel Towers General information and data Manufacturer company -

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Design and statical calculation corresponds with the specification and standards set out hereto Material used: a) Structural members according to If other, specify standard Qualities: according to for main stressed parts for other parts b) Bolts and nuts Qualities: Step bolt diameter (min.) Permissible stresses of structural members, bolts and nuts correspond with Bolt connections secured with washers and spring washers All tower steel parts hot dip galvanized Zinc coat: for steel sections for bolts and nuts standard standard grade grade standard class mm standard m m standard Unit

Bidder / Contractor

Data required

Data offered

yes

EN or Other EN 10025 S355JO / S355J2 G3/G4 S235JO / ISO 898 S235J2 G3/G4 5.6 or 8.8 16 EN 1993-1-1 EN 50341-1-J yes yes 85 55 ISO 1461

Quality and tests correspond with Min. diameter and number of bolts at stressed member connections bolt diameter Maximum slenderness ratio L/r: Main leg, stub and main compression members in crossarm All other members having computed stresses Redundant members without computed stressed Tension members only Minimum thickness (t) and size of steel members of towers shall be as follows:

mm

16

120 200 250 300

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Main leg, stub and main compression members in crossarm All other members having computed stresses Redundant members without computed stressed Gusset plates Minimum angle bars: equal angle sections unequal angle sections Maximum length of structural member Tolerances of finished members: Max. lateral variations of actual length between points of lateral supports Finished members without ends finished for contact bearing: - Members up to 3m length - Members greater than 3m length - 3m to 6m - greater than 6m Tower layout The reference weight and dimension of the structure shall be calculated taking into account the steel structure including foundation stubs, members, joint plates, bolts and galvanizing excluding excess material, insulator attachments, conductors and designed according to the specified loadings, span parameters and dimensional conditions (face slope, structure deflection) as set out in the Technical Requirements of Tower Design. mm mm mm m mm mm mm mm Unit

Bidder / Contractor

Data required

Data offered

6 5 5 6 L45x45xt L45x30xt 9

ratio

1/1000

1.5

2.5 3

Double Circuit Normal Suspension Tower Type NS Specific data:

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Design spans: Wind span Weight span max. Maximum span Minimum ratio weight to wind span for clearance check Main dimensions: Total height above ground for tower body/leg basic 0m Spacing of crossarms top-middle bottom m m m ratio Unit

Bidder / Contractor

Data required

Data offered

440 700 650 0.80

m m

Height of lowest crossarm above ground level for tower body/leg basic 0 m Width between tower stubs at ground level for tower body/leg basic 0 m Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for the tower body/leg basic 0 m Total weight of tower structures including 4 (four) legs basic 0 m and 4(four) stubs for following tower configurations for tower basic body 0 m Double Circuit Heavy Suspension Tower Type HS Specific data: Design spans: Wind span Weight span max Maximum span Minimum ratio weight to wind span for clearance check Main dimensions: Total height above ground for tower body/leg basic 0m Spacing of crossarms top-middle-bottom Height of lowest crossarm above ground level for tower body/leg basic 0 m
5413A08/FICHT-7269868-v8

m ()

kNm

kg

m m m ratio

800 1100 950 0.6

m m

164

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Unit

Bidder / Contractor

Data required

Data offered

Width between tower stubs at ground level for tower body/leg basic 0 m Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for the tower body/leg basic 0 m Total weight of tower structures including 4 (four) legs basic 0 m and 4(four) stubs for following tower configurations for tower basic body 0 m Double Circuit Light Angle Tower Type LA Specific data: Design spans & line angle: Wind span Weight span max./min. Maximum span Line angle Main dimensions: Total height above ground for tower body/leg basic 0m Spacing of crossarms top-middlebottom Height of lowest crossarm above ground level for tower body/leg basis 0 m Width between tower stubs at ground level for tower body/leg basic 0 m Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for the tower body/leg basic 0m Total weight of tower structures including 4 (four) legs basic 0m and 4(four) stubs for following tower configurations for tower basic body 0 m Double Circuit Heavy Angle / Terminal Tower Type HA / DE Specific data:

m ()

kNm

kg

m m m

440 +700/-350 650 0 30

m m m m ()

kNm

kg

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Design spans & line angle: Wind span Weight span max./min. Maximum span Line angle, as Angle tower Line angle, as Terminal tower m m m () ()
o o

Bidder / Contractor

Unit

Data required

Data offered

440 +700/-350 650 30 70 0-45 line direction 0-45 to S/S gantry

Main dimensions: Total height above ground for tower body/leg basic 0m Spacing of crossarms top-middlebottom Height of lowest crossarm above ground level for tower body/leg basic 0 m Width between tower stubs at ground level for tower body/leg basic 0 m Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for the tower body/leg basic 0 m Total weight of tower structures including 4 (four) legs basic 0 m and 4(four) stubs for following tower configurations, without additional terminal tower jumper crossarms for tower basic body 0 m Double Circuit Transposition Tower Type TP Specific data Design spans & line angle: Wind span Weight span max./min. Maximum span Line angle
5413A08/FICHT-7269868-v8

m m m

m () kNm

kg

m m m ()

440 +700/-350 650 0-2


166

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Main dimensions : Total height above ground for tower body/leg basic 0 m Spacing of crossarms top-middle-bottom Height of lowest crossarm above ground level for tower body/leg basic 0 m Width between tower stubs at ground level for tower body/leg basic 0 m Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for tower body/leg basic 0 m Total weight of tower structures including 4 (four) legs basic 0 m and 4 (four) stubs for following tower configurations for tower basic body 0 m Double Circuit Normal Suspension Tower Type NS h Specific data: m m m m () kNm Unit

Bidder / Contractor

Data required

Data offered

kg

Design spans: Wind span Weight span max. Maximum span Minimum ratio weight to wind span for clearance check Main dimensions: Total height above ground for tower body/leg basic 0m Height of crossarm above ground level for tower body/leg basic 0 m Width between tower stubs at ground level for tower body/leg basic 0 m Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for the tower body/leg basic 0 m Total weight of tower structures including 4 (four) legs basic 0 m and 4(four) stubs for following tower configurations for tower basic body 0 m
5413A08/FICHT-7269868-v8

m m m ratio

440 700 650 0.80

m m ()

kNm

kg
167

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Double Circuit Heavy Suspension Tower Type HSh Specific data: Design spans: Wind span Weight span max Maximum span Minimum ratio weight to wind span for clearance check Main dimensions: Total height above ground for tower body/leg basic 0m Height of crossarm above ground level for tower body/leg basic 0 m Width between tower stubs at ground level for tower body/leg basic 0 m Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for the tower body/leg basic 0 m Total weight of tower structures including 4 (four) legs basic 0 m and 4(four) stubs for following tower configurations for tower basic body 0 m Double Circuit Light Angle Tower Type LAh Specific data: Design spans & line angle: Wind span Weight span max./min. Maximum span Line angle Main dimensions: Total height above ground for tower body/leg basic 0m Height of l crossarm above ground level for tower body/leg basis 0 m Width between tower stubs at ground level for tower body/leg basic 0 m
5413A08/FICHT-7269868-v8

Bidder / Contractor

Unit

Data required

Data offered

m m m ratio

800 1100 950 0.6

m ()

kNm

kg

m m m

440 +700/-350 650 0 30

m m m

168

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for the tower body/leg basic 0m Total weight of tower structures including 4 (four) legs basic 0m and 4(four) stubs for following tower configurations for tower basic body 0 m Double Circuit Heavy Angle HAh Specific data: Design spans & line angle: Wind span Weight span max./min. Maximum span Line angle, as Angle tower Line angle, as Terminal tower () Unit

Bidder / Contractor

Data required

Data offered

kNm

kg

m m m () ()
o o

440 +700/-350 650 30 70 0-45 line direction 0-45 to S/S gantry

Main dimensions: Total height above ground for tower body/leg basic 0m Height of crossarm above ground level for tower body/leg basic 0 m Width between tower stubs at ground level for tower body/leg basic 0 m Slope angle to the vertical of one tower face Maximum design bending moment calculated with factored actions, for the tower body/leg basic 0 m Total weight of tower structures including 4 (four) legs basic 0 m and 4(four) stubs for following tower configurations, without additional terminal tower jumper crossarms for tower basic body 0 m m m

m () kNm

kg

6. Conductor and OPGW

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TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description 6.1 Phase Conductors General information and data: Manufacturer Standards for design (construction and material) Conductor Aluminum Steel Total Conductor diameter Conductor structure /stranding: Aluminum Steel Ultimate breaking load, min. max. working stress EDS (25C, still air) 0 DC resistance at 20 C, max Weight Modulus of elasticity Thermal expansion coefficient Conductor length on drum Gross weight per drum incl. conductor No / mm No / mm kN N/mm N/mm Ohm/km kg/km N/mm 1/ C m kg
0 2

Bidder / Contractor

Unit

Data required

Data offered

company standard type mm mm mm


2

ASTM B232 ACSR BLUEJAY 564.0 39.3 564.0 31.96

mm

45 x 3.995 7 x 2.684 133

0.05118

72500 0.0000208

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Long term thermal current carrying capacity (for 40 C ambient temperature, 0.5 m/sec wind velocity, solar 2 radiation of 1250W/m for 85 C conductor endtemperature) A Unit

Bidder / Contractor

Data required

Data offered

6.2 Earthwire (non-insulated) General information and data: Manufacturer Standards for design (construction and material) Earthwire Stranding and wire diameters: Aluminum Steel Design cross-sectional areas: Aluminum Steel Total Conductor diameter Ultimate breaking load min. max. working stress EDS (25C, still air) Weight Coefficient of linear expansion Modulus of elasticity mm mm mm
2

company standard type

EN 50182 ACSR 95/55

No / mm No / mm

12 x 3.20 7 x 3.20

96.5 56.3 152.8 16.0 77.85


2

mm kN N/mm 2 N/mm kg / km 1/deg N/mm

0.0000153 107000

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Standard delivery length per drum Gross weight per drum incl. conductor Maximum DC resistance (T = 20 C) 6.3 Earthwire (insulated - ISWER) General information and data: Manufacturer Standards for design (construction and material) Earthwire Stranding and wire diameters: Aluminum Steel Design cross-sectional areas: Aluminum Steel Total Conductor diameter Ultimate breaking load min. max. working stress EDS (25C, still air) Weight Coefficient of linear expansion Modulus of elasticity mm mm mm
2

Bidder / Contractor

Unit

Data required

Data offered

m kg /km 0.2992

company standard type

EN 50182 ACSR 185/30

No / mm No / mm

26 x 3.00 7 x 2.33

183.8 29.8 213.6 19.0 65


2

mm kN N/mm 2 N/mm kg / km 1/deg N/mm

0.0000189 77000

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Standard delivery length per drum Gross weight per drum incl. conductor Maximum DC resistance (T = 20 C) 6.4 OPGW and OPPC General information and data: Manufacturer Standards for design (construction and material) company standard m kg /km Unit

Bidder / Contractor

Data required

Data offered

0.1571

EN 50182 IEC 60794-1-1 IEC 60794-1-2 IEC 60794-4 ITU-T G655, ITU-T G.652D EN 50182 IEC 60104 IEC 61232 IEE Std.1138 IEC 60793-1-1 IEC 60793-1-2 IEC 60793-1-3 IEC 60793-1-4 IEC 60793-1-5 similar to AL/ACS 95/55

OPGW (non-insulated) Stranding and wire diameters: Aluminum Steel Design cross-sectional areas: Aluminum Steel Total Conductor diameter

type

No / mm No / mm

mm mm mm

mm

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Ultimate breaking load min. max. working stress EDS (25C, still air) Weight Coefficient of linear expansion Modulus of elasticity Standard delivery length per drum Gross weight per drum incl. conductor Maximum DC resistance (T = 20 C) OPPC (insulated - ISWER) Stranding and wire diameters: Aluminum Steel Design cross-sectional areas: Aluminum Steel Total Conductor diameter Ultimate breaking load min. max. working stress EDS (25C, still air) Weight Coefficient of linear expansion mm mm mm
2

