Bid Document of 4th B Lift

KRISHNA BHAGYA JALA NIGAM LIMITED
(A GOVERNMENT OF KARNATAKA ENTERPRISES)
MULWAD LIFT IRRIGATION SCHEME UNDER UPPER KRISHNA

PROJECT, STAGE III
TH
MULWAD 4 B LIFT IRRIGATION SCHEME
BID DOCUMENT
Name of the work
------------------------------------------------------------------------------------------Design, Supply, Installation, Testing and Commissioning of Lift Irrigation systems of 4th B Lift
work in Bijapur District under Mulwad LIS UKP Stage III Works off taking from Km - 18.95 of
Basavana Bagewadi Canal comprising of Intake Canal, Fore bay, Jack well Cum Pump House,
Trash racks, Stop log gates, Embedded parts, Mono rail arrangement for operation of gates, VT
Pumps coupled to HT Motors with SCADA system (7 working pumps des igned for peak discharge
with 1 standby provision) EOT Crane, MS Manifold, necessary transformers ( 1 working + 1
standby) 220 KV Terminal bay and 220 KV /6.6 KV SC line on DC towers, Electrical Sub -Station
with Mulsifyre system, comprising of Electrical Panel, Soft Starters, Capacitors, Valves, HT Switch
Gear, HT Metering Equipment for KPTCL metering, Supply and fixing of Control and Relay Panels,
HT Cabling, Earthing with necessary arrangements to receive power supply from KPTCL, requisite
number of MS Rising Main with necessary Air valves, Zero velocity valves, NRVs, Thrust Blocks,
Surge protection measures, Delivery Chamber, Structures along Intake Canal and Rising main if
any, Construction of 220 KV / 6.6 KV SC line on DC towers including Terminal Bays as per KPTCL
norms, store room, O&M staff and watchman quarters at Jack well cum Pump House site,
protective fencing to Jack well and Electrical Sub-Station, Asphalt approach road from Masabinal Ingleshwar road to Jack well cum Pump House along Intake c anal, Supply of spare parts, tools,
operation and maintenance of system for Five years after successful commissioning on lump sum
Turn-Key basis.
OFFICE OF THE
EXECUTIVE ENGINEER
KBJNL,MLI DIVISION-04,
DEVAR HIPPARAGI CAMP,ALMATTI
MULWAD 4th B LIFT IRRIGATION SCHEME

BID DOCUMENT
TABLE OF CONTENTS
Sl. No.
PARTICULARS
PAGE NO
From
To
1.
Tender Face Sheet
2.
Abbreviation
3.
Invitation for Bids (IFB)
23
24
35
36
40
41
68
69
108
109
116
117
140
A. Electrical Works
141
422
B. Mechanical Works
423
453
C. Specification for Civil works
454
621
622
631
632
650
651
668
668
671
SECTION-1
4.
Instruction to Bidders (ITB)
SECTION-2
5.
Forms of Bid and letter of Acceptance
SECTION-3
6.
Conditions of Contract
SECTION-4
7.
General Conditions of Contract
SECTION-5
8.
Schedule-D
SECTION-6
9.
Contract Data and Scope of work
SECTION-7
10.
Technical Specifications
SECTION-8
11.
Schedule-B
Bill of Quantities
SECTION-9
12.
Forms of Securities
SECTION-10
13.
Data Sheets
SECTION-11
14
Drawings & Annexure

DRAFT TENDER PAPERS

TENDER DOCUMENT
Name of the work
Design, Supply, Installation, Testing and Commissioning of Lift Irrigation systems of 4th B Lift
Pumps coupled to HT Motors with SCADA system (7 working pumps designed for peak discharge
standby) 220 KV Terminal bay and 220 KV / 6.6 KV SC line on DC towers, Electrical Sub-Station
norms, store room, O&M staff and watchman quarters at Jack well cum Pump House site,
protective fencing to Jack well and Electrical Sub-Station, Asphalt approach road from Masabinal Ingleshwar road to Jack well cum Pump House along Intake canal, Supply of spare parts, tools,
operation and maintenance of system for Five years after successful commissioning on lump sum
Turn-Key basis.
OFFICE OF THE
EXECUTIVE ENGINEER
M.L.I. DIVISION NO.4,
DEVAR HIPPARAGI

(A Government of Karnataka Enterprise)
TENDER FACE SHEET

(TO BE FILLED AT THE TIME OF ISSUE OF TENDER DOCUMENT)
1. NAME OF WORK: - Design, Supply, Installation, Testing and Commissioning of
Lift Irrigation systems of 4 th B Lift work in Bijapur District under Mulwad LIS
UKP Stage III Works off taking from Km - 18.95 of Basavana Bagewadi
Canal comprising of Intake Canal, Fore bay, Jack well Cum Pump House,
Trash racks, Stop log gates, Embedded parts, Mono rail arrangement for
operation of gates, VT Pumps coupled to HT Motors with SCADA system
(7 working pumps designed for peak discharge with 1 standby provision)
EOT Crane, MS Manifold, necessary transformers ( 1 working + 1 standby)
220 KV Terminal bay and 220 KV /6.6 KV SC line on DC towers, Electrical
Sub-Station with Mulsifyre system, comprising of Electrical Panel, Soft
Starters, Capacitors, Valves, HT Switch Gear, HT Metering Equipment for
KPTCL metering, Supply and fixing of Control and Relay Panels, HT Cabling,
Earthing with necessary arrangements to receive power supply from KPTCL,
requisite number of MS Rising Main with necessary Air valves, Zero velocity
valves, NRVs, Thrust Blocks, Surge protection measures, Delivery Chamber,
Structures along Intake Canal and Rising main if any, Construction of 220 KV
/ 6.6 KV SC line on DC towers including Terminal Bays as per KPTCL norms,
store room, O&M staff and watchman quarters at Jack well cum Pump House
site, protective fencing to Jack well and Electrical Sub-Station, Asphalt
approach road from Masabinal - Ingleshwar road to Jack well cum Pump
House along Intake canal, Supply of spare parts, tools, operation and
maintenance of system for Five years after successful commissioning on
lump sum Turn-Key basis.
2. Tender Schedule sold to
3. Whether the contractor has been
enrolled in KPWD & KBJNL select List
4. Category of Contractor
5. Whether a Joint Venture and if so
whether required conditions are

met with
6. Date of issue of blank tender
document to the contractor
7. Pre bid meeting
: ___ - ___- 2014
up to 5.00 PM
: ___ - ___- 2014
at 11.00 AM
: ___ - ___- 2014
up to 5.00 PM
: ___ - ___- 2014
at AM (Technical bid)
8. Last date of receipt of tender

document
9. Date of opening of tender
Accounts Superintendent
Executive Engineer
KBJNL ,MLI Division. No 4
Devar Hipparagi
TO BE FILLED AT THE TIME OF OPENING THE TENDERS

1. Whether the contractor has
remitted the required E.M.D.

or not, and how ?
2.
No. and date and amount of DD/
Bankers Cheque /Bank Guarantee

3.
Name of Bank
4. Validity Period
5.
Whether the contractor fulfills all
the conditions of EMD

6.
Whether the tender fulfills all the
conditions of Tender Notice and

conditions of contract etc.
7. Whether counter conditions if any
are put by the contractor

Recommendations of the
Engineer-in-Chief/Executive
Engineer for processing
of the tender
Opened by me on this day...........................................at.................................
i)
No of Corrections..
ii) No of Over Writings

iii) No of Insertions .
Total No. of corrections in the tender:
Place:
Date :
Executive Engineer
KBJNL, MLI Division.No.4
Devar Hipparagi
ABBREVIATIONS ADOPTED IN THE TENDER

DOCUMENTS AND THEIR EXPANSION
Sl.No.
Abbreviation
Expansion
1.
Meter
m2 or Sqm
Square meter
m3 or Cum
Cubic Metre
Mm
Milli Metre
Cm
Centimeter
KM
Kilometre
Kg
Kilogram
Kg/cm2
Kilogram per square centimeter
Metric Tonnes
10
Litres
11
R.C.C.
Reinforced Cement Concrete
12
C.C.
Cement Concrete
13
C.M
Cement Mortor
14
No.
Number
15
S.T.
Sales Tax
16
E.M.D.
Earnest Money Deposit
17
N.S.C.
National Savings Certificate
18
U.C.R
Uncoursed Rubble Masonry
19
Rmt
Running Meter
20
KWH
Kilo watt Hour
21
D.D
Demand Draft
22
KBJNL
Krishna Bhagya Jala Nigam Limited
23
NIGAM
Krishna Bhagya Jala Nigam Limited

MULWAD 4TH B LIFT IRRIGATION SCHEME

BID DOCUMENT
INVITATION FOR BIDS (IFB)

(A Government of Karnataka Enterprises)
Office of the Executive Engineer, KBJNL, MLI Division No.4, Devar Hipparagi
Tq: Sindagi, Dt: Bijapur, Karnataka
SHORT TERM TENDER NOTIFICATION.
(Through e- Procurement only)
No: KBJNL/MLID-4/Stage-III/4th B Lift/PB/2014-15/325
1)
Date: 11-11-2014
On behalf of Managing Director, KBJNL, Bangalore, the Executive Engineer, KBJNL, MLI
Division No.4, Devar Hipparagi invites bids for the following work from KBJNL Category-I enrolled
contractor/ Class-I Registered Contractors of Karnataka PWD/PWD of any State/CPWD/any other
Government undertaking. The two cover bid submission p rocedure as per Rule 28 of KTPP Act
shall be followed. The bidders are requested to submit their bids in two cover system including
EMD in e-cash. The first cover (Technical Bid) should contain the documents as mentioned in
Para 1.1. The second cover shall contain the financial bid. The cover-I (technical bid) will be
opened first. Thereafter, cover-II (financial bid) of only those bidders who have paid the requisite
EMD and fulfill the conditions contained in Para 1.1 will be opened.
Table showing details of work put to tender is as under:
Approximate Earnest
No.
1
Name of work
Design, Supply, Installation, Testing
and Commissioning of Lift Irrigation
systems of 4th B Lift work in Bijapur
District under Mulwad LIS UKP Stage
III Works off taking from Km - 18.95
of Basavana Bagewadi Canal
comprising of Intake Canal, Fore bay,
Jack well Cum Pump House, Trash
racks, Stop log gates, Embedded
parts, Mono rail arrangement for
operation of gates, VT Pumps coupled
to HT Motors with SCADA system (7
working pumps designed for peak
discharge with 1 standby provision)
EOT Crane, MS Manifold, necessary
amount put
Money
to tender
Deposit
(Rs In
(Rs In
Lakhs)
Lakhs)
11524.24
115.50
Transaction
Stipulated
fee (Only for
period for
the
completion
tenderers
of work
who wish to
(including
participate)
monsoon)
As per
18
e-portal
months
transformers ( 1 working + 1 standby)

220 KV /6.6 KV Electrical Sub-Station
with Mulsifyre system, comprising of
Electrical Panel, Soft Starters,
Capacitors, Valves, HT Switch Gear,
HT Metering Equipment for KPTCL
metering, Supply and fixing of Control
and Relay Panels, HT Cabling,
Earthing with necessary arrangements
to receive power supply from KPTCL,
requisite number of MS Rising Main
with necessary Air valves, Zero
velocity valves, NRVs, Thrust Blocks,
Surge protection measures, Delivery
Chamber, Structures along Intake
Canal and Rising main if any,
Construction of 220 KV / 6.6 KV SC
line on DC towers including Terminal
Bays as per KPTCL norms, store
room, O&M staff and watchman
quarters at Jack well cum Pump
House site, protective fencing to Jack
well and Electrical Sub-Station,
Asphalt
approach
road
from
Masabinal - Ingleshwar road to Jack
well cum Pump House along Intake
canal, Supply of spare parts, tools,
operation and maintenance of system
for Five years after successful
commissioning on lump sum Turn-Key
basis.
Instruction to Bidders
1.0
The bids should be submitted in two covers apart from EMD.
1.1
COVER-1 (Technical bid) shall contain the following documents.
i)
valid copy of the KBJNL Categorization certificate (Category -I) or the certificate of
registration issued by Public Work Department of Karnataka state or Public works Department of
any state or Central Public Works Department or any other Government under takings.
ii) The requisite Earnest Money Deposit.(e-cash)
iii) A copy of the Income Tax return filed for the financial year 2013-14 mentioning PAN and Tan
Numbers.
iv) Sales Tax clearance certificate of financial year period ending March-2014.
v) Valid Employees Provident Fund Registration Certificate.
vi) The details of tie up with pump manufacturer, for execution of Electro mechanical components
of Lift Scheme.
vii) The details in support of pre-qualification criteria as mentioned in Para 4 below.

viii) Technical details containing document with preliminary designs in support of their bid.
1.2
2.
COVER-II Shall contain the financial bid.

The Cover-I (Technical bid) will be opened first and evaluated to determine their eligibility.
Thereafter Cover-II (Financial bid) of only those bidders who fulfill the pre -qualification criteria and
other conditions as mentioned at para 1.1 will be opened.
3.
Issue and submission of tender documents.
3.1
E-Tendering
3.1.1 Aspiring bidders who wish to undergo training to e -tendering should submit their request in
writing to e-governance MS building, Bangalore-1 and the training will be conducted for such
contractors up to 28-11-2014.
3.1.2 The aspiring contractors who have not previously obtained the user ID and Password for
participating in e-tendering may now obtain the same by requesting in writing to the Managing
Director, KBJNL Regd. office, Bangalore office on or before 28-11-2014.
3.1.3 The Contractors can request for e-tendering documents from 21-11-2014 to 20-12-2014 in the
KBJNL web site http://eproc.karnataka.gov.in/eportal/index.seam link e-tender document on
payment (non refundable) fee as per e-portal towards the transaction fee. While applying the
contractors can pay the transaction fee in the e-procurement portal using payment modes- 1) Credit
card/ Direct debit/ National electronic fund transfer (NEFT) / over the counter (OTC) upto 5.00pm.
3.1.4 The contractor can have access to e-tender document from 21-11-2014 to 20-12-2014 up to
5.00 pm.
3.1.5 A pre-bid conference will held on 29-11-2014 at 11.00 am at the office of the Chief Engineer,
KBJNL, Dam Zone Almatti. The bidders should submit their queries if any for clarifications on or
before 28-11-2014 up to 5.00pm positively through following e-mail only.
cedam_almatti@yahoo.co.in
3.1.6 Submission of completed e-tendering document will be 20-12-2014 up to 5.00 pm.
3.1.7 Cover-I (Technical bid) will be opened in the office of the Executive Engineer, KBJNL, MLI
Division No.4, Devar Hipparagi on 24-12-2014 at 11.00 am in the presence of the bidders who wish
to participate.
3.1.8 Cover-II (Financial bid) date will be intimated later for technically responsive bidders.
3.1.9 The Contractor should pay Rs. 115.50 Lakhs of the earnest money deposit (EMD) in eprocurement portal in any mode of payment such as Credit card/ direct debit/ national electronic
fund transfer (NEFT)/ Over the counter (OTC), The EMD amount submitted by the contractor
should govern the following condition.
a)
The EMD amount of Rs. 115.50 Lakhs accepted in the form of electronic cash (and not
through demand draft or Bank Guarantee) will be maintained in the Govt. Central Pooling Account
at Axis Bank until the contract is concluded and Agreement is signed which includes furnishing of
Security Deposit equivalent to EMD in the form of Bank Guarantee/ Demand Draft/ Banker Cheque
of any Nationalized Bank.
b)
The entire EMD amount is to be paid in a single transaction.
c)
The inviting authority would release EMD taken in cash through e -procurement against Bank
guarantee for similar work.

3.1.10 The necessary certificates/ documents in support of pre qualification criteria fulfilled as
stipulated shall be scanned and attached to e-tender document. Scanned signature of the bidder/
authorized representatives of the bidder shall be attached while uploading the bid document.
3.1.11 Prior to awarding of the work the Lowest (L-1) bidder should produce the original
documents in support of the uploaded documents to enter into the agreement. IF the Lowest bidder
( L-1 ) does not produce the Original documents for entering into the agreement then his bid can be
treated as non responsive bid as per Clause 26(4) of the KTPP Rules. The names of the bidders
who does not produce the original documents shall be removed from select list of KBJNL
Enrollment and barred from participation in any of the tenders to be invited by KBJNL apart from
forfeiting the EMD paid through e-cash. Further the Lowest bidder (L-1) can be determined
amongst the other responsive bidders.
3.1.12 Further
information
about
electronic
tendering
can
be
had
from
http://eproc.karnataka.gov.in/eportal/ines.seam
4.
Pre-qualification criteria:
Pre-qualification criteria:
1) The intending bidders should be a registered contrac tor of KBJNL enrolled Category-I / KPWD /
PWD of any State / CPWD / any other Government undertaking and should have tie-up with pump
manufacturer for supply of pumps. The agreement of tie-up should have been concluded before
submitting the bid.
2) The intending bidder should have satisfactorily completed (not less than 90% of contract
value) as a prime contractor, one similar work costing not less than 80% of the amount put
to tender on turnkey basis during the last 10 financial years reckoned from 2014-15. The
work done certificate should be obtained duly signed from an officer not below the rank of
Executive Engineer of the concerned Division and counter signed by the Superintending Engineer
of the same circle or equivalent in case of other Government undertaking within India. The cost will
be updated to the present value by giving a weightage of 10% for each year, if the work is
completed prior to the year 2014-15.
Note-1: Similar work means the work should comprise of LIFT IRRIGATION SCHEME
INVOLVING LIFT COMPONENTS INCLUDING CONSTRUCTION OF INTAKE CANAL,
JACKWELL CUM PUMP HOUSE, MS RISING MAIN AND DELIVERY CHAMBER.
Note-2: The intending bidders should upload the copies of R.A Bills in support of their
claim.
3) The intending bidder should have average annual turnover at least Rs.240.00 crores in any of
the two financial years during the last 10 financial years i.e., between 2004-05 to 2013-14.
Audited Profit and Loss account certified by a practicing Chartered Accountant along with copy of
Income Tax returns filed for the years indicated above should be furnished.
Note: If the audited profit and loss account certified by a practicing Chartered Accountant
along with copy of tax returns filed for the years indicated is not uploaded, the bid shall be
treated as non-responsive. No correspondence in this regard would be entertained.
4) The pre-qualification criteria can be satisfied by individual / joint venture to be formed prior to the
bidding. The lead partner should have at least 50% of the annual turnover prescribed in any of the
2 financial years during the last 10 financial years (2004-05 to 2013-14). Audited Profit and Loss
account certified by a practicing Chartered Accountant along with copy of income Tax returns filed
for the years indicated above should be furnished. The lead partner should have completed similar
type of work on turnkey basis.
5) Tendering by a joint venture is permissible subject to the following conditions.
(a)
The joint venture shall have been formed prior to the tendering and blank tender
forms shall have been applied for and purchased by the joint venture itself.
(b)
Every partner of the joint venture shall have been enrolled in the KBJNL Category I enrolled contractor / Class-I registered contractors of Karnataka PWD/PWD of any
state/CPWD/any other government undertaking.
(c)
One of the partner of joint venture duly authorized with a legally binding power of
attorney to apply for tender forms and to sign the tender and to make further
correspondence and deal with KBJNL on behalf joint venture shall have been enrolled in
the category eligible for tendering.
d) A contractor is not eligible to participate as a partner of more than one joint venture
6) The intending bidder should have tie-up or a joint venture with pump manufacturer who has
successfully commissioned at least 8 pumps each of capacity not less than 2.667 cumecs
with a static head not less than 57 meters during the last 10 financial years. The pumps
should have been installed and successfully commissioned within India in a project of any of the
State Government or Govt. of India or in any Public Sector Undertakings of Government. The work
done certificate should be signed and obtained from an officer not below the rank of Executive
Engineer of the concerned Division and counter signed by the Superintending Engineer of the
same circle or equivalent in case of other Government undertaking. There is no scope for altering
the number of pumps specified in the Bid-Document.
7) Multiple tie-up is not permitted.
8) The intending bidder should have fabricated, laid and tested MS rising main pipes of minimum
2.61 meter diameter for a total length of 0.6 KM during the last 10 financial years. The work done
certificate should be obtained duly signed from an officer not below the rank of Executive Engineer
of the concerned Division and counter signed by the Superintending Engineer of the same circle or
equivalent in case of other Government undertaking.
9) The lead partner shall be responsible for successful performance of the contract. The bid shall be
submitted by the lead partner for the entire work.
10) The lead partner and the co-opted partner/s shall enter into a joint venture agreement on Rs.200/stamp paper in the prescribed format which shall be concluded prior to bidding and enclosed to the
bid document and submit along with the request for bid document.
11) In case of joint venture, all the partners are jointly and severally responsible for successful
performance of the contractor.
12) One of consortium partners should have executed 110 KV transmission line work for a length of
11.00 km during last 10 financial year.
13) The lead partner or other partners in a joint venture are permitted to participate in the tender under
a single / joint venture only and are not permitted to participate under multiple / joint ventures. Any
violation will attract disqualification of the bid.
14) During technical evaluation, if the employer finds that any certification / information furnished is
false, such bidders will be disqualified and barred from participation in the bid.
15) If any bidder fails to satisfy all the conditions mentioned above, such bids will be rejected.
16) One of the consortium partners should have installed, commissioned and maintained
SCADA system for 2 years within India in a project of any of the State Government or
Government of India or in any public Sector Undertakings of Government which should
meet the following requirements.
(i) The consortium partner should be a reputed system Integrator who must have manufacturer /
integrated, tested and supplied equipments needed for SCADA system. The equipments offered
should strictly meet the requirement of the project.
(ii) The minimum required annual turnover in respect of supply, installation and commissioning of
goods for the successful bidder in any one of the last two (2) years shall be equivalent to Rs 200
Lakhs or above.
(iii) The manufacturer shall furnish and assure full guarantee and warranty obligations directly to the
Executive Engineer, KBJNL MLI Division No-4 Devar Hipparagi mentioning the partner or system
integrator who will be involved;
(iv) Consortium partners capability to supply, commission, support and maintain the equipments needed
for SCADA system.
The consortium partner must also provide evidence of having provided continuous
maintenance services under contract for a minimum period of 24 months in this Country
and the capacity to service and maintain the equipments.
The Executive Engineer, may evaluate, ask for technical demonstration, ask for samples
and cross verify the evidence from the Government sources, for ascertaining the relevant
contract information which should be clearly shown along with the work completion, and
maintenance certificates.
(v) The intending consortium partner shall produce the following documentary evidence to satisfy the
pre-qualification criteria specified above:
a) Documents defined the consortium or legal status of the company such as Memorandum of
Article or Certificate of Registration.
b) Attested documentary proof in original for having executed similar nature of work as defin ed in
qualification criteria no. (i) to (iv) above.
c) ISO certificate.
(vi) Previous successful commissioning and performance certificates for the installations counter signed
by the Superintending Engineer.
(vii) Existing maintenance contracts with performance certificate up to the month of the bid opening date
counter signed by the Superintending Engineer.
(viii) Furnish a copy of annual report for the preceding two financial years.
5. NOTES
5.1
The intending bidders are advised to visit the site of work, make themselves familiar with
local situation about the availability of construction material, work men, land required for
construction activities. The bidder should also acquaint himself of the access to the site of work
before attending the pre-bid meeting and also submitting their tenders.
5.2
The contractor / authorized signatory should attach his/her scanned signature to the
Schedule-B before uploading the documents.

5.3
If any of the dates mentioned above happen to be a general holiday, the next working day
holds good.
5.4
Further information can be had from the undersigned during office hours.
5.5
Conditional tenders are liable to be rejected. The officer competent to accept the tender shall
have the right to reject any or all the tenders without assigning any reason whatsoever.
5.6
Any Modification / clarification will be published in the e-portal / KBJNL web site. The
bidders are advised to visit the KBJNL web site / e portal regularly.
5.7
The intending bidders should note that, if any of lands either in part / parts or in whole
required for the work is not acquired by the Nigam, it shall be the responsibility of the bidder to take
possession of such land and start the work by consent of the land owners before commencement
of work at no extra cost to the Nigam and no claim / delays whatsoever relating to on account of
non availability of land would be entertained.
5.8
If the percentage quoted by the contractor for the work is below ninety percent of the
estimated amount put to tender or recast amount put to tender of the department, then the
contractor shall furnish an additional performance security in the form of Bank Guarantee for an
amount equivalent to the difference between the cost as per quoted percentage and 90% of the
estimated amount put to tender or recast amount put to tender. The additional performance
security will be released only after the entire work contracted is fully completed and so certified by
the Engineer.
5.9
They should abide by the directions of Government towards recovery of 1% (or as modified
by Govt from time to time) Cess from the contractors bill under the provisions of building and other
constructions worker welfare Cess Act 1996.
5.10 Successful bidders should execute the agreement within 15 days from the date of approval
intimated. If the contractor fails to enter into the agreement within the said period, the EMD of the
contractor shall be forfeited and action shall be initiated for banning to participate in the tender of
KBJNL.
5.11 Contractor shall bear the service tax as per the reverse charge mechanism as per
Government of India Notification No 30/2012 Service Tax Dated 20-6-2012
and any
modifications/charges notified by the Government of India from time to time and on date of
payment.
Further instructions about electronic tendering can be had from http://e-proc
.karnataka"gov.in/e portal/index.Seam and can be had from the undersigned during office hours.
Executive Engineer,
KBJNL, MLI Division No.4
Devar Hipparagi
FORMAL TENDER NOTICE

Adapted version of KPWD Form PWG 66
PART-I
Tenders in the prescribed forms are hereby invited by the Executive Engineer, KBJNL, Dam
Division , Almatti on behalf of the Managing Director of KBJNL for the following work/works.
NAME OF WORK:-
Design, Supply, Installation, Testing and Commissioning of Lift Irrigation
systems of 4th B Lift work in Bijapur District under Mulwad LIS UKP Stage III Works off taking
from Km - 18.95 of Basavana Bagewadi Canal comprising of Intake Canal, Fore bay, Jack well
Cum Pump House, Trash racks, Stop log gates, Embedded parts, Mono rail arrangement for
operation of gates, VT Pumps coupled to HT Motors with SCADA system (7 working pumps
designed for peak discharge with 1 standby provision) EOT Crane, MS Manifold, necessary
transformers ( 1 working + 1 standby) 220 KV Terminal bay and 220 KV /6.6 KV SC line on DC
towers, Electrical Sub-Station with Mulsifyre system, comprising of Electrical Panel, Soft Starters,
Capacitors, Valves, HT Switch Gear, HT Metering Equipment for KPTCL metering, Supply and
fixing of Control and Relay Panels, HT Cabling, Earthing with necessary arrangements to receive
power supply from KPTCL, requisite number of MS Rising Main with necessary Air valves, Zero
velocity valves, NRVs, Thrust Blocks, Surge protection measures, Delivery Chamber, Structures
along Intake Canal and Rising main if any, Construction of 220 KV / 6.6 KV SC line on DC towers
including Terminal Bays as per KPTCL norms, O&M staff and watchman quarters at Jack well cum
Pump House site, protective fencing to Jack well and Electrical Sub-Station, Asphalt approach road
from Masabinal - Ingleshwar road to Jack well cum Pump House along Intake canal, Supply of
spare parts, tools, operation and maintenance of system for Five years after successful
commissioning on lump sum Turn-Key basis.1.Estimated cost of the work : Rs. 11524.24 Lakhs.
2.
Blank Tender Document which includes the complete set of drawings, the complete
specifications of the work to be done, the schedule of quantities of various items of work to be done
and the set of Conditions of Contract to be complied with by the person whose tender may be
accepted, can be purchased at the web site line e -tender and can be submitted through electronic
tender box. The facility is available through click on link e -portal http;//eproc.karnatak.gov.in/e
portal/lines. seam. The contractor can request for e-tender form-----------to ----------------in
the web site http;//eproc.karnatak.gov.in/e portal/lines. Seam. The e -tender document will be
issued from --------------- to -----------------
3.
The tender is invited on two cover system basis the scanned documents consisting of pre -
qualification requirements scanned EMD (Cover-I) shall be attached which will be opened first on
the day of opening of tender.
The EMD (Earnest Money deposit) shall be in the e-procurement portal by issuing in any mode of
payment such as a) Credit card (b) direct debit (c) National electronic fund transfer (NEFT) (d)
over the counter (OTC). The entire EMD amount for a particular tender is to be pai d in a single
transaction and the EMD is accepted in form for electronic cash (and not through Demand draft or
Bank Guarantee) will be maintained in the Governments central pooling A/c. at Axis Bank until the
contract is closed. The validity of EMD shall be for a period of 180 days from the date of opening of
tender.
4.
Authorized copies of the specifications, designs and drawings and the schedule of rates and
any relevant documents required in connection with the work shall be open for inspection to the
tenderers at the concerned office of Executive Engineer, KBJNL MLI Division No-4 Mattihal,
District: Bijapur during office hours. The tenderers inspecting the documents should sign in the
register kept for this purpose in the office, in token of having see n those documents. The tenderers
should note that the quantities mentioned in the Schedule B of contract form are only
approximate.
5.
Each tenderer should give clearly in his tender, his residential address and postal address.
The delivery at the above named places or posting in the Post Box regularly maintained by the
Post Office or sending letter by Registered Post with Acknowledgement due or by other
communications by the Executive Engineer shall be deemed sufficient service thereof.
6.
The tender of the work shall not be witnessed by a contractor or contractors who has/have
tendered or who may tender for the same work. Failure to observe this condition will result in
rejection of tenders.
7.
The Schedule of materials to be supplied by the Department and their rates will be as
indicated in Schedule-A of contract form. Tenderers shall quote their rates for finished works
accordingly. Notwithstanding subsequent change in the market value for these materials, charges
to the contractor will remain as originally entered in the schedule-A.
8.
The amount quoted by the contractor must be inclusive of Sales Tax and any other duties,
taxes, etc. The contractor is also required to pay quarry Fees, Royalties, Octroi Dues levied by the
State Government or any Local Body or Authority and ground rent, if any, charged by the Executive
Engineer for stacking materials. No extra payment on this account will be made to the contractor.
9.
The person submitting the tender shall fill up the Schedule -B stating at what rate for each
item of work specified therein he is willing to undertake work. Only one rate for each item shall be
indicated in the schedule both in figures and in words. In order to make the evaluation process
simpler, the contractor in addition to quoting their amount for each item may indicate the amount
for each by multiplying the quantity. In addition, they may also be asked to indicate their total
quoted amount and percentage.
10.
The amount quoted shall be written in Ink Pen / Ball Point Pen only and such o f the tenders
where this condition is not complied with, will be rejected. DELETED

11.
Any Discrepancy/Error in the tender document would be dealt with and computed in the
evaluation as under : DELETED

i)
Where there is discrepancy between the ORIGINAL and the DUPLICATE tenders the entries
in the ORIGINAL shall prevail.

ii)
In case discrepancy between the prices quoted in words and in figures, lower of the two shall
be considered. The Contractor shall quote the rates both in figures and in words otherwise tender
will be treated as incomplete and will be rejected.
iii)
Where there is discrepancy between the unit rate and the total amount derived from the
multiplication of the unit rate and the quantity in the schedule B of Contract Form, the unit rate as
quoted will govern. However, if the Executive Engineer is of the opinion that there is an obviously
gross misplacement of the decimal point in the unit rate, then the total amount as quoted will
govern and the unit rate will be corrected.
iv)
The amount stated in the Schedule B of the contract form will be adjusted by the Executive
Engineer in accordance with the above procedure for the correction of errors, and with the
concurrence of the contractor, shall be considered as binding on the contractor. If the contractor
does not accept the amount so corrected, the tender will be rejected and earnest money will be
forfeited.
12.
Eligibility and qualification requirements:
(1)
The tenderer should have been enrolled in KBJNL under category I and above
(2)
DELETED-.
13.
The tenderer shall submit a copy of the letter of enrolment as documentary evidence for
satisfying the criteria set forth in the para 12 above along with the completed tenders.
14.
The Contractor should pay Rs. 115.50 Lakhs of the earnest money deposit (EMD) in e-
procurement portal in any mode of payment such as a) Credit card/ direct debit/ national electronic
fund transfer (NEFT)/ over the counter (OTC), The EMD amount submitted by the contractor
should govern the following condition.
a)
The EMD amount of Rs 115.50 Lakhs accepted in the form of electronic cash (and not
through demand draft or Bank Guarantee) will be retained till the completion of tender procedure
and after signing of the agreement transfer the e cash EMD of the successful bidder to KBJNL
account.
b)
The entire EMD amount is to be paid in a single transaction.
c)
Tender inviting authority will release EMD taken in cash through e procurement against the
Bank Guarantee for similar amount.

15.
The completed e-tender document will be received in the Office of the 1) Managing Director,
KBJNL, Almatti, Taluk: Basavana Bagewadi, District: Bijapur. 2) Managing Director, KBJNL, PWD
Annexe Building, IIIrd Floor, K.R.Circle, Bangalore 3) Executive Engineer, KBJNL/Dam Division,
Almatti Dist: Bijapur upto _______PM from __________ to __________.DELETED
16.
a) The cover-A (Technical bid) will be opened by the Superintending Engineer KBJNL Dam
Circle , Almatti at the undersigned office at ________ on ___________ or on any other convenient
date in the presence of contractors or their representatives who may be present at the time.
b)
The cover-B (Financial bid) of the qualified contractor will be opened by the Superintending
Engineer KBJNL Dam Circle , Almatti at the undersigned office at ________ on ___________ or
on any other convenient date in the presence of contractors or their representatives who may be
present at the time.
17.
(a)
The tenders for works remain open for acceptance for a period of one hundred
eighty days from the date of opening of tenders. If any tenderer withdraws his tender before the
said period or makes any modifications in the terms and conditions of the tender which are not
acceptable to accepting Authority then the whole amount of Earnest Money Deposit specified in
Para 14(a) shall be forfeited to KBJNL. The department is also at liberty to take any other penal
action as it deems fit against such contractor.
(b)
If delay in deciding the tender is considered to be inevitable the Executive Engineer may
seek in advance, the consent of the tenderers agreeing to keep open their offers for further period
specified by the Executive Engineer.
(c)
In case the evaluation of tenders and award of contract is not completed within extended
period, all the tenders shall be deemed to have become invalid and fresh tenders will be c alled for.
18.
If the amount quoted by the bidder is below 90% (Ninty Percent) of the estimated amount of
the department then the bidder shall furnish an additional performance security in the form of Bank
Guarantee for an amount equivalent to the difference between the cost as per quoted amount and
90% of the amount put to tender.
The additional performance security furnished would be released only after the entire work under
contract is fully completed and so certified by the Engineer
19.
Tenders not submitted in the prescribed form and in due time will be rejected, tenders which
propose any alteration in the work specified in the Tender Notice or in the time allowed for carrying
out the work or which contain any condition put forth by the contractor, will be rejected.
20.
The authority competent to accept the tenders shall have the right of rejecting all or any of
the tenders without assigning any reasons and will not be bound to accept the lowest tender.
21.
Earnest Money Deposit of the tenders shall be refunded/re turned, on applications from them,
after 7 days.
(a)
from the date of final decisions on the tenders received in the case of rejected tenders.
(b)
from the date of expiry of the initial validity period of 180 days in the case of tenders who do
not extend the validity of their offer beyond that period.

No interest will be paid by the Krishna Bhagya Jala Nigam Limited on the Earnest Money
deposited.
22.
The successful tenderer must produce the latest Income Tax Clearance Certificate before
the work is entrusted to him. DELETED

23.
The contractor whose tender is accepted shall attend the office of the Executive Engineer on
the date fixed by written intimation, for executing Agreement Bond and completing other requisite
formalities.
24.
The successful tenderer shall pay Security Deposit in value equivalent to 6.5% of the cost of
work (including earnest money) as laid down in Clause 1(a) of Contract Form.
25.
Failure on the part of the successful tender to pay the Security Deposit amount and to
execute the Contract Agreement would constitute a breach of the contract and hence he shall be
liable for all the consequences resulting there from. Such failure would entail forfeiture of Earnest
Money Deposit. Such failure would also entail removal of contractors name from the select list of
contractors. In addition, the competent authority is entitled to have the work executed at the risk
and cost of the contractor. The contractor shall be responsible for making good, in cash, this extra
expenditure failing which the same shall also be recove red from his dues for other works as
contemplated in Clause 36 of the Conditions of Contract.
26.
The successful tenderer shall pay compensation to workmen working under him for any
injury caused during the execution of work as per Workmens Compensation Act in force from time
to time, failing which the amount will be deducted from his bills and paid to the injured workmen.
27.
If any part or whole of land required for the work is not yet acquired by the KBJNL it shall be
the responsibility of the contractor to procure possession of such land by consent of the land owner
before commencement of work at no extra cost to KBJNL and no claim whatsoever relating to nonavailability of land would be entertained.
28.
The submission of tender by a contractor implies that the contractor has read the contents of
the Tender Notice and Contract Form and all other papers included in the tender document and
made himself aware of the scope and the specifications of the work to be done and the availability
of the quantity of materials required.
29.
The tender of any contractor who does not accept the conditions contained in the Tender
Documents shall be rejected.


BID DOCUMENT
SECTION - 1
INSTRUCTIONS TO BIDDERS (ITB)
INSTRUCTIONS TO BIDDERS
A. GENERAL
1.
SCOPE OF BID
1.1
The Krishna Bhagya Jala Nigam Ltd., (KBJNL) (referred to as employer in these documents) invites
bids for the construction and installation of works (as defined in these documents and referred to as the
works) detailed in IFB. Pre qualified bidders may submit bids for the works given in IFB.
1.2
The successful bidders will be expected to complete the works by the intended completion date
specified in the contract data.

2.
SOURCE OF FUNDS
Eligible payment under the contract for works will be made from the own source of the Krishna
Bhagya Jala Nigam Ltd.