Bidder / Contractor

Unit

Data required

Data offered

kN N/mm 2 N/mm kg / km 1/deg N/mm m kg /km type


2

44.5

0.2992 similar to AL/ACS 185/30

No / mm No / mm

mm kN N/mm 2 N/mm kg / km 1/deg


2

65

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Modulus of elasticity Standard delivery length per drum Gross weight per drum incl. conductor Maximum DC resistance (T = 20 C) Electrical Characteristics Short Circuit Test N/mm m kg /km Unit

Bidder / Contractor

Data required

Data offered

0.1571

- T initial - Fault current intensity - Fault current duration - Maximum temperature of optical fiber unit Lightning strike - Current - Duration - Charge transfer Temperature cycling - TA - TB Type test certificate for OPGW / OPPC Proof of operation experience Fiber Characteristics: No. of optical fibers

C kA s C

40 7 1 160

kA s C

100 0,5 50

C C -

+ 10 + 40 yes yes

quantity

48

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Fiber Type ITU-T G.655 Fiber excess length Core diameter Transmission wavelength Mode field diameter at 1550 nm (including tolerances) Optical cladding diameter Cladding non-circularity Core concentricity error Fiber coating: Material Nominal diameter Cable attenuation: ( maximum ) - for every fiber in every drum at optical wavelength of 1550nm Joint attenuation for every fibre measured on the fully installed joint: - at optical wavelength 1550 nm Max. total dispersion: -at optical wavelength 1530nm-1565nm -at 1565nm-1625nm PMD Cable cut off wavelength Core numerical aperture:
ps/km.nm

Bidder / Contractor

Unit

Data required

Data offered

promille m nm m m % m 8.0 to 11 10 % 1550 10.5 0.7 125 1 m <2 0.8 m

m 250+/-10

dB/km

0.25

average maximum

dB dB

0.08 0.10

ps/km.nm

ps/ km nm 1450

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Life span: (min) Refractive index at 1550 nm Proof test 1 second at 1550 nm Fiber Type ITU-T G.652.D Fiber excess length Core diameter Transmission wavelength Mode field diameter Optical cladding diameter Cladding non-circularity Core/cladding concentricity error Fiber coating: Material Nominal diameter Attenuation at 1310 nm average average maximum dB/km dB/km m promille m nm m m % m years % Unit

Bidder / Contractor

Data required

Data offered

30

8.6 9.5 125 1.0 0.6

0.4

Attenuation at 1550 nm average maximum dB/km dB/km nm 0.25 1300

Cromatic dispersion 0 min

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description 0 max S0 max nm
ps/nm2 x km

Bidder / Contractor

Unit

Data required

Data offered

1324 0.092

Joint attenuation for every fibre measured on the fully installed joint: - at optical wavelength 1550 nm PMD Cable cut off wavelength average maximum dB dB ps/ km nm 1260 0.08 0.10

Core numerical aperture: Life span: (min) Refractive index at 1550 nm Refractive index at 1310 nm Proof test 1 second Minimum bending radius

years % mm 30

7. Insulators and Fittings Insulator manufacturer company

Fittings manufacturer 7.1 Performances for 400 kV equipment Power frequency withstand voltage wet one minute Impulse withstand voltage 1.2/50 ms - positive Impulse withstand voltage 1.2/50 ms - negative Wet switching impulse withstand voltage

company

kV kV kV kV

630 1425 1425 1050

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Corona test voltage Min. creepage distance per string normal pollution Radio interference voltage: - Power frequency test voltage - Maximum RIV above 1V Spark gap of arcing devices Single I suspension set Double suspension set Double tension set Specific data: Insulator Type for Suspension and Tension Sets Composite IEC designation Insulating material Minimum leakage path Power frequency flash over voltage ( wet ) - min Lighting impulse withstand voltage - min Minimum power frequency puncture voltage Min. electro-mechanical failing load Single suspension set for NS towers Double suspension set for NS towers Double suspension set for HS towers kN kN kN term type mm kV kV kV mm mm mm kV dB kV mm/kV Unit

Bidder / Contractor

Data required

Data offered

267 25

267 46

long rod composite

160

160

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Double tension set for all tension towers Overall length of insulator sets Single suspension set for NS towers Double suspension set for NS towers Double suspension set for HS towers Double tension set for all tension towers arcing gap Fittings for Insulator Sets General information and data: Manufacturer Standards for: - design - material and construction - factory tests - galvanization Specific data of material to be used for: - suspension clamps - tension clamps - eyes - swivels - turn buckles type type type type type standard standard standard process standard company mm mm mm mm mm kN Unit

Bidder / Contractor

Data required

Data offered

210

hot dip ISO 1416

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180

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description - yokes - bolts and nuts - split pins for bolts Arcing Devices for Insulator Sets type type type Unit

Bidder / Contractor

Data required

Data offered

General information and data:

Design corresponds with specification

yes/no

Standards applied for

- electrical design

standard

- material and construction

standard

Material

shape

Solid round bar

- upper corona rings - lower corona rings - Arcing devices are galvanized Thickness of horn: - of upper device - of lower device Diameter of horn - of upper device - of lower device

material material -

Alloy Alloy yes/no

mm mm

mm mm

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description End of lower device provided with ball Specific data: Tension clamps (for phase conductors) Type Kind of connection of conductor By means of separate compression sleeve bolted to clamp body Material used for: Outer sleeve material type system Unit

Bidder / Contractor

Data required

Data offered

yes

Inner sleeve Split pins Connection head with bolt Suitable for cross-sections: Suspension clamps (for phase conductors)

material material mm
2

high tensile corrosive resistant Al alloy stainless steel

Type Kind of connection with conductor Material used

type system material high tensile corrosive resistant Al alloy

Production method Suitable for cross-sections: Joints (for phase conductors) Type

process mm
2

type

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Material used for: Unit

Bidder / Contractor

Data required

Data offered

Outer sleeve

material

high tensile corrosive resistant Al alloy

Inner sleeve Suitable for cross-sections: Repair sleeves (for phase conductors) Type Material

material mm
2

type material
2

Suitable for cross-sections 7.2 Performances for 36kV equipment Power frequency withstand voltage wet one minute Impulse withstand voltage 1.2/50 ms - positive Impulse withstand voltage 1.2/50 ms - negative Min. creepage distance per string normal pollution Specific data: Overall length of insulator sets I Suspension set V Suspension set Tension set arcing gap

mm

kV kV kV mm/kV

70 170 170 25

mm mm mm mm

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Insulator Type for Suspension and Tension Sets Composite IEC designation Insulating material Minimum creepage distance Power frequency flash over voltage ( wet ) - min Lighting impulse withstand voltage - min Minimum power frequency puncture voltage Fittings for Insulator Sets General information and data: Manufacturer Standards for: - design - material and construction - factory tests - galvanization Specific data of material to be used for: - suspension clamps - tension clamps - eyes - swivels - bolts and nuts type type type type type standard standard standard process standard company term type mm kV kV kV Unit

Bidder / Contractor

Data required

Data offered

long rod composite

hot dip ISO 1416

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description - split pins for bolts Arcing Devices for Insulator Sets General information and data: Design corresponds with specification Standards applied for - electrical design - material and construction Arcing gap Material - upper and lower corona horns Tension assembly Manufacturer Type Kind of connection By means of helical grip type Material used for helical grips: Dead-end Protection and suitable for vibration dampers install material material mm
2

Bidder / Contractor

Unit

Data required

Data offered

type

yes/no

standard standard mm shape material Solid round bar Alloy

company type system type

Suitable for cross-sections: Suspension assembly Manufacturer

company

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Type Kind of connection with conductor Material used for: clamp body clamp protection spiral wires Suitable for cross-sections: material material material mm
2

Bidder / Contractor

Unit

Data required

Data offered

type system

7.3 Performances for earthwire/ OPGW General information and data: Manufacturer Standard Parts made of steel or iron-material are galvanized Kind of galvanizing Quality and tests correspond with Factory tests acc. to For tension assemblies: Minimum failing load referred to minimum failing load of earthwire/ OPGW For suspension assemblies: Minimum failing load referred to maximum acting forces Slipping load Specific data: % 95 company standard process standard standard yes hot dip IEC 61284

% kN

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Tension assembly Manufacturer Type Kind of connection of OPGW By means of helical grip type Material used for helical grips: Dead-end Protection and suitable for vibration dampers install material material mm
2

Bidder / Contractor

Unit

Data required

Data offered

company type system type

Suitable for cross-sections: Suspension assembly Manufacturer Type Kind of connection with conductor Material used for: clamp body clamp protection spiral wires

company type system

material material material mm


2

Suitable for cross-sections:

7.4 Joints OPGW/ OPGW and OPGW/ OPUG OPPC/ OPPC and OPPC/ OPUG Manufacturer company

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Type: - Var. A: - Splicing along an OHL - Var. B: - Terminal, at gantry Number of cable entries Locking facilities Splice spare length Outer box material Enclosure - complete with Organizer tray Or Splice cassette - accommodation for multiple cassettes - splice cassette suitable for heat shrinkable connectors Temperature Humidity Class of protection Minimum allowed bending diameter of optical fibers
0

Bidder / Contractor

Unit

Data required

Data offered

type type no. m material properly yes 1 Oil resistant and metallic

yes/no

mm

yes/no 200-300 yes

% class mm IP 54 or better

8. Dampers 8.1 Vibration Dampers for earthwires

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Manufacturer Type Material used for: - Counter weights - Elastic cable - Clamp body and keeper Iron and steel parts galvanized Kind of galvanizing Quality corresponds with Weight of damper Distance of damper fixing point from next clamp, and in case two dampers shall be fixed, required distance between damper fixing points Clamping bolts diameter Material: - stainless steel material material material process standard kg company type Unit

Bidder / Contractor

Data required

Data offered

yes hot dip

mm mm

yes/no

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description - galvanized steel - tensile strength - tightening torque N/mm Nm
2

Bidder / Contractor

Unit

Data required

Data offered

yes/no 80 44

Non metallic material temperature withstand Max. bending stress of conductor Expected life of conductors Drainage holes diameter 8.2 Spacer Dampers for phase conductors Manufacturer Type Material used for: - Counter weights - Elastomer - Clamp body and keeper Quality corresponds with Weight of spacer damper Maximum distance between two spacer damper Clamping bolts Material: - stainless steel - galvanized steel

10-60 150 100 6

m Years mm

company type

material material material standard kg m mm

yes/no yes/no

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description - tensile strength - tightening torque Non metallic material temperature withstand Max. bending stress of conductor Expected life of conductors N/mm Nm
0 2

Bidder / Contractor

Unit

Data required

Data offered

80 44 10-85 150 100

m Years

9. Aircraft Warning System

9.1 Red /White painting of tower structure Primer and Touch-up Primer (epoxy zinc phosphate primer) Type Total volume of solids (minimum) Dry film thickness Color Color code RAL Flash Point (tag open cup) Drying time of coating : - at 20 C - at 50 C Type of thinner Type of cleaner h h type type % m color code C Epoxy Polyamide-cured 50 40 - 80 Red / brown

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Intermediate Coat (two pack epoxy, micaceous iron oxide, polyamide cured) Type Total Volume of solids (minimum) Dry film thickness Color Flash point (tag open cup) Drying time for coating : - at 20 C - at 50 C Type of thinner Type of cleaner Final Coat, Red and White (two pack acrylic resin, cured with linear isocyanate, high gloss) Type Total Volume of solids (minimum) - red - white Dry film thickness (minimum) - red (two coats) m % % type h h type type type % m color C Unit

Bidder / Contractor

Data required

Data offered

epoxy 60 100 red and silver grey

aliphatic urethane gloss enamel

55 55

50 75

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description - white (two coats) Color - red - white Flash point (tag open cup) Drying time of coating : - at 20 C - at 50 C Type of thinner Type of cleaner 9.2 Aircraft Warning Spheres - Fitted to earthwires - Diameter - Material - Color (fadeless) - Drainage - Fitting materials - Positioning (staggered) - Spheres separation 9.3 Aircraft Lighting System Manufacturer company m material mm material color h h type type code code C m Unit

Bidder / Contractor

Data required

Data offered

50 - 75

RAL 2002 RAL 9010

yes 600 fiber glass international re and white yes mild steel galvanized yes 60

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Experience Rated voltage Temperature range Humidity Obstruction lights type: ICAO Annex 14, low intensity Rated Power Photovoltaic modules: Type Rated voltage Rated peak output Bird protection Length Width Depth Weight No. of modules per system Batteries: Type Rated voltage Capacity type V Ah mm mm mm Kg no. type V W years V C % type Cd W Unit

Bidder / Contractor

Data required

Data offered

10

0 to 60 100 LED clustered

Yes

sealed maintenance free

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194

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Length Width Depth Weight No. of batteries per system Battery charge regulator mm mm mm kg no. system Unit

Bidder / Contractor

Data required

Data offered

to suit optimally battery characteristics to protect all components from atmospheric degradation yes yes yes

System enclosure

system

5 years guaranteed continuous operation Spare parts for 30 years maintenance Drawing of Aircraft Lighting System

10. Tower Earthing Earthing conductor round steel galvanized or galvanized steel tape 11.5 40 x 6 >70

Material Diameter round steel cross section tape Zinc coat thickness Earth rods Material Length

mm 2 mm m

round steel galvanized 2.0

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Diameter Zinc coat thickness Type of connection Connections: Tower ground connector Bolt/nut/lock washer Compression type connector 11. Site Offices (data per office) 11.1 For TANESCO Minimum square area WC compartments with low level suite and toilet roll holder Sanitary rooms/Shower rooms units Wash hand basin with mirror, and towel rail Bowel type electric lighting fixture Continuous electricity, water, internet supply Air conditioner (capacity 18000 BTU) Laptops with Intel Pentium4, 3.8Ghz, 1GB of DDR-533 or above,300GB, 10k rpm or above internal DVD, internal CD-WR, Professional 3D graphic windows XP, Professional factory pre-loaded +recovery CD and manual, 20 TFT colour, flat screen Refrigerator Writing desks Swivel armchair m
2

Bidder / Contractor

Unit

Data required

Data offered

mm m -

15 70

steel

25 2 2 2 1 1 2 4

no. no. no. no. lot no.

no.

no. no. no.