3.
ELIGIBLE BIDDERS
This Invitation for Bids is open to all pre-qualified bidders.

All bidders shall provide Forms of Bid and a statement it is necessary that the bidder is not associated,
nor has been associated in the past, directly or indirectly, with KBJNL, for this package. A firm that has
been engaged by the employer to provide consulting services for the preparation of supervision of the
works, and any of its affiliates shall not be eligible to bid.
Government owned enterprises in India may only participate if they are legally and financially
autonomous and operate under commercial law.
Bidders shall not be under a declaration of ineligibility for corrupt and fraudulent practices in accordance
with sub-clause 31.
Bidder for the works should enclose performance certificate from the concerned Executive Engineer for
having satisfactorily executed the works undertaken by him under K.B.J.N.L. The tender received without
performance certificate or with unsatisfactory performance shall be liable for rejection.
4.
QUALIFICATION OF THE BIDDER
All bidders shall provide Forms of Bid and a preliminary description of the proposed work method and
schedule, including drawings and charts, as necessary.
All bidders shall include the following updated information and documents with their bids in technical
stage.
I)
Evidence of adequacy of working capital for this contract (access to line (s) of credit and
availability of other financial resources);

II)
Authority to seek references from the Bidders bankers;
III)
Information regarding any litigation, current or during the last eight years, in which the Bidder is
involved, the parties concerned, and disputed amount
IV)
Proposals for subcontracting components of the Works amounting to more than 10 percent of the
Contract Price; and

V)
The proposed methodology and program of construction, backed with equipment planning and
deployment, duly supported with broad calculations and quality control procedures proposed to be
adopted, justifying their capability of execution and completion of work as per technical specifications
within the stipulated period of completion as per Milestones.
BID IS OPEN TO ONLY TO BIDDERS PRE-QUALIFIED
If the bid is made by a firm in partnership, it should be signed by all the partners of the firm, giving
their full names and current addresses, or by a partner holding the power of attorney of the firm to sign
the application. In such cases, a certified copy of power of attorney shall accompany the application. A
certified copy of the partnership deed, current addresses of all the partners of the firm shall also
accompany the bid.
If the bid is made by a limited company or a corporation, it shall be signed by a duly authorized
person holding power of attorney for signing the bid in which case, a certified copy of power of attorney
shall accompany the bid.
Even though the bidders have been pre-qualified, they are subject to be disqualified subsequently if
they have:
(i)
Made misleading or false representations in the forms, statements and attachments submitted in
proof of the qualification requirements; and / or

(ii)
Record of poor performance such as abandoning the works, not property completing the
contract, inordinate delays in completion, litigation history, or financial failures etc, and / or
5.
COST OF BIDDING
The bidder shall bear all costs associated with the preparation and submission of his Bid, and the
Employer will in no case be responsible and liable for those costs.

6.
SITE VISIT
The Bidder, at his own responsibility and risk is encouraged to visit and examine the Site of Works and its
surroundings and obtain all information that may be necessary or have a bearing for preparing the Bid
and entering into a contract for execution of the Works. The costs of visiting the Site shall be at the
Bidders own expense.
B. BIDDING DOCUMENTS
7.
CONTENT OF BIDDING DOCUMENTS

The set of bidding documents comprises the documents listed in the table below and addenda issued
in accordance with Clause 9:

INVITATION FOR BIDS
Section
1
Instruction to Bidders
Forms of Bid and Qualification Information
General conditions of contract
Tender Schedules
Contract Data
Specifications (A. Electrical, B. Mechanical, C. Civil)
Schedule B
Forms of securities
10
Data sheets
11
Basic parameters and Index map of the project
8.
CLARIFICATION OF BIDDING DOCUMENTS

8.1 A prospective bidder requiring any clarification of the bidding documents may notify the Employer
in writing or by cable (here in after cable includes telex and facsimile) at the Employers address
indicated in the Invitation for Bids. The Employer will respond to any request for clarification, which he
received earlier than 15 days prior to the deadline for submission of bids. Copies of the Employers
response will be forwarded to all purchasers of the bidding documents, including a description of the
enquiry but without identifying its source.
8.2 PRE-BID MEETING
8.2.1 The bidder or his official representative is invited to attend a pre -bid meeting which will take
place at the office of the, Managing Director, KBJNL PWD Office Annexe, III Floor, Bangalore-560001, at
11.00 A.M. on - -
The purpose of the meting will be to clarify issues and to answer questions on any matter pertaining to
the works that may be raised at that stage.
8.2.2 The bidder is requested as far as possible to submit any questions in writing or by cable to reach
the Employer not later than one week before the meeting. It may not be practicable at the meeting to
answer questions received late, but questions and responses will be transmitted in accordance with the
following sub-clause.
8.2.3 Minutes of the meeting including the text of the questions raised (without identifying the source of
enquiry) and the responses given will be transmitted without delay to all purchasers of the bidding
documents. Any modification of the bidding documents listed in Sub -Clause 7.1, which may become
necessary as a result of the pre-bid meeting shall be made by the Employer exclusively through the
issues of an Addendum pursuant to Clause 9 and not through the minutes of the pre-bid meeting.
8.2.4 Non-attendance at the pre-bid meeting will not be a cause for disqualification of a bidder.
9.
AMENDMENT OF BIDDING DOCUMENTS
9.1 Before the deadline for submission of bids, the Employer may modify the bidding documents by
issuing addenda.
9.2. Any addendum thus issued shall be part of the bidding documents and shall be communicated in
writing or by cable to all the purchasers of the bidding documents. Prospective bidders shall acknowledge
receipt of each addendum by cable to the Employer.
9.3
To give prospective bidders reasonable time in which to take an addendum into account in
preparing their bids, the Employer shall extend as necessary the deadline for submission of bids, in
accordance with Sub-Clause 18.2 below.
C. PREPARATION OF BIDS
10.
LANGUAGE OF THE BID
10.1
All documents relating to the bid shall be in the English language.
11.
DOCUMENTS COMPRISING THE BID

The bid uploaded and submitted by the bidder shall comprise the following:
PRICE BID:
(i)
Lump sum price & supporting BOQ with schedule;
And any other materials required to be completed and submitted by bidders in accordance with
these instructions. The documents listed under Sections 2, 5 and 9 of Sub -Clause 7.1 shall be
filled in without exception.
TECHNOCOMMERCIAL BID:
(i)
Bid Security;
(ii)
Up to-date Income Tax and sales Tax clearance certificates;
(iii)
Technical Bid;
(iv)
Commercial Terms & conditions;
12.
BID PRICES
12.1
All Bid prices and rates shall be quoted both in figures and words for all the items
12.2
All duties, taxes, and other levies payable by the contractor under the contract. or for any other
cause shall be included in the rates , prices and total Bid Price submitted by the Bidder
12.3
The rates and prices quoted by the bidder are subject to adjustment during the performance of
the contract in accordance with the provisions of clause 40 of the conditions of contract.
13.
CURRENCIES OF BID AND PAYMENT
13.1
The bidder entirely in Indian Rupees shall quote the prices.
14.
BID VALIDITY
14.1
Bids shall remain valid for a period not less than one hundred and Eighty days after the deadline
date for bid submission specified in Clause 18. The Employer as non-responsive shall reject a
bid valid for a shorter period.
14.2
In exceptional circumstances, prior to expiry of original time limit, the Employer may request that
the bidders to extend the period of validity for a specified additional period. The request and the
bidders response shall be made in writing or by cable. A bidder may refuse the request without
forfeiting his bid security. A bidder agreeing to the req uest will not be required or permitted to
modify his bid, but will be required to extend the validity of his bid security for a period of the
extension, and in compliance with Clause 15 in all respects.
15.
BID SECURITY
15.1
The Bidder shall furnish, as part of his Bid, a Bid security for the amount as shown in clause 9 of
Invitation for Bids.
15.2
This security shall be in favour of the Managing Director, KBJNL and may be in one of the
following forms. Cash, Bank draft or Pay Order drawn on any Nationalised /Scheduled Bank or
BG issued by the Schedule Bank in favour of Managing Director, KBJNL and payable at
Bangalore.
15.3
Any bid not accompanied by an acceptable Bid Security and not secured as indicated in Sub Clauses 15.1 above shall be rejected by the Employer as non-responsive.
15.4
The Bid Security of unsuccessful bidders will be returned as promptly as possible upon award of
contract, but in any event not later than 28 days of the end of the bid validity period specified in
sub-clause 14.1. No interest shall be paid by the employer on the bid security.
15.5
DELETED
15.6
The Bid Security may be forfeited
(a) if the bidder withdraws the Bid after Bid opening during the period of Bid validity;
(b) if the bidder does not accept the correction of the Bid Price pursuant to Clause 2.5 or
(c) in the case of a successful Bidder, if the Bidder fails within the specified time limit to
(i)
sign the Agreement or
(ii)
furnish the required performance Security
16.
FORMS AND SIGNING OF BID
16.1
The uploading shall be done as described in vendor help .The Signature of authorized person
shall be scanned and attested as described in vendor help.
D. SUBMISSION OF BIDS
17.
SEALING AND MARKING OF BIDS
17.1 The tender shall be submitted in Two (2) parts viz., Techno commercial bid and price bid.
17.2 The contents of each two (2) bids shall be as described in the subsequent clauses . for all
further references, these envelopes will be referred to briefly as:
- Techno-commercial bid.
- Price bid.
17.3 Techno commercial bid shall contain the following in the sequence indicated below.
i.
Covering letter
ii.
Checklist
iii.
The Bid Security
iv.
Letter of Tender
v.
Declaration by the Tenderer that his Tender is without any technical and commercial deviations in
the format of the letter enclosed with the Tender.

vi.
Certified Power of Attorney authorizing a representative or representatives of the Firm to sign the
Tender and all subsequent communication.

vii.
Latest Income Tax Clearance Certificate and Sales Tax Clearance Certificate.
viii.
The second identical copy of the Tender document and drawings with all pages and drawings shall
duly signed by the authorized signatory of the Tenderer and stamped with the company scale. This
document shall be returned as it is (with signature and scale) in token of having read. Understood and
accepted the various terms, conditions, specifications and drawings of the Tender document.
ix.
Full technical description of the items and services proposed by the Tenderer including makes,
Technical data sheet, pump performance curves to be enclosed.

x.
Bar Chart and PERT charts for execution of works.
xi.
Details of drawings and documents proposed by the Tenderer.
xii.
Confirmation of performance guarantee and Defects Liability Period in accordance with clause 20 &
7 of the contract data.

xiii.
Confirmation of technical specification and terms and conditions.
xiv. Confirmation of commercial terms and conditions. There shall be no reference to the price.
xv.
Any other technical details.
17.4 Techno commercial bid shall not contains following;

i.
Schedule of Prices of the Tender Document constituting the Lump Sum Tender Price
ii.
Any indication either direct or indirect or implicit or explicit or implied regarding the Tender Price or
its break up details or any other related price indication etc. shall be cause fo r outright disqualification of
the entire Tender.
17.5
Price bid contain the following.
i.
Covering letter
ii.
Bidder should quote his Lumpsum price in the bid documents supplied and marked Original and
Duplicate with each page signed, dated and stamped with the scale of firm.
iii.
Details of the customs duty classification and the rate taken into consideration for the computation
of the customs duty as per the format in annexure.

iv.
Apart from the above documents, Tenderers shall not enclose any other document that influences
the lumpsum price.

18.
DEADLINE FOR SUBMISSION OF THE BIDS
18.1 Bids must be uploaded before the deadline fixed i.e., not later than 5.00 PM on xx-xx-xxxx.
18.2 The Employer may extend the deadline for submission of bids by issuing an amendment in
accordance with Clause 9, in which case all rights and obligations of the Employer and the bidders
previously subject to the original deadline will then be subject to the new deadline.
19.
LATE BIDS:
19.1 The E-Tendering supporting system does not permit late submission after date and time of
submission.
E. BID OPENING AND EVALUATION

20.
BID OPENING
20.1 The Employer will open the Envelope-II Bids received (except those received late), in the presence
of the Bidders or their representatives who choose to attend at 11.00 hrs. on the date and the place
specified in Item 8 of the detailed tender notification. In the event of the specified date of bid opening
being declared a holiday for the employer, the bids will be opened at the appointed time and lo cation on
the next working day.
20.2 The bidders names, the presence or absence of bid security, and such other details as the
Employer may consider appropriate, will be announced by the Employer at the opening bids. The tender
price envelope will not be opened on the same day but on another day in the presence of the qualified
Tenderers or their authorized representatives. The date and time of opening the tender price envelope
will be advised to the qualified tenderers in writing.
20.3 The Employer shall prepare minutes of the Bid opening, including the information disclosed to
those present in accordance with Sub-Clause 20.2.
21.
PROCESS TO BE CONFIDENTIAL
21.1 Information relating to the examination, clarification, evaluation, and comparison of price Bids and
recommendations for the award of a contract shall not be disclosed to Bidders or any other persons not
officially concerned with such process until the award to the successful Bidder to influence the Employers
processing of Bids or award decisions may result in the rejection of his bid.
22.
CLARIFICATION OF BIDS AND CONTACTING THE EMPLOYER:
22.1 To assist in the examination, evaluation, and comparison of Bids. The Employer may at his
discretion, ask any Bidder for clarification of his Bid. The request for clarification and the response shall
be in writing or by cable, but no change in the Lump sum price or substance of Bid shall be sought,
offered, or permitted except as required to confirm the correction of arithmetic errors discovered by the
Employer in the evaluation of the Bids in accordance with Clause 25.
22.2 Subject to sub-clause 22.1 no Bidder shall contact the Employer on any matter relating to its bid
opening to the time the contract is awarded. f the Bidder wishes to bring additional information to the
notice of the Employer. It should do so in writing.
23.
EXAMINATION OF BIDS AND DETERMINATION OF RESPONSIVENESS
23.1 Prior to the detailed evaluation of Bids, the Employer will determine whether each Bid (a) meets the
eligibility criteria defined in clause 3 (b) has been properly signed (c) is accompanied by the required
securities and (d) is substantially responsive to the requirements of the Bidding documents.
23.2 A substantially responsive Bid is one which conforms to all the terms, conditions, and specifications
of Bidding documents, without material deviation or
reservation. A material deviation or reservation is one (a) which affects in any substantial way the scope,
quality, or performance of the works; (b) which limits in any substantial way, inconsistent with the Bidding
documents, the Employers rights or the Bidders obligations under the contract; or (c) whose rectification
would affect unfairly the competitive position of other Bidders presenting substantially responsive Bids.
23.3 If a Bid is not substantially responsive. It will be outright rejected by the Employer and this may not
subsequently be made responsive by correction or withdrawal of the non-conforming deviation or
reservation.
24
CORRECTION OF ERRORS
24.1 Bids determined to be substantially responsive will be checked by the Employer for any arithmetic
errors. Errors will be corrected by the Employer as follows:
(a) Where there is a discrepancy between the rates in figures and in words. The lowest of the two will
govern and
24.2 The Lump sum amount quoted in the Bid will be adjusted by the Employer in accordance with the
above procedure for the correction of errors and with the concurrence of the Bidder shall be considered
as binding upon the Bidder. If the Bidder does not accept the corrected amount the Bid will be re jected.
And the Bid security may be forfeited in accordance with Sub -Clause 15.6(b).
25
EVALUATIONS AND COMPARISON OF BIDS
25.1 The Employer will evaluate and compare only the Bids determined to be substantially responsive in
accordance with Clause 23.
25.2 In evaluating the Bids, the Employer will determine for each Bid the evaluated Bid Price by
adjusting the Bid Price as follows:
(a)
Making any correction for errors pursuant to Clause 24: or
(b)
Making an appropriate adjustment for any other acceptable variations, deviations.
25.3 The Employer reserves the rights to accept or reject any variation or deviation offer. Variations,
deviations and other factors, which are in excess of the requirements of the Bidding documents or
otherwise result in unsolicited benefits for the Employer shall not be taken into account in Bid evaluation.
F. AWARD OF CONTRACT
26.
AWARD CRITERIA
26.1 The Employer will award the contract to the Bidder whose Bid has been determined to be
substantially responsive to the Bidding documents and who has offered the lowest evaluated Bid Price,
provided that such Bidder or Bidders or any obligation to inform the affected Bidder or Bidders of the
grounds for the Employers action.
27.
EMPLOYERS RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL BIDS
27.1 The Employer reserves the right to accept or reject any Bid. And to cancel the Bidding process and
reject all Bids. If any time prior to the award of Contract without thereby incurring any liability to the
affected Bidder or Bidders or any obligation to inform the affected Bidder or Bidders of the grounds for the
Employers action.
28.
NOTIFICATION OF AWARD AND SIGNING OF AGREEMENT
28.1 The Bidder whose Bid has been accepted will be notified of the award by the Employer prior to
expiration of the Bid validity period by cable. Telex or facsimile confirmed by registered letter. This letter
(hereinafter and in the conditions of contract called the Letter of Acceptance) will state the sum that the
Employer will pay the contractor in consideration of the execution completion, and maintenance of the
works by the contractor as prescribed by the contract (hereinafter and in the contract called the contract
price)
28.2 The notification of award will constitute the formation of the contract, subject only to the furnishing
of a performance security in accordance with the provisions of Clause 29.
28.3 The Agreement will incorporate all agreements between the employer and the successful Bidder.
On payment of the performance security by the successful bidder, the Employer will issue an unfilled
document to the bidder who has to arrange for affixing the special adhesive stamp for a value not less
then Rs.10\- and produce it back to the Employer. The Employer will then prepare complete set of
document in which the Employer and successful bidder will sign. The exercise should be complete within
28 days from the date of issue of Letter of Acceptance.
28.4 Upon the furnishing by the successful Bidder of the Performance Security, the Employer will
promptly notify the other the Bidders that their Bids have been unsuccessful.
29.
PERFORMANCE SECURITY
29.1 Within 21 days of receipt of the Letter of Acceptance, the successful Bidder shall deliver to the
Employer a performance Security in any of the forms given below for an amount equivalent to 1% of the
Contract Price.
- An irrevocable bank guarantee in the form given in section 8, validity shall be up to
maintenance period.
end of
In the form of NSC/NSS/Deposits valid for the required contract period and pledged in favor of
Managing Director, KBJNL and shall have the necessary transfer endorsement of the Post Office.
- Fixed Deposit for the required period from Nationalized/Scheduled Bank in favor of Managing Director,
KBJNL.
Certified cheque / Bank Draft in favor of KBJNL payable at Bangalore.
A receipted challan from KBJNL As Cash Counter.
29.2 If the performance security is provided by the successful Bidder in the form of a Bank Guarantee. It
shall be issued either (a) at the Bidders option, by a Nationalized /Scheduled Indian bank loc ated in India
and acceptable to the Employer.
29.3 Failure of the successful Bidder to comply with the requirements of Sub -Clause 29.1 shall
constitute sufficient grounds for cancellation of the award and forfeiture of the Bid Security.
30. ADVANCE PAYMENT AND SECURITY
DELETED -e Employ er will provide an Advance Payment on the Contract Price as stipulated in the Conditions of Contract, subject to m
stated in the
clause 16 of the Contract Data
1.
CORRUPT OR FRAUDULENT PRACTICES
31.1 The Employer requires that Bidders observe the highest standard of ethics during the evaluation
and execution of such contracts. In pursuance of this policy , the Employer:
(a) Defines, for the purposes of this provision, the terms set forth below as follows:
(i) Corrupt practice means the offering giving, receiving or soliciting of any thing of value to influence
the action of a public official in the evaluation process or in contract execution;
And
(ii) Fraudulent practice means a misrepresentation of facts in order to influence an eval uation process
or the execution of a contract to the detriment of the Employer and includes collusive practice among
Bidders ( prior to or after bid submission ) designed to establish bid prices at artificial non-competitive
levels and to deprive the Employer of the benefits of free and open competition.
(b) Will reject a proposal for award if it determines that the Bidder recommended for award has engaged
in corrupt or fraudulent practices in competing for the contract in question;
(c) Will declare a firm ineligible, either indefinitely or for a stated period of time, to be awarded a contract
if it at any time determines that the firm has engaged in corrupt or fraudulent practices in competing for or
in executing a contract.
32.
Third party Inspection: -
32.1 KBJNL shall engage an agency to conduct third party inspection regarding quality of works being
executed by the contractor. The cost of same shall be borne by KBJNL. However, in case, the qualities of
works executed are proved to be defective / substandard, the cost of Inspection shall be debited to
contractor proportionately.


BID DOCUMENT
SECTION - 2
FORMS OF BID AND
LETTER OF ACCEPTANCE
CONTRACTORS BID
Description of works:
To:
Address
Managing Director,
KBJNL, PWD Office Annexe, III Floor
Bangalore-560 001
GENTLEMEN:
We offer to execute the Works described above in accordance with the conditions of Contract
accompanying this Bid for the Contract price stated in the Financial Bid.
This Bid and your written acceptance of it shall constitute a binding contract between us. We
understood that you are not bound to accept the lowest or any Bid you receive.
We undertake that in competing for (and, if the award is made to us, in executing) the above contract .we
will strictly observe the laws in force in Indian namely Prevention of Corruption Act 1988.
We confirm that this Bid complies with the Bid Validity and Bid Security required by the Bidding
documents.
We attach herewith our current income tax and sales tax clearance certificates.
Yours faithfully,
Authorized Signature:
Name & Title of
Signature:__________________________________________
Name of Bidder: _____________________________________
Address:___________________________________________
LETTER OF ACCEPTENCE:
(FORMAT)
(Letterhead paper of the Employer)
__________________[Date]
To,____________________________________________________________
[Name and address of the contractor]
Dear Sirs,
This is to notify you that your Bid dated _________________ for execution of the
__________________________________________[name of the contract and identification number, as
given
in
the
Instructions
to
Bidders]
__________________________________________(
for
the
Contact
Price
of
Rupees
[Amount in words and figures], as corrected and modified in accordance with the Instructions of Bidders is
hereby accepted.
You are hereby required to furnish performance Security, in the form detailed in Para 29 of ITB for
an amount of Rs._________________________ within 21 days of the receipt of this letter of acceptance
valid up to 28 days from the date of expiry of Defects Liability Period i.e. up to
______________________ and sign the contract; failing which action as stated in Para 29.3 of
instructions of Bidders will be taken.
Yours faithfully,
Authorized Signature
Name and Title of Signature
Name of Agency
ISSUE OF NOTICE TO PROCEED WITH THE WORK

(LETTERHEAD OF THE EMPLOYER)
(FORMAT)
__________________ (Date)
To,
______________________________ (Name and address of the contractor)
______________________________
______________________________
Dear Sirs,
Pursuant to your furnishing the requisite security as stipulated in ITB clause 29 and signing of the
contract
for
the
construction
of
______________________@
Bid
Price
of
Rs.
______________________. Your are hereby instructed to proceed with the execution of the said works in
accordance with the contract documents.
Please note that the period of contract will be reckoned from this date.
Yours faithfully,
(Signature, name and date of

Signatory authorized to sign
On behalf of Employer)
AGREEMENT FORM
AGREEMENT
This agreement, made the ______________________day of________________200 between
______________________________________________________________
[Name and address of Employer] (Hereinafter called the Employer) and
____________________________________________________________________________________
________________________________________________________
[Name and address of contractor](Hereinafter called the Contractor of the other part)
Whereas the Employer is desirous that the Contractor execute
____________________________________________________________________________________
________________________________________________________
[Name and identification number of Contract] (Hereinafter called the Works) and the Employer has
accepted the Bid by the Contractor for the execution and completion of such Works and the remedying of
any defects therein, at a cost of Rs...
NOW THIS AGREEMENT WITNESSETH as follows
1.
In this Agreement, words and expression shall have the same meanings as are respectively
assigned to them in the Conditions of Contract hereinafter referred to, and they shall be deemed to form
and be read and construed as part of this Agreement.
2.
In consideration of the payments to be made by the Employer to the Contractor as hereinafter
mentioned. The contractor hereby covenants with the Employer to execute the complete the Works and
remedy any defects therein in all aspects with the provisions of the Contract.
3.
The Employer hereby covenants to pay the Contractor in consideration of the execution and
completion of the works and the remedying the defects wherein the Contract Prices or such other sum as
may become payable under the provisions of the Contract at the
4.
The following documents shall be deemed to form and be read and construed as part of this
Agreement, viz:
Letter of Acceptance;
i)
Notice of proceed with the work;
ii)
Contractors Bid;
iii)
Contract Data
iv)
Conditions of Contract (General and Special);
v)
Specifications;
vi)
Drawings;
vii)
Bill of Quantities; and
viii) Any other document listed in the Contract Data as forming part of the Contract.
In witness whereof the practices there to have caused this Agreement to be executed the day and
year first before written,
The Common Seal of
_______________________________________________
Was hereunto affixed in the presence of;
Signed, Sealed and Delivered by the said
____________________________________________________________________ ________________
____________________________________________________________________________________
__________________________________________
in the presence of ;
Binding Signature of Employer

_____________________________________________________
Binding Signature of Contractor

______________________________________________________


BID DOCUMENT
SECTION - 3
CONDITIONS OF CONTRACT
32
TABLE OF CONTENTS
General
C.
Quality Control
1.
Definitions
27.
Identifying Defects
2.
Interpretation
28.
Tests
3.
Language and Law
29.
Correction of Defects
4.
Engineers Decisions
30.
Uncorrected Defects
5.
Delegations
6.
Communications
D.
Cost Control
7.
Subcontracting
31.
Bill of Quantities
8.
Other Contractors
32.
Changes in the Quantities
9.
Personnel
33.
Variations
11. Employers risk
34.
Invoicing forecasts
12. Contractors Risks
35.
Payment Certificates
13. Insurance
36.
Payments
14. Site Investigation Reports
37.
Tax
15. Queries about the Contract
38.
Currencies
39.
Retention
40.
Liquidated Damages
19. Safety
41.
Securities
20. Discoveries
42.
Cost of Repairs
10. Employers & Contractors

Risks
Data
16. Contractor to Construct the
works
17. The Works to be completed by
the intended completion date
18. Submission of specification
and drawings for temporary
works
21. DELETED
22. Access to site
E.
Finishing the Contract
23. Instructions
43
Completion
44
Taking Over
45.
Final Account
46.
Operating and Maintenance
B.
Time Control
24. Program
Manuals
25. Extension of the Intended
47.
Payment upon Termination
48.
Property
49.
Release from performance
F.
Special Conditions of
Completion date
26. Delays Ordered by the
Engineer
Contract
A.
GENERAL.
1.
DEFINITIONS:
1.1
Terms, which are defined in the Contract Data, are not also defined in the Conditions of Contract
but keep their defined meanings. Capital initials are used to identify terms.
Bill of Quantities means the priced Bill of Quantities indicated by the Bidder supporting the quoted Lump
sum price and forming part of the Bid.
The Completion Date is the date of completion of the works as certified by the Engineer in accordance
with Sub Clause 45.
The Contract is the contract between the Employer and the Contractor to execute, complete and
maintain the Works. It consists of the documents listed in Clause 2.3 below.
The Contract Data defines the documents and other information which comprise the Contract.
The Contractor is a person or corporate body whose Bid to carry out the Works has been accepted by
the Employer.
The Contractors Bid is the completed Bidding document submitted by the Contractor to the Employer.
Days are calendar days; months are calendar months.
A Defect is any part of the Works not completed in accordance with the Contract.
The Defects Liability Period is the period named in the Contract Data and calculated from the
Completion Date.
The Employer is the party who will employ the Contractor to carry out the Works.
The Engineer is the person named in the Contract Data (or any other competent person appointed and
notified to the contractor to act in replacement of the Engineer) Who is responsible for supervising the
contract, administering the Contract, certifying payme nt due to the Contractor, issuing and valuing
Variations to the Contract, awarding extensions of time.
Equipment is the Contractors machinery and vehicles brought temporarily to the Site to construct the
Works.
The Initial Contract Price is the Contract Price listed in the Employers Letter of Acceptance.
The Intended Completion Date is the date on which it is intended that the Contractor shall complete the
works. The Intended Completion Date is specified in the Contract Data. The Intended Completion Date
may be revised only by the Engineer by issuing an extension of time.
Materials are all supplies including consumables, used by the contractor for incorporation in the Works.
Plant is any integral part of the works, which is to have a mechanical, electrical, electronic, or chemical or
biological function.
The Site is the area defined as such in the Contract Data.
Site Investigation Reports are those, which were included in the Bidding documents and are factual
interpretative reports about the surface and sub surface conditions at the site.
Specification means the Specification of the Works included in the Contract and any modification or
addition made or approved by the Engineer.
The Start Date is given in the Contract Data. It is the date when the Contractor shall commence
execution of the works. It does not necessary coincide with any of the Site Possession Dates.
A Subcontractor is a person or corporate body who has a Contract with the Contractor to carry out a
part of the work in the Contract which includes work on the Site.
Temporary Works are works designed, constructed, installed, and removed by the Contractor, which are
needed for construction or installation of the Works.
A Variation is an instruction given by the Engineer, which varies the Works.
The Works are what the Contract requires the Contractor to construct, install, and turn over the
Employer, as defined in the Contract Data.
2.
2.1
INTERPRETATION
In interpreting these Conditions of Contract, singular also means plural, male also means female
or neuter, and the other way around. Headings have no significance. Words have their normal
meaning under the language of the Contract unless specifically defined. The Engineer will
provide instructions clarifying queries about the Conditions of Contract.
2.2
If sectional completion is specified in the Contract Data, references in the Conditions of Contract
to the Works, the Completion Date, and the Intended Completion Date apply to any Section of
the Works (Other than references to the Completion Date and Intended Completion date for the
whole of the Works).
2.3
The documents forming the Contract shall be interpreted in the following order or priority:
1)
Agreement
2)
Letter of Acceptance, notice to proceed with the works
3)
Contractors Bid
4)
Contract Data
5)
6)
Specifications
7)
Drawings
8)
Any other document listed in the Contract Data as forming part of the Contract.
3.
LANGUAGE AND LAW
3.1
The language of the Contract and the law governing the Contract are stated in the Contract Data.
4.
ENGINEERS DECISIONS
4.1
Except where otherwise specifically stated, the Engineer will decide contractual matters between
the Employer and the Contractor in the role representing the Employer.
5.
DELEGATION
5.1
The Executive Engineer may delegate any of his duties and responsibilities to o ther people after
notifying the Contractor and may cancel any delegation after notifying the Contractor.
6.
COMMUNICATIONS
6.1
Communications between parties which are referred to in the conditions are effective only when in
writing. A notice shall be effective only when it is delivered (in terms of Indian Contract Act).
7.
SUBCONTRACTING
7.1
The Contractor may subcontract with the approval of the Engineer but may not assign the Contract
without the approval of the Employer in writing. Subcontracting does not alter the Contractors obligations.
8.
OTHER CONTRACTORS
8.1
The Contractor shall cooperate and share the Site with other contractors, public authorities, utilities,
and the Employer between the dates given in the Schedule of other Contractors. The Contrac tor shall as
referred to in the Contract Data, also provide facilities and services for them as described in the
Schedule. The employer may modify the schedule of other contractors and shall notify the contractor of
any such modification.
9.
PERSONNEL
9.1
If the Engineer asks the Contractor to remove a person who is a member of the Contractors staff
or his work force stating the reasons the Contractor shall ensure
the that the person leaves the Site within seven days and has no further connection with the work in
contract.
9.2
Non- employment of Project Manager and other Key Personnel shall be liable for a fine as specified
in Contract Data.
10.
EMPLOYERS AND CONTRACTORS RISKS
10.1 The Employer carries the risks which this Contract states are Employers risks, and the Co ntractor
carries the risks which this Contract states and Contractors risks.
11.
EMPLOYERS RISKS
11.1 The Employer is responsible for the excepted risks which (a) in so far as they directly affect the
execution of the Works in the Employers country, the risks of war, hostilities, invasion, act of foreign
enemies rebellion, revolution, insurrection or military or usurped power, civil war, riot, commotion or
disorder (unless restricted to the Contractors employees), and contamination from any nuclear fuel or
nuclear waste or radioactive toxic explosive, or (b) a cause due solely to the design of the Works, other
than the Contractors design.
11.2 The Contractor shall not be liable for forfeiture of his performance security, pre -estimated damages,
or termination for default, if and the extent that his delay in performance or other failure to perform his
obligations under the contract is the result of an event of Force Majeure.
11.3 For purpose of this clause, Force Majeure means an event beyond the control of the Contractor
and not involving the Contractors fault or negligence and not foreseeable. Such events may include, but
are not restricted to, acts of God either in sovereign or contractual capacity, wars or revolutions, fires,
cyclones, earthquake, floods, epidemics, quarantine restrictions and freight embargoes.
11.4 If a Force Majeure situation arises, the Contractor shall promptly notify the Employer in writing of
such condition and the cause thereof. Unless otherwise directed by the Employer in writing, the
Contractor shall continue to perform its obligations as far as is reasonably practical and shall seek all
reasonable alternative means for performance not prevented by the Force Majeure event.
12.
CONTRACTORS RISKS
12.1 All risk of loss or damage to physical property and of personal injury and death, which arise during
and in consequence of the performance of the Contract other than the excepted risks are the
responsibilities of the Contractor.
13.
INSURANCE
13.1 The Contractor shall provide necessary Insurance in terms approved by the Employer to cover the
following in the joint names of the Employer and the Contractor and a copy / copies of the policy / polices
shall be furnished to the Employer within one month from the award of the Contract.
a)
Contractor All Risk Insurance policy covering loss or damage due to Fire, Lighting, collapse,
Defective workmanship and / or materials, flood. Storm, theft burglary, malicious damage, subsidence
riots etc.
b)
Third Party Liability
c)
Workmens Compensation in accordance with latest, revised statutory provision.
d)
Contractors, tools, tackles and machinery.
e)
All Risks to materials during transit.
f)
Any other Insurance required for fully indemnifying the Employer from any claim that may arise on
account of the Contractors operations at site.

13.2 Policies and certificates for insurance shall be delivered by the Contractor to the Engineer for the
Engineers approval within two weeks of the Start Date. All such insurance shall provide for compensation
to be payable in the types and proportions of currencies required to rectify the loss or damage incurred.
13.3 If the Contractor does not provide any of the polices and certificates require, the Employer may
effect the insurance which the Contractor should have provided and recover the premiums the Employer
has paid from payments otherwise due to the Contractor or, if no payment is due, the payment of the
premiums shall be a debt due.
13.4 Alterations to the terms of insurance shall not be made without the approval of the Engineer.
13.5 Both parties shall comply with any conditions of the insurance policies.
14.
SITE INVESTIGATION REPORTS
14.1 The Contractor, in preparing the Bid, shall rely on any site Investigation report referred to in the
Contract Data, supplemented by any information available to the Bidder.
15.
QUERIES ABOUT THE CONTRACT DATA
15.1 The Engineer will clarify queries on the Contract Data.

16.
CONTRACTOR TO CONSTRUCT THE WORKS
16.1 The Contractor shall construct and install the Works in accordance with the Specification and
Drawings.
16.2 The basic centerlines, reference points and benchmarks will be fixed by Employer at site within four
weeks of the Start Date.
16.3 The Contractor shall establish at his cost, at suitable points, additional reference lines, benchmarks
as may be necessary. The Contractor shall remain responsible for the sufficiency and accuracy of all his
benchmarks and reference lines. He shall take precautions to see that the lines, points and benchmarks
fixed by Employer are not disturbed by his work and shall make good any such damage.
17.
THE WORKS TO BE COMPLETED BY THE INTENDED COMPLETIONDATE
17.1 The Contractor may commence execution of the Works on the Start Date and shall carry out the
works in accordance with the program submitted by the Contractor, as updated with the approval of the
Engineer and complete them by the Intended Completion Date.
18.
18.1
SUBMISSION OF SPECIFICATION AND DRAWINGS OF TEMPORARY WORKS

The Contractor shall submit brief Specification and Drawings showing the proposed Temporary
Works to the Engineer, before starting such work.
18.2 The Contractor shall be responsible for design of Temporary Works. Engineers comments if any
on drawings of Temporary Works, shall be incorporated by the Contractor.
18.3 The Engineers comments shall not alter the Contractors responsibility for design of the Temporary
Works.
18.4 If directed by the Engineer, the Contractor shall obtain approval of third parties to the design of the
Temporary Works wherever required.
18.5 All Design Drawings prepared by the Contractor for the execution of the permanent Works, are
subject to prior approval by the Engineer before their use. Engineer will communicate his approval /
comments at the earliest on receipt of design / drawings.
19.
SAFETY
19.1 The Contractor shall be responsible for the safety of all activities on the Site.
20.
DISCOVERIES
20.1 Anything of historical or other interest or of significant value unexpectedly discovered on the site is
the property of the Employer. The Contractor is to notify the Engineer of such discoveries and carry out
the Engineers instructions for dealing with them.
21.
DELETED
22.
ACCESS TO THIS SITE
22.1 The Contractor shall allow the Engineer and any person authorized by the Engineer access to the
Site, to any place where work in connection with the Contract is being carried out or is intended to be
carried out and to any place where materials or plant are being manufactured / fabricated / assembled for
the works.
23.
INSTRUCTIONS
23.1 The Contractor shall carry out all instructions of the Engineer which comply with the applicable laws
where the Site is located.
B.
TIME CONTROL
24.
PROGRAM
24.1 Within the time stated in the Contract Data the Contractor shall submit to the Engineer for approval
a Program showing the general methods, arrangements order, and timing for all the major activities in the
Works along with monthly invoicing forecast.
24.2 An update of the Program shall be a program showing the actual progress achieved on each
activity and the effect of the progress achieved on the timing of the remaining work including any changes
to the sequence of the activities.
24.3 The Contractor shall submit to the Engineer, for approval, an updated program at intervals no
longer than the period stated in the Contract Data. If the Contractor does not submit an updated Program
within this period, the Engineer may with hold the amount stated in the Contract Data from the next
payment certificate.
24.4 The Engineers approval of the program shall not alter the Contractors obligations. The Contractor
may revise the Program and submit it to the Engineer again at any time. A revised Program is to show
the effect of variations.
25.
EXTENSION OF THE INTENDED COMPLETION DATE
25.1 The Engineer shall extend the Intended Completion Date if a variation is issued which makes it
impossible for Completion to be achieved by the Intended Completion Date without the Contractor taking
steps to accelerate the remaining work and which would cause the Contractor to incur additional cost.
25.2 The Engineer shall decide whether and by how much to extend the Intended Completion Date with
21 days of the Contractor asking the Engineer for a decision upon the effect of a variation and submitting
full supporting information. If the Contractor has failed to give early warning of a delay or has failed to
cooperate in dealing with a delay, the delay by this failure shall not be considered in assessing the new
Intended Completion Date.
26. DELAY ORDERED BY THE ENGINEER
26.1 The Engineer may instruct the contractor to delay the start or progress of any activity within the
Works.
27. IDENTIFYING DEFECTS
27.1 The Engineer shall check the Contractors work and notify the Contractor of any Defects that are
found. Such checking shall not affect the Contractors responsibilities. The Engineer may instruct the
Contractor to search for a Defect and to uncover and test any work that the Engineer considers may have
a Defect.
28. TESTS
28.1 If the Engineer instructs the Contractor to carry out a test not specified in the Specification to check
whether any work has a Defect and the test shows that it does, the Contractor shall pay for the test and
any samples. If there is no Defect, cost of such test will be born by KBJNL.
29.
CORRECTION OF DEFECTS
29.1 The Engineer shall give notice to the Contractor of any Defects before the end of the Defects
Liability period, which begins at Completion and is defined in the Contract Data. The Defects liability
Period shall be extended for as long as Defects remain to be corrected.
29.2 Every time notice of a Defect is given, the Contractor shall correct the notified Defect within the
length of time specified by the Engineers notice.
30.
UNCORRECTED DEFECTS
30.1 If the Contractor has not corrected a Defect within the time specified in the Engineers notice, the
Engineer will assess the cost of having the Defect corrected, and the Contractor will pay this amount.
D.
COST CONTROL
31.
BILL OF QUANTITES
31.1 The Bill of Quantities shall contain items for the construction, installation, testing and
commissioning work to be done by the Contractor.
31.2 The Bill of Quantities is used to make progressive payment for various items of supplies and works.
The Contractor is paid progressively for the item of work done at the rate in the Bill of Quantities for the
respective item.
31.3 Payment made as above, do not alter the Lump sum Contract price except as otherwise provided
for in the Contract.
32.
CHANGES IN THE QUANTITIES
32.1 If the final quantity of any item of the work done differs from the quantity indicated by the Contractor
in the Bill of Quantities for the said item by more than 25 percent, the Engineer may adjust the rate of that
particular item for the purpose of making progressive payment.
32.2 Changes in quantity of any item or addition or deletion of any item w.r.t. the Bill of Quantities
submitted by the Contractor do not affect the total Lump sum price provided there is no change in scope
of work described in tender Document or otherwise provided for in Contract.
32.3 If requested by the Engineer, the Contractor shall provide the Engineer with a detailed cost
breakdown of any rate in the Bill of Quantities.
33.
VARIATIONS
33.1 All Variations shall be included in updated Programs produced by the Contractor.
34.
INVOICING FORECASTS
35.1 When the program is updated, the contractor is to provide the Engineer with an updated invoicing
forecast.
35.
PAYMENT CERTIFICATES
35.1 The Contractor shall submit to the Engineer monthly statements of the estimated value of the work
completed less the cumulative amount certified previously.
35.2 Payments will be made to the Contractor under the certificates to be issued at reasonably frequent
intervals by the Engineer. Within twenty eight days of the date of each certificate an intermediate
payment will be made by the Engineer to a maximum of 95% towards civil works, electrical & mechanical
works as stated in the contract data under Clause 19 of the value of work subject to the conditions
deducting all dues towards recovery of advances, interests, fines etc., as per terms of contract and for the
cost of materials, if issued, at the term stipulated in the agreement. Further 6.5 percent will be with held
and retained as a further security deposit (FSD) for the due fulfillment of the contract. Under the
certificate to be issued by the Engineer on the comple tion of the entire works, the Contractor will receive
the final payment of all the moneys due to payable to him under or by virtue of the Contract except
security deposit and a sum equal to 6.5 % of the total value of the work done provided there is no
recovery or forfeiture.
The amount withheld from the final bill will be paid to the Contractor together with the security deposit
after a period of 24 months of satisfactory performance of the entire Works or soon after the expiry of
such periods. No certificate of the Engineer shall be considered conclusive evidence as to the sufficiency
of any work or materials or correctness of measurements to which it relates, nor shall it relieve the
Contractor from his liability to make good defects as provided by the co ntract. The Contractor when
applying for a certificate shall prepare a sufficiently detailed bill based on the original figures or quantities
and rates in the Bill of Quantities to the satisfaction of the Engineer to check the claim and issues the
certificate. The certificates as
such of the claims mentioned in the application as are allowed by the Engineer shall be issued within
fourteen days of the applications. No application for a certificate shall be a within fourteen days of a
previous application.
35.3 The value of work executed shall be determined by the Engineer
35.4 The value of work executed shall comprise the value of the quantities of the items in the Bill of
Quantities completed.
35.5 The Engineer may exclude any item certified in a previous certificate or reduce the proportion of any
item previously certified in any certificate in the light of later information.
35.6.
If for any reason, the Contractor or his authorized agent is not available and / or the work is
suspended by Employer, recording of measurements will be done by Employer without the presence of
the Contractor or his authorized representatives and the Employer shall not entertain any claim from the
Contractor for any loss on this account. If the Contractor or his authorized agent or representative does
not remain present at the time of such measurements, after the Contractor has been given a three day
notice in writing, such measurements may be taken in his absence and shall be deemed to be accepted
by the Contractor.
35.7.Payment for the work done by the Contractor will be based on either measurements recorded at
various stages of the Work or on stage completion basis. The Contractor or his authorized agent, or
representative shall be present at the time of recording of each set of measurements and sign the
measurement book or level / field book in token of their acceptance.
36.
PAYMENTS
36.1 Payments shall be adjusted for deductions for advance payments, retention and other recoveries in
terms of the contract and deduction at source of taxes as applicable under the law.
36.2
Items of the Works for which no rate or price has been entered in will not be paid for by the
Employer and shall be deemed covered by other rates and prices in the Contract.
37.
TAX
37.1 The rates quoted by the Contractor shall deemed to be inclusive of the sales and other taxes that
the Contractor will have to pay for the performance of this Contract. The Employer will perform such
duties in regard to the deduction of such taxes at source as per applicable law.
37.2 1% or as modified by Govt from time to time labour cess will be recovered
in the contract value
as per the provisions of the building and other construction workers welfare cess act 1996 and relevant
Government notification
38
CURRENCIES
38.1 All payments shall be made in Indian Rupees

39
RETENTION
39.1 The Employer shall retain from each payment due to the Contractor the
proportion stated in the
Contract Data clause 12 until completion of the whole of the Works.

39.2 On completion of whole of the works, the contractor may substitute retention money with an on
demand Bank Guarantee, which shall be valid till end of defect liability period of 24 months.
39.3 Any recovery advised by the Employer shall be recovered from any bill or money retained from this
Contract.
40
LIQUIDATED DAMAGES
40.1 The Contractor shall pay liquidated damages to the Employer as stated in the Contract Data for
everyday that the Completion Date is later than the Intended Completion Date (for the balance portion of
the works for individual milestone as stated in the contract data). The total amount of liquidated damages
shall not exceed the amount defined in Clause 15 of the Contract Data. The Employer may deduct
liquidated damages from payments due to the Contractor. Payment of liquidate d damages does not affect
the Contractors liabilities.
40.2 If the Intended Completion Date is extended after liquidation damages have been paid, the
Engineer shall correct any over payment of liquidated damages by the Contractor by adjusting the next
payment certificate
41
SECURITIES
41.1 The performance Security shall be provided to the Employer not later than the date specified in the
Letter of Acceptance and shall be issued in the amount and form and by a bank or surety acceptable to
the Employer, and denominated in Indian Rupees. The Performance Security shall be valid until a date
28 days from the date of expiry of Defects Liability period
42
COST OF REPAIRS
42.1 Loss or damage to the works or Materials to be incorporated in the Works between the Start Date
and the end of the Defects correction periods shall be remedied by the Contractor at the Contractors cost
if the loss or damage arises from the Contractors act or omissions.
E.
FINISHING THE CONTRACT
43
COMPLETION
43.1 The Contractor shall request the Engineer to issue a Certificate of Completion of the Works and the
Engineer will do so upon deciding that the Work is completed.
44
TAKING OVER
44.1 The Employer shall take over the site and the Works within 30 days of the Engineer issuing a
certificate of Completion.
45.
FINAL ACCOUNT
45.1 The Contractor shall supply to the Engineer a detailed of the total amount that the Contractor
considers payable under the Contractor before the end of the Defects Liability Period. The Engineer shall
issues a Defect liability Certificates and certify any final payment that is due to the Contractor within 56
days or receiving the Contractors account if it is correct and complete. If it is not, the Engineer shall issue
within 56 days a schedule that states the scope of the corrections or additions that are necessary. If the
Final Account is still unsatisfactory after it has been resubmitted, the Engineer shall decide to the amount
payable to the Contractor and issue a payment certificate, within 56 days of receiving the Contractors
revised account.
46
AS BUILT DRAWINGS / O & M MANUALS
46.1 If As Built drawings and / or O & M Manuals are required, the Contractor shall supply them before
final payment is released.
46.2 If the Contractor does not supply the Drawings and / or manuals by the dates stated in the Contract
Data or they do not receive the Engineers approval, the Engineer shall with hold the amount stated in
Clause 18 of the Contract Data from payments due to the Contractor.
47.
PAYMENT UPON TERMINATION
47.1 If the Contract is terminated because of a fundamental breach of Contract by the Contractor, the
Engineer shall issue a certificate for the value of the work done less advance payments received up to
the date of the issue of the certificate has other recoveries due in terms of the contract, less taxes due to
be deducted at source as per applicable law and less the percentage to apply to the work not completed
as indicated in the Contract Data. Additional Liquidated Damages shall not apply. If the total amount due
to the Employer exceeds any payment due to the Contractor the difference shall be a debt payable to the
Employer.
47.2 If the Contract is terminated at the Employers convenience or because of a fundamental breach of
Contract by the Employer, the Engineer shall issue a certifica te for the value of the work done, the
reasonable cost of removal of Equipment, repatriation of the Contractors personnel employed solely on
the works, and the Contractors costs of protecting and securing the Works and less advance payment
received up to the date of the certificate, less other recoveries due in terms of the contract and less taxes
due to be deducted at source as per applicable law.
48.
PROPERTY
48.1 All materials on the Site, Plant, Equipment, Temporary Works and Works are deemed to be the
property of the Employer, if the Contract is terminated because of a Contractors default.
49
RELEASE FROM PERFORMANCE
49.1 If the Contractor is frustrated by the outbreak of war or by any other event entirely outside the
control of either the Employer or the Contractor the Engineer shall certify that the Contract has been
frustrated. The Contractor shall make the site safe and stop work quickly as possible after receiving this
certificate and shall be paid for all work carried out before receiving it and for any work carried out
afterwards to which commitment was made.
SPECIAL CONDITIONS OF CONTRACT

PART I
1.
LABOUR:
The Contractor shall, unless otherwise provided in the Contract, make this own arrangements for the
engagement of all staff and labour, local or other, and for their payment, housing, feeding and transport.
The Contractor shall, if required by the Engineer, deliver to the Engineer a return in detail, in such form
and at such intervals as the Engineer may prescribe, showing the staff and the numbers of the several
classes of labour from time to time employed by the Contractor on the Site and such other information as
the Engineer may require.
2.
COMPLIANCE WITH LABOUR REGULATIONS:
During continuance of the contract the Contractor and his sub contractors shall abide at all times by all
existing labour enactments and rules made there under, regulations, notifications and by laws of the
State or Central Government or local authority and any other labour law (including rules), regulations bye
laws that may be passed or notification that may be issued under any labour law in future either by the
State or Central Government or the local authority. The Contractor shall keep the Employer indemnified in
case any action is taken against the Employer by the competent authority on account of contravention of
any of the provisions of any Act or rules made there under, regulations or notifications including
amendments. If the Employer is caused to pay or reimburse, such amounts as may be necessary to
cause or observe, or for non-observance of the provisions stipulated in the notifications / bye laws / Acts /
Rules / regulations including amendments, if any, of the part of the Contractor, the Engineer / Employer
shall have the right to deduct any money due to the Contractor inc luding his amount of performance
security. The Employer / Engineer shall also have right to recover from the Contractor any sum required
or estimated to be required for making good the loss or damage suffered by the Employer in this context.
The employees of the Contractor and the Sub-Contractor in no case shall be treated as the employees of
the Employer at any point of time.
SPECIAL CONDITION OF CONTRACT

PART 2
1.
CONTRACTORS RESPONSIBILITY
The information given hereunder and provided elsewhere is given in good faith but the contractor shall
satisfy himself regarding all aspects of site conditions and no claim whatsoever will be entertained on the
plea that information supplied by the Engineer is insufficient,
CONSTRUCTION WATER
The Contractor shall make his own arrangement for the fresh water required for manufacturing of the
pipes, construction of civil works and testing of pipeline as well as for the potable water required for his
factory and labour camps.
2.
CONSTRUCTION POWER
The contractor shall make his own arrangement for supply of electrical energy required at his sites and
the works from KPTCL.
The Contractor is forewarned that there can be interruptions in power supply for reasons beyond the
control of the KPTCL and therefore the contractor is advised to make his stand by arrangement to provide
and maintain all essential power supply for his work are at his expense. The Contractor shall not be
entitled to any compensation for any loss or damage to his machinery or any equipment or any
consequential loss in progress of work and idle labour.
3.
SURVEY
The Contractor shall, at his own expense provide and maintain survey stations which he may require to
carry out the works and shall remove the same on completion of the works. The contractor shall, at his
own expense, carry out all the necessary surveys, measurements and setting out of the works and shall
for this purpose engage qualified and competent engineering surveyors whose names and qualifications
shall be submitted to the Engineer for his approval.
The Contractor shall for the purpose of checking the survey and setting out, provide to the Engineer all
the assistance, which he may require. The surveyor shall be selected having appropriate experience and
as far as possible, the same surveyor shall be provided throughout the contract period. Before
commencing any work at any locations the contractor shall give the Engineer not less than 24 hours
notice of his intention to set out or give levels for any part of the work in order that arrangements may be
made for inspection. The contractor shall provide for the sole use of the Engineer and his staff all
necessary survey instruments and other equipment and all technicians, labour and attendants which the
Engineer may require for checking the setting out and marking of the works. The contractor shall maintain
in good working order at all time during the period of contract the instruments provided by him, for the
proper setting out of the works.
The contractor shall make available at his own expense, any poles, staging templates.
4.
TEMPORARY FENCING
The contractor shall at his own expenses, erect and maintain in good condition temporary fences and
gates along the boundaries of the areas assigned, if any, to him by the employer for the purpose of the
execution of the works.
The contractor shall, except when authorized by the Engineer, confine his men, materials and plant within
the site of which he is given possession. The contractor shall not use any part of the site for purposes not
connected with the works unless prior written consent of the Engineer has been obtained. Access shall
be made to such areas only by way of approved gateways.
5.
RETURN OF LABOUR AND PLANT
The contractor shall supply to the Engineer by 9 a.m. every working day a return of the men e mployed by
him and his sub-contractors on the previous working day and all of the work on which they were engaged
specifying also the number employed in each trade. He shall also supply monthly any other returns which
may be required as to the number of men and constructional plant employed and the nature and type of
the work done.
6.
SANITARY FACILITIES
The contractor shall provide and maintain in a clean and sanitary condition adequate W.C.s and wash
places, which may be required on the various parts of the site for use of his employees, to the satisfaction
of the Engineer. The contractor shall make all arrangements for the disposal of sewage or drainage in
accordance with the directions of the Engineer.
7.
RESTRICTED ENTRY TO SITE
The contractor shall get the prior permission of the Engineer before any person not directly connected
with the works visits the site.
8.
EXISTING SERVICES
Drains, pipes, cables, overhead electric wires and similar services encountered in the course of the works
shall be guarded from injury by the contractor at his own cost, so that they may continue in full and
uninterrupted use to the satisfaction of the Employer and the contractor shall not store materials or
otherwise occupy any part of the site in a manner likely to hinder the operation of such services, should
any damage be done by the contractor on any mains, pipes, cables or lines (whether above or below
ground), whether or not shown on the drawings, the contractor must make good or bear the cost of
making good the same without delay to the satisfaction of the Engineer and of the Employer.
9.
LOCAL ROADS AND HAUL ROADS
1.
The approach roads and other public roads in the state may be used by the contractor to haul
construction materials and equipment subject to restriction of load carrying capacity of the roads in
particular over bridges and culverts. However, the contractor will have to pay customary vehicles license
and permit fees for use of public roads.
2.
The contractor shall plan transportation of construction materials to site in suc h a way that road
accidents are avoided.

10.
PERMISSION FOR ROAD CUTS
Wherever the Contractor considers that it is necessary to cut through an existing road or track he shall
submit details to the Engineer for approval a minimum of seven days before such work commences.
11.
TEMPORARY DIVERSION OF ROADS
During the execution of the works the contractor shall make at his cost all necessary provision for the
temporary diversion of roads, cart-tracks, footpaths, drains, water courses, channels etc., Should he fail
to do so, the same shall be done by the Engineer and the cost thereof will be recovered from the
Contractor.
12.
NOTICE TO TELEPHONE, RAILWAYS AND ELECTRICITY SUPPLY UNDERTAKING
Before commencing operations the Contractor has to obtain specific permission from local bodies /
Highways Department when he wants to cut any section of the road. Where operations involve cutting of
roads, shifting utilities etc, during the process of work, the Contractor shall also give notice to the
concerned authorities viz., The Panchayats / the Municipalities, the Railways Department, the Electricity
Board, Telegraphs Department, the Traffic Department attached to the police and other departments or
companies as may be affected by the work. The notice should identify the specific detail s so that the
necessary diversion of traffic may be arranged and permissions obtained. The Contractor shall co operate with the department concerned and provide for necessary barricading of roads, protection to
existing underground cables etc, met with during the excavation of trenches. The Contractor shall provide
at his own expenses watching and lighting arrangements during the day and night and put the required
notice board such as Caution Road Closed for Traffic" etc., He should also provide and maintain at his
own cost the necessary supports for underground cables etc. to afford best protection to them in
consultation with the authorities in-charge of the properties and to their best satisfaction.
14
BARRICADING
The pit/trench shall be barricaded on all four sides. The contractor who has dug up the trench shall be
responsible for any mishap, which may occur.
15
WATCHING AND LIGHTING
The contractor shall at his expense provide at the site of work sufficient lighting and watching and fencing
by night and by day and shall in every respect conform to the police regulations in these matters and he
shall free and relieve the Board. Should he neglect to do so, the same shall be provide by the Engineer
and the cost thereof will be recovered from the Contracto r.
16
FREE FLOW OF TRAFFIC
While executing the work, as soon as possible, the Contractor should allow as much traffic as possible on
the road streets, by refilling the trenches cut across.
17
TOOLS AND PLANTS
All tools and plants required for the work including sheet piles and timber for shoring and strutting, pump
sets etc. shall be supplied by the contractor at his own cost. The rate s of the relevant item of works are
inclusive of all such tools and plants and apparatus required for the execution of the work. If however,
there is any difficulty in procurement of the above tools and plants by the contractor. The Employer may
make available such of the tools and plants which are available in which case necessary hire charges will
be recovered from the contractor as per the KBJNL's rules in force. But it should be clearly understood
that any assistance to be rendered by the Employer is not obligatory and not to be taken for granted.
Non-supply and/or delayed supply of such tools and plant materials cannot be c ited as reasons for any
slow progress by the contractor.
18
EXCESS MATERIALS
The Contractor shall be responsible for the procurement of required quantity of materials like pipes.
special machinery, electrical items etc. any materials procured for the wo rk even though as per Bill of
Quantities, if found excess due to any reasons after completion of the works. shall be taken back by the
Contractor and the Employer/Engineer shall not be responsible for such excess materials. Amount paid if
any for such excess materials shall be deducted from any bills payable to the Contractor.

PART - 3
1.
GENERAL
Before submitting the bids, the bidder should carefully go through all the bid documents and in particular
the bid schedule and the drawings also inspect the place of work so as to get full and first knowledge or
the site conditions based on which he has to quote his rates.
2.
ACCIDENTS
It shall be the duty of the contractor to arrange for the execution of the works in such a manner as to
avoid the possibility of the accidents to persons or damage to the properties at any stage of the progress
of work. Nevertheless he shall be held wholly responsible for any injury or damage to persons and
properties which may occur irrespective of any precautions he may take during the execution of the
works. The contractor shall make good all claims and loss arising out of such accidents and indemnify the
Employer from all such claims and expense on account thereof.
3.
FLOOD DAMAGES ETC.
The contractor may take risk insurance at his cost against losses due to unprecedented floods and other
acts of God. No claim shall be entertained on this account and paid for.
4.
WATER AND LIGHTING
The contractor shall pay all fees and provide water and light as req uired from Municipal mains or other
sources and shall pay all charges, thereof (including storage tanks, meters etc.) for the use of the works
and workmen. unless otherwise arranged and decided on in writing by the Engineer. The water used for
the works shall be free from earthy vegetable or organic matter and from salts or other substances likely
to interfere with the setting of mortar or otherwise proved harmful to the work and shall conform to
relevant standards
5.
RATES
The contractor shall particularly note that the lump sum amount quoted shall be inclusive of all incidental
charges such as bailing by manual labour, dewatering, shoring etc., if found necessary during the
execution and no extra shall be due therefore on any account during the currency of the contract.
6.
ROYALTY CHARGES
The royalty will be charged for the materials obtained from P W Department or other Government
quarries. Assistance as necessary will be given to the contractor by the Engineer. No plot rent shall be
charged for materials stacked on KBJNL's lands during the course of construction provided all such
materials are removed within one month after the work is completed. Royalty or charges due in the case
of private quarries and private bodies shall be paid by the contractor.
7.
PAYMENT TO LABORERS
The contractor should note that the event of specific emergency to be formally declared by the Engineer,
he shall pay his laborers every day and if this is not done, KBJNL may make requisite payment and
recover the cost from the contractor. The contractor shall not employ any laborer below age of 12 years.
8.
NIGHT WORKS
If night work is required to fulfill the agreed rate of progress and to complete the work within the period
stipulated, prior written approval is necessary and all arrangements shall be made by the contractor
including lighting without any claim for extra rate.
9.
ERRORS, OMISSIONS AND DISCREPANCIES
In the case of errors, omissions, and/or disagreement between the written and the scaled dimensions on
the drawings or between the drawings and the specifications, the following order of precedence shall
apply:
i)
In case of discrepancies in dimensions of any item of work as described between the descriptive
specifications and detailed working drawings. the dimensions given in the detailed working drawings shall
apply.
ii)
In case of discrepancies in description of scope of work between what is indicated in the item of
work given in Bill of Quantities and the corresponding detailed technical specifications, the latter shall
apply.
iii)
Figured dimensions shall supersede scaled dimensions. The drawings on a large scale shall take
precedence over those on a smaller scale.

iv)
Drawing issued as construction on drawings from time to time shall supersede the corresponding
drawings previously issued.

10.
EQUIVALENCE OF STANDARDS AND CODES
Whenever reference is made in the contract to the respective standards and codes in accordance with
which plant, equipment or materials are to be furnished and work is to be performed or tested the
provisions of the latest current edition or revision of the relevant standards and codes in effect shall apply,
unless otherwise expressly set forth in the contract. Where such standards and codes are national in
character, or relate to a particular country or region, other authoritative standards which ensure equal or
lighter quality than the standards and codes specified will be accepted subject to the prior review and
written approval by the Engineer. Difference between the standards specified and the proposed
authoritative standards must be fully described in writing by the Contractor and submitted to the Engineer
well in advance for approval. If on the prior review, the Engineer determines that such proposed
deviations do not
ensure equal or higher quality, the Contractor shall comply with the standards set forth in the contract
document.
11.
BIDDER TO INFORM HIMSELF
It will be the Contractor's responsibility to satisfy himself form the inspection of the site that sufficient
quantities of construction materials required for the works exist in the borrow areas and quarry sites.
Failure by the contractor to have done all the things which in accordance with this condition he is deemed
to have done shall not relieve him of the responsibility for satisfactory completing the work as required.
12.
EMPLOYMENT OF SCARCITY LABOUR
If Government of Karnataka declares the state of scarcity or famine to exist within 16 kms of the project
site, the Contractor shall be required to employ in his works for which he will need unskilled labour and to
the extent his works can accommodate any person or persons certified to him by the Engineer to be in
need of relief and the Contractor shall pay to such persons wages not below the minimum wage which
the Government may fix in his behalf from time to time.
13.
All laborers and other employees of the contractor should be covered by a suitable accident
insurance policy to cover liabilities under the Workmen's Compensation Act.

14.
ELECTRICITY TARIFF
The unit rates and prices quoted by the Bidder in the Bill of Quantities shall include the cost of electric
energy required for construction at the rates fixed by the KPTCL.

PART - 4
SAFETY PROVISION
1.
Suitable scaffolds shall be provided for workers for all that cannot safely be done from the ground
or from solid construction, except such short period work, as can be done safely from ladder. When a
ladder is used, an extra mazdoor shall be engaged for holding the ladder and if the ladder is used for
carrying materials as well suitable footholds and handholds shall be provided on the ladder and the
ladder shall be given an inclination no steeper than 1/4 to 1(1/4 horizontal to 1 vertical). Site code s for
scaffolding and ladders 1.23696-19196 part - I and part - II and latest revisions to be followed.
2.
Scaffolding or staging more than 3.25 meters above the ground or floor swing or suspended from
an overhead support or erection with stationary support, shall have guard rail properly attached bolted,
braced and otherwise secured at least 1 metre high above the floor or platform of such scaffolding of
staging and extending along the entire length of the outside and ends thereof with only such openings as
may be necessary for the delivery of materials. Such scaffolding or staging shall be so fastened as to
prevent it from swaying from the building or the structure.
3.
Working platform, gangways and stairways shall be so constructed that they do not sag unduly or
unequally, and if height of a platform or gangways or stairways is more than 3.25 meters above ground
level, it shall be closely boarded, have adequate width and be suitably fenced, as described in 2 above.
Every opening in floor of a building or in a working platform shall be provided with suitable means to
prevent fall of persons or materials by providing suitable fencing or railing with a minimum height of 1
meter. Safe means of access shall be provided to all working platforms and other working places. Every
ladder shall be securely fixed. No portable single ladder shall be 7 meters in length, width between side
rails in a rung ladder shall in no case be less than 30 cm, for ladder, this width shall be increased by
atleast 6mm for each additional 30cm length. Uniform steps spacing shall not exceed 30cm.
4. Adequate precautions shall be taken to prevent danger from electrical equipment. No material on any
of the sites shall be so stocked or placed as to cause danger or inconvenience to any person or to the
public. The contractor shall provide all necessary fencing and lights to protect public from accidents and
shall be bound to bear expenses of defense of every suit, action or proceedings at law that may be
brought by any person for injury sustaining, owing to neglect of the above precautions and to any such
suit, action or proceedings to any such person or which may with the consent of the contractor be paid to
compromise any claim by any such person.
5. All necessary personal safety equipment as considered adequate by the Engineer shall be available
for use of persons employed on the site and maintained in a condition suitable for immediate use and the
contractor shall take adequate steps to ensure proper use of equipment by those concerned.
a) Workers employed on mixing asphaltic materials, cement and lime mortars/concrete shall be
provided with protective footwear, hand gloves and goggles.
b) Those engaged in handling any materials, which is injurious to eyes, shall be provided with protective
goggles.
c) Stone breakers shall be provided with protective goggles and protective clothing.
d) The contractor shall not employ men below the age of 15 and women on the work of painting with
products containing lead in any form. Whenever men above the age of 18 are employed on the work of
lead painting the following precautions shall be taken.
i)
No paint containing lead or lead products shall be used except in the form of paste or readymade
paint.
ii)
Suitable facemasks shall be supplied for use by workers when paint is applied in the form of spray
or a surface having lead paint dry rubbed and scraped.

iii)
Overalls shall be supplied by the contractor to workmen and adequate facilities shall be provided to
enable working painters to wash during and on cessation of works.

6. When the work is done near any place there is risk of drowning, all necessary equipment shall be
provided and kept ready for use and all necessary steps taken for prompt rescue of any person in danger
and adequate provisions made for prompt first aid treatment of all injuries likely to be sustained during the
course of the work.
7. Use of hoisting machines and tackles including their attachments, anchorage and supports shall
conform to the following:
a)
i)
These shall be of good mechanical construction, sound material and adequate strength and free
from patent defects and shall be kept in good repair and in good working order.
ii)
Every rope used in hoisting or lowering material or as a means of suspension shall be durable
quality and adequate strength, and free from patent defects.

b)
Every crane driver or hoisting appliance operator shall be properly qualified and no person under
the age of 21 years shall be in-charge of an hoisting machine, including any scaffold winch or give signals
to Operator.
c)
In case of every hoisting machine and of every chain ring hook, shac kle, swivel and pulley block
used in hoisting machine or lowering or as means of suspension safe working load shall be ascertained
by adequate means.
Every hoisting machine and all gear referred to above shall be plainly marked with safe working load. In
case of hoisting machine having a variable safe working load and the conditions under which it is
applicable shall be clearly indicated. No part of any machine or of any gear referred to above in the
paragraph shall be loaded beyond safe working load except for the purpose of testing.
d)
In case of departmental machine, safe working load shall be notified by the Engineer. As regards
contractor's machine, the contactor shall notify safe working load of each machine to the Engineer.
Whenever he brings to the site of work and gets it verified by the Engineer.
8.
Motors, gearing, transmission, electrical wiring and other dangerous parts or hoisting appliance
shall be provided with such means as will reduce to the minimum risk and accidental descend of load:
adequate precautions shall be taken to reduce to the minimum risk of any part of a suspended load
becoming accidentally displaced. When workers are employed on electrical installations which are
already energized, insulating mats, wearing apparel such as gloves, sleeves and boots, as a may be
necessary shall be provided. Workers shall not wear any rings, watches and carry keys or other
materials, which are good conductors of electricity.
9.
All scaffolds ladders and other safety devices mentioned or described here in shall be maintained
in a safe condition and no scaffold ladder or equipment shall be altered or removed, while it is in use.
Adequate washing facilities shall be provided at or near place of work.
10.
The safety provision shall be brought to the notice of all concerned by displaying on a notice board
at a prominent place at the work spot, persons responsible for ensuring compliance with the safety
provision shall be named therein by the contractor.
11.
To ensure effective enforcement of the rules and regulations relating to safety precautions,
arrangements made by the contractor shall be open to inspection by the Engineer or his representative
and the Inspecting Officer.
12.
The Contractor shall obtain previous permission of the competent authority s uch as Chief of Fire
services for the site, manner and method of storing explosives near the site of work. All handling of
explosives including storage, transport shall be carried out under the rules approved by the "Explosive
Department of the Government".
13.
The Contractor shall at his own cost provide and maintain at the sites of works, standard first aid
box as directed and approved by the Engineer for the use of his own as well as the Employer's staff on
site.
14.
Not withstanding the above provision 1 to 13 contractor is not exempted from the operation of any
other Act or rules in force relating to safety provisions.

15.
ENVIRONMENTAL PROTECTION WORK
15.1
The Contractor shall have to take following measures during construction and commissioning of
works for protection of environment as under to avoid environmental impacts on air, water and
land.
15.2 SITE CLEARANCE

The site clearance shall be done with minimum damage or existing structures, flora and fauna, electricity
and telephone lines and other infrastructures service.
15.3 EARTH WORK AND EXCAVATION
The Contractor shall inform the local authorities/government if any fossils, coins, artifacts of value
or antiquity, structures and other remains of geological or archaeological interests and excavation shal l
be stopped until identification of cultural relies by the authorized institution is completed.
The Contractor shall dispose off surplus/waste material at identified sites approved by the
Engineer. The Contractor shall ensure that there is minimum hindrance to normal activities and business.
The Contractor shall avoid damage to permanent structures and shall avoid loss of standing crops along
the road.
15.4 REPLANTATION
The Contractor shall carry out Re-plantation on areas/on the periphery of constructio n sites to
minimize visual impact and soil erosion. The Contractor shall pay special attention to the type of trees to
be replanted to prevent fouling of water through falling leaves and bird droppings. A list showing the types
of tress to be planted will be got approved before replanting and trees.
15.5 SOIL EROSION AND WATER QUALITY
The Contractor shall ensure that earth and stone do not silt up existing irrigation/drainage systems.
The Contractor shall take suitable measures to prevent direct discharge o f polluted waters form
construction activity into lakes/rivers/irrigation channels.
The Contractor shall minimize exposure of soil types susceptible to wind and water erosion.
The Contractor shall control run-off and erosion through proper drainage channels and structures.
15.6 SOIL COMPACTION
The Contractor shall restrict traffic movement and use low ground pressure machines.
The contractor shall preserve topsoil to be replaced after completion of construction activity. The
Contractor shall avoid wet soils.
15.7 SOCIAL DISTRUPTION
The Contractor shall minimize interruptions to utility services through proper planning and
scheduling of activities. The contractor shall provide temporary roads and diversions as may be
necessary for smooth flow of traffic.
The Contractor shall preferably use local labour/skilled persons during construction.
15.8 DUST/AIR POLLUTION

The Contractor shall provide effective dust control through sprinkling/washing of construction sites and
access roads.
The Contractor shall cover/water steeples and storage areas to prevent dust pollution.
The Contractor shall cover trucks transporting construction materials to minimize spills.
The Contractor shall have a preventive maintenance programme for construction equipment and vehicle
to meet emission standards.
15.9 NOISE POLLUTION
The Contractor shall normally undertake construction work during daytime only (between 7:30 to 18:00
hrs) and when authorised to work beyond these hours adopt suitable noise control methods during such
works. The contractor shall maintain machines and trucks to keep them with low noise.
The Contractor shall install sound barriers and plant tree as appropriate during construction.
15.10 CONSTRUCTION CAMPS
The contractor shall take adequate measures such as provision of septic tank/pit latrines at construction
site/camps.
The Contractor shall provide crches to working to working women labour.
The Contractor shall provide drinking water conforming to IS:10500
The Contractor shall provide garbage cans at suitable fixe d place and have the garbage disposed off
regularly.
15.11 AESTHETIC IMPROVEMENTS
The contractor shall through proper house keeping enhance aesthetic appearance of construction sites.
The Contractor shall dispose-off construction wastes at approved disposal sites.
The Contractor shall remove after completion of construction, all temporary structures and restore the
project and surrounding areas nearest possible to the pre -construction condition.
15.12. CONSERVATION OF ECOLOGICAL RESOURCES
The Contractor shall not use farmland and forest belts as materials borrow sites.
The contractor shall not select arable land as material borrows site. In case excavation in arable land is
unavoidable, topsoil layer (30 cms depth) shall be saved and returned after construc tion work is
completed so as to minimize impact on ecosystem, agriculture and animal husbandry.
The Contractor shall educate construction workers to protect natural resources, wild plants and animals.
15.13. RISK OF ACCIDENTS
The Contractor shall provide efficient lighting equipment and safety signs on temporary roads during
construction and shall adopt and implement adequate traffic regulation.
The Construction shall take effective safety and warning measures to reduce accidents.
The Contractor shall provide suitable temporary crossings to facilitate normal life and business.
15.14. RESPONSIBILITY FOR ACCIDENTS, DAMAGES ETC.
The care of the whole of the permanent work until their completion as defined and for the period
prescribed and of the whole of the temporary work until their removal shall remain with the Contractor
who shall be responsible for all accidents or damages from whatever cause arising and chargeable for
anything that may be stolen, removed, destroyed or damaged to whomsoever belonging and al so for
making good all defects and damages to the said workers or to any property adjoining or any cause
whatever, whether such damage or defects here occasioned by the negligence of the Contractor or not or
may be or might have been discovered during the progress of the works or in consequence thereof or
shall appear to be known after the completion whereof or whether payment may wholly or partially have
been made or the works approved as supposed to have been properly done and no certificate or
approval of any works by any officers or members of the Board shall effect.
SECTION - 4
GENERAL CONDITIONS
OF
CONTRACT
GENERAL CONDIONS OF CONTRACT

(Adapted version of KPWD form PWG65
SECURITY DEPOSIT
Clause 1(a) - The person/persons whose tender may be accepted (herein after called the contractor
which expression shall unless the context otherwise requires, includes his heirs, executors,
administrators and assigns) shall pay security deposit in Demand Draft/Bank Guarantee/Banker's Cheque
of any National Bank equivalent to the Earnest Money Deposit indicated in Column (ii) of the table given
and shall permit Nigam (a) to deduct at the percentage mentioned in column (ii) of the table given below
of all moneys payable for work done under the Contract, at the time of making suc h payments to
him/them and (b) to hold such deduction as Further security Deposit.
Estimated cost of the work
(*) E.M.D percentage
Upto Rs 20,00,000
Above Rs.20,00,000 upto
Rs. 10.00 crores

Above Rs.10.00 crores
percentage
2.5%
5%
2% subject to minimum of Rs.
5.5%
Rs. 100,00,000
Above Rs.100,00,000 upto
(**)F.S.D
50,000/1.5% subject to minimum of
6%
Rs. 2.00 lakhs

1% subject to minimum of Rs.
6.5%
15.00 lakhs
(*) E.M.D = Earnest Money Deposit
(**)F.S.D = Further Money Deposit
ADDITIONAL OR REDUCTION IN SECURITY DEPOSIT:
(b) In case where additions are made to the tendered work under the provisions of clause - 13 an
additional amount of Security deposit at the rates mentioned in Sub -clause (a) above should be paid by
the Contractor. If a portion of the work is withdrawn from the contractor under the provisions of Clause 15(1) a proportionate reduction in the amount of security deposit may be allowed by the executive
Engineer.
CONVERSSION TO INTEREST BEARING SECURITIES:

(c)
The security Deposit paid in cash as also the F.S.D. deducted from the bills, may at the cost of
the Depositor, be converted into interest bearing securities provided that the depositor has expressly
desired this in writing.
RELEASE AGAINST BANK GUARANTEE:
(d)
When the Further security Deposit deducted from the bills exceeds Rs. One Lakh. The amount in
excess of Rs. One Lakh at the request of the contractor be released to him against the production of
Bank Guarantee for an equivalent amount in the prescribed form. The Bank guarantee should be kept
valid till the completion of the period mentioned in Sub -clause (f) below.
DUES TO NIGAM, TO BE SET OF AGAINST SECURITY DEPOSIT
(c)
All compensation or other sums of money payable by the Contractor to Nigam under the terms of
this contract may be realized or deducted from any security Deposit payable to him or from the interest
arising there form, or from any sums which may be due to may become due by Nigam to the Contractor
on any account whatsoever and in the event of his security de posit being reduced by reason of any such
realization or deduction as aforesaid, the Contractor shall, within ten days thereafter, make good in cash
any sum or sums which have been deducted from, or raised by sale of his security deposit or any part
there of.
Refund of security deposit:
(f)
The Security deposit lodged/paid by a Contractor shall be refunded to him after the final bills are
paid or after twelve months, from the date of completion of the work, during which period of work should
be maintained by the contractor in good order, whichever is later.
PENALTY FOR DELAY
WRITTEN ORDER TO COMMENCE WORK
Clause 2:
(a)
After acceptance of the tender, the Executive Engineer shall issue a written order to the
successful tender to commence the work. The Contractor shall enter upon the commence any portion of
work only with the written authority and instructions of the Executive engineer. Without such instructions
the Contractor shall have no claim to demand for measurements of or payment for, work done by him.
PROGRAMME OF WORK
(b)
The time allowed for carrying out the work as entered in the tender shall be strictly observed by
the contractor. It shall be reckoned from the date of issue of written orders to commence work. The work
shall throughout the stipulated period of the contract be proceeded with, with all due diligence (time being
deemed to be the essence of the contract on the part of the Contractor). To ensure good progress during
the execution of the work, the contractor shall be bound (in all cases in which the time allowed for any
work exceeds one month) to comply with the time schedule according to the programme of execution of
the work as agreed upon and enclosed to the contract. In the absence of specific agreed programme the
contractor shall be bound to complete.
1/4 of the work in
1/4 of the time
1/2 of the work in
1/2 of the time
3/4 of the work in
3/4 of the time
Note: The quantity of the work to be done within a particular time to be specified above when the
programme chart is not annexed, shall be fixed and inserted in the blank space kept for the purpose by
the officer competent to accept the contract after taking into consideration the circumstances of each
case, and the contractor shall abide by the programme of detailed progre ss laid down by that officer.
The following proportions usually be found suitable in 1/4,1/2,3/4 of the time:
(i)
Reasonable progress of each work that could be achieved will be 1/6. 1/2,3/4 the
respective pf total value of the work to be done.
(ii)
Reasonable progress of masonry work that could be achieved will be 1/10th,

4/10th,8/10th of the total value of the work to be done.
REVIEW OF PROGRESS AND RESPONSIBILITY FOR DELAY ETC.