1 4 4

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Filing Cabinets Bookshelves Drawing Table Storage Locker Pin board Heavy duty colour printer Heavy duty colour photocopying machine (A4 & A3 size) Fire extinguisher Set window curtains for all windows Cooker Latest version of software: Autodesk-AutoCAD Desktop computer, Intel Pentium4, 3.8Ghz, 1GB of DDR533 or above,300GB, 10k rpm or above internal DVD, internal CD-WR, Professional 3D graphic windows xp Professional factory pre-loaded +recovery CD and manual, 20 TFT colour, flat screen no. no. no. no. no. no. no. no. set no. no. Unit

Bidder / Contractor

Data required

Data offered

2 2 1 1 1 1 1 1 1 1 1 2

no.

11.2 For OISF Minimum square area WC compartments with low level suite and toilet roll holder Sanitary rooms/Shower rooms units Wash hand basin with mirror, and towel rail Bowel type electric lighting fixture Continuous electricity, water, internet supply m
2

25 2 2 2 1 1

no. no. no. no. lot

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Air conditioner (capacity 18000 BTU) Refrigerator Filing Cabinets Bookshelves Storage Locker Pin board Fire extinguisher Set window curtains for all windows Cooker no. no. no. no. no. no. no. set no. Unit

Bidder / Contractor

Data required

Data offered

2 1 2 2 1 1 1 1 1

12. Vehicles 12.1 Four Wheel Drive Station Wagon Standard The vehicle shall be new, unused, not more than 12 Months from date of manufacture; and suitable for operation in Tanzania A. Mandatory Specification A.1 Main Dimensions i Four-wheel drive (4WD) ii Gross Weight: 3100 3300kg iii Ground clearance: 225 250mm iv Seating capacity: Not less than 8 passengers v Wheel base: 2700 2900 mm vi Wheel track: Front 1600 1650 mm Rear 1595 1645 mm vii Five (5) door sitting for not less than 8 passengers A.2 Engine i. 8 cylinder 32-valve DOHC, Diesel Engine 4.5 Litres (4461 CC) (1VD-FTV Without Intercooler), ii. Power output (DIN,SAE). 136-170KW @3200-4000rpm iii. Torque ( DIN, SAE) 400Nm-450Nm @1400-3500rpm

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description A.3 Clutch i. Single heavy duty dry friction disc ii. Diaphragm spring pressure plate iii. Hydraulic operation A.4 Transmission i. Automatic or ii. Five (5) speed+reverse gear/ Manual transmission A.5 Wheel, tires i. Best quality 285/65 R16 (8 J alum) 8-12 ply ii. One Spare tire suitably mounted and locked with key iii. All tires fitted shall comply with internationally recognized standards A.6 Suspension Front: High mount double wishbone using coil spring Rear: Four link coil independent stabilizer front and rear A.7 Brake system i. Power assisted, independent dual hydraulic circuit ii. Front and Rear ventilated brakes A.8 Steering Right Hand Drive, Power assisted. A.9 Electrical i. 12 or 24 volt system ii. Hazard warning lights, exterior lights and indicators and twin fog lights that shall comply with Tanzania Road regulations iii. 6 CD Changer + Cassette + AM/FM with 6 speakers iv. Air conditioner provided with own regulation by passengers at the back B. General Specification B.1 Instruments and gauges i. Odometer and speedometer reading in kilometre ii. All instruments and gauges shall comply with an internationally recognized standards Unit

Bidder / Contractor

Data required

Data offered

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199

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description B.2 Body and Accessories Not less than, but not limited to: i. SRS front dual air bags front (driver + passenger) and curtain front second rear & third rear seats and knee panel front (driver + passenger) 8 air bags in total ii. Rear window defogger iii. Rear child proof lock iv. Door ajar warning v Seat belts on all seats and seat belt warning vi. First aid kit vii. High mounted rear stop lamp viii Paint protection film & body rust protection ix. Factory equipment fire extinguisher with caution plates ( two triangles ) x. Multi reflector halogen headlamps xi. Seat material Leather xii. Coat hooks xiii. Central power door lock and power windows xiv. Two sun visors xv. Double fuel tank with total capacity not less than 138 litres, air cleaner: Pre-Cleaner +Schorkel xvi. Fuel lid tank lockable and open able from inside xvii. Touch up paint xiii Driver/Operator instruction manual xix. Workshop instruction manuals B.3 Color White B.3 General Information i. Manufacturer ii. Model iii. Year of Manufacture iv. Authorized Sales representative in Tanzania /Dealer + spare parts/ B.4 Warranty Period Vehicles to be covered by factory warranty for a period of minimum of 12 months after delivery. or 50,000 km (which ever comes first) Unit

Bidder / Contractor

Data required

Data offered

12.2 Four Wheel Drive Double Cabin A. Mandatory Specification 1.0 Dimensions 1.1 G.V.W. (kg). 2500-2800 1.2 Wheel base (mm). 3000-3100

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description 1.3 Wheel track (mm). Front 1510 - 1540 Rear 1500 - 1530 1.4 Ground clearance (mm). 270-300mm 2.0 Engine 2.1 4 cylinder, in - line OHC (Diesel) 2.2 Power output (max) (DIN, SAE).70-75KW/ 4000rpm 2.3 Torque(max)(DIN, SAE).195-200kw/2000-2200rpm 3.0 3.1 3.2 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 Steering Right-hand. Power assisted. Clutch Single heavy duty dry friction disc. Diaphram spring pressure plate. Hydraulic operation. Transmission Manual. Floor mounted shift lever. 5 forward gears synchromesh, 1 reverse. Unit

Bidder / Contractor

Data required

Data offered

5.4 Four-wheel Drive - Heavy duty 5.5 Anti theft gear locking system 6.0 6.1 6.2 6.3 7.0 7.1 7.2 7.3 8.0 8.1 Suspension Front: Coil spring with stabilizer bar Rear: Leaf spring Heavy duty double acting shock absorbers front and rear. Brakes Power assisted, hydraulic operation Disc type for front, drum type for rear. Mechanical parking. Wheel, tyres Best quality 16 inch rims.
201

5413A08/FICHT-7269868-v8

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description 8.2 Size 205R16 Unit

Bidder / Contractor

Data required

Data offered

9.0 Electrical 9.1 volt system 12- 24V. 9.2 Air conditioner (front and rear) with own regulation by passengers at the back. 10.0 Instruments and gauges Odometer and speedometer reading in kilometers. 11.0 Body and accessories 11.1 One 2 kg dry powder fire extinguisher. 11.2 First aid kit. 11.3 Two warning triangles. 11.4 Full vehicle tool kit including jack and wheel brace. B. General Specification 12.0 Requirements 12.1 Long wheel base four door Double cabin, seating for 5 persons. 12.2 Color Green. 12.3 Single or Double fuel tank with total capacity not less than 80 litres 12.4 Fuel lids tank. 12.5 Driver/ Operator instruction manual. 12.6 Workshop instruction manuals. 13.0 Wheel, tyres 13.1 Best quality radial ply on/ off highway tyres. 13.2 One spare tyre mounted and locked with key 13.3 All tyres fitted shall comply with internationally recognized standards. 14.0 Electrical 14.1 Horn and 2 speed wiper with windshield washer 14.2 Hazard warning lights, exterior lights and indicators shall comply with Tanzanian regulations. 14.3 MV/SW/FM radio and clock. 15.0 Instruments and gauges

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description All instruments and gauges shall comply with internationally recognized standards. 16.0 Body and accessories 16.1 Inertia safety belt. Manufactured and fitted in accordance to international recognized standards. 16.2 Two outside mirrors and one rear view mirror. 16.3 Two sun visors. 16.4 Mudsplash guards, front and rear. 16.5 Two hooks front and rear. 17.0 General information 17.1 Manufacturer 17.2 Model 17.3 Year of manufacturing 17.4 Authorized sales representative in Tanzania Name: Address: Unit

Bidder / Contractor

Data required

Data offered

13. E&S Manager and PIU offices in Dar es Salaam (Lot 1 only) GPS System 1200+ Real Time Kinematics (RTK systems) GX1230 GG Base Station, 72 channels, (2) Batteries, Serial 350080 with associated accessories ATX-1230 Smart Rover, (1) Li-ion Battery, Dual Frequency, Bluetooth, weights 2.7kg, serial 156017 with associated accessories TCA1205 Total Station with associated accessories Reflector less range 1000 m Pin Point accuracy 2 mm Laser dot size 2 cm/50 m Geo-office & micro station no. 2 no. no. no. 1

3
1

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Geo-office & micro station softwares (1 piece each) GIS SOFTWARE that can: Perform advanced GIS data analysis and modeling Perform overlay analysis, proximity analysis, surface analysis, and raster processing and conversion Publish and convert data in many formats Create and manage personal geodatabases, multiuser geodatabases, and feature datasets Use high-end cartography tools to generate professional-quality, publication-ready maps Design customized symbols and place sophisticated annotation and labels on your maps. Plotter Print Size: Up to 44" x 300" Resolution: 2400 x 1200 dpi Print Speed: 15 min per page at Best Quality up to 17 ft Memory: 128 MB Connectivity: One 10/100 BT Ethernet, One USB 2.0 high-speed certified port, One EIO Jetdirect accessory slot Environments: PC and Mac Laptop Computer (as specified above) Handheld GPSMAP 60CSx accuracy 0.5m to 5m Satellite based radio equipment Digital camera 14 and above mega pixels 10 x and above, wide angle optical image DIGIC 4 image processor Continuous shooting at 3.7 fps 3-inch LCD monitor 1080p HD video at 24, 25, or 30fps JPEG and RAW image formats EF-S 18-55mm f/3.5-5.6 IS kit lens Captures to SDHC/SDXC memory cards Rechargeable lithium-ion battery Stabilized Zoom and Build in GPS function Digital Video Camera no. no. no. no. no. no. Unit

Bidder / Contractor

Data required

Data offered

2 3 6 10

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Digital Zoom: 300 x Sensor Resolution: 2.99 mega pixels Total Pixels: 3.89 mega pixels Optical Sensor Size: 1/4" Optical Sensor Type: CMOS Min Illumination: 0.4 lux Analog Video Format: Multi Purpose (NTSC/PAL) Video Format: MPEG-4 AVCHD Image Stabilizer: Optical Super Range) Max Shutter Speed: 1/2000 sec Printer/Scanner/Photocopy machine (Including supply of 30 rims of A4 and 10 rims of A3 printer/copier papers per month as well as services and consumables such as cartridges for the entire contract period). Heavy Duty Printer, latest version Heavy Duty Scanner, latest version Heavy Duty Photocopy machine, latest version no. no. no. Unit

Bidder / Contractor

Data required

Data offered

1 1 1

14. O&M Tools for Lot 1 only 1. HOOK LADDER Material; Aluminum, Length; 8.0m, working load 600kg, weight; 27kg, 2. WIRE ROPE Material: steel wire with Diameter: 16mm diameter, strength: 230kN, Length: 150m, Tapered end, Hooked end, with reel 3. TOOL BOX- Mechanical, Contents; open spanners; 16mm 38mm, ring spanners; 16mm38mm, Vanier Caliper, Torque wrench, Combination pliers, Screw drivers set, Steel punch, Flat & Round file25 Hammer 1.5kg, Sledge hammer 5kg, Knife, Iron, Brush, Measuring tapes 30m & 50m, Bow saw & Saw blades, Spirit Level, plug Box spanner size 64mm length 30mm, and Pipe Wrench

no.

no.

no.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description 4. CONDUCTOR TRIMMER WITH ONE POPULAR BUSHING MORE BUSHING Duty & Bushing: to trim 85 sizes of ACSR cable, one standard bushing included, 5. COME ALONG CLAMPS FOR 185 mm sq. Floating jaws: Removable, 6. COME ALONG CLAMPS FOR BLUE JAY CONDUCTOR Floating jaws: Removable 7. SWIVEL GRIPS FOR BLUE JAY CONDUCTORS no. 8. SWIVEL GRIPS FOR EARTH WIRE Material;185 mm sq. ACSR Unit

Bidder / Contractor

Data required

Data offered

no.

no.

no.