(c) Review of progress of all works costing Rs. 1 lakh and above shall be reviewed by the executive
Engineer with the contractor during the first fortnight of every month. Such review shall take into
account the programme fixed for the previous month. obligations on the part of the department like
the supply of materials, drawings, etc., and also the obligations on the part of the contractor.
APPOINTMENT OF RESPONSIBILITY FOR DELAY BETWEEN CONTRACTOR AND NIGAM
In case the progress achieved falls short by more than 25 percent of the cumulative programme, the
reasons for such shortfall shall be examined and a record made thereof apportioning the responsibilities
for the delay between the Contractor and the Department. This record should be signed in full and dated
both the Executive engineer and the Contractor.
SHORTFALL IN PROGRESS MADE UP SUBSEQUENTLY.
To the extent the shortfall is assessed as due to the delay on the part of the contractor, a notice shall be
issued to him by the executive Engineer to make up the shortfall in the succeeding month. If the shortfall
is not made up before the progress of the work is reviewed during the second month succeeding the
month in which the shortfall was observed, the contractor shall be liable to pay penalty as indicated in
Clause 2(d) below.
GRANT OF EXTENSION OF TIME:

If the delay is attributable to reasons beyond the control of the Contractor, requisite extension of time
shall be granted by the executive engineer in accordance with Clause 5 after obtaining the approval of his
higher authorities, wherever necessary.
REVIEW OF PROGRESS BY SUPERINTENDING ENGINEER/CHIEF ENGINEER:
The superintending engineer shall review the progress once in every six months all contracts of value
more than Rs. 5 Lakhs and upto Rs. 100 lakhs. In respect of contracts of value Rs. 100 lakhs and above
the review shall be done by the Chief Engineer once in six months. These reviews are in addition to the
monthly reviews required to be done by the executive engineer. The results of the review by the higher
authorities shall, wherever necessary, be incorporated in the next review by the Executive Engineer.
SETTLEMENT OF DISPUTE REGARDING SHORTFALL IN PROGRESS:
In case of dispute between the Executive Engineer and the Contractor regarding the responsibility for the
shortfall in progress, the matter shall be referred to the managing director, KBJNL, who shall there upon
give a decision within one month of the date of receipt of reference. The decision of the Managing
Director shall be final and binding on the Contractor and the Executive Engineer.
PENALTY FOR DELAY:
(d) In respect of the shortfall in progress, assessed as due to the delay on the part of Contractor as per
Clause 2(b) and 2(c), the Contractor shall be liable to pay as penalty an amount equal to one percent of
the estimated cost of the balance work assessed. Accord ing to the programme, for every day that the due
quantity of work remains incomplete; provided always that the total amount of penalty to be paid under
the provisions of this clause shall not exceed 7.5 percent of the estimated cost of the entire work as
shown in the tender, provided further that in the event of the contractor making up the shortfall in
progress within the stipulated or extended time of completion; the penalty so recovered may be refunded
on an application in writing by the contractor.
Note: If the Executive Engineer considers a necessary he shall be entitled to take action as indicated in
clause 3(d) also.
ADJUSTMENT OF EXCESS/OVER PAYMENT:
(d)
Excess/over payments as soon as they are discovered should be adjusted in the next running
account bill of the contractor and in case the final bill has already been paid, the excess/over payment
made shall be recovered from the security deposit of the contractor together with interest at 6 percent or
such other percentages as Nigam may decide from time to time from the date of such excess or over
payment to the date of recovery.
ACTION WHEN WHOLE OF SECURITY DEPOSIT IS FORFEITED:

Clause 3 -In any case in which under my clause or clauses of this contract the contractor shall have
rendered himself liable to pay compensation and/or penalty amounting to the whole of his security deposit
including the amount deducted in Installments from his bills as further security Deposit the Executive
Engineer, on behalf of the Managing Director, KBJNL shall have power to adopt any of the following
courses as he may deem best suited in the interest of Nigam.
FORFEITURE OF SECURITY DEPOSIT
(a) Without prejudice to Nigam's right to recover any loss from the Contractor under sub clauses (b) and
(c) of Clause 3 of the Contract to rescind the Contract (of which recession notice in writing to the
Contractor under the hand of the Executive Engineer shall be conclusive evidence) and in that case, the
security deposit of the contractor including whole or part of the lump sum deposited by him and also the
amount absolutely at the disposal of the Nigam.
DEBITING COST OF LABOUR AND MATERIALS SUPPLIED
(e) To employ labour paid by the Nigam and to supply materials to carry out the work or any part of the
work debiting the contractor with the cost of the labour and the price of the materials (as to the
correctness of which cost and price the certificate of the Executive Engineer shall be final and
conclusive against the contractor) and crediting
(f) him with the value of the work done in all respects in the same manner and at the same rates as if it
had been carried out by the contractor under terms of his contract, and in that case the certificate of
the Executive engineer as to the value of the work done shall be final and conclusive against the
contractor.
RECOVERY OF EXTRA COST ON UNEXECUTED WORK
(c) To measure up the work of the contractor and to take such part thereof as is remaining unexecuted
out of his hands, and to give it to another contractor to complete it in which case any expenses whi ch
may be incurred in excess of the sum which would have been paid to the original contractor, if the whole
work had been executed by him (as to the amount of which excess expenses the certificate in writing of
the Executive Engineer shall be the final and conclusive) shall be borne and paid by the original
contractor and shall be deducted from any money due to him by the Nigam under the contract or
otherwise or from his security deposit or the proceeds of the sale thereof, or a sufficient part thereof.
ACTION AGAINST UNSATISFACTORY PROGRESS
(d) If the contractor does not maintain the rate of progress as required under Clause 2 and if the progress
of any particular portion of work is unsatisfactory even after taking action under Clause 2(c) and 2(d) the
executive engineer shall be entitled to take action under Clause 3 (b) or 3(c) at his discretion in order to
maintain the rate of progress after giving the contractor 10 days notice in writing where upon the
contractor will have no claim for any compensation for any loss sustained by him owing to such actions.
NO COMPENSATION FOR LOSS SUSTAINED ON ADVANCE ACTION
(e) In the vent of any of the above course, being adopted by the Executive engineer the contractor shall
have no claim to compensation for any sustained by him by reason of his having purchased, or procures
any materials, or entered into any engagements, or made any advances on account of or with a view to
the execution of the work or the performance of the contractor. And in case the contract shall be
rescinded under the provision aforesaid the contractor shall not be entitled ti recover or be paid any sum
for any work there for actually performed by him under his contract unless and until the Executive
Engineer shall have certified in writing the performance of such work and the amount payable in respect
thereof and he shall only be entitled to be paid the amount so certified.
CONTRACTOR TO REMAIN LIABLE TO PAY COMPENSATION IF ACTION IS NOT TAKEN UNDER
CLAUSE 3
Clause 4 In any case in which any of the powers conferred upon the Executive Engineer by Clause 3
thereof shall have become exercisable and the same shall not have been exercised, the non-exercise the
roof shall not constitute a waiver of any of the conditions hereof and such powers shall not withstanding
be exercised in the event of any future case of default by the contractor for which under any Clause
hereof he is declared liable to pay compensation of penalty amounting to the whole of his security deposit
and the liability of the contractor for post and future compensation or penalty shall remain unaffected.
POWER TO TAKE POSSESSION OF OR REQUIRE REMOVAL OF OR SELL CONTRACTOR'S
PROPERTIES
In the event of the Executive Engineer taking action under sub -clause (a) or (c) of Clause - 3. he may, if
he so desires, to possession of all or any tools, plant, materials and stores in or upon works or the site
thereof or belonging to the contractor, or procured by him and intended to be used for the execution of
the work or any part thereof, paying or allowing for the same in account at the contract rates, or in the
case of contract rates not being applicable, at current market rates, to be certified by the Executive
Engineer whose certificate thereof shall be final. In the alternative, the Executive Engineer may, after
giving notice in writing to the contractor or his clerk of the works, foreman or other authorized agent,
require him to remove such tools, plant, materials or stores from the premises within a time to be
specified in such notice; and in the event of the contractor failing to comply with any such requisitions, the
Executive Engineer may remove them at the contractor's expense or sell them by auction private sale on
account of the contractor and at his risk in all respects, and the certificate of the Executive Engineer as to
the expense of any such removal, and the amount of the proceeds and expense of any such shall be final
and conclusive against the contractor.
GRANT OF EXTENSION OF TIME:

Clause 5
(a) If the contractor shall desire an extension of the time for completion of the work on the ground of his
having been unavoidably hindered in its execution or on any other ground, he shall apply in writing to the
Executive Engineer before the expiration of the period stipulated in the tender or befo re the expiration of
30 days from the date or which he was hindered as aforesaid or on which the cause for asking extension
occurred. which ever is earlier and the Executive Engineer or other competent authority may, if in his
opinion there are reasonable grounds for granting an extension, grant such extension as he thinks
necessary or proper. The decision of such competent authority in this matter shall be final.
(b) The time limit for completion of the work shall be extended commensurate with its increase in cost
occasioned by alterations or additions and the certificate of the Executive Engineer or other competent
authority as to such proportion shall be conclusive.
ISSUE OF COMPLETION CERTIFICATE - CONDITIONS REGARDING
Clause - 6 On completion of the work the contractor shall report in writing to the Executive Engineer the
completion of the work. Then he shall be furnished with a certificate by the Executive Engineer of such
completion, but no such certificate shall be given nor shall the work be considered to be complete until
the contractor shall have removed from the premises on which the work shall have been executed, all
scaffoldings, surplus materials and rubbish and shall have cleaned thoroughly all wood work, doors,
windows, walls, floor, or other parts of any building in or upon which the work has been executed or of
which he may have had possession for the purposes of executing the work, nor until the works shall
have been measured by the Executive Engineer or other competent authority, or where the
measurements have been taken by his subordinates until they have received the approval of the
Executive Engineer or other competent authority the said measurements being binding and conclusive
against the contractor. If the contractor shall fail to comply with the requirements of this clause as to the
removal of scaffolding, surplus materials and rubbish and cleaning on or before the date fixed for the
completion of the work, the Executive Engineer or other competent authority may, at the expense of the
contractor remove such scaffolding, surplus materials and rubbish and dispose of the same as he thinks
fit and clean off such dirt, etc., as aforesaid and contractor shall be liable to pay the amount of all
expenses so incurred but shall have no claim in respect of any such scaffolding or surplus materials as
aforesaid except for any sum actually realized by the sale thereof, closure of contract pending completion
of minor items.
Note - In cases where it is not desirable to keep the building contract o pen for minor items, such as
flooring in the bath rooms, etc., which can be carried out only after installation of sanitary work, the main
contract may be finalized after getting a supplementary agreement executed in the prescribed form by the
same contractor for doing the residual work.
CONTRACTOR TO SUBMIT BILLS MONTHLY IN PRINTED FORM
Clause 7:
a) A bill shall be submitted by the contractor on or before the 15th of each month for all items of work
executed in the previous month.
All bills shall be prepared in the prescribed printed or typed form in quadruplicate and handed over to the
subordinate in-charge of the work/Sub-Division or Division office and acknowledgement obtaine d.
The charges to be made in the bills shall always be entered at the rates specified in the tender in full or in
part as the case may be. In the case of any extra work ordered in pursuance of these conditions, and not
mentioned or provided for in the tender, the charges in the bills shall be entered at the rates here inafter
provided for such work.
SCRUTINY OF BILLS AND MEASUREMENT OF WORK
(b) The details furnished by the Contractor in the bill should be completely scrutinised and the said work
should be measured by the subordinate in the presence of the Contractor or his duly authori zed agent.
The countersignature of the contractor or the said agent in the measurement book shall be sufficient
proof to the correctness of the measurements which shall be binding on the contractor in all respects. If
the contractor does not submit the bills within the prescribed time the Executive Engineer may depute
within seven days of the prescribed date, a subordinate to measure up the said work.
The
countersignature of the contractor shall be obtained in the Measurement Book concerned with reference
to which the bill may be prepared by the department.
FILLlNG OF OBJECTIONS TO MEASUREMENTS, BY CONTRACTOR
(c) Before taking any measurement of any work as has been referred to in Clause 7 (b) above the
Executive Engineer or a sub-ordinate deputed by him shall give reasonable notice to the contractor. If
the Contractor fails to attend at the measurements after such notice or fails to countersign or to record the
difference within a week from the date of measurements in the manner required by the Executive
Engineer, then in any such event, the measurements taken by the Executive Engineer or by the
subordinate deputed by him as the case may be shall be final and binding on the contractor and the
contractor shall have no right to dispute the same.
(d) One copy of the passed bill shall be given to the Contractor without any charge.
PAYMENT PROPORTIONATE TO WORK APPROVED AND PASSED

Clause 8:
The contractor shall, on submitting the bill and after due verification by the subordinate as per Clause 7
(b) be entitled to necessary payment proportionate to the part of the work then approved and passed by
the Executive Engineer or other competent authority whose certificate of such approval and passing of
the sum so payable shall be final and conclusive against the contractor.
PAYMENT AT REDUCED RATES
The rates for several items of works agreed to within shall be valid only when the items concerned are
accepted as having been completed fully in accordance with the stipulated specifications. In case where
the items of work are not accepted as so completed, the Executive Engineer or other competent authority
may reject the items of work or may make payment on account of such items at such reduced rates as he
may consider reasonable in the preparation of final or on account bills.
PAYMENT ON INTERMEDIATE CERTIFICATES BE REGARDED AS ADVANCES
All such intermediate payments shall be regarded as payments by way of advance against the final
payments only and not as payments for work actually done and completed, and shall not prec lude the
Executive Engineer or other competent authority from requiring any bad, unsound, imperfect or unskillful
work to be removed or taken away and reconstructed or re -erected nor shall any such payment be
considered as an admission of the due performance of the contract or any part thereof in any respect or
the accruing of any claim, nor shall it conclude, determine or affect in any other way the powers of the
Executive Engineer or other competent authority as to the final settlement and adjustment, of the
accounts or otherwise or in any other way vary or affect the contract.
SUBMISSION OF FINAL BILL AND ITS SETTLEMENT
The final bill shall be submitted by the Contractor within one month of the date of actual completion of the
work in all respects. His claims shall be settled (except those under dispute) within two months thereafter
in respect of works costing up to Rs.2 lakhs and within five months thereafter in respect of works costing
more than Rs.2 lakhs.
DISPUTED ITEMS
The Contractor shall submit a list of the disputed items within 30 days from the disallowance thereof and
if he fails to do so this, his claim shall be deemed to have been fully waived and absolutely extinguished.
STORES SUPPLIED BY NIGAM
Clause 9:
If the specification or estimate of the work provides for the use of any special description of materials to
be supplied from the store of the Nigam or if it is required that the Contractor shall use certain stores to
be provided by the Executive Engineer or other competent authority (such material and stores, and the
prices to be charged there for as hereinafter mentioned being so far as practicable for the convenience of
the contractor but not so as in any way to control the meaning or effect of this contract specified in the
schedule or memorandum hereto annexed) the contractor shall be supplied with such materials and
stores as may be required from time to time to be used by him for the purposes of the contract only and
the value of the full quantity of the materials and stores so supplied s hall be set off or deducted from any
sums then due, or thereafter to become due to the contractor under the contract, or otherwise, or from the
security deposit, or the proceeds of sale thereof.
M a te r ia ls s h al l re m ai n the ab so l u te p ro p e r ty o f Nig a m a nd b e o p e n to i nsp e c tio n.
All materials supplied to the contractor shall remain the absolute property of Nigam and shall on no
account be removed from the site of work, and shall at all times be open to inspection by the Executive
Engineer or other competent authority. Any such materials unused and in perfectly good condition at the
ti me o f co mp le tio n o r d e te rm in a tio n o f the co ntr ac t sha ll b e re tu r ne d to the Nig am
stores, if the Executive Engineer or other competent authority so requires by a notice in writing g iven
under his hand; but the contractor shall not be entitled to return any such materials except with the
consent of the Executive Engineer or other competent authority and he shall have no claim for
compensation on account of any such material supplied to him as aforesaid but remaining unused by him
or for any wastage in or damage to any such materials.
UNUSED MATERIALS
Clause 10(a):
(i) The contractor shall see that only the required quantities of materials are indented. Any such materials
remaining unused and in perfectly good condition at the time of completion or determination of the
contract, shall be returned to the Executive Engineer at a place where directed by him, if by a notice in
writing under his hand, he shall require them. Credit for such materials will be given at the issue rate
actually charged for these materials excluding storage charges, or market rate, whichever is lower. The
contractor shall not be entitled to cartage and incidental charges for returning the surplus materials from
and to the stores
RECOVERY OF COSTS FOR MATERIALS DRAWN IN EXCESS OF ACTUAL REQUIREMENTS.
After the completion of the work the actual quantity of departmentally supplied materials consumed in the
various items or work shall be assessed on the basis of the measurements recorded in the measurement
books for purpose of payment. Over this quantity a variation shall be reasonably allowed for wastage of
materials during execution.
If the materials are drawn from Nigam Stores in excess of actual
requirements of the works as assessed above (including the reasonable variation towards wastage as
stated above) the cost of excess materials drawn from the Nigam stores, and not returned by the
contractor in good condition shall be recovered at twice the issue rate including storage charges.
Recovery of cost of materials disposed off unauthorisedly or not stored at site-black listing of
contractor.
(b) In cases where it is noticed that materials and stores supplied to the contractor have not been stored
at the site of work or have been unauthorisedly disposed off, the cost of such materials shall be
recovered at twice the issue rate including storage charges or at twice the market rate, whichever is
higher, action may also be initiated for the removal of the name of the contractor from the approved list of
contractors and also to black list the contractor.
NO CLAIM TO COMPENSATION ON ACCOUNT OF LOSS DUE TO DELAY IN SUPPLY OF
MATERIALS BY KBJNL.
Clause 11
(a)
The contractor is required to keep himself in touch with day-to-day position regarding supply of
materials specified in Schedule-A and make adjustments in the programme of work to the extent possible
and desirable.
(b)
The contractor shall not be entitled to claim any compensation from Nigam for the loss suffered by
him on account of any delay by Nigam in the supply of materials entered in Schedule. However, in the
case of such delays in the supply of materials, the Nigam shall grant such extension of time for the
completion of the works as shall appear to the Executive Engine er or other competent authority to be
reasonable in accordance with the circumstances of the case. The decision of the Executive Engineer or
other competent authority as to the extension of time shall be accepted as final by the Contractor.
PROCUREMENT OF SCHEDULE-A STORE BY CONTRACTOR
(c.)
In case of non-availability of materials specified in Schedule-A, the Executive Engineer may
permit the Contractor in writing to procure such materials from his own source and then use on works
provided that the materials are in accordance with the standards and specification stipulated in the
Tender, designs and drawings. The contractor is not entitled to any claim on account of higher rates paid
by him than those specified in Schedule A for materials procured by him.
DEFINITION OF WORK
Clause 12
(a)
The expression 'Work' in or 'Works' where used in these conditions, shall unless there be
something in the subject or context repugnant to such construction, be constructed to mean the work or
works contracted to be executed under or in virtue of the contract, whether temporary or permanent and
whether original, altered, substituted or additional.
Work to be executed in accordance with specifications, drawings, orders etc.
(b)
The contractor shall execute the whole and every part of the work in the most sound and
substantial and workmanlike manner, and in strict accordance with the specifications both as regards
materials and workmanship. The work shall also conform exactly, fully and faithfully to the designs,
drawings and instructions in writing relating to the work signed by the Executive Engineer or other
competent authority and lodged in his office and to which the contractor shall be entitled to have access
at such office, or on the site of the work for the purpose of inspection during office hours and the
contractor shall, if he so requires, be entitled at his own expense to obtain copies of the specifications
and of all such designs and drawings and instructions as aforesaid.
THE DETAILED TECHNICAL SPECIFICATIONS
The detailed Technical Specifications, which forms a part of the contract, accompanies
the Tender
Document. In carrying out the various items of work as described in Schedule B of the Tender Document
and the additional, substituted, altered items of work these Detailed Technical Specifications shall be
strictly adhered to, supplemented by relevant provisions of the Indian Standard Specifications, the Code
of Practice, etc.
of which a list is furnished therein. The Indian Standard Specifications and code of practice to be
followed shall be the latest versions of those listed in the Detailed Technical Specifications. Any class of
work, not covered by the Detailed Technical Specifications, shall be executed in accordance with the
instructions and requirements of the Engineer and the relevant provisions of the Indian Standard
Specifications.
Clause 13 DELETED
TIME LIMITS FOR UNFORESEEN CLAIMS
Clause 14:
Under no circumstances whatever shall be contractor be entitled to any compensation from the KBJNL on
any account unless the contractor shall have submitted claim in writing to Executive Engineer or other
competent authority within 30 days of the cause of such claim occurring.
NO CLAIM TO ANY PAYMENT FOR COMPENSATION FOR DELETION OF WHOLE OR PART OF
WORK
Clause 15:
(a)
If at any time after the execution of the contract documents, the Executive Engineer or other
competent authority shall, for any reason whatsoever, require the whole or any part of the work, as
specified in the tender, to be stopped for any period or require the whole or part of the work (i) not to be
carried out at all or (ii) not to be carried out by the tendered contractor, he shall give notice in writing of
the fact to the contractor who shall thereupon suspend or stop the work totally or partially as the case
may be. In any such case, except as provided hereunder, the contractor shall have no claim to any
payment of compensation whatsoever on account of any profit or advantage which he might have derived
from the execution of the work in full but which he did not so derive in consequence of the full amount of
the work not having been carried out, or on account of any loss that he may be put on account of
materials purchased or agreed to be purchased, or for unemployment of labour recruited by him. He
shall not also have any claim for compensation by reason of any alterations having been made in the
original specifications, drawings, designs and instructions which may involve any curtailment of the work
as originally contemplated.
PAYMENT FOR MATERIALS ALREADY PURCHASED OR ORDERED BY CONTRACTOR
(b)
Where, however, materials have already been purchased or agreed to be purchased by the
contractor before receipt by him of the said notice the contractor shall be paid for such materials, at the
rates determined by the Executive Engineer or other competent authority provided they are not in excess
of requirements and are of approved quality and/or shall be compensated for the loss, if any, that he may
be put to, in respect of materials agreed to be purchased by him, the amount of such compensation to be
determined by the Executive Engineer or other competent authority whose decision shall be final.
LABOUR CHARGES DURING STOPPAGE OF WORK
(c)
If the contractor suffers any loss on account of his having to pay labour charges during the period
during which the stoppage of work has been ordered under this clause, the contractor shall on
application, be entitled to such compensation on account of labour charges as the Executiv e Engineer or
other competent authority, whose decision shall be final, may consider reasonable, provided that the
contractor shall not be entitled to any compensation on account of labour charges if in the opinion of the
Executive Engineer or other competent authority, the labour could have been employed in the same
locality by the contractor for the whole or part of the period during which the stoppage of the work has
been ordered as aforesaid.
TIME LIMIT FOR STOPPAGE OF WORK
(d)
The period of stoppage ordered by the Executive Engineer or other competent authority should
not ordinarily exceed six months. Thereafter the portion of works stopped may be treated as deleted from
this agreement if a notice in writing to that effect is given to the Executive Engineer or other competent
authority by the contractor within seven days after the expiry of the above period.
EXECUTION OF WORK DELETED
The portion of work thus deleted may be got executed from the same contractor on supplemental
agreement on mutually agreed rates which shall not exceed current Schedule of Rates plus or minus
tender percentage.
ACTION AND PENALTY IN CASE OF BAD WORK

Clause 16:
If at any time before the security deposit is refunded to the contractor, it shall appear to the Executive
Engineer or other competent authority or his subordinate in charge of the works that any work has been
executed with unsound, imperfect or unskillful workmanship or with materials of inferior quality, or that
any materials or articles provided by him for the execution of the work are unsound, or of a quality inferior
to that contracted for, or are otherwise not in accordance with the contract, it shall be lawful for the
Executive Engineer or other competent authority to intimate this fact in writing to the contractor and then
notwithstanding the fact that the work, materials or articles complained of may have been paid for, the
contractor shall be bound forthwith to rectify, or remove and reconstruct the work so specified in whole or
in part as the case may require, or if, so required shall remove the materials or articles at his own cost
and in the event of his failing to do so within a period to be specified by the Executive Engineer or other
competent authority in the written intimation aforesaid, the contractor s hall be liable to pay a penalty not
exceeding one percent of the amount of the estimate for every day not exceeding ten days during which
the failure, so continues and in the case of any such failure the Executive Engineer or other competent
authority may rectify or remove, and re-execute the work or remove and replace the materials or articles
complained of as the case may be, at the risk and expense in all respects of the contractor. Should the
Executive Engineer or other competent authority for any valid reasons consider that any such inferior
work or materials as described above is to be accepted or made use of, it shall be within his discretion to
accept the same at such reduced rates he may fix thereof.
WORK TO BE OPEN TO INSPECTION CONTRACTOR OR RESPONSIBLE AGENT TO BE
PRESENT
Clause 17:
(a)
All works under or in course of execution or executed in pursuance of the contract shall at all times
be open to the inspection and supervision of the Executive Engineer or other competent authority and his
subordinates, and the contractor shall at all times during the usual working hours, and at all other times at
which reasonable notice of the intention of the executive Engineer or other competent authority or his
subordinate to visit the work shall have been given to the contractor, either himself be present to receive
orders and instructions or have a responsible agent duly accredited in writing present for the purpose.
Orders given to the contractors duly authorized agent shall be considered to have the same fo rce and
effect as if they had been given to the contractor himself.
EMPLOYMENT OF TECHNICAL STAFF

(b)
The Contractor shall employ the following technical staff during execution of this work:
(i)
One Graduate Engineer when the cost of the work to be executed is Rs. 25 Lakhs or more:
(ii)
One qualified Engineering Diploma Holder when the cost of the work to be executed is more than
Rs.10 Lakhs but less than Rs.25 Lakhs.

(iii)
In addition to (i) and (ii) above, the contractor shall employ different types of such technical
personnel as may be directed by the Executive Engineer to ensure efficient execution of work.
The technical staff so employed should be available at site whenever required by the Engineer- inCharge to take instructions.
(c)
If the Contractor fails to employ technical staff as aforesaid he shall be liable to pay a sum or
Rs.10000 (Ten Thousand Only) for each month of default in the case of Graduate Engineer and Rs. 5000
(Rupees Five Thousand Only) for each month of default in case of Diploma Holders.
(d)
If the Contractor himself possesses the required qualification and is available at the site for
receiving instructions from the Executive Engineer or other competent authority vide sub -clause (a)
above it will not be necessary for the technical staff to be available at site for receiving instructions.
NOTICE TO BE GIVEN BEFORE WORK IS COVERED UP
Clause 18 The contractor shall give not less than five days notice in writing to the Executive Engineer
or his subordinate in charge of the work before covering up or othe rwise placing beyond the reach of
measurement any work in order that the same may be measured, and correct dimensions thereof taken
before the same is covered up or placed beyond the reach of measurement, and shall not cover up of
place beyond the reach of measurement, any work without the consent in writing of the Executive
Engineer or other competent authority or his subordinate in charge of work; and if any work shall be
covered up or placed beyond the reach of measurement without such notice having been given or
consent obtained, the same shall be uncovered at the contractors expense, and in default thereof no
payment or allowance shall be made for such work or for the materials with which the same was
executed.
CONTRACTOR LIABLE FOR DAMAGE DONE AND FOR IMPERFECTIONS FOR TWELVE MONTHS
AFTER CERTIFICATE OF COMPLETION
Clause 19 If the Contractor or his workmen or servants shall break, deface, injure or destroy any part of
a building, structure, embankment or canal in which they may be working, or any bui lding, structure,
embankment canal, road, fence, enclosure or grassland or cultivated ground contiguous to the premises
on which the work or any part thereof is being executed, or if any damage shall be done to the work,
while it is in progress from any cause whatever or if any imperfections become apparent in it within
Twelve months of the grant of a certificate of completion, final or otherwise, by the Executive Engineer or
other competent authority the contractor shall make good the same at his own expense, or in default, the
Executive Engineer or other competent authority may cause the same to be made good by other
workmen, and deduct the expenses (of which the certificate of the Executive Engineer or other competent
authority shall be final) from any sums that may be due or may thereafter become due to the contractor,
or from his security Deposit or the proceeds of sale thereof , or of a sufficient portion thereof.
CONTRACTOR TO SUPPLY PLANT, LADDERS, SCAFFOLDINGS, ETC., AND IS LIABLE FOR
DAMAGES ARISING FROM NON-PROVISION OF LIGHTS, FENCING, ETC.,
Clause 20 The contractor shall supply at his own cost all materials (except such special materials, if
any, as may, in accordance with the contract, he supplied from the Nigam Stores) plant, tools,
appliances, implements, ladders, cordage, tackle, scaffolding and temporary works requisite or proper for
the proper execution of the work, whether, in the original, altered or substituted form and whether
included in the specifications, or other documents forming p art of the contract or referred to in these
conditions or not and which may be necessary for the purpose of satisfying or complying with the
requirements of the Executive Engineer or other competent authority as to any matter as to which under
these conditions he is entitled to be satisfied, or which he is entitled to require together with carriage
therefore, to and from the work. The contractor shall also supply without charge the requisite number of
persons with the means and materials necessary for the p urpose of setting out works, and counting,
weighing and assisting in the measurement or examination at any time from time to time of the
work or the materials. Failing this, the same may be provided by the Executive Engineer or other
competent authority at the expense of the contractor and the expense may be deducted from any money
due to the contractor under the contract or from his Security Deposit or the proceeds of sale thereof, or a
sufficient portion thereof. The contractor shall provide all necessary fencing and lights required to protect
the public from accident, and shall also be bound to bear the expense of defense of every suit, action or
other legal proceedings, that may be brought by any person of every suit, action or other legal
proceedings, that may be brought by any person for injury sustained wing to neglect of the above
precautions, and to pay any damages and costs which may be awarded in any suit, action or proceedings
to any person, or which may with the consent of the contractor be paid for compromising any claim by
any such person.
ISSUSE OF PLANT AND MACHINERY ON HIRE
Clause 21:
(a)
Wherever plant and machinery required for the work is available with the department, the plant and
machinery so available may be issued to contractor on hire subject to the conditions prescribed in
Schedule C of the Agreement Form. Hire charges payable shall be recovered from the running account
bills of the contractor. The issue of machinery, etc., will, however, be purely within the discretion of the
Department.
Contractors responsibilities regarding working conditions, damages, loss.
(b)
Not withstanding the fact that the machinery is operated by the department contractor shall be
responsible to return the plant and machinery in such work condition in which it was issued to him subject
to reasonable wear and tear. He shall also be responsible for all damages caused to the said plant and
machinery at site of work or elsewhere when in operation or otherwise or during transit, including damage
to or loss of part/ parts, as also for losses due to failure to return them soon after completion of the work
for which they were issued. The Executive Engineer shall determine the liability of the Contractor on
account of damage and/or losses, if any, and shall be entitled to assess such damage and / or loss and
recover the same from the bills of the contractor or from any other sums due to him. In the event of any
dispute as to the nature and extent of damage/loss the decision of the Executive Engineer shall be final
and binding on the Contractor..
NIGAM TO BEAR REPAIR CHARGES OF NORMAL WEAR AND TEAR AS DECIDED BY
SUPERINTENDING ENGINEER.
(c)
During the period of hire, Nigam shall bear the charges for repairs necessitated by normal wear
and tear of tools, plant and machinery hired. The cost of the repairs necessitated by negligent use of
tools, plant and machinery shall be borne by the Contractor. As to what repairs shall under the category
of repairs due to normal wear and tear, the decision of the Superintending Engineer shall be final.
Contractor has to pay compensation to the Nigam crew as per Workmens Compensation Act.
(d)
The Contractor shall be liable to pay all compensation to the departmental crew as per Workmens
Compensation Act 1923 (VIII of 1923 hereinafter called the said Act) for injuries caused to the
departmental crew on the job with the machine at site of work or elsewhere when in operation or
otherwise during transit, as though the crew was employed by the contractor himself. If such
compensation is paid by Nigam as principal under sub-section (1) of the section 12 of the said Act on
behalf of the contractor it should be recoverable by Nigam from contractor under sub -section (2) of the
said section. Such for the purpose in the contract.
MEASURES FOR PREVENTION OF FIRE
Clause 22 The contractor shall not set fire to any standing jungle, trees, brushwood or grass without a
written permit from the Executive Engineer.
When such permit is given and also in all cases when destroying cut or dug up tress, brushwood, grass,
etc., by fire, the contractor shall take necessary measure to prevent such fire spreading to or other wise
damaging surrounding property.
LIABILITY OF CONTRACTOR FOR ANY DAMAGES DONE IN OR OUTSIDE WORK AREA
Clause 23 Compensation for all damages done by contractor or his men whether in or beyond the limits
of Nigam property including any damage caused by spreading of fire mentioned in Clause 22 shall be
estimated by the Executive Engineer, and the estimate of the Executive Engineer, subject to the decision
of the Superintending Engineer on appeal, shall be final and the contractor shall be bound to pay the
amount of the assessed compensation on demand failing which the same will be recovered from the
contractor as damages in the manner prescribed in Clause I or deducted by the Executive Engineer or
other competent authority from any sums that may be done or become due from Nigam to the contractor
under this contract or otherwise.
The contractor shall bear the expenses of defending and action or other legal proceedings that may be
brought by any person for injury sustained by him owing to neglect of precautions to prevent the spread
of fire and shall pay any damages and cost that may be awarded by the court in consequence.
EMPLOYMENT OF FEMALE LABOUR
Clause 24 The employment of female labourers on works in the neighborhood of soldiers barracks
should be avoided as far as possible.
WORK ON NOTIFIED HOLIDAY
Clause 25 No work shall be done on any notified holiday without the sanction in writing of the Executive
Engineer or other competent authority.
CONSEQUENCES OF SUBLETTING WORK WITHOUT APPROVAL, THE CONTRACTOR
BECOMING INSOLVENT, BRIBING ETC, BY CONTRACTOR
WORK NOT TO BE SUBLET
Clause 26- (a) The contract shall not be assigned or sublet by the Contractor. Ho wever, any specific
portion of the work which is of a specialized nature and normally not executable by a general Contractor
could be got done by the specialized agencies which are executing such works, after obtaining the
specific approval of the Executive Engineer in writing in each case. Such consent to sublet the work, if
given, shall not relieve the Contractor from any liability or obligation under the contract and he shall be
responsible for the acts, defaults and neglects of any sub -contractor or his agents, servants or workmen
as fully as if they were the acts, defaults or neglects of the contractor, his agents, servants or workmen.
If the contractor shall assign or sublet his contract or any portion thereof without the specific approval of
the Executive Engineer or attempts to do so or become insolvent or commence any proceedings to get
himself adjusted as insolvent or make any composition with his creditors or attempts so to do or if any
bribe, gratuity, gift, loan, perquisite reward or advantage, pecuniary or otherwise, shall either directly or
indirectly be given, promised or offered by the Contractor or any of his servants or agents to any officer or
person in the employ of Nigam in any way relating to his officer employment or if any such officer or
person shall become in any way directly or indirectly interested in the contract, the Executive Engineer or
other competent authority may there upon by notice in writing rescind the contract and the security
deposit of the contractor shall there upon stand forfeited and be absolutely at the disposal of Nigam, and
the same consequences shall ensure as if the contract had been rescinded under Clause 3 here of and in
addition, the contractor shall not be entitled to cover or bed paid for any work actually performed under
contract.
RECOVERY OF EXCESS PAYMENTS BASED ON EXCESS MEASUREMENTS AND ACTION
AGAINST CONTRACTOR.
(b)
Whenever it is noticed that excess payments have been made to the contractor based on excess
measurement recorded by the subordinate in the me asurement book and countersigned by the contractor
or his duly authorized agent, action shall be taken to recover the excess payments together with interest
immediately. Action may also be taken to remove the name of the contractor from the approved list o f
contractors and also to black list him.
CHANGE IN CLASSIFICATION OF EXCAVATIONS ACCEPTED NOT PERMITED
Once the measurements mentioning the classification of the excavations are recorded in the
measurement book and the same is signed by the contractor or his authorized agent in token of
acceptance, no request for reclassification by the contractor shall be entertained.
CRIMINAL PROCEEDING AGAINST DEPARTMENTAL OFFICERS AND CONTRACTOR FOR THE
LAPSES
(C)
Nigam also reserves the right to initiate criminal proceedings against the concerned departmental
officers who have colluded with the departmental officers in the lapse and fraudulently received amounts
not due to them legitimately.
SUM PAYABLE BY WAY OF COMPENSATION TO BE CONSIDERED AS REASONABLE
COMPENSATION WITHOUT REFERENCE TO ACTUAL LOSS
Clause 27 All sums payable by contractor by way of compensation under any of these conditions shall
be considered as reasonable compensation to be applied for the use of Nigam without reference to the
actual loss or damage sustained and whether any damage has or has not been sustained.
APPROVAL OF EXECUTIVE ENGINEER IS NECESSARY FOR CHANGING THE CONSTITUTION OF
A FIRM OR BEFORE ENTERING INTO PARTNERSHIP AGREEMENT CONSEQUENCES OF NOT
OBTAINING PRIOR APPROVAL.
Clause 28 - Where the contractor is a partnership firm, the precious approval in writing of the Executive
Engineer shall be obtained before any change is made in the Constitution of the Firm. Where the
contractor is an individual or a Hindu undivided family business\concern, such approval as aforesaid,
shall likewise be obtained the contractor shall be deemed to have been assigned in contravention of
Clause 26 thereof and the same action may be taken and the same consequences shall ensure as
provided in the said Clause 26.
SETTLEMENT OF DISPUTES-TIME FOR DECISION
Clause29:
(a)
If any dispute or difference of any kind whatsoever were to arise between the Executive Engineer/
superintending Engineer and the contractor regarding the following matters namely.
(i) The meaning of the specification, design, drawings and instructions here in before mentioned.
(ii) The quality of workmanship or materials used on the work and
(iii) Any other question, claim, right, matter, thing whatsoever, in any way arising out of or relating to
the contract, designs, drawings, specifications, estimates, instructions, or orders, or those conditions or
failure to execute the same whether arising during the progress of the work, or after the completion,
termination or abandonment thereof, the dispute shall, in the fist place, be referred to the Chief Engineer
who has jurisdiction over the work specified in the contract. The Chief Engineer shall, within a period of
sixty days from the date of being requested by the Contractor to do so, give written notice of his decision
to the contractor. If the contractor is aggrieved by the decision of the Chief Engineer, of if the Chief
Engineer fails to give written notice of his decision within the above said period of sixty days, the
contractor may appeal to Managing Director KBJNL within 60days from the receipt of written notice of
Ch i e f E ng i ne e r s d e ci s io ns o r fro m the e xp i r y o f fi r s t n a me d p e r io d o f 6 0d ay s.
(b)
Subject to the Managing Directors decision on appeal and subject to other form of settlement
hereafter provided. The Chief Engineers decision in respect of every dispute or difference so referred
shall be final and binding upon the contractor. The said decision shall forthwith be given effect to and
contractor shall proceeds with the execution of the work with all due diligence.
REMEDY WHEN MANAGING DIRECTOR'S DECISION ON APPEAL IS NOT ACCEPTABLE TO
CONTRACTOR
(c)
In case the decision of the Managing Director is not acceptable to the contractor, he may
approach the Law Courts at Bijapur for settlement of dispute after giving due written notice in this regard
to the Managing Director within a period of Ninety days from the date of receipt of the written notice of the
decision of the Managing Director.
TIME LIMIT FOR NOTICE TO APPROACH LAW COURT BY CONTRACTOR
(d)
If the Managing Director has given written notice to the contractor of his decision on his appeal
and no written notice to approach the law court has been communicated to him by the contractor within a
period of ninety days from receipt of such notice, the said decision shall be final and binding upon the
contractor.
TIME LIMIT FOR NOTICE TO APPROACH COURT OF LAW BY CONTRACTOR, WHEN DECISION IS
NOT GIVEN BY THE MANAGING DIRECTOR.
(e)
If the Managing Director fails to give notice of his decision within a period of ninety days from the
receipt of the contractor's appeal, the Contractor may within ninety days after the expiry of the above
named period of ninety days approach the Law Courts at Bijapur (*) giving due notice to the Managing
Director.
Note: (*) In sub clauses (c) and (e) specify the place where the Court under whose jurisdiction the work is
situated/is located.
(f)
Whether the claim is referred to the Chief Engineer or Managing Director or to the Law Courts, as
the case may be, the contractor shall proceed to execute and c omplete the works with all due diligence
pending settlement of the said dispute of differences.
OBLIGATIONS OF THE EXECUTIVE ENGINEER AND CONTRACTOR SHALL REMAIN UNALTERED
DURING CONSIDERATIONS OF DISPUTE
(g)
The reference of any dispute or difference to the Chief Engineer or Managing Director or the Law
Court may proceed not withstanding that the works shall then be or be alleged to be complete, provided
always that the obligations of the Executive Engineer and the contractor shall not be altered by reaso n of
the said dispute or difference being referred to the Chief Engineer or Managing Director or the Law Court
during the progress of the works.
(h)
deleted.
CONTRACTOR TO PAY COMPENSATION UNDER WORKMEN'S COMPENSATION ACT
Clause 30:
(a)
The contractor shall be responsible for and shall pay any compensation to his own workmen
payable under the Workmen's Compensation Act. 1923 (VIII of 1923 ) (hereinafter called the said Act) for
injuries caused to the workmen. If such compensation is paid by Nigam as principal under sub-section
(1) of Section 12 of the said Act on behalf of the contractor, it shall be recoverable by Nigam from the
contractor under sub-Section (2) of the said Section. Such compensation shall be recovered in the
manner laid down in Clause 1 above.
CONTRACTOR TO PAY EXPENSES OF PROVIDING MEDICAL AID TO WORKMEN
(c)
The contractor shall be responsible for and shall pay the expenses of providing medical aid to any
workmen who may suffer a bodily injury as a result of an accident. If such expenses are incurred by
Nigam, the same shall be recoverable from the contractor forthwith and be deducted without prejudice to
any other remedy of Nigam from any amount due or that may become due to the contractor.
CONTRACTOR HAS TO PROVIDE PERSONAL SAFETY EQUIPMENT, FIRST AID APPARATUS,

TREATMENT, ETC.
Clause 31:
The contractor shall provide all necessary personal safety equipment and first aid apparatus for the use
of the persons employed on the site, and shall maintain the same in good condition suitable for
immediate use, at any time and shall comply with the following regulations in connection therewith
i)
The workers shall be required to use the equipment so provided by the contractor and the
contractor shall take adequate steps to ensure proper use of the equipment by those concerned.
ii)
When work is carried on in proximity to any place where there is a risk of drowning, all necessary
steps shall be taken for the prompt rescue of any person in danger.
iii)
Adequate provision shall be made for prompt first-aid treatment of all injuries likely to be sustained
during the course of the work.

MINIMUM AGE OF PERSONS EMPLOYED BY CONTRACTOR
Clause 32
(a)
No contractor shall employ

(i)
Any person who is under the age of 12 years.
(ii)
Who does not produce a valid certificate of vaccination against small-pox in respect of
himself/herself as well as the members of his/her family.

Employment of Donkeys and other Animals
(d)
No contractor shall employ donkeys or other animals with breaching of string or thin rope. The
breaching must be atleast three inches wide and should be tape.

No animals suffering from sores, lameness or emaciation or which is immature shall be employed on the
work.
(d)
The contractor shall provide for drinking pure of potable water facilities to the workers.
REMOVAL OF PERSON OR ANIMAL NOT SATISFYING CONDITIONS (A)

(e)
TO (C)
The Executive Engineer or other authority is authorised to direct the removal or to remove
through his own agency, from the work any person or animal referred to in sub -clauses (a) to (c) above
not satisfying these conditions and no responsibility shall be accepted by the Nigam for any delay caused
in the completion of the work by such directions for removal.
PAYMENT OF FAIR AND REASONABLE WAGES BY CONTRACTOR
(f)
The contractor shall pay fair and reasonable wages, which shall not be less than the minimum
wages fixed by Government from time to time to the workmen employed by him in the contract
undertaken by him. In the event of any dispute arising between the contractor and his workmen on the
ground that the wages paid are not fair and reasonable the dispute shall be referred without delay to the
Executive Engineer or other competent authority, who shall decide the same. The decision shall not in
any way affect the conditions in the contract regarding the payment to be made by Nigam at the agreed
tender rates.
(g)
The Contractor shall follow the relevant provisions of Employees State Insurance Act and the
Employees Provident Fund Act and shall be responsible for all omissions and commissions with regards
to the above two acts and shall keep the Nigam and its officers indemnified against any losses or
damages.
EMPLOYMENT OF SCARCITY LABOUR, ETC.,
Clause 33:
(a)
If Government declares a state of scarcity or famine to exist in any village situated within 15
kilometers (10 miles) of the work, the contractor shall employ upon such parts of the work as are suitable
for unskilled labour, any person certified to him by the Executive Engineer, or by any person to whom the
Executive Engineer may have delegated this duty in writing to be in need of relief and shall be bound to
pay to such persons wages not below the minimum which Government may have fixed in this behalf. Any
dispute which may arise in connection with implementation of this clause shall be decided by the
Executive Engineer or other competent authority whose decision shall be final and binding on the
contractor.
(b)
The contractor shall employ any famine, convict or other labour of a particular kind or class, if
ordered in writing to do so by the Executive Engineer or other competent authority. Contractor not entitled
to any claim or compensation for delay in execution of work due to water in borrow pits.
Clause 34:
The contractor shall not be entitled to claim compensation if there is any delay in execution of the work on
account of water standing in borrows pits and compartments. The rates of borrowing earth and of
excavation hold good for all situations such as hard or cracked soils, excavation in mud, subsoil water or
water standing in borrow pits and no claim for extra rate shall be entertained, unless otherwise expressly
specified.
METHOD OF PAYMENT OF BILLS
Clause 35:
Payment to contractors shall be made by cheques.
SET OFF AGAINST ANY CLAIM OF NIGAM / GOVERNMENT UNDER OTHER CONTRACTS.
Clause 36:
Any sum of money due and payable to the contractor (including the security deposit returnable to him)
under this contract may be appropriated by the Nigam and set off against any claim of
Nigam/Government in respect of a payment of a sum of money arising out of or under any other contract
made by the contractor with the Nigam/Government.

RATES INCLUSIVE OF SALES TAX, ETC.
Clause 37:
(a)
The rates to be quoted by the contractor must be inclusive of sales tax, all other levies and taxes
whatsoever in nature. No extra payment on this account will be made to the contractor.
The contractor shall bear the service tax as per the reverse charge mechanism as per
Government of India Notification No 30/2012 Service dated 20-6-2012 and any modifications/charges
notified by Government of India from time to time as on date of payment.
CONTRACTOR TO PAY QUARRY FEES, ROYALTY, ETC.,
(b)
All quarry fees, royalties, octroi dues levied by the State Government or any local body or
authority and ground rent, if any, charged by the Executive Engineer for stacking materials,
should be paid by the contractor.
CONTRACTOR TO OBTAIN LABOUR ETC., FROM NEAREST EMPLOYMENT EXCHANGE

Clause 38:
The contractor should as far as possible obtain his requirement of labour, skilled and unskilled from the
nearest Employment Exchange. The contractor should give preference to the employment of released
bonded labour on the work entrusted to him.
DUES TO BE RECOVERED AS IF THEY WERE ARREARS OF LAND REVENUE
Clause 39:
All money due from the contractor under this contract may be recovered by KBJNL/NIGAM without
prejudice to the other remedies, as if they were arrears of Land Revenue.
CONTRACTOR TO COMPLY WITH THE PROVISIONS OF APPRENTICE ACT
Clause 40:
The contractor shall comply with the provisions of the Apprentice Act 1961 and Rules and Orders issued
there under from time to time. If he fails to do so, his failure will be a breach of contract and the
Superintending Engineer may at his discretion cancel the contract. The contractor shall also be liable for
any pecuniary liability arising on account of any violation by him of the provisions of the Act.
CONTRACTOR TO SUBSCRIBE TO WORKERS AND CONTRACTORS' BENEVOLENT FUND
Clause 41:
The contractor shall subscribe to the Workers' and Contractor's benevolent fund at the rate of 0.10% of
the gross amount of each bill payable to him in respect of the contract. The amount of subscription
should be recovered out of the amount payable to him in each bill. Lump sum on estimate payment to
contractor
Clause 42: Deleted.
CONTRACTOR NOT TO QUOTE PRICE EXCEEDING CONTROLLED PRICE FIXED BY

GOVERNMENT
Clause 43:
The price quoted by the contractors shall not in any case exceed the controlled price if any, fixed by
Government or reasonable price which it is permissible for him to charge a private purchaser for the
same class and description of goods under the provisions of Hoarding or Profiteering Prevention Act
1943 as amended from time to time.
COMPLIANCE WITH THE PROVISION OF HOARDING AND PROFITEERING PREVENTION ACT
If the price quoted exceeds controlled price or price permissible price under Hoarding and Profiteering
Prevention Act, the contractor will specifically mention this fact in his tender along with the reasons for
quoting such higher price. The purchaser at his discretion will in such case exercise the right of revising
the price at any stage so as to conform to the controlled price or the price permissible under the Hoarding
and Profiteering Prevention Act. This discretion will be exercised without prejudice to any other action that
may be taken against the contractor.
CHANGE IN COSTS PRICE ADJUSTMENTS
Clause 44: PRICE ADJUSTMENT CLAUSE FOR WORKS CONTRACTS
Price Adjustment:
Contract price shall be adjusted for increase or decrease in rates and prices of labour, materials,
fuels and lubricants in accordance with the principles and procedures and as per G.O.No.FD 3 PCL 2008
dated: 21-11-2008.
Price Adjustment Formula:

Adjustment for labour component:
i)
Price adjustment for increase or decrease in the cost due to labour shall be paid in accordance with
the following formula:

VL = 0.85 x PL / 100 x R x (Li-Lo)/Lo where,
VL= Increase or decrease in cost of work during the quarter under consideration due to changes in rates
for local labour:
Lo = The average consumer price index 2 for industrial workers for Hubli Centre for the quarter preceding
the date of opening of tenders as published by the Labour Bureau, Ministry of Labour, Government of
India;
Li = The average consumer price index for industrial workers for Hubli centre for the quarter under
consideration as published by Labour Bureau, Ministry of Labour, Government of India;
PL = Percentage of labour component of the work
Adjustment for Cement Component:

(ii)
Price adjustment for increase or decrease or decrease in the cost of cement component procured
by the contractor shall be paid in accordance with the following formula.

Vc = 0.85 x Pc / 100 x R x (Ci-Co)/Co where,
Vc= Increase or decrease in cost of work during the quarter Under consideration due to changes in
rates for cement;
Co= The all India average wholesale price index
for cement Ordinary Portland cement) for the
quarter preceding the date of opening of the tenders as published by the office of Economic Advisor,
Ministry of Commerce and Industry, Government of India, New Delhi;
Ci = The all India average wholesale price index for cement (Ordinary Portland cement) for the
quarter under consideration as published by the Office of Economic Advisor, Minis try of Commerce and
Industry, Government of India, New Delhi;
Pc = Percentage of cement component of the work.
Note: For the application of this clause, index of Ordinary Portland Cement has been chosen to
represent Cement group.
Adjustment for steel component:

iii)
Price adjustment for increase or decrease in the cost of steel procured by the contractor shall be
paid in accordance with the following formula.

Vs = 0.85 x Ps/100 x R x (Si-So)/So Where,
Vs = Increase or decrease in cost of work during the quarter under consideration due to changes in rates
for steel;
So = The all India average wholesale price index for steel (M.S.Bars and rods) for the quarter preceding
the date of opening of Bids as published by the Office of Economic Advisor, Ministry of Commerce and
Industry, Government of India, New Delhi;
Si = The all India average wholesale price index for steel (M.S.,Bars and rods) for the quarter under
consideration as
published by the Office of Economic Advisor, Ministry of Commerce and Industry, Government of India,
New Delhi;
Ps = Percentage of bitumen component of the work.
Note: For the application of this clause, index of M S rods, bars and steel plates for fabrication of
M S rising mains have to be chosen to represent relevant and appropriate Steel groups.
Adjustment of Fuel and Lubricant component:

(V)
Price adjustment for increase or decrease in the cost of Fuel and Lubricants shall be paid in
accordance with the following formula.

VF = 0.85 x PF / 100 x R x (Fi-Fo)/Fo Where,
VF = Increase or decrease in cost of work during the quarter under consideration due to changes in rates
for Fuel and Lubricants;
Fo= The official retail price of High Speed Diesel (HSD) at the IOC /HPCL/BPL or other consumer pump
at Bijapur on the day 30 days prior to the date of opening of Bids;
Fi = The official retail price of HSD at the IOC/HPCL/BPL or other consumer pump at Bijapur for the 15 th
day of the middle calendar month of the quarter under Consideration;
PF = Percentage of Fuel and Lubricant component of the work.
Note: For the application of this clause, the price of HSD has been chosen to represent Fuel and
Lubricant Group.
Adjustment for Plant and Machinery Spares component:

(Vi) Price adjustment for increase or decrease in the cost of plant and Machine ry Spares Procured by the
contractor shall be paid in accordance with the following formula.
Vp = 0.85 x Pp/100 x R x (Pi-Po) / PoWhere,
Vp = Increase or decrease in cost of work during the quarter under
consideration due changes in
rates for plants and machinery spares;

Po= The all India average wholesale price index for Heavy Machinery and Parts for the quarter preceding
the date of opening of bids, as published by the Office of the Economic Advisor, Ministry of Commerce
and Industry, Government of
India, New Delhi;
Pi = The all India average wholesale price index for Heavy Machinery and Parts for the quarter under
consideration as published by the office of the Economic
Adviso r, Ministry of
Commerce and Industry, Government of India, New Delhi;

Pp = Percentage of plant and Machinery Spares component of the work (PF )
Note : For the application of this clause index of Heavy Machinery and parts 10 has been chosen to
represent the plant and Machinery Spares Group.
Adjustment for Other materials:

(Vii) Price adjustment for increase or decrease in the cost of other materials other than cement, steel,
bitumen and Fuel and Lubricants
11,
procured by the contractor shall be paid I accordance with the
following formula.
VM = 0.85 x PM / 100 x R x (Mi-Mo) / Mo Where,
VM = Increase or decrease in cost of work during the quarter under consideration due to changes in rates
for local materials other than cement, steel, bitumen and Fuel & Lubricants;
Mo = The all India average wholesale aprice index for all commodities for the quarter preceding the date
of opening of bids, as published by the Office of the Economic Advisor, Ministry of Commerce and
Industry,
Government
of
India,
New Delhi;
Mi = The all India average wholesale price index for all commodities for the quarter under consideration
as published by the office of the Economic Advisor, Ministry of Commerce and Industry, Government of
India, New Delhi;
PM = Percentage of other material component (Other than cement, steel, bitumen and Fuel and
Lubricants) of the work.
The following percentage will govern the price adjustment for the entire contract
1. Labour-PL
- 20%
2. Cement-Pc
- 10%
3. Steel-
Ps
4. Fuel & Lubricants-Pf
40%
5%
5. Plant & machinery spare-Pp
6. Other materials Pm
- 5%
Total
20%
- 100%
SECTION - 5
SCHEDULE A
AND
SCHEDULE C
DELETED
SCHEDULE B
ENCLOSED SEPARATELY
SCHEDULE D
TO BE FILLED UP BY THE CONTRACTOR
List of Plant and Machineries in working condition available with the person tendering.
Sl.
No.
Brief of description such

Type of Machinery
Nos Available
make, capacity condition of

plant and machinery
1.
Lorries / Tippers
2.
Tractor
3.
Water Tankers
4.
Concrete Mixers
5.
Vibrator (Pin)
6.
Vibrator (Plate/Sheet)
7.
Any other Plant and Machineries with

details
SCHEDULE E
LIST OF MATERIALS ON HAND WITH THE CONTRACTOR
Sl.
Details
No.
1.
Centering Materials
47.1.1.1
Steel
47.1.1.2
Wooden
2.
Shuttering for form work

a) Steel
b) Wooden
3.
Other Materials such as wood etc.,
Quantity
Brief
Available
Description
SCHEDULE F
LIST OF WORKS COMPLETED BY THE TENDERER
Sl.
No.
Description of Work
Contractor
Period taken for
Cost
Completion
Quantity
5
SCHEDULE G
LIST OF WORKS UNDER EXECUTION BY THE TENDERER
Sl.
Description of
Contractor
Due Date of
Present
No.
Work
Cost
Completion
Stage
Remarks
6
COMMERCE INDUSTRIES SECRETARIAT NOTIFICATION NO CI-56 MMN 2006 BANGALORE

DATED 23 JUNE 2007
SCHEDULE-2
(See sub rule (1) of Rule 36)
ROYALTY
Rate per unit
Sl.
Name of the Minor Mineral
No.
1.
Area of Applicability
Volume of
Quantity Rs.
Ornamental and Decorative building

stones: as defined clause (m) of rule 2
A
Dyke Rocks - 1
.
i)
Black Granites
a) Mysore Dist.
Rs. 3000/M3
b) All other districts other than Rs. 2500/M3

(a) above.
c) Above.
ii)
Other varieties of dykes than
Entire state
Rs. 1500/M3
black granites
B
i)
Pink & Red Granites 2
i) hungund & Badami Taluk of Rs. 2500/M3
II.KALPINK VARITY
Bijapur Dist. Rushtagi of Koppal

Dist.
ii)
Pink & red granites gneisses
ii) Entire State
Rs.1500/M3
and their textural & structural

varieties (other than ILKAL
pink)
C Grey & White Granites & their
.
varieties 3
i)
Very
fine
grained
grey
granites (SIRA GREY) variety
i) Chintamani, Siddlaghatta of Rs.2000/M3

Chikkabalapur District, Hoskote
of Bangalore District
ii)
Grey & White Granites & their

textural
varieties
having
shades of Grey black & white
Entire State
Rs.1400/M3
Sl.
No.
Rate per unit

Volume of
Quantity Rs.
colors (other than (i) above

3
iii)
Grey Granite of Sadarahally,

koira of Bangalore Rural
Rs.800/M3
District
2.
Felsites & varieties suitable for use as
Entire State
Rs.1800/M3
Entire State
Rs.1800/M3
Entire State
Rs.1800/M3
ornamental stone
3.
Quartizites & sand stones & other

varieties suitable for use of ornamental
stone.
4.
Marble or Crystalline lime stone as

ornamental stone
5.
Bentonite
Entire State
Rs.400/tonne
6.
Fullers Earth
Entire State
Rs.125/tonne
6A
Buff Color ( Waste)
Rs.60/tonne
The permits should not exceed 20 % of

permit issued for Fullers Earth
7.
Lime stone under the title Shahadad
Entire State
Rs.150 /10 m2
Entire State
Rs.40/tonne
Stone
8.
Lime stone (non-cement) when used for

building constrution
9.
Ordinary Building Stone (4)
Entire State
Rs.60 tonne
10.
Lime shell
Entire State
Rs.100/tonne
11.
Lime Kankar (non cement)
Entire State
Rs.50/tonne
12.
Agate / chalcedone flint
Entire State
Rs.240/tonne
13.
Ordinary Sand
Entire State
Rs.60/tonne
14.
Stetite and sand stone used for making Entire State
Rs.40/tonne
household utensils / articles
Rate per unit
Sl.
No.
Volume of
Quantity Rs.
15.a)
b)
Murrum ( All type of soils )
Entire State
Clay used for manufacturing tiles and
Rs.20 tonne
Rs.40 tonne
bricks
16.
All other minor minerals
Entire State
30% of sale
value pit head
17.
Waste rocks generated in ornamental Entire State
Rs.
200/
stone quarry 5
tonne or Rs.
600/M3
18.
Irregular shape waste rock generated in Entire State
Rs. 30/MT
stone quarry, which is not suitable for

ornamental purposes.
19.
Waste rock generated in Shahabad Entire State
Rs. 30/tonne
stone quarries 6
20.
Finished kerb stone
Entire State
Rs. 80/tonne
By order and in the name of the Government of Karnataka,

H. V. RAMACHANDRARAO
Desk Officer ( Mines)
Commercial and Industries Department
Note:
The royalty charges will be recovered as per the Government orders issued from time to time.
NOTE:
1)
The royalty charges will be recovered as per the govt. Orders issued from time to time.
2)
The following conversion factors shall be adopted under KBJNL for calculation of royalty Charges.
No.
Type of materials
Weight per cum of material
Stones
Basalt/Trap
2.90 tonnes/cum
Gneiss
2.45 tonnes/cum
Lime Stones
2.60 tonnes/cum
Granite
2.60 tonnes/cum
Laterite
2.25 tonnes/cum
Quartzite
2.64 tonnes/cum
Sand Stone
2.30 tonnes/cum
Shale
2.80 tonnes/cum
Ordinary Sand
1.84 tonnes/cum
Murrum, All Kinds Of Soil
1.80 tonnes/cum
ANNEXURE -D
PROCEEDINGS OF THE GOVERNMENT OF KARNATAKA
Sub: Deduction of Shrinkage of settlement in earthwork embankment.
Ref: Correspondence ending with the letter No. BRP/EBR/TE-77/TA-4 dated 11th
November
1965 from the Chief Engineer, Irrigation Project, Bangalore.

PREMABLE :4
The Chief Engineer, Irrigation Project has reported that there was no uniform practice of standard vouge for
deduction for deduction for settlement in earth work embankment and that it was discussed in the meeting of Chief
Engineers held in 1961 who have made certain recommendations. The recommendations on receipt in government
were examined and Government asked Chief Engineer, Irrigation project to obtain report in the matter. Then the
matter, has been referred to the Director, Karnataka Engineering Research Station, K.R. Sagar for conducting
experiments on various types of the embankments and under various condition in order to take decision on the
uniform procedure to be adopted in making deductions for shrinkage settlement in earthwork embankments. The
Director Karnataka Engineering Research Station has made the following recommendations
Settlement in percent of height of bank

Sl.
Type of Embankment
Monsson
Before
After
1.
AfterNo.
Monsoonsecond Third
Mansoon
After
Dry unrolled embankment in clay
25
Mansoon
4
12.50
6.5
Nil
10.00
5.00
Nil
soil including black cotton soils.

2.
Dry unrolled embankment in all 20

soils other than clayey soil
3.
Compacted embankments without

field control of placement
a)
Manual labour or rollers 15
7.50
3.75
Nil less than
5.00
2.50
Nilthan
2.50
Nil
six tonnes.
b)
By power rollers of more 10
six
tonnes.
4.
compacted embankment with
Nil
field
control placement
The Matter was further referred to the Board of Chief Engineer for consideration and opinion. The board
holds that the recommendations of Director are based on generalization and are indication of general
trends in different types of soils. However, soil differs from place to place and it is desirable that actual
tests are carried out and averages applied in individual cases. Where it is not possible to carry out the
individual experiments the general values may be adopted.
ORDER NO. PWD / II / GMS / 64, BANGALORE DATED 10TH MARCH 1966
After considering all aspects of the case and also the opinion furnished by the Board of Chief
Engineers, Government hereby directs that in respect of all important bank works actual tests are
carried out and average applied and where it is not possible to carry out individual experiment the values
given by the Director, K.E.R.S. as noted in the preamble may be adopted.
By Order and in the Name of the Government of Karnataka
(M.CHANNAPPA)
Deputy Secretary to Government P.W.D.
SECTION 6
CONTRACT DATA
CONTRACT DATA
1.0
Site information and Location
1.1
Scope of work
1.2
Schematic diagram of the scheme.
Mile Stone
Programme of Works
Site Possession works
Defect liability period
Insurance
Programme of updating
Penalty for Late submission of program
Language of contract
10
Law applicable
11
Currency
12
Retention of Money
13
Liquidated Damages
14
Submission of as built drawings
15
Mobilization advance
16
Terms of payment
17
Guarantee/Warranty
18
Operation and Maintenance
19
Replacement defective parts and Materials
20
Bid evaluation factors
21
Penalty for shortfall in performance pumps
22
Performance within maintenance period
23
Capitalization of losses, Power Transformer
24
Penalty for non fulfillment of guaranteed losses
SITE INFORMATION
1.
1.
2.
Temperature
a)
Maximum Temperature during May
45 0C
b)
Minimum Temperature during January
25 0C
c)
Mean Temperature
35 0C
510.00 mm
Bijapur 35 km
Rainfall
Average maximum rainfall in mm at Bijapur
3.
Communication
a) Nearest Railway Station
b) Nearest National highway
22 km from National Highway

No (NH) 13
c) Nearest Airport
Belgaum(Sambra)Airport
215
Km
d) Nearest Telephone Exchange
Bijapur Dist Bijapur
e) Nearest Post Office
Bijapur Dist Bijapur
4.
Latitude @ Head works
160-40-04(North)
5.
Longitude @ Head works
750-58-11(East)
6.
G.T.S bench Mark
i) G.T.S. BM @ Near field bund

70 m SE transformer, near
Masibinal Village, Bijapur district
Ultimate FRL of Almatti Reservoir
RL 524.256 m
MDDL of Almatti Reservoir
RL 506.000 m
9.
Bed level of Krishna river at Head works
RL 585.359 m
SCOPE OF WORK:
The Upper Krishna Project is a major irrigation project in Karnataka taken up in stages. This Project
constitutes of two Dams across Krishna River (1) Almatti dam near Almatti village, Basavana Bagewadi
taluka, Bijapur district and (2) Narayanapur dam near Siddapur village, Muddebihal taluka, Bijapur district
to irrigate land in drought prone North Karnataka districts. The Stage -I and Stage -II works are completed
for utilization of 173 TMC of water, under UKP Stage - III, it is proposed to irrigate 227966 Ha of drought
prone areas of Bijapur, Muddebihal, Sindagi, Basavana Bagewadi and Indi taluks of Bijapur district
including Jamkhandi and Bilagi taluks of Bagalkot district. Krishna Bhagya Jala Nigam limited is
implementing several lift irrigation schemes on the Krishna basin to lift water from Almatti and
Narayanapur reservoirs to irrigate lands in Gulbarga, Bijapur, Bagalkot and Raichur districts.
4th 'B' Lift under Mulawad LIS,UKP stage-III:
The 4th B Lift under Mulwad LIS, UKP Stage III envisages lifting of water from Ch: 18.95 Km
of Basavan Bagewadi Branch Canal upto RL 640.00 M, where a Delivery Chamber will be constructed
from which Salvadagi Mian Canal take off at RL 640.00m and Takkalaki, Sankanal and Dindwar Branch
Canals are takes off from Salavadagi Main Canal to irrigate lands between RL 640m and RL 590.00m.
The scope of work of 4th 'B' Lift under Mulawad LIS,UKP stage-III comprises of the following main
components.
1) Intake Canal and Fore bay
2) Jack Well Cum Pump House
3) Pumping Machineries
4) Electrical Works
5) MS Rising Main and
6) Delivery Chamber etc.
7) Construction of Terminal Bay and Erection of 220 KV SC line on DC Towers.
8) Construction of 220 KV Electrical Sub - station
The salient features of the Scheme are as under:

Peak Discharge required for 4th 'B 'Lift Scheme
= 18.067 Cumecs (For Present Requirement)
Length of Intake Canal
= 0. 70 Km ( Approximately)
i) Canal bed level at off take
= RL 585.359 m
ii) Maximum water level in sump while drawing

peak discharge of 18.067 Cumecs
= RL 589.124 m
iii) Minimum Water Level at sump
= RL 585.860 m
iv) Length of MS Rising Main
= 1.14 Km ( Approximately)
v) Delivery Level
= RL 642.600m
vi) Static Head
= 56.74 m
vii) Number of Pumps
= 8 (7 working for peak discharge of 18.067 Cumecs,

2.667 Cumecs each + 1 Standby of equal capacity of
2.667 Cumecs each )
INTAKE CANAL:
Intake canal takes at Ch. 18.950 Km of Basavana Bagewadi Canal. Required discharge for 4th 'B' Lift
Scheme is 18.067 Cumecs. Hence the Intake Canal is to be designed for 10% extra of the required
discharge for length of 700.0 m (approximately) including forebay. The canal shall be lined up to FSD+FB
level with suitable grade of concrete with appropriate thickness as per relevant IS using mechanical
pavers. 1 number of Road Bridge are to be constructed where the Intake canal crosses cart track.
Necessary service road and inspection path are to be pro vided. Along the service road of Intake canal,
asphalt road as per MORTH Standards is to be designed from off take point up to Jack Well cum Pump
House and got approved by the Chief Engineer and shall be executed accordingly.
JACK WELLCUM PUMP HOUSE:
The Jack Well Cum Pump House shall be suitable size to accommodate 8 number of pumps
( 7 nos working to be designed for peak discharge of 18.067 Cumecs 2.667 Cumecs each and 1 no
standby of equal capacity each of 2.667 Cumecs ) with pump floor, motor floor , Panel room and control
room with necessary Fore bay to receive water from the Intake Canal. Trash Racks are to be provided for
each compartment of the Jack Well. Behind the Trash Racks, grooves for inserting stop log gates with
embedded parts shall be provided. There shall be monorail arrangement covering all the bays of Jack
Well suitable for electrical as well as manual operation of Trash Racks and stop log gates. The motor
floor level should match with the ground level and the valve floor level shall be above FSL+FB Board at
the location.
The Pump House Shall be of size to accommodate the electrical control panel, EOT crane of
required capacity mounted on monorail and also to accommodate other necessary equipments and
accessories. The loads due to pumps and motors also shall be considered as per relevant IS while
designing the Jack well cum Pump house. The Pump house shall be sufficiently ventilated by providing
suitable numbers and size of aluminum windows and ventilators. The Pump house opening on approach
road side shall be sufficient for allowing movement of vehicles with pump accessories and the opening
shall be provided with rolling shutters operated with motors. Proper illumination both inside and outside
the Pump house shall be provided. Flooring shall be of superior quality mosaic tiles and roofing shall be
with Galvalume sheets mounted on trusses. All the pump house items shall be executed as per relevant
IS specifications of latest version. Grade of concrete for all the structural concrete works shall be not less
than M-25.
Watchman and O & M Staff Quarters shall be constructed near the Jack well. Entire area
accommodating the Jack well cum Pump house, Electrical Sub -Station, Manifold, portion of Rising main
Staff Quarters etc., shall be provided with protective chain link fencing with gates at suitable locations,
necessary anti-reptile fixtures/ arrangements shall be provided along the fencing. The area around the
Jack well and Electrical Sub-Station shall be provided with suitable asphalt roads. The design, drawing,
layout drawing shall be got approved from the Chief Engineer.
PUMPING MACHINERY:
8 Numbers of Vertical Turbine Pumps (7 Numbers working for peak discharge of 18.067 Cumecs
each of 2.667 Cumecs and 1 Number standby of equal capacity of 2.667Cumecs) coupled to HT Motors
shall be provided. The 7 numbers of working pumps shall meet the current peak discharge requirement of
18.067 Cumecs and 1standby pump of equal capacity of 2.667 Cumecs shall be provided. Necessary
electrically actuated Butterfly valve, Dual plate check valve, Kinetic Air Valves, Pressure gauges,
dismantling joints MS manifold, EOT Crane of suitable capacity with main/auxiliary hoists shall be
designed to meet peak discharge requirement, got approved and provided. There is no scope for altering
the number of pumps specified. The Design, supply, installation, testing and commissioning of HT panel,
soft starters, HT Capacitors & LT Capacitors with APFC Panel ( power factor shall be improved to 0.95
lag ), HT Cabling, Remote control panel, temperature scanner auxiliary supply AC with LTAC panel,
auxiliary transformers, LT cabling, DC supply with battery charger ( one spare battery charger shall be
provided) cum DCDB, battery bank, Control cabling, Valve actuator panel, APFC panel for improvement
of power factor, level indicator, small power outlets, circulating cooling water pumps, sump, Header piping
valves, filters for cooling of HT motors/pumps are also included in the Scope of work.
The scope includes conducting trial runs, commissioning and continuously operating the system for
90 days and performance guarantee tests as stipulated in the Bid document.
Necessary Sump model study shall be conducted before finalizing the design criteria of various
components of the Scheme. MS manifold of suitable size shall be designed, got approved from
competent authority and shall be provided accordingly. The entire pumping network components shall be
provided with SCADA system.
RISING MAIN :
From the manifold, MS Rising main of suitable size, thickness and numbers shall be designed for
approximate length of 1.14 KM to carry the total discharge of 7 nos of pumps of each
2.667 Cumecs capacity which is equal to 18.669 Cumecs got approved, and provided up to Delivery
chamber. MS rising main shall be factory made spirally welded with specified thickness of inner lining of
15 mm and outer guniting of 25 mm as per IS Code 1916, 3589 and 5812 shall be got approved from the
Chief Engineer and delivered to the site.
Necessary Civil works such as excavation, construction of concrete pedestals below rising main
pipes and providing necessary kinetic air valves, scour valves, NRVs valve chambers, thrust blocks, MS
bends, MS specials as per ground profile providing necessary surge protection eq uipments and
construction of structures along rising wherever required, back filling the rising main trench after testing
and formation of service road along the rising main up to Delivery chamber are included in the scope of
work.
The velocity in the rising main pipe shall be limited to 1.75 m/s. The D/t ratio shall be 165. Wall
thickness of MS rising main pipe shall be without any negative tolerance . The exit end of Raising main
pipe shall be kept 0.15 m above FSL of Delivery chamber i.e., at EL 642.750 m. Delivery chamber is to
be designed for peak discharge of 21.336 Cumecs with 90 seconds retention period and 0.75 m as free
board. Rising main pipes should enter the delivery chamber from the bottom side and raised above the
FSL with funnel arrangement.
Sump Model Study is to be conducted before construction of the fore bay and Jack well cum
pump house.
The entire process right from design to commissioning shall be carried out as per relevant IS
Standards.
DELIVERY CHAMBER:
The Delivery chamber shall be a ground level reservoir of suitable size with 90 seconds retention
period considering the discharge requirement of 21.336 Cumecs when all the pumps are working and
shall be designed, got approved and constructed. The delivery end of rising main pipe s hall be so
provided in the chamber that, the pipe rises vertically from the bottom of the chamber. The top level of
pipe shall be at free board level of delivery chamber so that, the residual energy is dissipated. The
delivery end of pipe shall be provided with safety grill. Grade of concrete for delivery chamber shall not be
less than M-20. Necessary water cushion shall be provided in the delivery chamber. The gates of suitable
sizes with regulating arrangement with electrically operated hoisting arrangeme nts for designed hoist
capacity for off take of Salvadagi Branch Canal shall be provided. Necessary energy dissipating
arrangements on the downstream of openings shall be provided. Al-round walls of delivery chamber shall
be provided with protective railing at the top.
220 KV/6.6 KV ELECTRICAL SUB-STATION:

The scope includes construction of 220 KV/ 6.6 KV Electrical Sub station including design, supply,
erection, testing and commissioning of Power transformer of 27.0 MVA
capacity 2 numbers
(1 working + 1 standby of same capacity) with OLTC and RTCC panels to meet the load requirement of
pumping station, with Mulsifyre system as per electrical inspectorate norms shall be provided. The
capacity of the transformer is such that it can cater the requirement o f running the additional pump also in
future if necessary.
Power supply at 220 KV/6.6 KV shall be arranged up to receiving gantry of substations. The
substation equipment shall consist broadly of the following:
1.
LILO Arrangement shall be considered for incoming and outgoing 220 KV feeder.
2.
Line protection bay with lightening arrestors, CT bus bar, SF6 circuit breakers, HT isolations with
line protection panel housed in control room shall be envisaged.