10

no.

15. O&M Equipment for Lot 2 only 1. INFRA RED CAMERA FLIR COMPLETE WITH LAPTOP SOFTWARE AND TRAINING Imaging performance

no.

2 3.2 M pixel full colour PIP with 5,6 LCD Automatic

Image presentation PIP with 5,6 LCD Measurement

Image storage

Removable SD card Standard JPEG

Voice annotation images

Video storage MPEG -4 Video streaming MPEG-4,IP-link Laser locate IR AlGalnp Diode Laser AC adapter or 12v
206

Power source

5413A08/FICHT-7269868-v8

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Environmental Unit

Bidder / Contractor

Data required

Data offered

-15C to +50C Physical characteristics 1.7kg w/battery 2. SOFTWARE FOR MECHANICAL AND ELECTRICAL DESIGN (JOVE) 3. PORTABLE GENERATOR Type: Brushless, self exciting, 2-pole, 1-phase, Voltage output: 240,AC-50Hz, Power output: 10KW, Cooling system: Air, Cycles: 4, Fuel, Gasoline, Starting system, Recoil starter(electric starter optional) 4. HAND OPERATED HYDRAULIC WIRE CUTTER Maximum cutting capacity: for wire diameter of 32mm, Output: 20 ton, Weight: 8kg, Length: 610 mm, 5. HIGH VOLTAGE DETECTORS CABLE TO DETECT VOLTAGE UP TO 500 KV Type: Electronic capacitive, Operating power, voltage: 90 500kV, Instruction Manual Connecting accessories including auxiliary earth rod and probe; Application: For detecting voltages on overhead transmission lines,

no.

no.

no.

no.

6. HIGH FREQUENCY EARTH RESISTANCE MEASURING INSTRUMENT DIGITAL GROUND TESTER Application: For high frequency determination of earthing resistance of overhead transmission line towers with tower-top earth wire Operating voltage: Battery, Facility for charging battery: In built,

no.

7. GROUNDING STICKS SET : Type screw type contact clamp; Suitable conductor diameter 5mm -60 mm; Maximum current capacity 23.9kA

no.

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description 8. SAFETY BELT: Material : nylon Safety ropes length mm : 2000 Safety rope diameter: 14mm 9. SAFETY HELMET Yellow colour 10. DESIGN SOFTWARE AND LAPTOP COMPUTERS Unit

Bidder / Contractor

Data required

Data offered

no.

20

no.

40

LAPTOP COMPUTER with preinstalled version of the tower spotting and design soft ware " such as: PLS CADD, STADD, AUTOCARD, MS Office and MICRO STATION for design of transmission line purpose.

no.

16. OPGW Tools/Equipment for Lot 3 only

1. FAULT LOCATOR

Wavelength 635 nm Batteries 2 x alkaline AAA Battery life 40 / 80 hours CW / Pulsed Pulsed at 2~3 Hz Connector types 2.5mm universal adapter which accepts any 2.5mm ferrule such as FC, ST and SC. 171 x 18 mm

Operation mode

Size

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Weight include batteries Unit

Bidder / Contractor

Data required

Data offered

< 100 g Coupled power 9/125 m or larger fiber core: 0.6 mW or -2.2 dBm2 type 2 in accordance with IEC 825-2 IP67 Ferrule retention force 1-2N Operating / storage -10 to +45C / 40 to +70C

Laser safety class

Environmental rating

2. SPLICER

Applicable fibres

Fibre Count Cladding diameter Coating diameter Fibre cleaved length

SM (ITU-T G.652), MM (ITU-T G.651), DS (ITU-T G.653), NZDS (ITU-T G.655) and other SMF Single including ITU-T G.657 fibres 80 to 150m 100 to 1000m 8mm to 16mm using Sheath Clamp A, B or C/ 10mm using FH60-250, FH-60900 0.02dB with SM, 0.01dB with MM, 0.04dB with DS, 0.04dB with NZDS. Typical 9sec. with standard
209

Actual average splice loss

Splice time

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Splicing modes Unit

Bidder / Contractor

Data required

Data offered

Return loss Splice loss estimate

Attenuation splice function

Storage of splice result

Fibre display

Magnification

Viewing method

Image change over

Operating condition

Mechanical proof test

SM fibre. Total number available equals 100; for pre-set modes and user programmable modes 60dB or greater Several types of core deformations as well as core axis offset are taken into account Intentional high splice loss of 0.1dB to 15dB (0.01dB step) can be made for an inline fixed attenuator The last 2000 results to be stored in the internal memory. X/Y, or both X and Y simultaneously 300x for single X or Y view, or 187x for X and Y view. By two CMOS cameras for fibre viewing and 4.1inches TFT colour LCD monitor The fibre image is turned upside down automatically according to the monitor position. 0-5000m above sea level, 0-95% RH and -10 to 50C respective2N (standard) ly. 4.4 N (optional)

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Tube heater Unit

Bidder / Contractor

Data required

Data offered

Tube heat time

Applicable protection sleeve length

No. of splice/heating with battery

Built-in auto-start tube heater with 10 heating modes and up to 20 for reference Typical 30sec.with FP03 protection sleeve. 60mm, 40mm and a series of micro sleeves. 160 cycles with BTR-08. Auto voltage selection from 100 to 240Va.c. or 10 to 15Vd.c. USB1.1 (USBwith ADC-13. Mini B) for data 13.2Vd.c. with and video signal BTR-08 transfer to PC. Max. wind velocity of 15m/s. For 250m coating/ For 900m coating For coating diameter up to 250m, 8mm to 16mm cleave; For coating diameter of over 250m, 16mm cleave Spares 1

Power supply

Terminals

Wind protection

Fibre Holder

Sheath Clamp

Electrodes Wind Protector Mirror

Carrying case

Cleaver

3. POWER METER

Battery life

360 hours laser off / 190 hrs Laser on


211

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Size Unit

Bidder / Contractor

Data required

Data offered

Temperature

Memory Case

190 x 130 x 70 mm, 7.5 x 5.1 x 2.8 -15 to 55C (Operating) / -25 to 70C (Storage) 1900 dual tests Polycarbonate, 1 metre drop tested 2 alkaline C cells (7.6 A/Hr) External DC with 2.5mm +ve pin or via USB port. Selectable auto-off, low battery indicator, backlit display SC connector adaptor FC connector adaptor ST connector adaptor C cell batteries & AA-to-C battery size converter Carry Pouch, Carry strap & Leather protective holster KITS Recording/Reporting software USB A/B cable Carry Case for 2 Instruments Carry Case includes Cletop, Cleaning Sticks
212

Power

Standard accessories

Carrying case

4. OTDR
5413A08/FICHT-7269868-v8

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description General Specifications Operating environment Unit

Bidder / Contractor

Data required

Data offered

Humidity

Storage temperature Battery

Rated power voltage Rated supply frequency Power consumption Laser safety standards

Safety standard Emission

Immunity Horizontal Axis Parameters

Temperature 0 to 45C (0 to 35C when charging the battery) 85% RH or less (no condensation) -20 to 60C Operation time 6 hours Recharge time 5 hours *2 100 to 240 VAC 50 to 60 Hz Max 70 W Class 1 M (IEC 60825-1:1993 + A2:2001)*3 21CFR1040.10* 4 EN61010-1 EN61326-1 Class A EN55011 Class A Group 1 EN61326-1 Table 2

Sampling resolution

5 cm, 10 cm, 20 cm, 50 cm, 1 m, 2 m, 4 m, 8 m, 16 m, 32 m 1 cm (Min.)

Readout resolution

Number of sampled data Group refractive index

Unit of distance Distance measurement accuracy

Up to 50,000 points 1.30000 to 1.79999 (in 0.00001 steps) km, kf or miles Sum of the following 3 errors: Offset error: 1 m Scale error:
213

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Unit

Bidder / Contractor

Data required

Data offered

Measurement distance 2 10-5 Sampling error: 1 sampling resolution Vertical Axis Parameters Vertical axis scale 0.2 dB/div, 0.5 dB/div, 1 dB/div, 2 dB/div, 5 dB/div, 7.5 dB/div 0.001 dB (Min.) * 0.05 dB/dB *When the measuring loss is 1 dB or less, the accuracy is within 0.05 dB.

Readout resolution Loss measurement accuracy

OTDR Measurement Function Distance measurement Displays up to eight digits of the relative one-way direction between two arbitrary points on the trace. Loss measurement Displays one-way loss in steps of 0.001 dB to a maximum of 5 digits. Displays the one-way loss, loss per unit length, and splice loss between any arbitrary points on the trace. Return loss measurement Measures return loss and total return loss of a fiber cable or between two arbitrary points on the trace. Scheduling function Performs measurements and saves results onto a USB storage in a user defined time frame and interval automatically.

OTDR Analysis Functions Analysis functions Multi trace analysis, 2 way trace analysis, differential trace analysis, section analysis

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Internal Memory Memory capacity 1000 waveforms or more Can store measured waveforms and measurement conditions Display Display Unit

Bidder / Contractor

Data required

Data offered

Total number of displayed pixels

8.4-inch color TFT LCD, semitransparent 640 (horizontal) 480 (vertical) pixels The LCD may contain some pixels that are always ON or OFF (0.002% or fewer of all displayed pixels including RGB), but this is not indicative of a general malfunction. USB1.1 Type A and Type B, one each Type A: For external memory Type B: For connecting to an external PC for remote control or access to the OTDR's internal memory

External Interface USB

File Formats

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description File Formats Unit

Bidder / Contractor

Data required

Data offered

Read: SOR, TRD, TRB, SET (AQ7270/75) Write: SOR (Telcordia), SET, CSV, BMP, JPG, PNG

Stabilized Light Source Function

Optical connector

Center wavelength

Shared with the OTDR (at the same port) OTDR's center wavelengths -5 dBm or more (at 23C2C) 0.1 dB (0.15 dB for 1650 nm) CW, 270 Hz

Light output level

Output level stability

Modulation frequency

Visible Light Source

Optical connector

Center wavelength

Port is not shared with the OTDR 650 nm 20 nm

Light output level

Peak value -3 dBm or more 2 Hz

Modulation frequency

Laser safety standard

Class 3R

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part B1)

Technical Schedules 400 kV Overhead Transmission Line BIDDERS / CONTRACTORS GUARANTEED DATA Description Power Monitor Function Optical connector Unit

Bidder / Contractor

Data required

Data offered

Measurement wavelength

Measurement range (CW light, absolute maximum input level 0 dBm (1 mW)) Measurement accuracy CW light, wavelength 1310 nm, -10 dBm for input, 23C2C Dummy Fiber Optical fiber

Shared with the OTDR (at the same port) 1310, 1490, 1550, 1625, 1650 nm -50 to -5 dBm

0.5 dB

SM (ITU-T G.652) Approx. 100 m

Optical fiber length

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part C)

C
Employers Requirements Drawings
5413A08/FICHT-7370493-v1

C1-1

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI (Part C)

List of Annexes
Annex 1 Preliminary Line Route Annex 1.1 Overview Map Annex 1.2 Field Data Sheets Annex 1.3 Line Route Maps (separate CD-ROM) Annex 1.4 Substations Annex 1.4.1 Iringa Substation Annex 1.4.2 Dodoma Substation Annex 1.4.3 Singida Substation Annex 1.4.4 Shinyanga Substation Annex 2 Tower Outline Annex 2.1 Compact Tower Outline Annex 2.2 Horizontal tower Outline Annex 3 Annex 4 Typical Foundation Outline 400kV Insulator String Outline

Annex 5 SWS/ISWER Installations Annex 5.1 ISWER Attachment, T-off at suspension tower Annex 5.2 ISWER Insulator Sets Annex 5.3 OPPC Tension String with Joint Box Annex 5.4 OPGW Tension String with Joint Unit OPPC-OPGW Annex 5.5 OPPC Tension Set with Termination Unit Annex 6 Annex 7 Typical Tower Earthing Bird Protection

5413A08/FICHT-7370493-v1

1.1 1.2

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Iringa Dodoma

Annex 1.2 Field Data Sheet

Point No.