3.
SITC 220 KV Isolators with earth switch and without earth switch.
4.
HT metering bays with CTs, PTs with 2 cores & electronic trivector meters of 0.2 S accuracy with
metering cubicle, marshaling bore, as required by KPTCL shall be installed.

5.
220 KV bus bar formation with rigid aluminum tube type bus bars mounted on towers with Bus PT,
PI Insulators etc., as per required hardware.
6.
Transformer protection bay with isolator, CT, PT SF6 circuit breakers for line protection and for
Transformer protection, GI mounting structures and marshalling box for each transformer shall be
provided.
7.
1 number Incomer for each Power Transformer, 8 numbers of Motor Feeders, 2 numbers of
Auxiliary Transformer feeders, 1 number Capacitor feeder for each transformer , 1 number BUS PT, 1
number BUS coupler and 3 numbers of spare feeders shall be provided. Entire electrical sub station from
sending end to receiving end stations shall be provided with SCADA System .
8.
2 nos of Power transformer 220/6.6 KV of 27.0 MVA each ( 1working and 1 standby of same
capacity ) , ONAN , of required rating with OLTC/RTCC panels with radiator banks, conservator oil tank,
buckholtz relay, surge relay with valves, piping, HV bushings and LV cable core outdoor type with neutral
CT, NGT and NGR etc., as required shall be installed. Overloading of transformers as per IS 6600 shall
not be applicable and the transformers capacity shall be arrived with minimum 10% spare capacity.
9.
Design shall include 220 KV bus duct system from transformers LV side up to HT panel to be
housed in control room from where further power shall be distributed to HT motors.
10.
SITC capacitor voltage transformers (CVTS), current transformers ( CTs), Electro -magnetic
voltage transformers(EMVTS), Lightening arrestors shall be provided as required.

11.
Scope also includes providing 8 numbers of Motor capacitors, 2 numbers Transformer capacitors
and 2 numbers of Auxiliary load capacitors with APFC panel of required rating to improve the power
factor to 0.95 Lag.
12.
Battery bank of 110 V, 300 Ah capacity with boost cum float battery charger
( 1 working + 1 stand by ) and DCDB with adequate numbers of DP meters shall be provided.
13.
C&R panels for line protection and transformer protection shall be provided.
14.
11 KV XLPE cables of required rows and required capacity with short circuit rating of 28 KA shall
designed considering all de rating factors and installed and connected to 11 KV HT panels.
15.
The earth grid shall be designed based on KPTCL approved designs and number of earth
stations with 110 mm CI pipe electrode shall be installed and connected to equipments.
16.
Supply, erection, tests and commissioning of 2 numbers of Auxiliary transformers
( 1 working + 1 stand by ) of minimum 750 KVA, 6,6/433 V rating shall be in the scope of bidder.
17.
Switching yard lighting includes number of pole mounted. Bulk head HPSV light fitting 1 x 250 W
to the entire area with provision of gate lights, control room, internal/lighting including D board, LT
cabling, earthing etc complete.
18.
Civil work of substation consist of following:
a.
Construction of control room as per KPTCL standards shall be suitable for housing HT panels, C&R
panels, RTCC panels, LTAC panel, 110 volts battery bank 300 AH cap with float cum boost charger (
one spare battery charger ) with DCDB with minimum 15 Nos DP MCB of 20 Amps each. Rooms shall
have sufficient space for supervisory staff, room for storing spare parts, tools and provision for toilets.
b.
Construction of equipment foundations, cable ducts, chain link fencing with gates, concrete
approach road and internal roads up to transformer foundation, c onnecting road to control room, cable
duct with precast covers from control room to various equipments, fire wall between two transformers for
fire safety.
c.
Laying and water supply line with independent bore well with p umps up to all Earthings for watering
and also for toilets.

d.
Spreading of gravel in the switch yard area.
e.
Construction of oil soak pits of sufficient capacity with connecting pipeline.
f.
Construction of Separation wall between Two Power Transformer.
g.
Supply of recommended spares for above equipments.
19.
The Contractor shall be responsible for submission of designs, drawings to Chief Engineer (P&C)
KPTCL Bangalore including getting approval and arrange to submit all drawings to CEIG and obtain their
approval, get the testing of meters, relays etc. fro m MRT cell, KPTCL/HESCOM and shall be responsible
for liaising works with KPTCL till power supply is energized and substation is commissioned and R R
Number is issued from HESCOM Starting from taking power approval from KPTCL.
20.
Contractor shall be responsible for operation and maintenance of
substation for a period of 5
years from the date of commissioning.

21.
Scope includes fire protection system(as per requirement of CEIG) with number of CO2 fire
Extinguisher of sufficient capacity, foam type fire extinguisher near transformers, sand buckets, insulator
earth mat, insulated hand gloves, Hickery rod, safety instrument, Danger boards, artificial respiration
charts, fire safety instruction boards etc. shall be provided.
22.
General: the scope described as above generally covers items required to complete works in all
respects however, any item not specifically mentioned above but found required for the completion are
deemed to be included in the scope of the bidder.
CONSTRUCTION ,TESTING AND COMMISSIONING
CONSTRUCTION OF 220 KV SC TRANSMISSION
OF 220KV TERMINAL BAY AND
LINE WITH DRAKE CONDUCTOR ON DC
TOWERS
The scope of work involves the construction testing and commissioning of 220 KV Terminal Bay at
KPTCL substation ( as per the approval from KPTCL ) and construction of 220 KV SC Transmission line
on DC Towers from Terminal bay up to Receiving Gantry of 220 KV LILO line and substation to be
constructed at Jack well site of 4th 'B' Lift under Mulwad LIS UKP Stage - III. The transmission towers are
to be fabricated as per the fabrication drawings of KPTCL and designs to be got approved from KPTCL
by the successful tenderer .The tenderer should note that if any alternate type of tower & section
indicated in the drawings due to the non availability / requirement of any specific size, the same size shall
be on the account of the contractor . All the material required for the construction of the Transmission
Line specially mentioned in these specifications or not shall have to be supplied and erected without any
extra cost by the successful bidder as per the specification contained herein.
i. Construction of 220 KV Terminal bay at 220 KV KPTCL sub-station consisting of following works
at location earmarked layout and approved by KPTCL.
The scope of work includes the following:
i)
Supply, erection, testing and commissioning of SF-6 circuit breaker of approved make 220 KV,
1250 A , 31.5/40 KA, a set of 3 single pole units outdoor mounting with operating mechanism and
mounting arrangements with local/remote control operation .
ii)
Supply, erection, testing and commissioning 2 sets of HT isolators 220 KV ,1250 A,31.5 KA,
double break, suitable for electrical cum manual operation ,outdoor type a set of 3 single pole units one
with earth switch and other without earth switch.
iii)
Supply, erection, testing and commissioning of current transformers 220 KV class 31.5 KA ,CT ratio
400-200/1-1-1A for metering ,backup protection and distance protection (for line protection).
iv)
Supply, erection, testing and commissioning of lightening arrestors metal oxide, gapless type ,
196 KV ,10 KA class-II type a set of 3 Nos.

v)
Supply, erection, testing and commissioning of control and relay panel 220 KV simplex type for line
protection.
vi)
Supply, erection, testing and commissioning
of starter structure mounting structures including
civil works bus bar formation including insulator hardware connection earth connection.
vii)
Supply, installation testing and commissioning control cable of insulated copper control cables
including construction cable duct required.

viii) Supply, installation testing and commissioning ground mat with earth stations and connecting to
all equipments and structure as per requirement .
ix)
Any other works which are not specifically mentioned above but required for completion terminal
bay as per KPTCL Norms.

Construction of 220 KV SC Transmission line on DC Towers.
The scope of work includes the following:
1.
Detailed Survey / check survey of the route of Transmission line obtaining PTCC approval and
other approvals from Electrical Inspectorate, KPTCL as necessary including payment of charges.
2.
Preparation of Profile sheets and tower spotting.
3.
Fabrication of transmission tower structures as per specifications.
4.
Supply, stringing of ACSR DRAKE conductor as per Specification.
5.
Supply of insulating strings including strain strings ,suspension strings and the associated
hardware as per the specifications.

6.
Supply of Conductor accessories
such as Mid span Compression joints, Repair sleeves,
Preformed Armour Rods, Vibration dampers etc, as per Specifications.

7.
Supply of 7/3.15 mm 1100 N Sq.mm quality Ground wire as per the Specifications.
8.
Supply of the Ground wire accessories such as suspension Clamps Tension Clamps , Mid - Span
Compression Joints and Flexible compression bonds etc., as per the Specifications.
9.
Excavation in all types of strata, Stub setting and Concreting Back filling and consolidation of Tower
Foundation including Soil Testing and Foundation Protection works wherever required.
10.
Erection of Tower Superstructure and all the associate accessories such as Danger Board Plates ,
Phase plates , number plates, Ant climbing devices etc.,

11. Measurement of Soil resistively and Grounding towers including Counter poise earthing , wherever
high soil resistively encountered.
12.
Stringing of Ground wires as per the Sag Tension Chart including its connections to the Tower
frame work using Flexible Copper Bonds including Tower earthing and counter poise earthing wherever
high soil resistivity is encountered.
13.
Stringing of Power Conductors as per the Sag Tension charts including hoisting of Insulators,
Clipping in and providing the necessary jumpers at the strain points and hooking on the Station Gantries.
14. Scope includes termination of single circuit at both ends.
15. Conducting pre commissioning tests and obtaining the approval of the Chief Electrical Inspectorate
to the Government of Karnataka and approval from KPTCL.
16. Maintenance of transmission lines and Terminal Bay equipment including replacement of defective
components during guarantee period of 12 months from the date of issue of completion certificate from
KPTCL .
Before submitting the offer, the tenderer shall inspect the proposed route of the line and make
himself conversant with the field conditions.
The bidder shall be responsible to obtain power approvals/sanctions and for all the necessary way leaves
and clearance required from various authorities such as Railway, Highways, Telecommunication
Authorities (PTCC approvals) / KPTCL etc, at his cost. KBJNL will give the required assistance in the
form of letters to be addressed to the concerned authorities wherever required. If any compensation is to
be provided to any party or individual of land and for the loss sustained by them by way of tree cutting,
damages to the crops or other materials, the same shall be paid by the Contractor at his cost. The quoted
cost shall include such costs. . The bidder shall take approval/sanction from CEIG/KPTCL/HESCOM
/PTCC and obtain the RR Number to the installation for charging & commissioning of 220 KV line and
sub station.
Consent from land owners shall be obtained before starting of the work. Making payment towards
Crop compensation, tree cut compensation etc., if any are in the scope of the bidder.
The Contractors proposals shall be based upon the use of all the materials complying fully with the
requirements as per the relevant standards. Such materials shall meet the performance requirements
specified and be acceptable to KPTCL ,KBJNL reserves the right to accept or reject such proposals
without assigning any reasons thereon.
The transmission line shall be complete in every respect with all mountings, fittings, fixtures and
standard accessories normally provided for such Transmission line and/ or needed for erecting,
completion and safe operation of the same as required inapplicable codes and as per the specifications
mentioned in the requirement of KPTCL
220 KV SC line on DC towers and 220 KV Terminal Bay approval has to be taken from KPTCL
before execution.
SCADA SYATEM
The SCADA System should be synchronized with the intake canal up to delivery chamber of 4 th B
Lift scheme and should have the devices to control discharge of canals off taking from the delivery
chamber.
The equipment manufacturing and software development centers quality manag ement system
should confirm to ISO 9001 standards, certificate should be enclosed.
The consortium partner shall have wide network of multi skilled industry experienced engineers to
undertake comprehensive installation, maintenance and commissioning services for water and gas data
logging applications amongst other services such as maintenance and optimization, meter verification,
field tests for hydraulic modeling, network design and investigation.
Engineers shall be available at locations close to the re gion. The consortium partner shall have well
developed processes and job management systems to support efficient operation of large scale turn key
projects and on going maintenance.
Supply of Spares and Tools:

The scope includes supply of recommended spares and set of tools as specified in the Bid
document.
Operation and Maintenance:
The scope also includes operation and maintenance of the scheme for a period of 5 years after
successful commissioning and establishing the design parameter as per relevant IS standard.
In the scope of work, attempt has been made to cover all the items of work and accessories.
However, in case mention of any component or accessory is left out, which may be necessary to
complete the work in full manner and commission the job Successful, the same shall be deemed
to have been included in the scope of work.
LIST OF TECHNICAL MANPOWER REQUIRED FOR OPERATION AND

MAINTENANCE OF TRANSFORMER CENTER, PUMP HOUSE AND
EQUIPMENTS FOR 5 YEARS PERIOD.
Sl.
Category
Qualification & Experience
No. of persons to
No.
1
be deployed
Project Manager
B.E. (Civil) with min. of 15 years experience
and should have been Project Manager for

at least one Project/Work of size similar to
the present contract. Period - Entire contract
period
2
Mechanical Engineer
B.E.(Mech)
with
Minimum
years
experience in O & M of pumps and
mechanical equipments
3
Foreman (Electrical)
Diploma in Electrical with Minimum 2 years
experience
4
Forman (Mechanical)
Diploma in Mechanical with Minimum 2 year
experience
5
Electrician
ITI certificate course in Electrical Engineer

with Minimum 2 years of experience in O &
M of substation equipments.
6
Fitter (Mechanical)
ITI
Certificate
course
in
Mechanical
Engineering with Minimum 2 years of

Experience in pumps valves etc.
Having sufficient experience to assist
Helper (E & M) General
electricians and fitters in O & M of substation
12
and pump house

7
Security Staff
Necessary watch & ward of substation pump
10
house. To work in shifts including Sunday

and Holidays
Note:
1. The above manpower at Sl.No.3 to 7 shall work in 3 shifts including Sundays and Holidays on
rotation basis.
2. The above manpower at Sl.No.3 to 7 is required for sub -station and pump house.
1.1 The Employer

Name:
Krishna Bhagya Jala Nigam Ltd.,
Address: KBJNL ,PWD Office Annexe, III Floor,

Bangalore 560001
Name of authorized Representative:-- Executive Engineer, KBJNL,
Mulwad Lift Irrigation Division. No. 4. D.Hipparagi
The Engineer is:
Name:
Name of authorized Representative
3.
The Contractor shall submit a program for the works within 30 days of delivery of Letter of
Acceptance.
4.
The Site possession date shall be within 15 days from the issue of notice to Proceed with the
works.
5.
The Defects Liability Period is
Civil Works
12 months defect liability and
Mech.& Elec. Works
24 months defect liability including maintenance. From the date of the

completion work including O&M.
6.
All risks insurance policy covering the total contract value shall be provided which shall be valid till
completion of maintenance period. As mentioned in Clause 13 in condition of contract.

7.
The period between Program updates shall be 30 days.
8.
An amount of Rs.1 lakh shall be deducted from the bills which is not refundable for late submission
of an updated Program.
9.
The language of the Contract documents is English.
10.
The law, which applies to the Contract, is the laws of Union of India, applicable to Karnataka.
11.
The currency of the Contract is Indian Rupees.
10 The proportion of payments retained towards Security Deposit shall he 6.5% from each Bill.
12.
RETANTION MONEY
The proportion of payments retained towards Security Deposit shall he 5.5% from each Bill. Apart
from EMD and 1% performance security deposits.

13.
The Contractor shall be liable to pay as penalty an amount equal to one percent of the estimated
cost of the balance work assessed according to the programme, for everyday that the due quantity of
work remains incomplete; provided always that the total amount of penalty to be paid under the
provisions of this clause shall not exceed 7.5 percent of the estimated cost of the entire work as shown in
the tender.
14.
SUBMISSION OF AS-BUILT DRAWINGS:
Contractor shall submit as built drawings in 20 sets to appropriate scaled within 28 days from the date of
issue of completion certificate failing which, an amount of Rs.5,00,000/ - shall be with held from the final
payment due to them.
15.
MOBILIZATION ADVANCE:
The Amount of the advance payment are:

Nature of
Amount (Rs)
Conditions to be fulfilled
Advance
Mobilisation
5% of the
On submission of unconditional invocable Bank
contract
Guarantee issued by a scheduled commercial bank
value
(to be drawn before end of 20% of contract period)

and valid during the subsistence of the advance.
Repayment of advance payment for mobilization and equipment:

The advance loan shall be repaid with an interest of 13.5% per annum with percentage deductions from
the interim payments certified by the Engineer under the contract. Deductions shall commence in the next
Interim Payment Certificate following that in which the total of all such payments to the contractor has
reached not less than 15 percent of the Contract price or 2 months from the date of payment of first
installment of advance, which ever period concludes earlier and shall be made at the rate of 15 percent of
the amounts of all Interim payments Certificates under such time as the loan has been repaid, always
provided that the loan shall be completely repaid prior to the expiry of 85 % of the original time for
completion pursuant to clauses 17 and 25 of condition of contract Payment of advanced 10 % payable
only for item No 1 of Schedule B recovery of advance should be done before 85 % of completio n period.
Note: This condition shall form a part of the bid document.
All other conditions remain same.
16.
TERMS OF PAYMENT:
PAYMENT TOWARDS CIVIL WORKS:
Payments will be made for civil works to extent of 95% of the value of the finished work done by th e
contractor. The balance 5% of such bills will be retained in the hands of the employer subject to the
maximum of 5% of contract value.
PAYMENT TOWARDS SUPPLY AND ERECTION OF EQUIPMENT AND PL ANTS:
a)
The payment of 70% will be made for the supply electromechanical equipments only after the
completion of jackwell civil work up to the pump floor level excluding MS pipes and spatial at site.
b)
20% of the contract price of each item on erection of equipment and plant in final position.
c)
5% of the contract price of each item after successful commissioning of equipment and plant.
Balance 5% to be retained till final payment.

In case of item of supplying, laying, jointing, testing and commissioning of MS pipes and specials the
rates quoted shall be paid in part as under:
Sl.
No.
Description
Rate of Payment
Supplying Mild Steel Pipes and specials

including necessary shop tests and
1.
Stacking at contractors yard with lining 45% of the quoted rate

and
outer
coating
at
site
and
transporting the pipes to work spot.

2.
3.
Laying, Jointing and testing as directed 45% of the quoted rate for
and as per specifications.
On satisfactory commissioning
pipeline
5% of the quoted rate for
pipeline
NOTE: The amount due under Sr. No.1 will be paid as follows:
(i) For the first and second consignment of pipes: Payment when the pipes and specials are accepted in
the pipe yard by the Engineer.
(ii) For the third and subsequent consignments: Payment when the pipes and specials are accepted in
the pipes yard by the Engineer and at least 50% of the pipes and specials supplied on previous
consignments are laid, jointed and tested to the satisfaction of the Engineer.
No separate payment for dewatering shall be made while executing any of the items of works and
contractors shall quote accordingly.
17.
GUARANTEE / WARRANTY:
The Contractor shall warrant that all the equipments and works executed in accordance with the contract
are free from defects in materials and workmanship for a period of (24) Twenty Four Calendar months
commencing after satisfactory commissioning and issue of completion certificate. The contractor shall
submit warranty / guarantee certificates in respect of all equipments installations before requesting for
issue of completion certificate.
Contractor shall undertake to replace any defective parts in the equipment at his own cost under normal
operation and arising solely from faulty, design, material and / or workmanship during five years warranty
period.
18.
OPERATION AND MAINTENANCE:
Contractor shall be responsible for proper operation of the installations during 5 years maintenance
period by engaging suitable qualified manpower. The employer shall arrange necessary power supply
and water required for operation and contractor shall be responsible to arrange all items like Insulating
Oil, SF-6 gas, Lubricants, Gland packing and any other consumables.
The spares and tools ordered separately shall be kept in stock and handed over to employer for their use
after successful completion of 5 years maintenance period. In case of emergency employer may permit
use of spare parts from the stock subject to replacement by contractor at the earliest time.
19.
REPLACEMENT OF DEFECTIVE PARTS AND MATERIALS:
In case, contractor fails to attend to the defects during five years warranty period, employer may, on
giving the contractor Seven (7) days notice in writing of his intentions to do so, proceed to get the
defective parts replaced or repairs carried out at the cost of the contractor and recover the same from the
security deposit or any amount due to him.
20.
BID EVALUATION FACTORS:
Bidder shall comply with the pump parameters as specified.

The efficiency is reckoned as wire to water, which means the losses in pump, coupling, vertical column,
filters all included.
For the purpose of Bid evaluation and performance guarantee, the duty point for individual pump set shall
be considering as follows.
Q max. Peak Discharge (Cumecs)
18.067 present & 21.33 cumecs for ultimate
requirment
Static Head (m)

56.74
For bid evaluation , loading will be at Rs 83400/- per pump set per kw for each differential among various
bids received in the guaranteed power input to motor at the duty point.
Bidder shall furnish motor efficiency which shall not be subject to any tolerance and guaranteed power
input to the motor corresponding to this efficiency.
Power input to pump and motor shall be calculated as follows:
Power input to pump motor output (Q) x (H) / (367.2 x ep)
Power input to motor in KW (Motor output) / (em)
Where
Q
= In cum/hr
= in m head plus, losses in the pump and hydraulic system upto the delivery pond.
Ep
= pump efficiency at duty point.
Em
= Motor efficiency at duty point.
Purchaser reserves the right to reject the motor if the efficiency of the motor at the duty point dewing full
load test is less than the guaranteed value even if the power input to motor is within the guaranteed
Value.
The bidder shall note that the duty point indicated is only for the purpose of evaluation. The bidder shall
arrive at the KW rating of the motor such that the pump sets shall be capable of meetings the head and
discharge requirements.
21.
PENALTY FOR SHORTFALL IN PERFORMANCE PUMPS
For each KW differential in the actual motor input over the guaranteed motor input at duty point indicated
in the technical specifications (without any further tolerance), penalty will be levied at Rs.1,66,800/- per
KW per pump set.
For this purpose the power input measured during performance test on the full size pump at employers
site will be considered.
Should the performance test results deviate from the guaranteed values subject to the tolerances
indicated the Contractor shall correct his equipment at no extra cost to the Engineer and repeat the
performance tests within a reasonable period as agreed to by the Engineer. As regards the power
consumption, If the Contractor fails to meet the g uaranteed values, the Engineer will levy a penalty as
indicated under this Clause. However, if the deviation in power consumption exceeds 5% of the
guaranteed value or the Contractor is unable to meet the guaranteed for items under correction, the
Engineer retains the option to reject the equipment in which case contractor shall replace the entire
equipment with one that meets the guaranteed values.
22.
PERFORMANCE WITHIN MAINTENANCE PERIOD
The purchaser reserves the right to carry out further test to check the performance and efficiency of the
plant at the end of maintenance period. Adjustments to the plant as may be considered part of normal
operating routine shall be carried out prior to these tests.
Should the results of such repeat tests carried out by the purchaser indicate that performance values
deviate from Guaranteed value or the power consumption exceeds 1.0% of the guaranteed value then
the contractor shall be given opportunity to take corrective measure s and carry out further test all at his
own expense. Should the test indicate performance and power consumption values below the guaranteed
value then a reduction in the contract price may be issued by the Engineer.
23.
CAPITALISATION OF LOSSES: FOR TRANSFORMERS
The no-load loss in Kilowatts at rated voltage and rated frequency and the load loss in Kilowatts at rated
output, rated voltage and rated frequency specified and at a temperature of 75 degree C shall be
guaranteed.
For the purpose of comparing of tenders the minimum of the losses quoted by the bidders will be
considered as base and the difference over the employee the minimum will be capitalized and added to
quoted price at the rate of Rs.2,90,000/- per KW of no-load losses and the rate of Rs.1,18,500/- per KW
of load losses on the head of above guaranteed losses figures.
Load losses at 25%, 50%, 70%, 90%, 100% rated load and rated voltage shall also be indicated in the
bid.
The Bidders shall note that the values assigned for the capitalization of losses are based on the present
worth.
24.
PENALTY FOR NON-FULFILLMENT OF GUARANTEED LOSSES:
The quoted load losses & iron losses will be compared with the guaranteed load loss and iron loss
offered by the bidders & loaded to the quoted cost.
The values of no-load and load losses obtained during tests will be compared with the guaranteed figures
as per Clause 20.1.In case the test values exceed the guaranteed figures (without tolerance), penalty will
be imposed at the following rates for the exceeded values in KW or part there of.
No load loss
Rs.2,90,000/- Per KW
Load loss
Rs.1,18,500/- Per KW
For fractional KW losses exceeding guaranteed values, pro rata- rates will be applicable.
SCOPE OF O&M WORK:The contract is for Installation of pumping machinery at Mulwad Head work, Rising Mains, construction of
Delivery Chamber at Mulwad and Lead off canal upto Mulwad Jack well including all structures on
turnkey basis.
The Agency shall take possession of the pumping stations, Head works, Rising mains, Feede r mains,
Distribution system and other components of the scheme, including as -built drawings, scheme trial run
reports & other relevant documents from KBJNL authorities.
Log books are to be maintained for recording up to date information related to day -to-day operation
& maintenance activities ( Quantum of water pumped to the delivery chambers, Pump operations at all
locations including information on performance of pump in comparison with design requirements, test
results, Preventive maintenance, occurrence of major breakdowns, examining & ensuring the correctness
of Electricity bills in a well defined structured formats.
The Agency shall comply with all applicable health and safety regulations in all his activities under
the contract. The Agency is responsible for ensuring the health and safety of his personnel.
Sufficient Stock of Consumables for, Daily maintenance of Electrical & Mechanical components
should be always maintained at required locations in the Head work
The Agency shall plan adequately for any accidents and shall make suitable arrangements with
KBJNL staff and local authorities, including the provision for training some of his staff in first aid, transport
so that, in the event of an accident, any injured personnel will be provided with all reasonable emergency
care and evacuated expeditiously to a hospital.
A Complaint register/registers for recording complaints and actions taken thereon shall be
maintained in the form prescribed by KBJNL Engineer and the monthly abstracts shall be furnished to the
JC in the form of reports.
Any activity not specifically mentioned herein but deemed to be fairly contingent to the intent and
spirit of contracted work, in the opinion of the Engineer, will form part of responsibility of the Agency.
House keeping - Premises of all components of the scheme Viz. Head works, pumping stations,
Transformer yards, Pump sets & Motors, All Units are to be maintained neat, free of dust, corrosion,
dampness, Cob webs & vegetation, as applicable and the agency shall ensure easy access for inspection
of each of the components.
RESPONSIBILITIES AND OBLIGATIONS OF THE AGENCY
The Agency will be responsible for the daily operation of pumping stations The Agency shall
optimize the operation of the pumping works in the most cost effective manner in terms of Power
consumption and working condition. The Agency should also ensure that the monthly Electricity bills do
not involve any kind of penalties.
The Agency will be totally responsible for the Preventive maintenance of every co mponent of the
scheme as per O & M Manual/Vendors Manual/contract document/Relevant codal provisions and as per
the directions of Engineer-In-Charge to ensure good working condition of the Pumps & Motors / Rising
mains / Head works and all other components of the scheme, so that the scheme functions under optimal
conditions to deliver the designed discharge at duty point and all components of the scheme are handed
back to the Employer at the end of the contract period, in a good working condition, as the scheme was
taken over from the Employer.
The Agency should provide all O & M personnel, required labour, materials, consumables, Tools &
equipment, Transportation & Communication facilities to O & M Personnel, setup a field office with
Electronic data feeding & report generating facilities required for the operation and maintenance of the
scheme.
The minimum size of O&M Staff to be deployed for the contracted work should be in conformity
with the field staff should be thoroughly trained about the operation & maintenance aspects of each and
every component of the scheme, their Preventive & Corrective maintenance particulars in well defined
formats, to maintain Log books on daily basis for recording particulars of water drawl at source point, ,
particulars of preventive & Corrective maintenance carried out for various components of the scheme,
and particulars of daily water releases, as per the directions of Engineer.
The Agency is responsible to make necessary arrangements to keep trained & qualified personnel
accessible all the 24 hours, for attending to emergent repairs/replacements and restore the system to
working condition, so that the maximum system breakdown period does not exceed several hours except
the situation where the reasons for non-supply of water are beyond his control, like non availability of
power/inadequate voltage at relevant pumping station/ Major pipe burst/major leakages in the pipe lines.
The Agency shall be responsible for watch & ward of the Pumping Stations, Head works, Water
treatment plant, Storage reservoirs, raw water & pure water Transmission mains, Transformers and other
components of the scheme, from thefts, tampering or misuse by any person/community. The Agency
shall appoint licensed security personnel to guard all components of the scheme and it is the sole
responsibility of the Agency to make good any damage/pilferage of any portion of the scheme.
System breakdown period should not exceed several hours. It would be the responsibility of O&M
Agency to have a mechanism in place to restore the system within this period. Liquidated damages will
be levied as specified in this document, in case of longer breakdowns.
Since power charges are as high as 60-75% of total O & M cost, an efficient use of power will form
an essential criteria in maintaining pump and related electric accessories. Hence the Agency shall
arrange his operations to restrict power consumption to be within the pre -determined limits & the power
factor shall be maintained at not less than 0.95 lag. The Agency shall maintain the entire electrical
installations from the express feeder main in accordance with the requirements and regulations of
KPTCL. in force and as may be amended from time to time.
In case penalties like Power factor penalty and (or) Recorded max imum demand for a particular
month is levied by KPTCL, the same will be inferred as resulted due to poor O & M practice and such
penalties will be recovered from the O&M Agency.
The Agency will be fully responsible for the adequacy of all his operation and maintenance
procedures to ensure the safety of his O & M personnel and safety & security of every component of the
scheme.
Performance of the Agency
The performance of the Agency will be reviewed on the basis of indicators mentioned below, besides
responsibilities and obligations of the agency specified in this contract document. Payment of contract
amount will be made on the Agencys performance during/till the month for which bill is submitted. If the
agency fails to achieve the set targets as indicated in performance indicators then KBJNL may levy
penalty as deemed reasonable.
HEAD WORKS
Design, Supply, Installation, Testing and Commissioning of Lift Irrigation systems of 4 th B Lift work in
Bijapur District under Mulwad LIS UKP Stage III Works off taking from Km - 18.95 of Basavana
Bagewadi Canal comprising of Intake Canal, Fore bay, Jack well Cum Pump House, Trash racks, Stop
log gates, Embedded parts, Mono rail arrangement for operation of gates, VT Pumps coupled to HT
Motors with SCADA system (7 working pumps designed for peak discharge with 1 standby provision)
EOT Crane, MS Manifold, necessary transformers ( 1 working + 1 standby) 220 KV Terminal bay and 220
KV / 6.6 KV SC line on DC towers, Electrical Sub-Station with Mulsifyre system, comprising of Electrical
Panel, Soft Starters, Capacitors, Valves, HT Switch Gear, HT Metering Equipment for KPTCL metering,
Supply and fixing of Control and Relay Panels, HT Cabling, Earthing with necessary arrangements to
receive power supply from KPTCL, requisite number of MS Rising Main with necessary Air valves, Zero
velocity valves, NRVs, Thrust Blocks, Surge protection measures, Delivery Chamber, Structures along
Intake Canal and Rising main if any, Construction of 220 KV / 6.6 KV SC line on DC towers including
Terminal Bays as per KPTCL norms, O&M staff and watchman quarters at Jack well cum Pump House
site, protective fencing to Jack well and Electrical Sub -Station, Asphalt approach road from Masabinal Ingleshwar road to Jack well cum Pump House along Intake canal, Supply of spare parts, tools, operation
and maintenance of system for Five years after successful commissioning on lump sum Turn-Key basis.
The agency should make a suitable plan for Inspection of structures at scheduled intervals and to record
the observations/defects (If any). If the defects noticed are of minor nature like development of surface
cracks, dampness on wall or roof surface, pealing of finished works like painting/plastering, corrosion of
exposed steel surfaces (Steel windows, Ventilators, M S Gate, Fencing, Steel surfaces of approach
bridge ), Termite attack & warping of wooden works, choking of inlet screens, Silting up of Intake/Jack
well are to be rectified immediately by the agency with an intimation to the EngineerIn-Charge. The
Agency should carry out complete painting of structures once during maintenance period or as per the
directions of Engineer-In-Charge.
PIPE LINES, RISING MAINS & GRAVITY MAINS
Leak detection Pipe line leaks should be detected either through Flow meters or through visual
observation (Where ever metering is not done). Visual observations shall be carried out for complete
stretch of pipe lines at scheduled intervals for signs of leaks such as a slump in the material over a
trench, abundant vegetation growth or surface moisture.
Valves are to be checked for leaks, at scheduled intervals.
Repairs of gland packing, valve gate, spindle, gland of sluice valves, replacement of floats of air
valves, repairs of all types of valves whenever required, gre asing of gear system of valves once in 15
days, replacement of rubber packing of sluice valves whenever required, tightening of nut bolts of
valves/replacement of nut bolts whenever required and also whenever directed by the Engineer or his
representative.
Removal of all types of leakages through, pipes/Sluice valves/Air valves/Scour valves including
cost of required labour & materials, earth work excavation, refilling, dewatering, lighting arrangements
required for attending to repairs, nut bolts, rubber p acking, floats, gland packing, M-seal or similar jointing
materials and chemicals required, P.V.C. resins, PVC couplers, lead jointing materials, dewatering by
required capacity diesel/electrical or kerosene driven pumps,
All welding works to arrest leaks (If any) noticed in Pipe lines, including cost of required
equipments electrical connection, all labors.
Repair of cement concrete/Masonry works of damaged thrust blocks/Valve chambers and
construction of new valve chambers in lieu of broken/damaged valve chambers including disposing the
dismantled stuff to final places of disposal.
Watch & ward of pipe line & ensuring of non-pilferage of water. The Agency will also be
responsible to ensure the safety of all pipe lines, appurtenances, chambers including covers thereon .
Maintenance of expansion joints by tightening of the nuts & adjusting the packing material at
regular intervals, including cost of providing and fixing of gaskets of expansion joints.
To deposit all the replaced material at the stores spe cified by the Engineer.
Log books are to be maintained for having clear record of repair and replacement works.
220 KV Express feeder lines and Transformers

1.
Daily visual inspection of the out door switchyard and work station for any loose contacts
abnormal sound of the equipments , Pump and motors

2.
Recording of daily energy meter reading, log of motor and pump and valve operation as directed
by the Engineer in charge

3.
Replacement of Jumps, Tightening of Jumps at accessible height and loose connection,
Replacement of fuses with appropriate capacity to the Distribution transformers.

4.
Reconditioning of Silica gel, Watering of Earth Pits, Checking of Earthing Connections, yard
cleaning, and Routine work and any other duties assigned by Engineer in charge.
5.
The Agency should display Shift Chart showing names of Agencys & Helpers performing
Operation & Maintenance work.

6.
Routine maintenance of Transformers, 11 KV line & other appliances should confirm to the guide
lines of KPTCL.
Documentation
All
records pertaining to contracted operation & Maintenance work, like
monthly Energy
consumption, Log book entries in prescribed formats pertaining to Operations & Maintenance of Pumps
& Motors, DI Units, Electrical appliances and all other units of water supply system, Test results
Particulars of system breakdowns, capacity building etc. should be documented in a systematic and
chronological order as per the Directions of Engineer & O & M manual and should be made available to
the Employer and Engineer, at prescribed intervals.
Cleanliness
The surroundings near the source, pump house, Raising Main should be kept clean, the valve
chambers if any should be free from water stagnation.
SECTION - 7
DETAILED TECHNICAL SPECIFICATIONS
ELECTRICAL WORKS
TECHNICAL SPECIFICATIONS FOR 220 KV TRANSFORMER

SECTION 1
TECHNICAL SPECIFICATIONS FOR POWER TRANSFORMER
Clause No.
Particulars
1.0
Scope
2.0
Standards
3.0
Service Conditions
SECTION II
GENERAL TECHNICAL REQUIREMENTS
1.01
General Design of Apparatus
2.0
Cores
3.0
Windings
4.0
Internal Earthing Arrangements
5.0
Tanks
6.0
Voltage Control
7.0
Parallel Operation of Transformer
8.0
Bushing Insulators and Terminals
9.0
Temperature Controllers
10.0 Gas and Oil actuated relays

11.0 Temperature Rise
12.0 Insulation Levels
13.0 Terminal Marking Tapping and Connections
14.0 Insulating Liquids
15.0 Marshalling Box
16.0 Transformer Protection
SECTION III
COMPONENTS OF THE TRANSFORMER
SECTION 1
TECHNICAL SPECIFICATIONS FOR POWER TRANSFORMERS : 220 kv

1.0
SCOPE:
The scope of this specification covers the design, manufacture, testing, supply delivery at sites including
unloading and commissioning of POWER TRANSFORMERS ( 1 working + 1 standby) required for
installation in 220 KV sub-stations with Mulsifyre system.
2.0
STANDARDS:
The applicable standards for Power Transformers including various accessories and fittings are specified
here below:
1.
Colours for paints and enamels
IS 5
2.
Ready mixed paint, brushing, zinc chrome plaster
IS 104
3.
Ready mixed paint, brushing, priming, plaster
IS 109
4.
Insulating Oil
IS 335
5.
Testing of steel sheets and strips for Magnetic circuits
IS 649
6.
Solid press board for electrical purposes
IS 1576
7.
Code of practice for maintenance of mineral insulating oil in
IS 1866
IS 1886
IS 2026 Part 1 to
10. Impulse voltage testing
IS 2070
11. High voltage testing
IS 2071
12. Porcelain bushings
IS 2099
13. Determination of water content in oil
IS 2362
14. Painting of transformer
IS 2932
15. Porcelain Transformer bushings
IS 3347
16. Gas operated relays
IS 3637
17. Application guide for gas operated relay
IS 3638
18. Fittings and accessories for Power Transformers
IS 3639
19. Clamping arrangement for porcelain transformer bushing
IS 4275
20. Electric Power Connectors
IS 5561
21. Testing of specific resistance of electrical insulating liquid
IS 6262
22. Method of test for power factor and Dielectric constant of
IS 6262
equipment
8.
Code of practice for installation and maintenance of

transformers
9.
Power transformers
electrical Insulating liquid
3.0
23. Guide for loading of oil immersed Transformers
IS 6600
24. Determination of electric strength of Insulating Oils
IS 6792
25. Oil impregnated, paper insulated of Condenser bushing
IS 12676
SERVICE CONDITIONS:
As per IS 2026 (part I) 1799, Clauses 3.1, 3.1.1 and 3.2.1.