Line Angle

UTM Coordinates East m North m

Distance km

Topography Crossings

Vegetation Present

Subsoil Expected

Remarks Photos

Field investigation tower nr. exis. 220 kV rounded to 5 hand-held GPS, no error differential correction typical inspan terrain, calc. from main objects only coordinates main vegetation within ~ 100m strip no test pits, subsoil assumed

particular observations

Data accuracy 1 nr. 2 100 m 100 m 0.15 km 10 houses 20% of density 1 cl. on soil state see report

Line Details Gantry 35 Grid Zone 36 M 801 040 9 138 120 800 960 9 138 200 0.72 80 r (2 x 40) gentle slope, workshop buildings, tel. overhead line new S/S Iringa scrub, grass land med. dense, clayey, coarse sand, boulders med. dense, clayey, coarse sand, boulders, partly ground water good access close to road

0.11

A1

35 r

A2

800 960

9 138 920 1.81

flat to steep slope, river b ~ 20m, Little Ruaha, grass land, small district gravel road, trees national asphalt road hilly terrain, seasonal rivers, localized erosion grass land, prone zones cultivation, scrub, some trees hilly terrain, hill foot, scattered small seasonal brooklet cultivation, some bush with trees steep slope, seasonal grass land, scrub, river some bush

dense, clayey, coarse sand, boulders

access from field track, upper part slope to construct, 2 angle towers 40 -

A3

40 l

802 740

9 139 230 0.45 dense, clayey sand, partly outcrop rock dense, coarse clayey sand, boulders and outcrop rock

A4

40 l

803 020

9 139 580 1.6

access slope to construct access from field track, 55m paral. exist. 220 kV

5413A08/FICHT-7268302-v1

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Iringa Dodoma UTM Coordinates East m North m Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos

Point No.

Line Angle

Subsoil Expected

12

30 r

802 900

9 141 200 5.9 scattered mountainous, flat, small cultivation, river Lihanga, erosion scattered small zone tower 18 trees flat, small river Lihanga scattered small trees, grass land, scrub grass land, scattered cultivation

27

805 400

9 146 500 2.8

soft rock, very dense to partly loose, coarse clayey sand, partly highly erosive, massive outcrop rock med. dense sand, clayey with some fine gravel, ground water dense, clayey sand, partly lateritic, qu ~ 1.5 kg/cm2, cu ~ 3 kg/cm2

extremely diff. access in mountain tension tower, diff. access on hill crest, 75 m paral. exis. 220 kV access by field track

34

40 l

806 600

9 149 000 13.6

flat, near airport, main gravel road, ~ 10 mud houses

68

30 r

804 000

9 162 300 extensive cultivation, scattered small trees clayey sand with some small rock fragments overlain by black cotton soil

near road, 55 m paral. exis. 220 kV

16.2

flat, seasonal rivers

near road, 55m paral. exis. 220 kV

109

75 l (45 + 30)

809 600

9 177 500 3.7 slightly hilly, ~ 5 brick houses, seasonal river

extensive cultivation, scattered small trees

clayey coarse sand, dense, underlain by rock blocks

near road, 55 m paral. exis. 220 kV

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Iringa Dodoma UTM Coordinates East m North m 806 600 9 179 600 7.6 138 40 r 800 300 9 183 900 5.1 151 60 r 799 000 9 188 800 2.5 157 50 l 800 800 9 190 500 9.0 180 20 r 800 100 9 199 500 6.3 196 45 r 802 000 9 205 500 13.8 231 10 l 814 600 9 211 100 3.7 A5 20 r 817 650 9 213 250 0.7 gentle slope some bush flat, village road, seasonal river open bush fine dense sand, traces of clay with some gravel dense fine sand, traces of clay with some gravel dense clayey sand, some boulders dense clayey sand, some boulders, outcrop rock flat, ~ 5 mud houses, dense to open seasonal rivers, erosion bush zone tower 168 med. dense, fine clayey sand, partly gravely, highly erosive flat, seasonal river dense bush, some trees dense, coarse sand with gravel, occas. lateritic steep mountain, flat, seasonal rivers forest, dense bush soft rock, dense coarse sand, boulders, gravel Distance km Topography Crossings hilly, steep mountain, rock bank, village road, seasonal river Vegetation Present scattered cultivation, forest, dense bush

Annex 1.2 Field Data Sheet Remarks Photos near road, 55 m paral. exis. 220 kV maint. access track, ends at tower 132 maint. access track, 55 m paral. 220 kV

Point No. 118

Line Angle 0

Subsoil Expected

clayey, dense coarse sand, fractured till solid massive rock

maint. track from road, 55m to 220 kV

access from road

flat, main gravel road, ~ open bush, some 30 mud houses, 0.4 kV trees distr. line, grave yard slightly hilly, main road and 33 kV line dense bush

maint. track from road, 55 m to 220 kV transposition tower, maint. track from road, 55 m paral. 220 kV field track from road -

5413A08/FICHT-7268302-v1

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Iringa Dodoma UTM Coordinates East m North m 818 300 9 213 450 7.6 295 20 l 824 900 9 217 200 flat to hilly, 1000m and 500m long span crossing lake Mtera, isolated suspension tower some bush, trees, grass land, localized dense bush fractured outcrop rock, compact coarse sand with some clay Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos field track from road -

Point No.

Line Angle

Subsoil Expected

A6

15 l

adjacent main road, 70m to 220 kV

2.1 300 5 r 826 400 9 218 700

flat, crossing twice the main gravel road

open bush, some trees

coarse, lateritic dense sand, partly some boulders

access from road, 55 m to 220 kV

6.9 Grid Zone 36M 318 30 l 831 400 9 223 500 7.0 Grid Zone 36M 336 2 l 170 300 9 223 500 4.2

flat to slightly hilly, ~ 5 mud houses

dense bush

very dense, clayey gravely sand access from road, 55 m to 220 kV

flat to slightly hilly

dense bush

very dense, clayey gravely sand, some boulders

access from road, 55 m to 220 kV

hilly

dense bush

dense, sandy gravel and rock fragments transposition tower, access from road, 55m to 220 kV

5413A08/FICHT-7268302-v1

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Iringa Dodoma UTM Coordinates East m North m 171 300 9 234 300 3.1 354 45 l 172 900 9 237 000 4.0 364 45 r 171 800 9 240 800 8.0 384 70 l 175 500 9 247 900 5.2 397 35 r 172 100 9 251 900 3.9 Grid Zone 37M 407 60 l 171 800 9 255 800 7.4 Grid Zone 36M 426 60 r 828 600 9 259 200 3.3 434 30 l 828 500 9 262 500 3.0 very hilly, seasonal river open bush, some trees compact sand, large boulders, rock blocks open to dense flat to hilly, village road, bush, some grass ~ 5 mud houses land med. dense, clayey sand flat, seasonal river scattered trees, partly dense bush med. dense to firm sand and clay flat, seasonal river open to dense bush dense, clayey fine sand flat, seasonal river grass land, scattered trees flat, ~ 5 mud houses, seasonal rivers hilly flat, village road, ~ 5 mud houses, grave yard dense bush dense, clayey sand with some fine gravel dense, clayey fine sand Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos transposition tower, access from road, 55m to 220 kV access from road, 55m to 220 kV access from road, 55m to 220 kV access from road, 55m to 220 kV access from road, 55m to 220 kV access from road, 55m to 220 kV access from road, 55m to 220 kV

Point No.

Line Angle

Subsoil Expected

346

15 r

extensive cultivations scattered cultivation, some trees

dense, clayey fine sand med. dense, clayey fine sand, occas. laterite intrusion

access from road, 55m to 220 kV -

5413A08/FICHT-7268302-v1

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Iringa Dodoma UTM Coordinates East m North m 826 900 9 265 100 6.0 457 30 r 821 700 9 268 000 13.7 491 40 l 814 500 9 279 700 2.2 496 30 r 812 400 9 280 300 12.9 528 40 r 803 300 9 289 400 18.2 574 20 l 801 800 9 307 500 8.9 hilly, main gravel road, ~ 15 mud houses, seasonal river scrub, open bushes hilly, main gravel road, district soil road, seasonal river scrub, open bush scattered flat, field track, ~ 5 mud cultivation, open houses scrub dense, coarse sand with some clay, partly ground water very dense sand with some clay and occ. boulders, partly outcrop rock very dense sand with some clay, partly boulders with rocky soil flat, main gravel road, seasonal river flat, main gravel road, village road, ~ 20 mud houses flat, village road Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos access from maint. track, 55m to 220 kV transpos. tower, access from village road, 55m to 220 kV access from village road, 55m to 220 kV access from village road, 55m to 220 kV access from field track, 55m to 220 kV without coordinates access from village road, 55m to 220 kV without coordinates access from field track, 55m to 220 kV -

Point No.

Line Angle

Subsoil Expected

442

30 l

scattered cultivation, some bush extensive cultivation, some trees some cultivation, partly dense scrub

dense, clayey sand, partly black cotton soil, ground water med. dense, clayey sand, partly ground water

dense, clayey sand

5413A08/FICHT-7268302-v1

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Iringa Dodoma UTM Coordinates East m North m 798 000 9 315 500 0.3 597 45 l 797 950 9 315 750 dense, clayey sand, seasonal ground water flat, 220 kV line between tower no. 596 and no. 597 scrub dense, clayey sand, seasonal ground water Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos access from field track, 55m to 220 kV access from field track, 55m to 220 kV -

Point No.

Line Angle

Subsoil Expected

596

60 r

0.6 599 90 l 797 850 9 316 350 0.1 600 ~ 0 797 750 9 316 325 0.1

flat

scrub, small trees

access from S/S flat scrub, cultivation dense, clayey sand, seasonal ground water dense, clayey sand, seasonal ground water access from S/S -

flat

scrub, cultivation

Gantry

~ 0

797 650

9 316 300

access from S/S -

38

angle

points

Total

225 km

5413A08/FICHT-7268302-v1

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Dodoma - Singida UTM Coordinates East m North m Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos

Point No.