SECTION II
GENERAL DESIGN OF APPARATUS:
The Transformers and accessories shall be designed and manufactured in accordance with IS 2026 and
Section A (General) of CBIP Technical report No.1 in regard to design, standardization, galvanizing,
labels, bolts and nuts, cleaning and painting, oil and prevention of acidity.
ELECTRICAL CHARACTERISTICS AND PERFORMANCE:
1.2.1 All transformers, unless otherwise specified shall be oil immersed and core type and shall be
suitable for outdoor installation.
Transformers designed for mixed cooling shall be capable of operating under the natural cooled
condition up to the specified load. The forced cooling equipment shall come into operation by pre -set
contracts in WTI and the transformer will operate as a forced cooled unit.
Transformers shall be capable of remaining in operation at full load for 10 minutes after failure of
blowers without the calculated winding hot-spot temperature exceeding 1400 C. Transformer fitted with
two coolers each capable of dissipating 50 percent of the heat at C.M.R. shall be capable of remaining in
operation for 20 minutes in the event of failure of blowers associated with one cooler without the
estimated winding hot-spot temperature exceeding 1400C.
1.2.2 CONTINUOUS MAXIMUM RATING AND OVER LAOD:
Transformers provided with ON AN/ONAF cooling shall in regard to raising, temperature and
overloads comply with Clause 4.0 of IS 2026, Part I with latest amendments there of.
1.2.3 VOLTAGE RATIO:
The voltage between phases on the higher and lower voltage windings of each transformer
measure at no load and corresponding to the normal ratio of transformation shall be those connected in
the ordering schedule. And shall be capable of giving rated volts from the secondary when rated primary
voltage is applied at the normal tap and at the rated frequency.
1.2.04 ELECTRICAL CONNECTIONS:

Transformer shall be connected in accordance with the IS Vector symbol specified.
The primary shall be connected in Delta and the secondary is Star following the Vector Group DY
II.DUTY UNDER FAULT CONDITIONS:
Except where modified below, it is to be assumed that the amount of generating plant Simultaneously
connected in and that normal voltage will be maintained on one side of and transformer when there is a
short circuit between phase or to earth on the other side. Any transformer may be directly connected to
an underground, or overhead transmission line and switched into and out of service together with its
associated transmission line.
The rated short time shall be 100/Z times the rated primary current for 3 seconds where Z is %
impedance of Transformer.
1.2.05 REQUIREMENTS WITH REGARD TO AVAILABILTY TO WITHSTAND AND SHORT CIRCUIT:
As per IS 2026 (Part I). Clause 8 and Sub-Clauses thereof.
1.2.06 DEMONSTRATION OF ABILITY TO WITHSTAND SHORT CIRCUIT:
As per IS 2026 (Part I) 1997, Clause 9 and Sub-Clauses thereof.
1.2.07 LOSSES
1.2.08.01
MEASUREMENT:
As per Clause 16.4 and 16.5 of IS 2026 (Part I) 1997.

1.2.08.02
TOLERANCE:
As per Clause 11 of IS 2926 (Part I) 1997

1.2.08.03
GUARANTEED LOSS:
ii) The bidder should clearly indicate the guaranteed value in respect of under mentioned losses at
normal tap.
(b)
No load loss at rated voltage and rated frequency.
(c)
Total losses including auxiliary losses at rated output, rated voltage and rated frequencies.
ii) The guaranteed values of the losses will be compared with that of tested values and in the event
tested values exceed former, the firm will be liable for penalty as detailed in Clauses 24.2 under contract
data.
In the event of measured losses exceeding the guaranteed loss penalty will be levied as per Clause 24.2
upto 10% excess losses. If the actual losses exceed 10% guaranteed values of losses the transformer
manufactured will be rejected.
iii) Guaranteed losses mentioned in the bid will be datum and proportionate loading deloading will be
done for the difference.
iv) No load loss and load loss are reckoned at Rs.2, 90,000/- and Rs. 1,18,500/- respectively per KW.
v) The bidder shall note that the values assigned for capitalization of the losses are based on present
worth.
vi) Fraction of KW of loss will be rounded to nearest number and penalty of loading will be done
accordingly.
1.2.09 REGULATION AND IMPEDANCE:
The impedance voltage at principal tap and rated KVA shall be stated in the bid and tolerance shall
be in accordance with IS: 2026.
1.2.10 FLUX DENSITY:
The maximum flux density in any part of the core yokes, at normal voltage and frequency of each
transformer shall be such that the flux density under over voltage condition shall not exceed 1.9 Tesla
(19,000 lines per Sqcm.).
1.2.11 SUPPRESSION AND HARMONICS:
All the transformers shall be designed with particular attention to the suppression of harmonic voltage,
especially the third and fifth, so as to eliminate wave from distortion and from any possibility of high
frequency disturbances, inductive effective or of circulating currents between the neutral points at
different transforming stations reaching such is magnitude as to clause interference with communication
circuits.
CORES:
2.01 CONSTRUCTION:
The cores shall be constructed from high grade cold rolled non-again grain oriented silicon steel
laminations.
2.01 MAGNETIC CIRCUIT:
The design of the magnetic circuit shall be such of to avoid static discharges, development of short-circuit
paths within itself or to the earthed champing structure and the prod ucing of flux components at right
angle to the plane of the laminations which may cause local heating.
a)
Every care shall be exercised in the selection, treatment and handling of core steel to ensure that
as far as is practicable the laminations are flat and the first assembled core is free from distortion.
b)
The oxide/silicate coating given on the core steel is adequate, however, laminations can be
insulated by the manufactures if considered necessary.

c)
Oil ducts shall be provided where necessary to ensure adeq uate cooling. The winding structure and
major insulation shall not obstruct the free flow of oil through such ducts. Where the magnetic circuit is
divided into pockets by cooling ducts parallel to the planes of the laminations or by insulating materials
above 0.25 mm thick, tinned copper strip bridging pieces shall be inserted to maintain electrical continuity
between pockets.
d)
The framework and clamping arrangements shall be earthed in accordance will Clause 4.01.
e)
The insulation structure for the core to bolts and core to clamp plates hall be such as to withstand
a voltage of 2000 V AC for one minute.

f)
For consideration of over fluxing the transformer shall be suitable for continuous operation for
values of over fluxing factor upto 1.1, this factor being v/vm x fn/f. The manufacturer shall state the over
fluxing capability and corresponding withstand durations for the transformers for factors 1.1, 1.25 and
1.4.
MECHNICAL CONSTRUCTION OF CORES:
All parts of the cores shall be of robust design capable of withstanding any shocks to which they may be
subjected during lifting, transport, installation and service.
All steel sections used for supporting the core shall be thoroughly sand blasted or shot blasted after
cutting, drilling and welding. Any non-magnetic or high resistance ally be of established quality.
Adequate-lifting lugs shall be provided to enable the core windings to be lifted.
Adequate provision shall be made to prevent movement of the core and winding relative to the tank
during transport and installation or while in service.
The supporting framework of cores shall be so designed upto avoid the presence of pockets which would
prevent complete emptying of the tank through the drain valve, or cause tapping of air during filling.
3.0
WINDINGS:
3.01 All star connected windings for system of 6.6 KV and above shall have graded insulation as defined
in IS: 2026. All windings for system voltages lower than 6.6 KV shall be fully insulated. All neutral points
shall be insulated for the voltage specified in IS: 2026.
3.02 Power transformers shall be designed to withstand the impulse and power frequency test voltages
as specified in IS: 2962.
3.03 The windings shall be designed to reduce to a minimum the out-of-balance forces in the
transformer at all voltage ratios.
3.04 The insulation of transformer windings and connections shall be free from insulating composition
liable to soften, ozone out, shrink or collapse and be non catalytic and chemically inactive in transformer
oil during service.
3.05 Windings shall be made using Class A paper insulated copper conductors. The Conductors shall
be electrolyte grade copper free from scales and burrs. The stacks of Windings shall receive adequate
shrinkage treatment before final assembly. Adjustable devices shall be provided for tak ing up any
possible shrinkage of coils in service.
3.06 The coil clamping arrangement and the finished dimensions of any oil ducts shall be such as will
not impede the free circulation of oil through the ducts.
3.07 No strip conductors wound on edge shall have a width exceeding six times its thickness.
3.08 The conductors shall be transposed at sufficient intervals in order to minimize eddy currents and
equalize the distribution of currents and temperatures along the windings.
3.09 Further, windings shall be so designed that all coil assemblies of identical voltage ratings shall be
interchangeable and that field repairs to the windings can be made readily without any special equipment.
The coils shall be supported between adjacent sections by insulating spacers and barriers.
3.10 All threaded connections shall be provided with looking facilities. All leads from the winding to the
terminal board and bushings shall be rigidly supported to prevent injury from vibration. Guides shall be
used wherever practicable.
3.11 The windings shall be clamped securely in place so that they will not be displaced or deformed
during the circuits.
3.12 The maximum current density in any winding shall not exceed 2.3 a/ sq.mm
BRACING OF WINDINGS:
The windings and connections of all transformers shall be braced to withstand shocks which may occur
during transport, or due to switching short circuit and other transent
Conditions having service.
4.0
INTERNAL EARTHING ARRANGEMENTS:
All metal parts of the transformer with the exception of the individual core laminations. Core bolts and
associated individual clamping plates shall be maintained at some fixed potential.
4.01 EARTHING OF CORE CLAMPING STRUCTURE:
The top core clamping structure shall be connected to the tank body by a copper strap. The bottom
clamping structure shall be earthed by one or more following methods.
a)
By connected through vertical tie-rods to the top structure.
b)
By direct metal-to-metal contact with the tank base maintained by the weight of the core and
windings.
c)
By the connection to the top structure on the same side of the core as the main earth connection of
the bank.
4.02 EARHING OF MAGNETIC CIRCUIT:
a)
The magnetic circuit shall be earthed to the clamping structures at one point only through a link
placed in an accessible position beneath an inspection opening in the tank cover. The connection to the
link shall be on the same side of the core as the main earth connection.
b)
Magnetic circuits having an insulated sectional construction shall be provided with a separate link
for each individual section. Where oil ducts or insulation barriers parallel to the plane of the laminations
divide the magnetic circuit into two or more electrically separate parts the ducts or barriers shall be
bridged in accordance with Clause 2.02(d) and the magnetic circuit shall not be regarded as being of
sectional construction.
4.03 SIZE OF EARTHING CONNECTION:
Where coil clamping rings are of meta at earth potential each ring shall be connected to the adjacent core
clamping structure on the same side of transformer as the main earth connections.
4.04 SIZE OF EARTHING CONNECTION:
All earthing connections with the exception of those from the individual coil clamping rings have a cross
sectional are of less than 0.2 Sq.Cm.
5.0
TANKS
5.01 CONSTRUCTIONS:
Conventional type of tank construction could be used as per design rating
The transformer tank and cover shall be fabricated from good commercial grade low carbon steel
suitable for welding and adequate thickness. The tanks of all transformers shall be complete with all
accessories and shall be designed so as to allow the complete transformer in the tank filled with oil to be
lifted by crane or jacks transported by road, rail without over straining any joints and without causing
subsequent leakage of oil.
The main tank excluding tap-changing compartments, radiators and coolers shall be capable of
withstanding vacuum:
Highest
system M V A rating
voltage K V
Vacuum
gauge (mm of H g)
pressure K N/ Sq.m.
As per design
The base of each tank shall be so designed that it shall be possible to move the complete transformer
unit by skidding in any direction without injury when using plates or rails.
Normally a detachable under base will be used, but in case transport facilities permit, a fixed under case
can be used.
Where the base of channel construction, it shall be designed to prevent retention of water.
Tank stiffeners shall be designed to prevent retention of water.
Where possible the transformer tank and its accessories shall be designed without pockets wherein gas
may collect pockets cannot be avoided. Pipes shall be provided to vent the gas into the main expansion
pipe. The vent pipe shall have a minimum inside diameter of 15 mm except for short branch pipes, which
may be 6 mm minimum inside diameter.
All joints other than those, which may have to be broken, shall be welded when required they shall be
double welded. All bolted joints to the tank shall be fitted with suitable oil tight gaskets, which shall give a
satisfactory service under the operating conditions and guaranteed temperature rise conditions. Special
attention shall be given to the methods of making hot oil tight joints between the tank and the cover as
also between the cover and the bushing and all other outlets to ensure that the joints can be remade
satisfactorily at side and with case with the help of semi skilled labour.
However the minimum thickness of the plate used for transformer Tanks shall not be less than 8 mm. For
the sides and not less then 10mm.for the bottom plate and top cover.
5.02 LIFTING AND HAULAGE FACILTIES:
Each tank shall be provided with:
a)
Lifting lugs suitable for lifting the transformer complete with oil.
b)
A Minimum of four jacking lugs, in accessible positions to enable the transformer complete with oil,
to be raised or lowered using hydraulic or screw jacks. The minimum height of the lugs above the base
shall be:
i)
Transformers up to and including 10 tones weight 300 mm excluding the under base dimensions, if
detachable.
ii)
Transformers above 10 tones weight 500 mm excluding the under base dimensions, if detachable.
c)
Suitable haulage holes shall be provided.
In addition the Transformers shall be provided with bollards on the Transformer Tank sides at the
top for lifting the transformer by a crane.
5.03 TANK COVER
Each tank cover shall be of adequate strength, and shall not distort when lifted. Inspection openings shall
be provided as necessary to give easy access to bushing or changing ratio or testing the earth purpose
for which it is provided and at least two opening one at each end of the tank, shall be provided.
The tank cover and inspection covers shall be provided with suitable lifting arrangements. Unless
otherwise approved inspection covers shall not weight more then 25 Kg. Each.
The tank cover shall be fitted with pockets for thermometer and for the bulbs of oil and winding
temperature indicators. Protection shall be provided where necessary for each capillary tube.
The pocket shall be located in the position of maximum oil temperature at C.M.R. and it shall be possible
remove the instrument bulbs, without lowering the oil of the tank.
5.04 AXLES AND WHEELS
All wheels should be detachable and shall be made cast iron or steel or required.
Wherever specified, flanged wheels shall be provided suitable for use on gauge track as specified in the
detailed specification and shall be so placed that pinch bar can be used to move the transformer.
The direction of motion shall be specified in case of unidirectional movement.

If wheels are required to swivel, they shall be arranged to that they can be turned through an angle of 90
degrees when the tank is hacked up clear of the rails or floor. Means shall be provided for locking the
swivel movements in positions parallel to and at right angles to the longitudinal axis of the tank. The
wheels shall be suitable for movement on a rail track, the gauge of which shall be 1676 mm standard
board gauge track.
5.05 CONSERVATOR VESSELS, OIL GAUGES AND BREATHERS:
A conservator complete with sump and drain valve shall be provided in such position and not to obstruct
the electrical connections to the transformer having a capacity between highest and lowest visible levels
to meet the requirement of expansion of the total cold oil volume in the transformer and cooling
equipment from minimum ambient temperature to 90C .The minimum indicated oil level shall be with the
feed pipe from the man tank covered with not less then 15 mm. Depth of oil and the indicated rang of oil
level shall be from minimum to maximum .
If the sum is formed by extending the feed pipe inside the conservator vessel. This extension shall be for
at least 25 mm. The conservator shall be designed so that it can be completely drained by means of the
drain valve provided, when mounted as in service.
One end of the conservator shall be boiled in to position so that it can be removed for
cleaning
purposes.
Normally one oil gauge magnetic /prismatic/plain type shall be provided.
The GL level at 30 C shall be marked on the gauge.
Taps or valves shall not be fitted to oil gauge.
The oil connection from the transformer tank to the conservator vessel shall be arranged at the rising
angle of 3 to 9 degree to the horizontal up to the Buchholz Relay and shall consist of
a)
For transformers up to and including 1000 KVA 25 mm, inside diameter pipes as per IS3639.
b)
For transformer from 1001 to 10,000 KVA 50 mm, inside diameter pipes as per IS 3639.
c)
For transformers of over 10,000 KVA 80 mm inside diameter pipes as per IS 3639.
A valve shall be provided at the conservator to cut off the oil supply to the transformer after providing a
straight run of pipe for at least a length of five times the internal diameter of the pipe on the tank side of
the gas and oil actuated relay and at least three times the internal diameter of the pipe on the conservator
side of the gas and oil actuated relay.
Each conservator vessel shall be fitted with weather in which silica gel is the dehydrating agent and
designed so that:
a) The passage of air is through the silica gel
b) The external atmosphere is not continuously in correct with the silica gel.
c) The moisture absorption indicated by a change in color of the tinted crystals can be easily observed
from distance
d)
All breathers shall be mounted at approximately 1.400 mm above ground level.
However the conservator main tank shall be provided with a magnetic oil gauge and the
partitioned conservator tank for the oil in the OLTC chamber shall be provided with a plain gas oil
tube gauge.
5.06 FILTER AND DRAN PLUGS, SAMPLING DEVICES AND AIR RELEASE PLUGS
Each transformer shall be fitted with the following.
a)
The filter and drain valves are specified.
b)
A drain valve as specified below shall be fitted to each conservator.
c)
For diameter up to 650 mm
Size of the valve 15mm
For diameter above 650 mm
Size of the valve 25 mm.
A robust oil-sampling device shall be provided at the top and bottom of the main tank. The
sampling device shall not be fitted on the filter valves specified under (a) above. However top, middle and
bottom oil sampling valve shall me mounted at the tank base through suitable internally located pipe
headers.
d)
One 15 mm air release plug.
All other valves opening at atmosphere shall fitted with blank flanges.
5.07 COOLER AND RADIATOR CONNECTIONS
Valve and valve mountings shall be provided as specified under Cooling Plant CL 7.0 Section-A
of CBIP manual.
All valves shall be of gunmetal or cast steel or may have cast iron bodies with gunmetal fittings. They
shall be of full way type with internal screw and shall be opened by turning counter clock wise when
facing the hand wheel.
Means shall be provided for padlocking the bottom valves in the open and closed positions. This required
for the valves where opening device like hand wheel keys etc,. are the integral part.
Every valve shall be provided with flanges having mechanical faces.
The drilling of valve flanges shall comply with the requirement of IS 3639.
5.08 PRESSURE RELIEF DEVICE:

The pressure relief device shall be provided of sufficient sizes of rapid release of any pressure
that may be generated within the tank and which might result in damage to the equipment. The
device shall operate at a static pressure of less than the hydraulic test pressure for transformer
tank. Means shall be provided to prevent the ingress of rain.
Unless otherwise approved the relief device shall be mounted on the main tank, and if on the cover shall
be fitted with skirt projecting 25 mm. Insider the tank and of such a design to prevent gas accumulation.
If a diaphragm is put at the base pipe, an oil gauge is require d on the standpipe for indicating fracture of
diaphragm.
One of the following methods shall be used for relieving or equalizing the pressure in the pressure relief
device.
a)
An equalizer pipe connecting the pressure relief device to the conservator, or

b)The fitting of a silica gel breather to the pressure relief device the breather being mounted in a
suitable position for access at ground level.

5.09 EARTHING TERMINAL:
Two earthing terminals capable of carrying for 4 second the full lower voltage. S hort circuit current of the
transformer. Provision shall be made at positions close to each of the bottom two corners of the tank for
bolting the ear thing terminals to the tank structure to suit local conditions.
5.10 RATING AND DIAGRAM AND PROPERTY PLATES:
The following plates shall be fixed to the transformer tank at an average height of about 1750 mm,
above ground level:
a)
A rating plate bearing the data specified in the approximate clauses of IS 1750
b)
A diagram plate showing the internal connection and also the voltage vector relationship of the
several windings in accordance with IS: 2026 and in addition a plan view of the transformer giving the
correct physical relationship of the terminals. When links are provided in accordance with clause 2.3 for
changing the transformer ratio. Then approved means shall be provided for clearly indicating ratio for
which the transformer is connected. No load voltage shall be indicated for each tap.
c)
Where specified a plate showing the location and function of all valves and air release cocks or
plugs. This plate shall also warm operators to refer to the maintenance instructions before applying the
vacuum treatment for drying.
The above plates shall be of material capable to withstanding continuous outdoor service.
5.11 JOINTS AND GASKETS:
All gaskets used for making oil tight joints shall be of proven material such as granulated cock bonded
with synthetic rubber gaskets.
5.12 COOLING PLAN:

The transformer shall be supplied with the requisite number of radiators and cookers.
Radiators and cookers shall be so designed as to avoid pockets in which moisture may collect
and shall withstand the pressure rests.
Unless the pipe work is shielded by adequate earthed metal the clearance between all pipe work and live
parts shall be more then the clearance for lives parts to earth.
Radiators connected directly to the tank shall be detachable and shall be provided with machined or
ground flanged inlet and outlet branches. 19-mm. Drain plug shall be provided at the bottom and 29 mm
air release plug shall be provided at the top of each radiator for draining and filling.
Valves shall be provided in the tank at each point of connection to the tank.
Where separate radiator banks are provided the conservator vessels specified in clause 6.5 section-A of
CBIP Manual can be mounted thereon.
All coolers shall be suitable for mounting on a flat concrete base.
The oil circuit of all coolers shall be provided with the following.
a)
A valve at each point of connection to the transformer tank.
b)
Removable blanking plates to permit the blanking off the main oil connection of each cooler.
c)
A drain valve 25 mm lowest point of each bank of cooler.
d)
A thermometer pocket fitted with a captive screwed cap on the inlet and outlet oil branches of each
separately mounted cooler bank.

e)
A fitter valve as specified in clause 6.6 Section-A of CBIP Manual at the top and bottom of each
cooler bank of cooler

f)
Air release plugs 15 mm
In addition the following are to be provided only with water -cooled oil coolers, which shall be IS: 6088.
a)
A suitable differential pressure gauge or equivalent suitable device fitted with electrical contracts to
given an alarm when differential pressure between cooler oil outlet and water inlet pressure drops below
a preset value.
b)
Oil and Water flow switches, fitted with electrical contacts in the pipe work adjacent to the coolers.
Water-cooled oil coolers shall be designed to facilitate cleaning without any risk of water mixing with the
oil. The material of the tube plates and tubes shall be such that corrosion shall not take place due to
galvanic action. A report of water analysis shall be furnished in time, to enable supplier to ensure a
suitable material for tube and tube plates.
Any leakage, which may take place in the oil cooler, shall be of the oil into the water and reserves and
means shall be provided to ensure that the pressure of the oil in the coolers is always greater than the
pressure of the water. The water pressure in the cooler will be kept as for as possible. Further, the
cooling water discharge should be free to the atmosphere to reduce the pressure in the cooler.
The necessary oil pumping shall be provided for connecting each transformer to the coolers and oil
pumps. The oil piping shall be with flanged gasketed joints. Cast iron shall not be used.
The drilling of all water and oil pipe flange shall comply with IS : 3939
A suitable expansion piece shall be provided in each oil pipe connection between the transformer and the
separately mounted oil coolers.
Drain valves/ plugs shall be provided in order that each section of pipe work can be drained
independently.
6.0
VOLTAGE CONTROL (ON-LOAD TYPE):
a)
The transformers shall be fitted with an on-load tap changer mechanism.
When specified each transformer shall be provided with voltage control equipment of the tap changing
type for varying its effective transformation ratio whilst the transformers are on load and without
producing phase displacement.
Equipment for local and remote electrical and local manual operation shall be provided and shall comply
with the following conditions. Local remote switch may be housed in remote control panel or in tap
changer driving unit.
It shall not be possible to operate the electric drive when the manual operating at the same ti me.
Operating from the local or remote control switch shall cause one tap movement only until the control
switch is returned to the off position between successive operations.
All electrical control switches and the local operating gear shall be clearly labeled in a suitable manner to
indicate the direction of tap changing.
The local control switches shall be mounted in the marshalling box, or driving gear housing.
The equipment shall be so arranged as to ensure that when tap change has been commenced it shall be
completed independently of the operation of the control relays or switches. If a failure of the auxiliary
supply during a tap change or any other contingency such as tap changer getting stuck would result in
that movement not being completed adequate means shall be provided to safeguard the transformer and
its auxiliary equipment.
Suitable apparatus shall be provided for each transformer to give indications as follows.
To give an indication mechanically at the transformer and electrically at the remo te control point if
specified of the number of tapping in use on the transformer.
To give an indication at the remote control point that a tap change is in progress, by means of an
illuminated lamp.
For remote control, the switches, tap position indicator, etc., shall be supplied as loose apparatus unless
a remote control panel is specified.
All relays and operating devices shall operate correctly, at any voltage between the limits specified in the
relevant Indian Standard.
Any enclosed compartment not oil fitted and shall be adequately ventilated, metal clad thermostatically
controlled heaters shall be provided in the driving mechanism chamber and in the marshalling box, all
contactors, relay coils or other parts shall be suitably protected against corrosio n or deterioration due to
condensation fungi etc.,
The tap changer contacts which are not used for making or breaking current like separate selector switch
contacts can be located inside main transformer tank where tap changer construction permit such an
arrangement. On load tap changes having separate compartment for selector contracts, the oil in such
compartment shall be maintained under conservator head by means of pipe connection from the highest
point of the chamber to the conservator. Such connection shall be controlled by suitable valve and shall
be arranged so that any gas leaving the chamber will pass in to the gas and oil actuated relay. A separate
Buchholz relay/ diverter switch may be provided for this compartment.
It shall not be possible for the oil in these compartments of the tap change equipment. Which contain
contacts used for making or breaking current, on mix with the oil in the compartments containing contacts
not used for making or breaking current.
Each compartment in which the oil is not maintained under conservator head shall be provided with a
suitable direct reading oil gauge.
The alternating supply for electrical operation of the control and indicating gear shall be
415 volts,
three phase & wire 50 Hz. Along with 240 volts, single phase, 2 wire 50 Hz, subject to a variation of 410
to 30% so that the equipment offered can withstand variation in A.C.
Limit switches shall be provided to prevent over running of the mechanism and shall be directly
connected in the circuit of the operating motor. In addition a mechanical stoop or other approved devices
shall be provided to prevent over running of the mechanism under any condition.
Limit switches may be connected in the control circuit of the operating motor provided that a mechanical
deducting mechanism incorporated.
Thermal devices or other means like motor circuit breakers with shunt trip coil shall be provided to protect
the motor and control circuits. All relays, switches, fuses etc., shall be mounted in the marshalling box o r
driving gear housing and shall be clearly marked for together with any voltage within 10 percent of
terminal valve.
The overload protection relay shall be of robust adjustable triple pole construction. It should provide
accurate and reliable protection against overload, single phasing, over heating and short circuit.
Contractors/ Relays shall be of robust and compact construction and shall comply with Indian Standard
IS: 2959
The Contractors shall be suitable for operation at 110 volts A.C. 15 percent to 10 percent 50 Hz. Main
and auxiliary contacts of contractors shall be suitably rated. For sufficient long life these contacts shall be
of double break type and shall make contacts practically bounce free.
The control supply transformer shall be single phase having ratio 415/55-0-55. Its insulation shall be
suitable impregnated to render it non-hyprospic.
All the control selector switches shall be robust and compact construction and shall comply with Indian
Standard IS: 4064 and 4047.
Remote tap position indicator mounted on remote control cabinet shall show accurately same tap position
as indicated by local tap position indicator on on-load tap changer. The remote indication can be by
means of an analogue indicator, or digital indicator or by means of lamp indications. The remote indicator
mounted on control cabinet shall not be affected by normal auxiliary voltage supply variation.
Necessary indicating lamps provided shall be of low watt consumption of H.D type.
Space heater of adequate capacity and robust construction shall be provided inside each control cabinet
to prevent moisture condensation. Space heaters shall be complete with miniature circuit breaker or ONOFF switch.
All the wiring shall be carried out for motor circuit with 1100 volts grade PV C insulated standard copper
conductors of size 2.5 sq.m and for control circuit with 440 volts grade PVC insulated copper conductor of
size 1.5 sq. m suitable for tropical atmosphere. All wiring shall be in accordance with relevant IS or BS.
Engraved core identification ferrules, marked to correspond with the wiring diagram shall be fitted at both
ends of each wire. Ferrules shall fit tightly on the wires and shall not fall of when the wire is removed. All
wiring shall be terminated on terminal blocks through suitable lugs. Insulated sleeves shall be provided at
all the wire terminations. All wiring shall be neatly bunched and cleared without affecting access to
equipment mounted within the cabinet.
Terminal board rows should be spaced adequately apart to permit convenient access to wires and
terminations
a.
Terminal boards hall be so placed with respect to the cable gland plate ( at a minimum distances of
200 mm) as to permit satisfactory arrangement of multi core cable tails with out undue stress or bends
opening of door should not disturb or stress the wire termination.
b.
The tap changer shall be located in the IIV windings. The tap change variation shall be in the range
of 45% to 15% of IIV in steps of 1.25 % i.e., 16 equal steps (number of position 17)
c.
Regarding 220 KV transformer, on-load tap changer shall consist of a separate selector to select
a tap and shall carry current but not make or break current in circuits as per ISI 8468 -1973. Clause 2.12
and 2.13
d.
On-load tap changer of Jenson system type D to be provided. The transitional resistance shall
be capable of with standing full load current of transformer for 1 sec.

Parallel operation of transformer with on-load tap changer: NOT APPLICABLE
Besides the local and remote electrical control specified on-load tap changers, when specified should be
suitable for remote electrical parallel control also.
In addition to the methods of control as in clause 9, section A of CBIP Manual. The following additional
provision shall be made.
Suitable selector switch be provided so that one transformer of the group can at a time be
selected as Maser, Follower, Independent
Necessary interlock blocking independent control when the units are in parallel, shall be provided.
The scheme will be such that only one transformer of group can be selected as Master
An out-of-step device shall be provided for each transformer which shall be arranged to prevent further
tap changing when transformer in a group operating Parallel Control are one tap out-of-step.
7.0
BUSHING INSULATIONS AND TERMINALS:
7.01
(a) Transformer shall be fitted either with bushing insulations or with cable boxes.
Clauses and fittings made of steel or malleable iron shall be galvanized. All bolt threads shall be
greased before erection.
The bushings flanges shall not be or re-entractshape, which may trap air.
Bushings turrets shall be provided with vent pipes which shall be connected to route and gas collection
through the Buchholz relay.
The clearance in air between live conductive parts and live cond uctive part to earthed structures shall be
as follows:
Rated
system Basic
voltage KV rms
insulation
level KV rms
Clearances
Phase to Phase Phase to Earth (mm)
(mm)
As Per design
NOTE:
1.
These clearances are applicable to the transformers to be installed upon an altitude of 1000m
above sea level.

2.
For altitudes exceeding 1000m above sea level, the clearance should be increased by 3 percent
for every additional 300 m.

3.
Air clearance of 3500 mm between phase to earth can be relaxed to the Maximum of 200 mm as
far air release pipe emanating from bushing turret is concerned.

The porcelain components shall be sound, free from defects thoroughly vitrified and smoothly
glazed.
Unless otherwise specified, the glaze shall be brown in color. The glaze shall cover all exposed porcelain
part of the bushings except those areas which are required to be left unglazed.
The design of the bushing shall be such that stresses due to expansion and contraction in any part of the
bushing shall not lead to deterioration.
Cement if used in the construction of the bushing shall not cause fracture by expansion or loosening by
contraction. Cement thickness shall be small and even as practicable.
All exposed ferrous metal parts shall be hot dio galvanized wherever possible.
No arching horns shall be provided on the bushings.
Any stress shield shall be considered as an integral part of the bushing assembly.
52 KV and above voltage class bushings shall be Oil impregnated paper (OIL) type condenser bushings.
The bushings below 52 KV volts class shall be porcelain, oil communicating or condenser type if
specified.
Each bushing shall have marked upon it the manufacturers identification mark.
The duration and rated short time current of the bushing for various voltage ratings shall be as specified.
Limits of temperature rise shall be in accordance with IS: 2099
Permissible variation in the value of capacitance and maximum value of dielectric dissipation factor (tan
delta) of bushing and the test tap on transformer bushings shall be as per IS: 2099 and IEC-137.
Bushing made of solid insulation and those having a filling, which does not flow under service conditions,
shall be suitable for mounting at any angle of inclination. Unless otherwise specified, those having a liquid
filling shall be suitable for mounting at any angle of inclination to the vertical, not exceeding 330 C
The cantilever strength of the bushing shall be in accordance with IEC-137 and IS:2099 unless otherwise
specified.
The profile of the porcelain and spacing of the petticoats shall suit the duty specified. When specified, the
petticoats of desired profile and petticoat spacing shall be offered.
The electrical characteristics of the bushings shall be accordance with IS: 2099.
The dimensional parameters of the bushings up to and including 36 KV voltage class shall be in
accordance with IS: 3347
Rated current voltage, basic insulation level: The rated voltage, current and basic insulation levels of the
bushings shall be in accordance with IS: 2099.
Interchangeability: All the bushing above 52 KV voltage rating shall be dimensions as mentioned in
Clause 4.3, section-P if CBIP manual, to enable interchangeability with parameters and dimensions
specified herein.
Other ratings of bushings not covered in the specificatio ns, shall be supplied if required.
The basic insulation level, rated voltage and current and creep age distances for various voltage class
bushings shall be as under:
Voltage Rating
BIL(KVP)
Current
Rating Creepage Distances
(Amps)
(mm)
As Per design
The minimum value of creepage distances specified is 25mm/KV of the rated voltage.
For area with very heavy or externally heavy or externally heavy pollution the minimum creepage
distance shall be as specified by the user.
The bushing shall be provided with oil level indicators as under:
245 KV and below Oil sight window.
The oil level indicator shall be so designed and dimensioned that oil level shall be clearly visible from
ground level.
( C) IS:2099-1973 electrical characteristics of bushings.
7.02 The 220 KV bushings shall be as per IS: 12676-1989 & IS: 3347-1982 and shall be provided with
universal bimetallic connectors suitable for vertical/ horizontal take off. The connectors of HV bushings
shall be suitable for ACSR (Robitt) of overall diameter of 28.14 mm.
7.03 The 6.6 KV LV bushings shall be provided with cable box suitable for XLPE cable connection.
8.0
TEMPRATURE CONTROLLER:
8.01 The transformer shall be provided with a 150mm dial type thermometer for top oil temperature
indicator, fitted with maximum rating pointer, resetting, device and two sets of electrical contacts. The
contacts shall be with mercury switches. Electrically independent ungrounded. The accuracy class shall
be 1-10%
8.02 The transformer shall be provided with the 150mm dial type winding temperature indicator, fitted
with maximum reading pointer. Resetting device and three sets of electrical contacts, the contacts shall
be with mercury switches. Electrically independent ungrounded. The accuracy class should be 1-1.0%
8.03 The temperature indicator shall be of dial type (not less than 150mmdia) and robust pattern.
8.04 The temperature indicator shall be fitted in a tank mounted, wheather proof, Marshalling box.
8.05 The tripping contacts of winding temperature indicators shall be adjustable to close between 60 C
and 120 C and both shall reopen when the temperature has fallen by about 5 C
8.06 All contacts shall be adjustable on a scale and shall be accessible for removal of the cover.
8.07 It shall be possible to check the operation of the contacts and associated equipment.
8.08 Connections shall be brought from the device to terminals placed inside the marshalling box.
9.0
GAS AND OIL ACTUATED RELAYS BUCHHOLTZ RELAY:
Each transformer shall be fitted with gas and oil actuated relay equipment to IS:3637 having contacts
which close following oil surge or low oil level conditions.
Each gas and oil actuated relay shall be provided with a rest cock to take a flexible pipe connection for
checking the operation of the relay.
Where specified to allow gas to be collected at ground level, a pipe approximately 5 mm inside diameter
shall be connected to the gas release cock of the gas and actuated relay and brought down to a point
approximately 1.25 mm above ground level. Where it shall be terminate a cock.
A machined surface shall be provided on the top of each relay to facilitate the setting of the relays and to
check the mounting angle in the pipe and the cross level of the relay.
The design of the relay mounting arrangements, the associated pipe work and cooling plant shall be such
that maloperation of the relays shall not take place under normal service conditions.
The pipe work shall be so arranged that all gas arising from the transformer shall pass into the gas and oil
actuated relay. The circuit through the relay shall not from a delivery path a parallel with any circulating oil
pipe. Not shall it be tied into or connected though the pressure relief vent, sharp bends in the pipe work
shall be avoided.
When a transformer is provided with two conservators the gas and oil actuated relays shall be arranged
as follows:
If the two conservators are connected to the transformer by a common oil pipe one relay shall be installed
in the common pipe.
If the two conservators are piped separately to the transformer two relays be installed, one in each pipe
connection.
Adequate clearance between oil and live metal shall be provided.
10.0 TEMPERATURE RISE:
As per clause 3.1 of IS: 2026 (Part-III 1977)
11.0 INSULATION LEVELS:
As per IS: 2026 (Part-III) 1977, clauses 3.0,5.0 and sub clauses thereof.
12.0 As per IS: 2026 (Part IV) 1977. However the transformer shall be designed for variable flux
voltage as per clause 3.2 of the said IS.
13.0 INSULATING LIQUIDS:
Mineral insulating oil to be used shall comply with IS:335-1972 (latest edition). Loose oil to be supplied
shall be in scaled oil drums with 10% extra quality over and above that required for the first filling.
14.0 MARSHALLING BOX:
A sheet steel vermin proof, well-ventilated and weather proof marshalling box of suitable construction
shall be provided for the transformer ancillary apparatus. The box shall have donned or sloping roofs and
interior and exterior painting shall be in accordance with clause 1.6.
The marshalling box, wherever provided shall accommodate the following equipments alternatively
weather proof instruments can be mounted outdoor:
a)Temperature indicators
b)
Control and protection equipment for the local electrical control of tap changer, if the same cannot
be accommodated in the motor driving gear housing.

c)
Control and protection equipment for the cooling plant, and
d)
Terminal boards and gland plates for incoming and outgoing cables.
All the above equipment except (d) shall be mounted on the panels and back of panel wiring shall
be used for interconnection.
The temperature indicators shall be so mounted that the dials are not more than 1600 mm from ground
level and the door(s) of adequate size.
To prevent internal condensation an approved type of metal clad heater shall be provided controlled by a
suitable switch. Ventilation louvers shall be provided.
All incoming cables shall enter the kiosk from the bottom and the gland plate shall be as less then 450
mm from the base of box. The gland plate and associated compartment shall be scaled in suitable
manner to prevent the ingress of moisture from the cable trench.
Undrilled gland plate shall be provided for accordonodating glands for incoming and outgoing cables.
15.0 TRANSFORMER PROTECTION:
1.0
DIFFERENTIAL PROTECTION:
a)
This shall consist of electronic static high impedance biased type differential type.
b)
The percentage bias settings shall be adjustable in steps of 10% over a range of 20 to 80%. The
percentage bias shall however be low near rated current sufficient to allow for OLTC tap variation and CT
errors but shall be increased automatically for severe through faults to ensure stability even under CT
saturation errors.
c)
The relay shall be very fast in operation with an operating time of not more than 20/30 milliseconds
for 4 or 5 times its value under all fault conditions and even in the presence of harmonics and CT
saturation.
d)
The relays shall be inherently stable for external through fault conditions alternatively the relay may
be provided with an unrestrained high set element with a pick up setting equal to 4 to 5 times the rated
current to ensure automatically through fault stability. However to have a quicker operation for severe
internal faults an unrestricted highest elements shall be provided.
e)
The relay shall offer a very low burden to the CT, each relay shall be provided with two sets of
changeover contacts for tripping. It should be possible to connect all such connects of all single phase
relays in tandem to obtain 6 sets close/open contacts for connection to multiple trip coils.
f)
The relay shall be accompanied by inter auxiliary current transformers to match the group of the
power transformers.
g)
Alternatively a 3 phase biased differential relay for the protection of 2 winding transformer having all
the features detailed above and in addition built in intermediate current transformers for matching current
and phase angle and current magnitude compensation by selector switches and easy integral test
facilities to check functions of internal circuits of relays by test push buttons in the panel can be offered.
2.
BACK-UP PROTECTION:
a)
Electronic type back-up protection shall be provided to the transformer.
b)
The protection on the HV side shall consist of three numbers of non-directional IDMT over current
relays and one earth fault relay, Relays to have 3-second characteristics and to be mounted horizontally
in common case.
c)
All over current and earth relays shall be provided with highest instantaneous elements. This
instantaneous element shall whatever applicable be directionalised.

d)
No relays are required for the 6.6 KV side as they will be provided in the 6.6 KV switchgear.
3.
RESTRICTED EARTH FAULT PROTECTION:
An instantaneous single pole circulating current or high impendence voltage type relay with a
suitable setting shall be provided. A stabilizing resistor shall be provided in the relay circuit.
These relays shall be provided on LV side of the contractor.
4.
TRIP CIRCUIT SUPERVISION PROTECTION:
a)
Each circuit breaker shall be provided with a trip circuit supervision relay. The relay shall be
mounted in front of the relay panel associated with these circuit relays.
b)
These relays shall monitor the whole of the trip circuit while the breaker is in open or closed
position and give an alarm for the loss of auxiliary DC supply or for faults in the trip circuit leads or for
faults in the breaker auxiliary contacts or for faults in the supervisory relay itself. The relay shall have a
delay on drop off to avoid a false alarm during a normal tripping operation.
5.
AUXILIARY TRIP RELAYS:
A master trip relay shall be provided to cause inter cropping of all the breakers connected to the
respective transformer winding when any one of the following protection scheme operates:
a)
Differential protection.
b)
Back up protection
c)
Restricted earth protection.
SECTION III
COMPONENTS OF THE TRANSFORMER
The transformer shall generally comprise of the following components/parts.
1)
HV line bushings.
2)
LV line bushings.
3)
LV neutral bushings.
4)
Bi-Metallic terminal connectors for HV.
5)
Bi-Metallic terminal connectors for LV. Cable for XLPE cable connections.
6)
Terminal connector for neutral suitable for connection to G.I.flats.
7)
Monogram plate.
8)
Main conservator with compartment of OLTC as per design with sump, drain valve lifts separate
conservator for OLTC optional as per design.