Line Angle

Subsoil Expected

Field investigation tower nr. exis. 220 kV rounded to 5 hand-held GPS, no error differential correction typical inspan terrain, calc. from main objects only coordinates main vegetation within ~ 100m strip no test pits, subsoil assumed

particular observations

Data accuracy 1 nr. 2 Line Details Gantry ~ 0 100 m 100 m 0.15 km 10 houses 20% of density 1 cl. on soil state see report

Grid Zone M36 797 550 9 316 250 797 450 9 316 200

0.1

flat

scrub

~ 0

1.5 6 85 r (2 x 45) 5 r 796 050 9 315 800 0.4 795 900 9 316 200 8.9 23 55 l 794 700 9 325 000 11.0 54 25 l 784 900 9 330 000 3.8

flat, 11 kV and 33 kV line

scrub, some cultivation

flat flat to gentle slope, 33 kV line, railway at ~ 90, main asphalt road at ~ 45 slightly hilly, village road

scrub

scrub, open bush, some trees

scrub, scattered cultivation

slightly hilly, main asphalt road, seasonal river

scrub, some cultivation, some trees

new S/S Dodoma dense, med. coarse clayey sand, seasonal maint. track from S/S, ~ groundwater 110m to 220 kV dense, med. coarse clayey sand, seasonal maint. track from S/S, groundwater 55m to 220 kV dense, med. coarse clayey sand, seasonal groundwater maint. track from S/S, 55m to 220 kV dense, med. coarse clayey sand, seasonal groundwater, after access from road and railway no ground field track water dense, clayey sand, outcrop weathering rock access from road, 55m paral. 220 kV dense, clayey coarse sand with occasional boulders

5413A08/FICHT-6290832-v

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Dodoma - Singida UTM Coordinates East m North m 781 100 9 330 100 8.0 83 20 l 774 200 9 334 200 12.2 113 50 r 762 400 9 337 300 8.6 131 60 l 758 500 9 345 000 9.5 151 30 l 749 100 9 346 200 0.9 154 40 r 748 300 9 345 900 4.9 167 20 l 744 000 9 348 200 flat, river b ~ 10m, main open bush, paddy asphalt road, railway at fields, swamp 60 angle flat, field tracks, ~ 5 mud houses, between tower 163-164, new line axis is 45m to prim. school buildg. Lusilile, District Manyoni flat, field track clayey med. dense sand, shallow ground water flat, village road, seasonal river flat, seasonal river scrub, scattered cultivation open bush, scattered cultivation, large trees, Baobab dense, clayey coarse sand with boulders med. dense to loose? sand, partly swampy with ground water slightly hilly, seasonal river scrub, scattered cultivation dense, clayey coarse sand with boulders Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos access from road, 55m paral. 220 kV access from road, 55m paral. 220 kV access from road, 55m paral. 220 kV access from road, 55m paral. 220 kV access from road, 55m paral. 220 kV access from road, 55m paral. 220 kV

Point No.

Line Angle

Subsoil Expected

63

30 r

slightly hilly, main asphalt road, ~ 5 mud houses

scrub, some cultivation, some trees

dense, clayey coarse sand with boulders

scrub, trees, land, swamp

some grass dense, clayey sand, partly seasonal partly swamp, ground water

access from road, 55m to 220 kV

5.1

scrub, grass land, some cultivation

dense, clayey sand, partly seasonal swamp, ground water

5413A08/FICHT-6290832-v

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Dodoma - Singida UTM Coordinates East m North m 738 900 9 348 700 10.3 204 2 r 728 800 9 350 700 8.0 223 15 r 721 000 9 352 500 4.2 234 3 r 717 400 9 354 600 2.9 242 25 r 715 000 9 356 200 5.1 254 30 l 712 600 9 360 700 12.0 283 45 r 702 600 9 367 400 flat, main gravel road (soon being asphalted) flat to gently slope, ~ 25 mud/brick houses, 0.4 kV and tel. line, old gravel main road, old railway 2x flat, partly gentle slope, old railway 2x, ~ 10 brick/mud houses, close to air strip by tower 284 lateral 60 at 700m only flat to very steep, outcrop rock bank, field track, ~ 5 mud/brick houses flat, village road, ~ 15 mud/brick houses dense bush, some grass land dense, coarse sand, outcrop rock, massive granite banks, partly strong rock flat, village road, seasonal river flat, ~ 10 mud houses, river b ~ 20m, Luwil scrub, grass land, some cultivation Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos access from road, 55m to 220 kV access from village road, 55m to 220 kV access from field track, 2.5 km to road, 55m to 220 kV access from village road, 55m to 220 kV access from main road, 55m to 220 kV access from main road, 55m to 220 kV access from village road, 55m to 220 kV access from village road -

Point No.

Line Angle

Subsoil Expected

179

5 r

dense, clayey sand, partly gravelly sand, ground water

dense, coarse sand, scattered scrub, partly swampy, grass land, swamp ground water

dense, clayey sand, open bush, some partly overlain by crops, partly black cotton soil, occ. swamp boulders dense, clayey sand open bush, partly overlain by black dense scrub, some cotton soil, ground swampy area water scattered cultivation, scattered trees, some scrub large stretch of very dense bush, some cultivation, some swampy area dense, clayey sand, partly overlain by black cotton soil

37.0 372 25 r 695 500 9 403 700

dense, clayey sand, seasonal swamp, ground water

5413A08/FICHT-6290832-v

10

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Dodoma - Singida UTM Coordinates East m North m Distance km Topography Crossings gentle slope, ~ 10 brick houses, river b ~ 10m, Ugino Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos

Point No.

Line Angle

Subsoil Expected

7.0

dense bush, some cultivation

dense, clayey sand, partly ground water access from main road, 55m to 220 kV access from main road, 55m to 220 kV transposition, access from village road, 55m to 220 kV access from main road, 55m to 220 kV access from village road -

390

10 l

697 400

9 410 400 11.9 flat, seasonal river dense bush, some cultivation scattered cultivation, some trees, some bush extensive cultivation, some bush extensive cultivation, some trees open bush, scattered scrub, some cultivation, some trees dense sand with some clay, partly ground water dense sand with some clay, black cotton soil, partly ground water dense, clayey sand dense sand with some clay, some outcrop rocks dense, clayey sand with large boulders, partly strong rock

418

15 l

698 600

9 422 200 11.1 flat, village road, ~ 5 brick/mud houses, seasonal river slightly hilly, seasonal river flat, 33 kV line, ~ 5 mud/brick houses, seasonal river slightly hilly, 33 kV line, behind construction quarry / camp, massive outcrop rock

445

1 l

696 800

9 433 200 5.0

458

25 r

695 900

9 438 100 9.2

483

30 l

697 900

9 447 100

6.0

5413A08/FICHT-6290832-v

11

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Dodoma - Singida UTM Coordinates East m North m 696 200 9 452 800 5.4 510 2 l 695 800 9 458 200 3.8 520 5 l 695 300 9 462 000 2.7 527 30 r 694 750 9 464 650 0.3 528 20 l 694 850 9 464 900 0.1 gentle slope, foot path scattered cultivation, some scrub dense, clayey sand with larger boulders gentle slope, seasonal river, scrub some scrub, some cultivation compact, coarse cristalline sand with larger boulders slightly hilly, outcrop scattered rock, seasonal river, 33 cultivation, scrub kV line 40m parallel compact, coarse cristalline sand with larger boulders slightly hilly, seasonal river scattered cultivation, scrub dense, clayey sand, partly fine gravel layers slightly hilly, ~ 5 mud houses, seasonal river Distance km Topography Crossings Vegetation Present

Annex 1.2 Field Data Sheet Remarks Photos access from village road, 55m to 220 kV access from village road, 55m to 220 kV access from field track, 55m to 220 kV access from field track, 55m to 220 kV access from field track, foot path

Point No.

Line Angle

Subsoil Expected

496

15 r

extensive cultivation, some trees

dense sand with some clay

Gantry

10

694 850

9 465 000

new S/S Singida -

30

angle

points

Total

217 km

5413A08/FICHT-6290832-v

12

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Singida - Shinyanga

Annex 1.2 Field Data Sheet

Point No.

Line Angle

UTM Coordinates East m North m

Distance km

Topography Crossings

Vegetation Present

Subsoil Expected

Remarks Photos

Field investigation tower nr. exis. 220 kV rounded to 5 hand-held GPS, no error differential correction typical inspan terrain, calc. from main objects only coordinates main vegetation within ~ 100m strip no test pits, subsoil assumed

particular observations

Data accuracy 1 nr. 2 Line Details Gantry Singida 1 (Term.) Arusha 7th (14) Arusha 10 90 l (2 x 45) 75 l (2 x 40) 100 m 100 m 0.15 km 10 houses 20% of density 1 cl. on soil state see report

Grid Zone M36 695 000 9 465 000 695 000 9 464 900

0.1

gentle slope, 220 kV line between tower 1 and 2 flat, village road, seasonal river flat to gentle slope, 220 kV line between tower 6 and 7, main gravel road, village road (bad. cond.), ~ 10 mud houses, seasonal river, swamp

cultivation, grass land some cultivation, some trees, some grass land

dense, clayey sand with some larger boulders dense, clayey sand, occ. large boulders, partly ground water dense, clayey sand, occ. boulders, partly outcrop rock, partly swampy, partly ground water

new S/S Singida field track from S/S 60m to 220 kV field track, 55m to 220 kV, 150m off tower 7 towards S/S Singida

1.9 696 850 9 464 800

9.5 A1 40 l 700 200 9 473 700

scattered cultivation, some trees, grass land, open bush

access from village road (bad condition)

1.0 A2 Shinyanga 42 Shinyanga 40 l 699 800 9 474 600

flat, swamp

grass land, some cultivation scattered cultivation, some trees, scrub, grass land

dense, clayey sand, occ. boulders with some gravel dense, clayey sand, occ. boulders, partly outcrop rock, partly ground water

35 r

689 400

9 479 400

11.5

gentle slope, hilly, district gravel road, ~ 5 mud houses, seasonal river, swamp

access from village road (bad condition) access from main road, 55m paral. to susp.

5413A08/FICHT-6290832-v

13

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Singida - Shinyanga

Annex 1.2 Field Data Sheet

Point No.

Line Angle

UTM Coordinates East m North m

Distance km

Topography Crossings

Vegetation Present

Subsoil Expected

14.3 77 30 l 682 200 9 491 700 11.9 106 15 r 672 100 9 498 000 3.2 115 25 r 670 000 9 500 400 8.9 134 35 l 667 050 9 509 250 5.0 147 20 l 663 200 9 512 400 4.5 157 20 l 659 000 9 513 900 6.0

flat, ~ 10 mud houses, seasonal river flat to hilly, 2x main asphalt road, Kitumbili River b ~ 20m

scattered cultivation, scrub and bush, some trees scattered cultivation, scrub and bush, some trees scattered cultivation, scrub and bush

Remarks Photos tower no. 42 of 220 kV to Shinyanga

dense, coarse clayey sand partly with fine gravel dense, coarse clayey sand partly with fine gravel

access from village track, 55m to 220 kV access from main road, 55m to 220 kV access from maint. track, 55m to 220 kV

flat to hilly, seasonal river

dense, coarse clayey sand

flat, 2x main asphalt road, 33 kV line

bush, scattered cultivation

dense, clayey sand access from field track, 800m to 220 kV -

flat

bush, scattered cultivation extensive cultivation, some trees

dense, clayey sand access from field track, 1km to 220 kV dense, clayey sand access from field track, 1km to 220 kV -

flat

flat, village road, seasonal river

extensive dense, clayey sand, cultivation, some partly with fine gravel trees, some scrubs

5413A08/FICHT-6290832-v

14

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Singida - Shinyanga

Annex 1.2 Field Data Sheet

Point No.

Line Angle

UTM Coordinates East m North m 653 000 9 513 900

Distance km

Topography Crossings

Vegetation Present

Subsoil Expected

Remarks Photos access from field track, 1km to 220 kV -

170

25 r

3.2 180 15 l 650 000 9 515 000 7.1 197 10 l 643 000 9 516 400 3.0 205 ~ 0 640 000 9 516 300 2.2 210 25 r 637 800 9 516 200 4.4 221 30 l 633 800 9 518 100 6.0 235 5 r 627 800 9 517 500

slightly hilly

scrub, some cultivation bush, open forest, partly some cultivation open forest, bush

dense, clayey gravelly sand dense, clayey sand with rock debris soft rock overlain by small to fine rock debris soft rock, clay and sand partly with ground water

access from field track, 1km to 220 kV access from gravel road, 400m to 220 kV on hill crest, access from gravel road, 300m to 220 kV access from main road, 55m to 220 kV access from main road, 55m to 220 kV access from main road, 55m to 220 kV

hilly very hilly, partly steep slope, 2x old gravel road very hilly to flat, old gravel road, new asphalt road, seasonal river

bush, some trees, extensive cultivation extensive cultivation, some trees extensive cultivation, some scrub

flat, seasonal river

clayey, med. dense sand, ground water

flat, seasonal river

dense, gravely clayey sand, ground water

3.0 242 20 l 624 800 9 517 300

flat to gentle slope, main asphalt road, ~ 20 brick/mud houses, 33 kV line, between tower scrub, grass land, 240-241 Zantel and some cultivation Celtel antennas h ~ 50m, 55m or 75m from the new 330 kV

dense, gravelly clayey access from main road, sand 55m to 220 kV

5413A08/FICHT-6290832-v

15

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Singida - Shinyanga

Annex 1.2 Field Data Sheet

Point No.

Line Angle

UTM Coordinates East m North m

Distance km

Topography Crossings gentle slope, seasonal river

Vegetation Present

Subsoil Expected

Remarks Photos

7.4 260 40 r 617 900 9 514 500

scrub

dense, gravelly clayey sand access from main road, 55m to 220 kV

2.5 265B 15 r 615 600 9 515 400 3.7 274 30 r 612 600 9 517 600 7.9 293 30 l 609 500 9 524 900 14.9 328 5 r 597 900 9 534 200 3.7

flat, seasonal swamp, between tower 260265B, 7 towers grass land, some replaced due to paddy fields corrosion damage to steel grillage foundation grass land, some scrub

flat, ~ 10 mud houses

med. dense, fine white sand overlain by black cotton soil, aggressive soil and access from main road, water, ground water 55m to 220 kV med. dense, clayey sand, ground water access from main road, 55m to 220 kV access from main road, 55m to 220 kV -

flat, ~ 5 mud houses

grass land, some scrub scattered cultivation, grass land, some scrub, some trees scattered cultivation, grass land, some scrub, some trees cultivation, grass land, some trees

med. dense, clayey sand, ground water

flat, ~ 5 mud houses, seasonal river

flat, ~ 5 mud houses, seasonal river

337

10 r

595 300

9 536 900 13.2 flat, ~ 10 mud houses, seasonal river

compact, cemented sand and fine gravel overlain by thick black access from main road, cotton soil 55m to 220 kV compact, cemented sand and fine gravel overlain by thick black cotton soil access from village compact, cemented road, 55m to 220 kV sand and fine gravel overlain by thick black cotton soil

5413A08/FICHT-6290832-v

16

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Singida - Shinyanga

Annex 1.2 Field Data Sheet

Point No.

Line Angle

UTM Coordinates East m North m

Distance km

Topography Crossings

Vegetation Present

Subsoil Expected

Remarks Photos access from village road, 55m to 220 kV access from village road, 55m to 220 kV access from village road, 55m to 220 kV access from village road, 55m to 220 kV access from village road, Jan. to Apr. flooding, 55m to 220 kV access from field track, 55m to 220 kV access from village road, 55m to 220 kV

368

10 l

587 300

9 547 400 6.7 flat, ~ 5 mud houses, seasonal river cultivation, grass land compact cemented sand and fine gravel overlain by thick black cotton soil dense, coarse to fine clayey sand overlain by black cotton soil, ground water

384

25 r

582 400

9 552 000 8.6 flat to gentle slope, cultivation, paddy ~ 5 mud houses, village fields road, seasonal river

405

25 r

579 100

9 559 900 5.1 flat, seasonal river b ~ 30m, Ngwawomba

dense, coarse sand paddy fields, grass overlain by black land, some bush cotton soil, ground water medium dense, coarse sand, partly with compact, cemented fine gravel, partly ground water compact, cemented gravelly sand, partly black cotton soil dense, clayey gravelly sand partly overlain by black cotton soil dense, coarse sand and coarse cobbles mixed with rock debris

418

3 r

579 100

9 565 000 flat to gentle slope, village road, ~ 10 mud houses, seasonal swamp, seasonal river b ~ 60m, Manonga slightly hilly, steep slope, seasonal river bush, scrub, grass land, some cultivation

4.6 429 6 l 579 300 9 569 600 4.5 440 20 l 578 900 9 574 100 5.2 453 25 r 576 700 9 578 800 2.1

scrub, grass land

slightly hilly, 2x village road, seasonal river

some cultivation, some trees, some scrub scattered scrub

flat

5413A08/FICHT-6290832-v

17

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP), Bidding Documents Line Section: Singida - Shinyanga

Annex 1.2 Field Data Sheet

Point No.

Line Angle

UTM Coordinates East m North m

Distance km

Topography Crossings

Vegetation Present

Subsoil Expected

Remarks Photos access from field track, 55m to 220 kV access from gravel road, 55m to 220 kV access from gravel road, 55m to 220 kV access from S/S road, 55m to 220 kV

458

10 l

576 600

9 580 900 10.7 flat to gentle slope, field grass land, scrub track, seasonal river cultivation, scattered trees, some scrub dense, clayey sand partly overlain by black cotton soil dense, coarse, clayey sand partly overlain by black cotton soil dense, coarse, clayey sand partly with boulders, outcrop rock very dense, partly lime-cemented coarse sand with larger boulders

484

35 l

574 500

9 591 400 9.1 gentle slope, ~ 15 mud houses, seasonal river

506

30 l

567 800

9 597 600 10.9 slightly hilly, ~ 3 mud houses, village road scrub, some cultivation

532

55 l

557 200

9 599 900 0.1 gentle slope, 220 kV line between tower 531 and 532 grass land, bush

Gantry

20 r

557 100

9 599 800

new S/S Shinyanga

36

angle

points

Total 228 km

5413A08/FICHT-6290832-v

18

Iringa

New Su

bstatio nA

lternati

ve

o Dod om Dod a

ma

Legend
Existing Installations
220 kV transmission line
SB MV

Substation Building Medium Voltage Switchyard SVC Installation 220 kV / MV Transformer 220 kV Line Feeder 220 kV Transformer Feeder 220 kV SVC Feeder 220 kV Reactor Feeder Space for 220 kV Spare Feeder

ra te t da u

SVC TR LF TF SVC

Ne w S u bstatio n

Ki

RF TF (LF) TF (LF) TR LF TR TR LF MV LF LF LF TF BC TF LF TF BC TR TF LF SVC TR SV CF LF

RF
R

New Installations
R
SB

220 kV Reactor 2013 220 kV Line Feeder 2013 (220 kV Transformer Feeder 2021) 220 kV Reactor Feeder 2013 220 kV Line Feeder 2013 (Space for 220 kV Spare Feeder 2021) EHV transmission line 2013 - 2021 220 kV interim connection strip 2013 - 2021 EHV transmission line 2021

LF(TF) RF LF

Future -

Future -

Kihansi

Existin g Alternati ve

220 kV

switchg

ear

TR TF LF BC

EHV / 220 kV Transformer EHV Transformer Feeder EHV Line Feeder EHV Bus Coupler Space for EHV Spare Feeder

New Su bstation

Mbeya

approximate TANESCO property boundery

Satellite picture:

2007 Digital Globe 2008 Europa Technologies 2007 Google

FICHTNER

ANNEX 1.4.1 New Iringa Shinyanga Transmission Line Iringa Substation - Incoming Transmission Line

Dodoma Legend
Existing Installations
New Subs tation
SB MV
LF LF LF LF R R BC TF TR LF RF TF TR MV

220 kV transmission line Substation Building Medium Voltage Switchyard 220 kV / MV Transformer 220 kV Line Feeder 220 kV Transformer Feeder 220 kV Reactor Feeder Space for 220 kV Spare Feeder

TR

LF LF RF RF LF
LF(TF)

LF TF RF

ingida Singida S

New Installations
R
SB

a Singid

220 kV Reactor 2013 220 kV Coupler Circut Breaker at Place of Spare Feeder 2013) 220 kV Line Feeder 2013 (220 kV Transformer Feeder 2021) 220 kV Reactor Feeder 2013 220 kV Line Feeder 2013 (Space for 220 kV Spare Feeder 2021) EHV transmission line 2013 - 2021 220 kV interim connection strip 2013 - 2021 EHV transmission line 2021

CCB TF LF

CCB LF(TF) RF LF

TR

r witchgea 220 kV S Existing

Iringa

n Location Substatio e Alternativ

Substatio n Location

TR TF LF BC

EHV / 220 kV Transformer EHV Transformer Feeder EHV Line Feeder EHV Bus Coupler Space for EHV Spare Feeder approximate TANESCO property boundery

Iringa

Mtera

Alternative

Satellite picture:

2007 Digital Globe 2008 Europa Technologies 2007 Google

FICHTNER

ANNEX 1.4.2 New Iringa Shinyanga Transmission Line Dodoma Substation - Incoming Transmission Line

Singida Legend
Existing Installations
220 kV transmission line
SB MV

Substation Building Medium Voltage Switchyard SVC Installation 220 kV / MV Transformer 220 kV Line Feeder 220 kV Transformer Feeder 220 kV SVC Feeder 220 kV Reactor Feeder Space for 220 kV Spare Feeder

New Substation
Future LF Future LF

SVC TR
LF LF

BC

TF

TF

LF

LF

LF TF SVC RF

Existing 220 kV Switchgear


SVC MV TR
TF TR TR

TR TR R R

SB

CCB LF TF RF SVC LF

Shinyanga
LF TF LF TF

RF

RF

LF

Shinyanga

New Installations
R

220 kV Reactor 2013 220 kV Coupler Circut Breaker at Place of Spare Feeder 2013) 220 kV Line Feeder 2013 (220 kV Transformer Feeder 2021) 220 kV Reactor Feeder 2013 220 kV Line Feeder 2013 (Space for 220 kV Spare Feeder 2021) EHV transmission line 2013 - 2021 220 kV interim connection strip 2013 - 2021 EHV transmission line 2021

Arusha

CCB LF(TF) RF

Arusha / Kenia
LF

TR

EHV / 220 kV Transformer EHV Transformer Feeder EHV Line Feeder EHV Bus Coupler Space for EHV Spare Feeder approximate TANESCO property boundery

Sh in ya ng a

Dod

TF LF BC

o Dod

Satellite picture:

oma Do d

a om

2007 Digital Globe 2008 Europa Technologies 2007 Google

ma

FICHTNER

ANNEX 1.4.3 New Iringa Shinyanga Transmission Line Singida Substation - Incoming Transmission Line

Shinyanga
w M an za ly Bu lu hu an

Legend
Existing Installations
220 kV transmission line 132 kV transmission line
SB MV SVC

Substation Building Medium Voltage Switchyard SVC Installation 220 kV / MV Transformer 132 kV Installations 220 kV Line Feeder 220 kV Transformer Feeder 220 kV SVC Feeder 220 kV Reactor Feeder Space for 220 kV Spare Feeder

agi zw Bu
TR C SV MV

TR
LF CF SV SB LF LF

132 kV LF TF

kV 20 g2 r stin gea Exi witch S

TF LF TF RF RF TF TF TR TR TR

Singi da

SVC

Singid a

RF

TR

TF

132 kV

New Installations
Sing ida
R CCB LF(TF) RF LF

220 kV Reactor 2013 220 kV Coupler Circut Breaker at Place of Spare Feeder 2013) 220 kV Line Feeder 2013 (220 kV Transformer Feeder 2021) 220 kV Reactor Feeder 2013 220 kV Line Feeder 2013 (Space for 220 kV Spare Feeder 2021) EHV transmission line 2013 - 2021 220 kV interim connection strip 2013 - 2021 EHV transmission line 2021

or Tab

BC TF LF LF

LF ure Fut LF ure Fut

nda Rwa

a and / Ug

New

tion sta Sub


TF LF BC

TR

EHV / 220 kV Transformer EHV Transformer Feeder EHV Line Feeder EHV Bus Coupler Space for EHV Spare Feeder approximate TANESCO property boundery

Satellite picture:

2007 Digital Globe 2008 Europa Technologies 2007 Google

FICHTNER

ANNEX 1.4.4 New Iringa Shinyanga Transmission Line Shinyanga Substation - Incoming Transmission Line

Pad & Chimney Foundation


Design Parameters C 0.3 m T 2.0 m B/T 0.5 1.0 D 0.1 x B 0.3 U 0.5 x D 0.2 Frustum 0 - 25
T` = 0.5m or 1.0m chimney extension if terrain flood > 1:4 ( 15) C` = 0.5m or 1.0m cap extension if seasonal terrain flod > 0.2m Connection beams between all footings if terrain slope > 1:2 or span > 500m

Composite Type Insulator String


a

450

450

450

300 mm

480 mm Black

White

Example of Bird Warning Flag

500 mm

Note: Minimum of eight rods plus one centre rod to prevent bird nesting, made of non-conductive material.

Example of Bird/Perch Rejector

BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI

Forms and Procedures


Form of Completion Certificate Form of Operational Acceptance Certificate Change Order Procedure and Forms Change Order Procedure Annex 1. Request for Change Proposal Annex 2. Estimate for Change Proposal Annex 3. Acceptance of Estimate Annex 4. Change Proposal Annex 5. Change Order Annex 6. Pending Agreement Change Order Annex 7. Application for Change Proposal 1 2 3 4 5 7 9 10 13 14 16

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TANESCO Bidding Documents Section VI

Form of Completion Certificate


Date: Loan/Credit No: IFB No:
______________________________

To: _________________________________ Dear Ladies and/or Gentlemen, Pursuant to GC Clause 24 (Completion of the Facilities) of the General Conditions of the Contract entered into between yourselves and the Employer dated _____________, relating to the ____________________, we hereby notify you that the following part(s) of the Facilities was (were) complete on the date specified below, and that, in accordance with the terms of the Contract, the Employer hereby takes over the said part(s) of the Facilities, together with the responsibility for care and custody and the risk of loss thereof on the date mentioned below. 1. 2. Description of the Facilities or part thereof: ______________________________ Date of Completion: __________________

However, you are required to complete the outstanding items listed in the attachment hereto as soon as practicable. This letter does not relieve you of your obligation to complete the execution of the Facilities in accordance with the Contract nor of your obligations during the Defect Liability Period. Very truly yours,

Title (Project Manager)

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TANESCO Bidding Documents Section VI

Form of Operational Acceptance Certificate


Date: Loan/Credit No: IFB No:
_________________________________________

To: ________________________________________ Dear Ladies and/or Gentlemen, Pursuant to GC Sub-Clause 25.3 (Operational Acceptance) of the General Conditions of the Contract entered into between yourselves and the Employer dated _______________, relating to the ___________________________________, we hereby notify you that the Functional Guarantees of the following part(s) of the Facilities were satisfactorily attained on the date specified below. 1. 2. Description of the Facilities or part thereof:

_______________________________

Date of Operational Acceptance: _______________________

This letter does not relieve you of your obligation to complete the execution of the Facilities in accordance with the Contract nor of your obligations during the Defect Liability Period. Very truly yours,

Title (Project Manager)

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI

Change Order Procedure and Forms


Date: Loan/Credit No: IFB No:

CONTENTS 1. 2. 3. General Change Order Log References for Changes

ANNEXES Annex 1 Annex 2 Annex 3 Annex 4 Annex 5 Annex 6 Annex 7 Request for Change Proposal Estimate for Change Proposal Acceptance of Estimate Change Proposal Change Order Pending Agreement Change Order Application for Change Proposal

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI

Change Order Procedure


1. General This section provides samples of procedures and forms for implementing changes in the Facilities during the performance of the Contract in accordance with GC Clause 39 (Change in the Facilities) of the General Conditions.

2.

Change Order Log The Contractor shall keep an up-to-date Change Order Log to show the current status of Requests for Change and Changes authorized or pending, as Annex 8. Entries of the Changes in the Change Order Log shall be made to ensure that the log is up-todate. The Contractor shall attach a copy of the current Change Order Log in the monthly progress report to be submitted to the Employer.

3.

References for Changes (1) Request for Change as referred to in GC Clause 39 shall be serially numbered CR-X-nnn. Estimate for Change Proposal as referred to in GC Clause 39 shall be serially numbered CN-X-nnn. Acceptance of Estimate as referred to in GC Clause 39 shall be serially numbered CA-X-nnn. Change Proposal as referred to in GC Clause 39 shall be serially numbered CPX-nnn. Change Order as referred to in GC Clause 39 shall be serially numbered CO-Xnnn. Requests for Change issued from the Employers Home Office and the Site representatives of the Employer shall have the following respective references: Home Office Site (b) CR-H-nnn CR-S-nnn

(2)

(3)

(4)

(5)

Note: (a)

The above number nnn is the same for Request for Change, Estimate for Change Proposal, Acceptance of Estimate, Change Proposal and Change Order.

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TANESCO Bidding Documents Section VI

Annex 1. Request for Change Proposal (Employers Letterhead) To: ____________________________________ Attention: ______________________________________ Contract Name: _________________________________ Contract Number: _______________________________ Date:

Dear Ladies and/or Gentlemen: With reference to the captioned Contract, you are requested to prepare and submit a Change Proposal for the Change noted below in accordance with the following instructions within _______________ days of the date of this letter ____________________. 1. 2. 3. Title of Change: ________________________ Change Request No. __________________ Originator of Change: Employer: _______________________________ Contractor (by Application for Change Proposal No. 1 _______ : Brief Description of Change: _________________________________________________ Facilities and/or Item No. of equipment related to the requested Change:
_____________

4. 5. 6.

Reference drawings and/or technical documents for the request of Change: Drawing No./Document No. Description

7. 8.

Detailed

conditions

or

special

requirements

on

the

requested

Change:

________________

General Terms and Conditions: (a) Please submit your estimate to us showing what effect the requested Change will have on the Contract Price. Your estimate shall include your claim for the additional time, if any, for completion of the requested Change.

(b)

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI

(c)

If you have any opinion negative to the adoption of the requested Change in connection with the conformability to the other provisions of the Contract or the safety of the Plant or Facilities, please inform us of your opinion in your proposal of revised provisions. Any increase or decrease in the work of the Contractor relating to the services of its personnel shall be calculated. You shall not proceed with the execution of the work for the requested Change until we have accepted and confirmed the amount and nature in writing.

(d)

(e)

(Employers Name)

(Signature)

(Name of signatory)

(Title of signatory)

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TANESCO Bidding Documents Section VI

Annex 2. Estimate for Change Proposal (Contractors Letterhead) To: ______________________________ Attention: _______________________________ Contract Name: _______________________________ Contract Number: _____________________________ Date:

Dear Ladies and/or Gentlemen: With reference to your Request for Change Proposal, we are pleased to notify you of the approximate cost of preparing the below-referenced Change Proposal in accordance with GC Sub-Clause 39.2.1 of the General Conditions. We acknowledge that your agreement to the cost of preparing the Change Proposal, in accordance with GC Sub-Clause 39.2.2, is required before estimating the cost for change work. 1. 2. 3. 4. 5. Title of Change: ________________________ Change Request No./Rev.: ____________________________ Brief Description of Change: __________________________ Scheduled Impact of Change: ___________________________ Cost for Preparation of Change Proposal: _______________2 (a) Engineering (i) (ii) Engineer Draftsperson Sub-total Total Engineering Cost (b) Other Cost hrs x hrs x hrs rate/hr = rate/hr = (Amount)

Total Cost (a) + (b)

(Contractors Name)
2

Costs shall be in the currencies of the Contract.


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TANESCO Bidding Documents Section VI

(Signature)

(Name of signatory)

(Title of signatory)

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TANESCO Bidding Documents Section VI

Annex 3. Acceptance of Estimate (Employers Letterhead) To: ______________________________ Attention: ________________________________ Contract Name: _____________________________ Contract Number: ___________________________ Date:

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

(Employers Name)

(Signature)

(Name and Title of signatory)

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI

Annex 4. Change Proposal (Contractors Letterhead) To: _______________________________ Attention: _______________________________ Contract Name: _______________________________ Contract Number: _______________________________ Date:

Dear Ladies and/or Gentlemen: In response to your Request for Change Proposal No. _______________________________, we hereby submit our proposal as follows: 1. 2. 3. Title of Change: _______________________________ Change Proposal No./Rev.: _______________________________ Originator of Change: Employer: [_______________________________ Contractor: _______________________________ Brief Description of Change: _______________________________ Reasons for Change: _______________________________ Facilities and/or Item No. of Equipment related to the requested Change:
_______________________________

4. 5. 6. 7.

Reference drawings and/or technical documents for the requested Change: Drawing/Document No. Description

8.

Estimate of increase/decrease to the Contract Price resulting from Change Proposal:3 (Amount) (a) (b) (c) (d) Direct material Major construction equipment Direct field labor (Total Subcontracts hrs)

Costs shall be in the currencies of the Contract.


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TANESCO Bidding Documents Section VI

(e) (f) (g)

Indirect material and labor Site supervision Head office technical staff salaries Process engineer Project engineer Equipment engineer Procurement Draftsperson Total hrs @ hrs @ hrs @ hrs @ hrs @ hrs rate/hr rate/hr rate/hr rate/hr rate/hr

(h) (i) (j)

Extraordinary costs (computer, travel, etc.) Fee for general administration, Taxes and customs duties % of Items

Total lump sum cost of Change Proposal


(Sum of items (a) to (j))

Cost to prepare Estimate for Change Proposal


(Amount payable if Change is not accepted)

9.

Additional time for Completion required due to Change Proposal

10. Effect on the Functional Guarantees 11. Effect on the other terms and conditions of the Contract 12. Validity of this Proposal: within [Number] days after receipt of this Proposal by the Employer 13. Other terms and conditions of this Change Proposal: (a) You are requested to notify us of your acceptance, comments or rejection of this detailed Change Proposal within ______________ days from your receipt of this Proposal. The amount of any increase and/or decrease shall be taken into account in the adjustment of the Contract Price. Contractors cost for preparation of this Change Proposal:2

(b)

(c)

Specify where necessary.


11

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TANESCO Bidding Documents Section VI

(Contractors Name)

(Signature)

(Name of signatory)

(Title of signatory)

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI

Annex 5. Change Order (Employers Letterhead) To: _______________________________ Attention: _______________________________ Contract Name: _______________________________ Contract Number: _______________________________ Date:

Dear Ladies and/or Gentlemen: We approve the Change Order for the work specified in the Change Proposal (No. _______), and agree to adjust the Contract Price, Time for Completion and/or other conditions of the Contract in accordance with GC Clause 39 of the General Conditions. 1. 2. 3. 4. Title of Change: _______________________________ Change Request No./Rev.: _______________________________ Change Order No./Rev.: _______________________________ Originator of Change: Employer: _______________________________ Contractor: _______________________________ Authorized Price: Ref. No.: _______________________________
__________________________ Foreign currency portion __________

5.

Date:

plus Local currency portion __________

6.

Adjustment of Time for Completion None days Increase _________ days Decrease
_________

7.

Other effects, if any

Authorized by: (Employer)

Date:

Accepted by: (Contractor)

Date:

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TANESCO Bidding Documents Section VI

Annex 6. Pending Agreement Change Order (Employers Letterhead) To: _______________________________ Attention: _______________________________ Contract Name: _______________________________ Contract Number: [_______________________________ Date:

Dear Ladies and/or Gentlemen: We instruct you to carry out the work in the Change Order detailed below in accordance with GC Clause 39 of the General Conditions. 1. 2. Title of Change: _______________________________ Employers Request for Change Proposal No./Rev.: _______________________________ dated: __________ Contractors Change Proposal No./Rev.:
__________ _______________________________

3. 4. 5. 6.

dated:

Brief Description of Change: _______________________________ Facilities and/or Item No. of equipment related to the requested Change:
_______________________________

Reference Drawings and/or technical documents for the requested Change: Drawing/Document No. Description

7. 8. 9.

Adjustment of Time for Completion: Other change in the Contract terms: Other terms and conditions:

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI

(Employers Name)

(Signature)

(Name of signatory)

(Title of signatory)

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BACKBONE TRANSMISSION INVESTMENT PROJECT (BTIP) 400kV Transmission Line Lot 1, 2 & 3

TANESCO Bidding Documents Section VI

Annex 7. Application for Change Proposal (Contractors Letterhead) To: _______________________________ Attention: _______________________________ Contract Name: _______________________________ Contract Number: _______________________________ Dear Ladies and/or Gentlemen: We hereby propose that the below-mentioned work be treated as a Change in the Facilities. 1. 2. Title of Change: _______________________________ Application for Change Proposal No./Rev.:
_______________________________

Date:

dated:
_______________________________

3. 4. 5. 6. 7. 8.

Brief Description of Change: _______________________________ Reasons for Change: Order of Magnitude Estimation (in the currencies of the Contract): Scheduled Impact of Change: Effect on Functional Guarantees, if any: Appendix:

(Contractors Name)

(Signature)

(Name of signatory)

(Title of signatory)

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