9)
Oil filling hole with bolted cover for main conservator.
10)
150mm dial magnetic oil level gauge with low level alarm contact.
11)
150mm dial winding temperature indicator with alarm trip contacts and maximum reading pointer.
12)
150mm dial oil temperature indicator with alarm and trip contacts and maximum reading pointer.
13)
Surge protection relay with one set of contact and one isolating valve on conservator side for
OLTC.
14)
Pressure relief device with one set of contact for 220 KV transformers.
15)
Buchholtz relay with alarm and trip contacts two wheel type isolating valves (50mm size) with
directions for mounting marked on Buchholtz relay.

16)
De-hydrating silica gel with oil seal and glass inspection window.
17)
Prismatic oil gauge.
18)
Thermometer pocket.
19)
Air release plugs on main tank and bushing turrets.
20)
Inspection cover lifting lug.
21)
Inspection covers on main tank and side manholes for OLTC conservator.
22)
WTICT test link box with access window for transformer of above 5 MVA capacity.
23)
Bath for oil temperature indicator with probe for capillary tubing.
24)
Bath for winding temperature indicator with probe for capillary tubing.
25)
Marshalling box with PVC copper cable wiring 660/1100 grade (tank mounted weather proof) along
with required control cables for connection to Buchholtz relay, temperature indicator etc.
26)
On-land tap changer with operation counter and single phase preventer if OLTC is of 3 phase 440
V design.
27)
Radiator with top and bottom shut off valve, lifting log, air release and drain plug.
28)
Combined rating and diagram plate and valve schedule line diagram. The rating plate shall be
minimum 1 mm thick anodized cadmium steel plate and it should containing of OLTAC also.
29)
Lifting Bollards.
30)
Jacking pads 500mm above the base with adequate pad area.
31)
Hauiage eyes.
32)
Earthing pads suit to receive plate with M12 tapped holes to suit 4 bolted connections.
33)
Earth connection between tank and cover.
34)
Drain valve with locking arrangement and blanking plate.
35)
Top filter valve (size 50mm) with blanking plate with 38 mm adopter with locking arrangement.
36)
Bottom filter valve (size 50mm) with blanking plate with 38 mm adopter with locking arrangement.
37)
Middle sampling valve (size 15mm) with plugs.
38)
Bottom sampling valve (size 15mm) with plugs.
39)
Piping arrangement from top and middle valve to the level of the bottom filter valve.
40)
Under base skid type.
41)
Bi-directional rollers to suit 1676 mm track with locking arrangements.
42)
Top stay bracket for supporting the conservator.
43)
Fans for cooling with fan control cubicle (if required).
44)
Remote OLTC control panel with 2312 height and 610 mm depth with single phase preventer
protection for driving mechanism motor and AC voltmeter of adequate rating (for 220 KV transformers).
45)
GI/Copper bar (2 Nos of flats) of adequate rating from neutral bushing mounted on insulators to a
convenient point near plate for neutral earth connection with terminal connection.
46)
DETAILS OF BUSHING:
Sl.
No.
MVA
Voltage Category
Rated Voltage (KV Current Amp)

HV Side
LV side
As per Design
1.0
TENDER DRAWINGS AND LITERATURES:

Duplicate copies of following drawings and literatures shall be submitted along with tender.
a)
GA drawing showing dimensional details
b)
Front and rear views of similar transformer with instrument and device position marked.
c)
Photographs of similar transformer supplied by the manufacturer.
d)
Illustrative descriptive literature, general technical data.
2.0
CONTRACT DRAWINGS:
Supplier shall submit drawings in quadruplicate for the approval of the employer prior to
manufacturer in A3/A4 size only. After the drawings are approved six copies of drawings shall be
supplied for immediate use.
The supplier shall forward the drawings and literature as follows:
a)
One set of reproducible originals and 6 sets of blue print copies of all approved drawings along with
6 sets of literature, commissioning and maintenance manuals to the employer.

b)
Four sets of blue print copies of all approved drawings along with four sets of literature and manual
in respect of each of the stations.

c)
Foundation drawings indicating the details of foundation plan cross section suitable for Normal; Dry
Soil taking SBC as 10 Tons/Sq.mt.

d)
Bushing assembly, plan, elevation, sectional view and details of joints, seals etc.,
e)
Radiator assembly: Sectional View of radiator.
f)
Interconnection diagram between Marshalling box and OLTC, Power transformer and other
associated equipments.
g)
Dimensional drawings showing cooling passage in transformer core and windings.
h)
Individual internal wiring diagram of all devices and elementary wiring diagram or relays for internal
wiring.
i)
Construction details of the switches, terminal blocks and test blocks etc.,
j)
Diagram and rating plates as per details in the specification, temperature rise oil and wind high
voltage test figures etc.

k)
Assembly of OLTC gear mechanism: Full details of the main parts, limits and fits wearing parts,
timing gear adjustments etc.

l)
Dimensional drawings showing cooling passage in transformer core and windings.
It may be noted non-supply or part supply of drawings literature and manuals will be deemed as
incomplete supply of Transformer.
3.0
TESTS AT FACTORY:
3.1
The following tests shall be carried out in addition to any other customary tests and seven copies of
test certificates shall be supplied before shipment of the equipment.

a)
Vacuum test with stand strength of tank.
b)
Tests for oil tightness.
c)
Materials tests on core, conductor and insulating materials.
d)
Leakage tests for radiators.
e)
All double weld shall be tested with nitrogen at not less than 7 Kg/Sq.Cm. To ensure that no weld
would sweat.
f)
Routine tests shall be carried out as per IS: 2026.
3.2
TYPE TESTS:
The tender shall submit with his tender, type test reports of type in conformity to IS: 2026.
Type test reports in conformity with clause 17.3 of CBIP manual shall be furnished.
After the completion of the manufacture, the routine tests shall be conducted on each unit. These
would be in conformity with IS: 2026 Clause 16.12 temperature rise test (Type Test) shall be
conducted at manufacturers factory.
The zero sequence test shall be conducted on each unit. This would in conformity with IS: 2026
Clause 16.13.
INSPECTION:
The inspection may be carried out by the employer at any stage of manufacture. The supplier shall
arrange free access to the employers representative at a reasonable time when the work is in progress.
Inspection and acceptance of any equipment under this specification by the employer shall not relieve the
supplier of his obligation of furnishing equipment in accordance with the specification and shall not
prevent subsequent rejection if the equipment is found to be defective.
The supplier shall keep the employer informed in advance about the manufacturing program so
that arrangement can be made for inspection.
The employer reserves the right to insist for witnessing the acceptance/routine testing of the bought out
item.
No material shall be dispatched from its point of manufacture unless the material has been satisfactory
inspected and tested unless the employer in writing waives the same.
AUXILIARY TRANSFORMER:
3.2.1
SCOPE
The specification given here below covers manufacture, testing at works, transportation including loading
at works, unloading at site, erection, commissioning, insurance, supply of outdoor plinth mounting 3
phase 50 cycles core type, oil immersed self cooled station Transformers confirming to IS: 2026 as
mended up-to-date. CBIP specification for distribution transformers and also applicable standards
mentioned in specification.
3.2.2
SYSTEM DETAILS:
The transformers, shall be suitable for outdoor installation in substations on 3 phase, 50 cycles, system in
which the neutral is effectively earthed and it should be suitable for service under fluctuations in supply
voltage upto as given elsewhere in this specification under the heading of Tap Changing Equipment.
3.2.3
STANDARDS:
It is not the intent to specify completely herein all details of design and construction of equipment.
However, the design, manufacture and performance of station transformers shall comply with all currently
applicable standards, regulations and safely codes in the locality where the equipment will be installed.
Unless, otherwise specified the equipment shall confirm to the latest Indian Standards and in particular to
the requirements as detailed below. The equipment shall be capable of continuous commercial operation
upto tenders guarantee in a manner acceptable to the purchaser who will interpret the meaning of the
drawing and specifications and shall have the power to reject any work and/or material which in his
judgment are not in full accordance therewith.
IS: 335
Insulating oil for transformer and switch gear
IS: 180
Distribution transformers
IS: 1886
Code of practice installation and maintenance of transformers
IS: 2026
Power transformers
IS: 2099
Bushings for alternating voltage above 1000 V.
IS: 3347
Dimensions for porcelain transformer bushings
IS: 3401
Silica Gel
IS: 4253
Cork and Rubber
IS: 5561
Electric power Connector
IS: 6600
Guide for loading of oil immersed transformers.
3.2.4 DESIGN AND CONSTRUCTIONAL DETAILS:

3.2.4.1 TRANSFORMER TANK:
The transformer tan shall be of robust construction and shall be built up of electrically welded polished
plates of suitable thickness (minimum 5 mm). All the joints of the transformer tank and fittings shall be hot
oil tight.
The transformer tank and tank cover shall be provided with suitable lifting lugs pulling eyes, etc. to
facilitate handling during erection maintenance over hauling transport etc.
The tank shall be of such that the complete transformer when filled oil may be shifted by the lifting lugs
provided. The tank shall be fitted with a suitable cover having necessary provisions for fixing of the
external fitting and accessories on the transformer.
The tank shall be of welded construction and fabricated out of tested qualify carbon steel.
All seams and joints shall be factory welded. Wherever possible they shall be double welded and all
welding shall preferably be stress relieved.
Tank stiffeners shall be provided for general rigidity and these shall be designed to prevent retention of
water.
The tank shall be designed to withstand.
Mechanical shocks during transportation.
Vacuum tilling of oil.
Continuous internal pressure of 0.35 Kg/cm2 over normal hydrostatic pressure of oil.
Wherever possible the transformer tank and it is accessories shall be designed without pocket wherein
gas may collect. Where pockets cannot be avoided pipes shall be provided to vent the gas into the main
expansion pipe.
Suitable guides shall be provided in the tank of positioning the core and coil assembly.
Adequate space shall be provided at the bottom of the tank for collection of sediment.
3.2.4.2 TANK COVER:
The tank cover shall be slotted to prevent retention of rainwater and shall not distort when lifted.
All bolted connections shall be fitted with weather proof, hot oil resistant gasket in between for c omplete
oil tightness. If gasket is compressible metallic stops shall be provided to prevent over compression.
The bushing explosion vent, radiators etc shall be so designed as to prevent ingress of water into or
leakage of oil from the tank.
3.2.4.3 BASE CHANNELS:
The transformers are required to be provided with channel, preferably of 100 mm x 50mm size of 6mm
thickness which shall be welded to the main tank body of the transformer. The base channels shall be
equidistant from the line of center of gravity of the transformer falling through its base, laid at a distance
of preferably 600 mm from each other. The holes of 22 mm (dia) shall be drilled into the base channels at
a distance of preferably 750 mm center to center from each other.
3.2.4.4 CONSERVATOR TANK:
The conservator tank shall have adequate capacity between highest and lowest visible levels to meet the
requirement of expansion of the total cold oil volume in the transformer and cooling equipment from
minimum ambient temperature to 900C.
The conservator tank shall be bolted into position so that it can be removed for cleaning purposes.
The conservator tank shall be provided in such a position as not to obstruct the electrical connections to
the transformer.
3.2.4.5 PRESSURE RELIEF DEVICE:

The pressure relief device provided shall be of sufficient size for rapid release of my pressure that may be
generated in the tank and which may result in damage of the equipment. The device shall operate at a
static pressure of less than hydraulic test pressure of transformer tank.
3.2.4.6 EARTHING TERMINALS:
Two earthing pads suitable for connection 50 x 60mm mild steel flat shall be provided at positions close
to each of the two bottom corners of tank. These grounding terminals should be suitable for bolted
connection.
3.2.4.7 CORE:
The core shall be constructed from high grade non-ageing cold rolled grain oriented silicon steel
laminations.
The design of the magnetic circuit shall be such as to avoid static discharges, development of short circuit
paths within itself or to the earthed clamping structure and production of flux component right angles to
the plane of laminations which may cause local heating.
The insulation of core to bolts and core to clamp plates shall be able to withstand a voltage of 2 KV RMS
for 1 minutes.
Cores and windings shall be capable of withstanding shocks during transport, installation, service and
adequate provision shall be made to prevent movement of core and winding relative to tank during these
conditions.
The core insulation shall be hot oil proof. The core clamping bolts shall be effectively insulated. The
transformer core shall be so fabricated as to reduce to minimum possibilities of vibration and noise when
in service.
The complete design of the core must ensure that the losses with continuous working of the transformer
are kept to the barest minimum. The value of the flux density allowed in the design and grade of the
lamination used shall be clearly stated in offer. Under no circumstances shall the flux density exceed 1.85
Tesla.
3.2.4.3 WINDINGS:
The conductors of the windings shall be copper. The insulation of the transformer windings and
connections shall be free from insulating compounds which are liable to soften, ooze out, shrink or
collapse and be non-catalytic and chemically insert in transformer oil during service.
Coil assembly and insulating spares shall be so arranged as to ensure free circulation of oil and to reduce
the hot spot of winding.
All the copper plates are exposed to atmosphere shall be tinned or nickel plated. 4 nuts and 3 washers
are to be used for each phase of both IIV & IV side.
3.2.4.4 INSULATING OIL:

The insulating oil used in the transformer shall be non-sluding with medium velocity and confirming to IS
335 1972 (and/or amendments, if any). Sufficient quantity of oil for first filling of the transform er shall be
supplied duly filled in.
The oil shall be filtered at manufactures work before first filling in assembled transformer and the di electric insulation strength as well as acidity tests shall be performed and their results shall be as per
relevant IS.
3.2.4.5 OIL PRESERVATION EQUIPMENT:
Conservator should breath to the atmosphere through a dehydrating filter breather. The dehydrating filter
breather shall be so designed that.
1.
Passage of air is through a dust filter and silica gel.
2.
Silica gel is isolated from atmosphere by an oil scale.
3.
Moisture absorption indicated by a change in colour of the tinted crystals can be easily observed
from distance.
4.
Breather is mounted not more than 1400 mm above ground level.
3.2.4.6 TERMINAL ARRANGEMENT:

Oil communicating type bushing shall be provided for IIV as well as LV terminals, including the neutral of
LV side. The high voltage bushing shall be made from the porcelain by the wet process and shall be free
from defects and smoothly glazed and shall be suitable for ACSR connectio ns. Bushings of the some
voltage class shall be interchangeable. The bushings used for all 6.6 KV voltage should be of 7.2 KV
class having the creepage distance 95 mm per KV with protected creepage distance 50% thereof. HV
busing shall have electrical characteristics as per IS: 2099 (latest). Copper arcing horns shall be provided
for HV bushings. The HV bushings stem shall be provided with suitable 1 type connector suitable for one
No.400 mm2 cable lugs and four brass nuts with check nuts and 4 brass washer with each lug for
tightening. The HV bushing shall be provided with connectors suitable for ACSR connection and each
bushing shall be provided with Nos brass washers. All the brass washers shall have minimum thickness
of 3 mm. All the brass washers and nuts shall be electrically tinned.
The HV & LV bushing shall properly mounted in straight lines parallel to each other along the length of
the transformer tank.
All the bushing of the LV side shall be covered with water retention proof metal sheet box of suitable
thickness (min .3 mm thick or of the nearest sheet gauge available) with 2 separate clamps on the bottom
side suitable for 400 mm armored PVC Coutgoingeable.
3.2.4.7 TERMINAL MARKINGS:

The terminal marking and physical position shall be in accordance with IS: 2026. The transformer shall
provided with a terminal marketing plate made of anodized aluminum or brass fitted with brass screws
showing the relative physical positions of the terminal and their marketings. The position of the tapping
connections shall also be shown in the plate and also the corresponding tapping voltages shall be
indicated there upon. The transformer shall be provided with rating, diagram and property plate furnishing
the information specified in IS: 2026. The rating and marking may be combined in one plate provided the
tenderer obtained the prior permission from the purchaser. The name of the purchaser viz Karnataka
KBJNL, Bangalore 560001 shall also be inscribed in bold capital letters upon the above mentioned
plate. Also the tender no against which the transformer has been manufactured all property, diagram and
other plates and labels shall be anodized aluminum fitted with brass screws mentioned above.
3.2.4.8 TAP CHANGING EQUIPMENT:
The transformer shall be provided with tap changing d evice off load type on the HV side to suit +/75% voltage in seven steps.
The tap change, switch shall be 3 phase and suitable for simultaneous switching of similar taps on the 3
phases operated by an external hand wheel. This hand wheel shall be easily operated by a man.
Arrangement shall be provided for securing and pad locking the tap changer wheel in any of the working
positions and it shall not be provide for setting or padlocking the wheel in any intermediate position. The
arrangement shall be such be such that no padlocking can be inserted unless all the taps are correctly
engaged and the switch set in position here no open short circuit is possible. An indicating device shall be
provided to show the tap in use.
3.2.4.9 NEUTRAL TERMINAL ARRANGEMENT:
The neutral terminal shall be provided with nuts and washers so as to award making of twin earthing
connections to it by means of 8 mm. Thickness copper flats.
3.2.4.10 PAINTING & FINSHING:
The exterior of the transformer and other ferrous parts shall be thoroughly cleaned, scrapped and given
one primary coat of zinc chromate and 2 finishing coats of durable oil and whether resisting enamel. The
color of the finishing coat shall be Mid Bronze Green confirming to shed No.233 of IS: 5 (colors of ready
mix paint).
All steel surfaces in contact with insulating oil shall be painted with 2 coats of heat resistant, oil insoluble,
insulating varnish.
All paint shall be carefully selected to withstand heat and extremes if the weather. The paint shall not
scale or crinkle or be removed by abrasion due to normal handling . the paints shall be of reputed make.
3.2.4.11 BOLTS AND NUTS:

Washers, nuts and bolts used shall be of reputed make and its mention made on the general
arrangement drawing.
Steel bolts and nuts of size 12mm and above which are exposed to atmosphere shall be of hot dip
galvanized. The weight of zinc coating on nuts, bolts and washers shall not be less than 600 gms/mm 2.
Nuts and bolts below 12mm size shall be of non-magnetic stainless steel. The chromium contents of the
stainless steel shall not be less than 16 %. Similarly all the plain washers shall be hot dip galvanized if
steel or wrought weight iron and min, thickness shall be
3 mm. Otherwise the washer shall be of
stainless steel, chromium contents of which shall not be less than 16%.
For sizes of 12mm and above, the spring washers shall be of reputed make and electro galvanized and of
thickness min. 3mm. For smaller sizes these shall be of non-magnetic stainless of spring steel grade.
All nut, bolts and pins shall be locked in position with the exception of those external to the transformer.
On outdoor equipment, all bolts, nuts and wisher in contact with non-ferrous parts, which carry current,
shall be of phosphor bronze of finned/ nickel plated brass where the trans fer current is through the bolts.
The percentage wise composition of the element in phosphor, bronze, etc., shall invariably be brought out
in the tender bid by the supplier.
3.2.4.12 RADIATOR TUBES FOR OIL COOLING:
Whenever the transformer offered is having radiator tubes for the cooling the oil, it shall be ensured that
the tubes are made of the finest grade structural steel. The grade of the steel used for the cooling tubes
shall be quoted in the tender bid. The thickness of the tube shall be min.3min. The sam e can be
preferably hot dip galvanized. If non-galvanized the same shall be painted properly in accordance with
the instructions contained in the specification for the painting of the transformer tank etc. If painted
cooling tubes or radiator have been offered, it shall be ensured that the clear spacing between (I) tubes,
(II) radiator fins (III) between the wall of the tank and the nearest surface of the cooling tube/ radiator fins
as the case may be shall not in any case be less than 50 mm.
Suitable drainage holes, oil filling holes, air release holes with plug, oil filling valves and oil drain valves
and valves for flirtation of oil shall be provided on the transformer.
The arrangement and the no. Of valve, plugs etc., to be provided for transformer shall be subject to the
approval of the purchaser or subsequent to the placement of the order.
The make of the valves shall be declared in the tender bid. However, the valves shall be only of reputed
makes and not otherwise. All the valves shall be provided with a removable blanking plate.
The joints between flanged oil pipes shall be made, preferably, by means of O rings. The material of the
gasket used for making oil leakage proof joins shall be such as to hot oil resistant and which does not
deteriorate under the surface conditions obtainable.
Attention in particular is invited to the arrangement of radiator tubes/ tubes with respect to the location of
HV & LV bushings shall be along the longitudinal sides of the tank whereas radiator tubes/ banks shall be
along with width sides of the tank of the transformer.
3.2.4.13 FITTINGS AND ACCESSORIES:
GENERAL
Each transformer shall be provided with the fittings and accessories as given in this specification. The list
of fittings and accessories as given in this specification is not necessarily exhaustive. The tender shall
include in the scope of supply all such equipment, fittings and accessories and other miscellaneous items
as are required for the efficient operation of transformer under site conditions and for its mainte nance.
Expert in so far as otherwise provided in this specification, all fittings and accessories shall generally be
located in the position as specified in IS: 2026 and the CBIP specification for power transformers.
All the fitting and accessories and other equipment supplied with the transformers shall be suitably
mounted on the transformers or installed nearby for ease of operation inspection and maintenance. The
arrangements of mounting or installing of these items shall be subject to the approval of the purchaser.
FITTINGS:
The transformer fittings to be provided with each transformer are as follows:
1.
Conservator with oil filling hoes, cap, drain valve, air vent pipe, filtration valves etc. 1 No.
2.
Pressure relief device either explosion vent (or pressure release valve, capable or resealing after
release of the pressure) 1 No.

3.
Air release devices.
4.
Dehydrating breather with first filling activated Alumina or Silica Gel and with Oil scal: 1 No.
5.
Diagram, Rating and property plate of the transformer.
6.
Terminal marketing plates.
7.
2 Nos of earthing terminals on the transformer tank body width lugs suitable for clamping
grounding terminal.
8.
Prismatic / toughened glass oil level gauge on the conservator: 1 No.
9.
A good quality thermometer measuring upto 13000 C temperature and suitable thermometer
pockets located on tank cover for measurement for top oil temperature. The thermometer pockets shall
be provided with screwed type brass caps which shall be Water retention proof.
10.
Oil sampling valves: 2 Nos from the top and bottom of the main tank to be provided at the bottom
level of the tank.

11.
Oil drain valve with pad locking arrangement.
12.
Filter valves (min. size 1 1/4th) with outlets at diagonally opposite ends on HV bushing side of the
transformer tank with pad looking arrangement.
13.
Pulling eyes and lifting lugs for pulling the transformer along with longer and shorter axis and lifting
the complete transformer, tank, core coil etc.

14.
Terminals are specified elsewhere.
15.
4 Nos of steel rollers with axles etc.
16.
Radiator of fixed type on the width side of the transformer.
17.
Off load tap changer with associate drive, gear, tap changer, hand wheel having arrangement as
specified elsewhere in the specification.

18.
HV bushing: 3 Nos.
19.
LV bushing: 4 Nos (The bushing shall be provided with connectors / lugs, plain washers and brass
nuts as specified elsewhere).

20.
Arcing horns made of copper for the HV bushing.
21.
Insulating oil for first filling for the transformer with 10% extra by weight.
22.
Gasket.
23.
Platform mounting channels as specified elsewhere: 2 Nos (with holes suitable for fixing the axis of
the roller and also for mounting the transformer either on the plinth or on the poles).
24.
Following spares items should be provided.
25.
Diaphragm for explosion vent: 2 Nos.
26.
Glass for oil gauge: 1 No.
27.
HV bushing: 3 Nos.
28.
HV bushing: 3 Nos.
Note 1: All valves shall be provided either with blind companion flanges or with pipe and plug for
protection.
Note 2: The fitting listed above are only indicative and any other fittings which are generally
required for satisfactory operation of the transformer are deemed to be included.
3.2.5 ELECTRICAL CHARACTERISTICS AND PERFORMANCE:
The maximum hot spot temperature shall be limited to 105 0 C under all operating conditions in service.
The basic ambient temperature and temperature rises shall be as specified below:
Max. ambient air temperature
500 C
Max. daily average ambient temperature
400 C
Max. yearly weighted average ambient temperature
320 C
Max. temperature rise in windings.
As per IS
Max. temperature rise in oil
1977 as amended
Max. temperature rise in core etc.
Upto date.
The temperature rise test as per IS: 2026 part H is required to be satisfactorily conducted at the tap which
gives maximum loss at rated full load.
The transformer shall be suitable for operation without danger on any particular tapping at the rated KVA
provided that the voltage does not vary byu more than 10% of the voltage corresponding to the tapping.
3.2.5.1 IMPEDANCE:
The impedance voltage at the normal tap with rated KVA inclusive of the permissible tolerance as per IS
2026 expressed as percentage at 750 C shall not be lower than 4% and more than 5%. The value of
impedance at all other tapings and tolerance there upon shall be stated by the tenderer in the bid. The
upper and lower impedance which can be offered by the tenderer without any increase in the quoted Pq =
(i) at normal tap and (ii) at extreme taps shall also be stated in the bid by him.
The use of additional series reactors for obtaining the specified percentage impedance between the
windings shall not be permitted.
3.2.5.2 FLUX DENSITY:
The maximum magnetic flux density in any part of the core and yokes of the transformer at the rated KVA
at normal voltage and frequency shall be such that and flux density under over voltage conditions as
given in this specification shall not exceed 1.85 Tesla.
3.2.5.3 VARIATION AND NOISE:
Every care shall be taken to ensure that the design, and manufacture of the transformer and its auxiliary
plant shall be such as to reduce noise and vibrations to the level of that obtained in good modern
practice. The supplier shall ensure that the noise level shall not exceed Sdb above the NEEMA standard
publication TR 1.
3.2.5.4 SUPPERSSION OF HARMONICS:
The transformer shall be designed with particular attention to the suppression of Harmo nic voltages,
especially the 3rd and the 5th so as to eliminate wave form distortion and any possibility of high
frequency disturbances, inductive effects or circulating currents between the neutral points at different
transforming stations reach such a magnitude as to cause interference with the communication circuits.
3.2.5.5 INSULATION LEVELS: WINDINGS:
The Di-electric strength of the insulation of windings shall be as per IS: 2962.
3.2.5.6 CLASS OF INSULATION:
The class of insulation for each winding should be F.
3.2.5.7 BUSHING AND OH:
The insulation level of bushings shall be in conformity with the values as specified elsewhere in this
specification in accordance with IS: 2099. The Dielectric strength of the transformer oil has been specified
separately under the heading of transformer oil.
3.2.5.8 ABBREVIATED NOTATION FOR INSULATION LEVELS:

The rating and diagram plate of the transformer shall incorporate the insulation levels of each winding as
per the abbreviated notation given for this purpose in IS: 2026, Part III (1981).
3.2.5.9 DUTY UNDER CONDITION:
The transformer shall be designed to be capable of withstanding without injury, thermal and mechanical
stress due to short circuit at the terminals of the winding for period of 3 seconds as specified in the IS:
2026. The transformer may be directly connected to underground or overhead transmission line and
switched into and out of service together with its associated transmission line.
The current density in any winding based on the RMS value of the initial symmetrical component of the
fault current shall not exceed the appropriate value as indicated in IS: 2026.
The tender should clearly indicate in his bid the method he has adopted to ensure that the winding etc.,
are not electrically and mechanically deformed, damaged under even the severes t short circuit conditions
the provision for making the winding stable under the short circuit conditions shall be supported by the
design calculations.
3.3
OUTDOOR TYPE SF6 CIRCUIT BREAKING: 220 KV
3.3.1 STANDARDS
Sl. No.
Standards
Description
1.
IS: 2516
Specification for outdoor Circuit Breaker
2.
IEC056
Specification for outdoor Circuit Breaker
3.
ICE 376
Specification for SE6 Gas.
3.3.2 TECHNICAL PARAMETERS

1.
Rated Voltage
220 kv line
2.
System Frequency
50 Hz
3.
Continuous Current Rating
As per requirement
4.
System Neutral Grounding
Delta Connected System
5.
Mounting
On hot dip galvanized steel support

structure.
6.
Type of operation
7.
Min. height to the lowest live part from :
Three single poles gang operated

2500 mm.
ground level
8.
Rated Operating Duty Cycle
As per IEC 56
9.
Min. Closing Time
10 Max. Total break time at rated breaking :

.
160 ms
As per design
capacity
11 1.2/50 a sec. Impulse withstand voltage
As per design
As per design
As per IEC 56
900 C
450 C
.
12 One Minute power frequency withstand
.
voltage
13 Short Circuit Current and duration

.
14 Permissible Limit of Temp:
.
i)
Max Permissible Temp
ii)
Temp. Rise at a Max. Air Temp.
not exceeding 450 C

3.3.3 OTHER CONSIDERATIONS:
The above breakers will be required to break small inductive current and line charging current without
causing excessive over voltage and charging current without restrike.
The breaker shall consist of three single phase units linked together electrically. The basic design, shall
be such that the closing and tripping time of individual pole shall be constant, under all conditions of faults
or normal tripping at specified range of pressure and temperature. All the three phases will be required to
open or close at atime and within the specified range of pole discrepancy.
The breaker shall be suitable for electrical local as well as remote operation from the control room. In
addition to this there shall be provision for local manual closing and tripping in case of failure of control
supply. The operating mechanism shall be spring charging type by electrical control under normal
operation. The mechanism shall be adequately designed for specified closing and tripping duty. The
entire operating mechanism, control circuitry spring motor etc., as required shall be housed in outdoor
type (waterproof), sheet steel box.
The box shall confirm to the degree of protection IP-55 of IS: 2147 and shall be mounted on a separate
concrete plinth of approx. 300 mm height.
3.3.3.1 CONTROL CIRCUITS
The breaker control circuit shall include the following features:
1.
Electrically independent trip circuit.
2.
One local/ remote selection switch.
3.
Conveniently located manual emergency trip.
4.
While opening and / or closing, all three poles shall operate simultaneously.
5.
Anti pumping feature.
6.
Independence of trip circuit from local/remote section.
7.
Alarms, indications, monitoring equipment and interlocks as specified elsewhere.
8.
Auxiliary switches each operating mechanism of the circuit breaker shall be provided with auxiliary
switches with ten (10) No. and ten (10) No. contacts exclusively the purchasers use. With continuous
rating of at least 10 A.D.C. breaking capacity of the contact shall be min. 2 Amp with circuit. Time
constant less than 20 mili seconds at the rate D.C. voltage, Normal position of auxiliary switches refers to
contact position when circuit breaker is open.
9.
Trip circuit supervision for pre-tips as well as post trip.
3.3.3.2 ALARM AND INDICATIONS:

Potential free contact shall be provided, duly wired upto the operating mechanism housing
control cabinet for the following alarm and indications on the control panel.
3.3.3.2.1
ALARAMS
1.
General lockout for SF 6 Gas.
2.
Low pressure of SF 6 Gas.
3.
Control Circuit unhealthy.
4.
Auxiliary D.C. supply failure.
3.3.3.2.2
INDICATIONS
i.
Breaker on off.
ii.
Spring charged.
3.3.3.2.3
MECHANICAL INDICATIONS
The operating mechanism housing shall be provided with the following Mechanical Indicting/
Counters.
i.
Breaker on-off.
ii.
Operating counter to register the No. of Breaker operations.
3.3.3.2.4
SF6 GAS AND FEATURES
The SF-6 breakers, shall be supplied with first filling of SF 06 gas with excellent insulating and nonpoisonous are extinguishing property.
Following features shall be provided for monitoring of SF 6 Gas in the breaker.
i)
SF-6 gas density meter with two potential free contacts of suitab le rating. One of these contacts
shall be used for annunciation of low density. The other contact shall be used by the supplier to ensure
breaker lockout in the event of low SF-6 Gas density. The successful bidder shall furnish a chart showing
relation between pressure and density of SF-6 Gas, as well as settings for alarm and lockout.
ii)
Suitable pressure gauges shall be provided for SF-6 Gas. Gauge drafts shall be clearly visible with
naked eye to an observer standing on ground.

iii)
Adequate no. of pressure switches shall be provided for monitoring pressure of SF-6 gas. The
pressure switches shall be provided with sufficient number of potential fee NO and NC contacts for
purchasers use in control, protection and alarm circuit.
The bidder shall furnish along with the bid, detailed schematic drawing showing all type of control
protection, monitoring schemes to be employed by him. The successful bidder shall be required to modify
the schemes, if necessary after discussion with the purchaser. Closing coil shall operate correctly at all
values of voltage between 85% and 110% at the rate control voltage and trip coil shall operate correctly a
values of voltage between 70% and 110% of the rated control voltage.
3.3.3.3 TAKE OF TERMINAL PADS
Terminal pads shall be provided with silver plating of at least 25 microns thickness as these are made of
metal other than Aluminums. No such plating shall be required if the terminal pad is made out of
Aluminum. The pads shall be suitably designed to take the approximate terminal loads, spec ified below.
The breaker shall be designed to withstand the rated terminal load, wind load/ earthquake load and short
circuit forces. The short circuit forces to be considered for the design shall be based on length of bus bars
consisting of conductors and phase spacing shown below.
VOLTAGE
PHASE TO PHASE SPACING
220 kv
As per design
The current density adopted for the design of the terminal pad shall in no case exceed 1.6A/Sq.mm for
pad made of other material.
The vertical clearance of lowest terminal pad from ground level (including concrete foundation plinth)
shall be as given below. In no case the height less than that indicated will be accepted.
220 KV breaker as per design
3.3.3.4 PORCELAIN HOUSING:
The porcelain Housing for the interrupter shall be of a single piece construction without any joint. It shall
be made of homogeneous. Vitreous porcelain of high mechanical dielectric strength. Glassing of
porcelain of high mechanical dielectric strength. Glassing of porcelain shall be of uniform brown or dark
brown color with a surface arranged to shed away rainwater or condensed water particles (fog).
Breaking units shall be mounted on insulator column. The clearance in air from the lower line terminal to
earth shall be as per standards.
3.3.3.5 GALVANIZING:
All ferrous parts including nuts, bolts, place and spring washers of size M10 and above, support
channels, confirming structures etc, shall be hot dip galvanized to latest IS: 2629 or any other equivalent
authoritative standard. All other fixing nuts, bolts washers o f size below M10 shall be made out of
stainless steel.
3.3.3.6 MOUNTING:
The design and supply of structure required for mounting the circuit breaker in purchasers switchyard
shall be in the suppliers scope. The suppliers scope also includes foundation nuts, bo lts, plain and
spring washers etc., necessary for the support structure. The support structure can be lattice type and
shall be made out of hot dip galvanized steel. Wheel mounted type support shall not be accepted. The
support structure shall be installed on a concrete plinth of 300 mm height. The height of support structure
shall meet the following requirements.
Vertical clearance of lowest terminal and as specified in above.
The circuit breaker shall be connected to adjacent equipment in the switch yard through ACSR conductor.
The loading data to be considered by the supplier for design of support structure shall include the
following:
i)
Dead weight of the circuit breaker, structure, bus bars.
ii)
Operational steady state and impact loading.
iii)
Wind load on the circuit breaker, structure, bus bar.
iv)
Short circuit forces.
The support structure shall be designed on the basis of applicable Indian / International standards and
codes of practice.
The successful bidder shall furnish following details along with first lot of drawings to be submitted by him.
i)
Mechanical loading data considered for design of support structure. This data should be supported
by calculations.
ii)
Detailed structural design calculations.
3.3.3.7 EARTHING:
The operating mechanism housing, support structure etc., shall be provided with two separate earthing
terminals for bolted connected top 50 x 8 mm M/S flat for connection to station earthmat. The connecting
point shall be clearly marked.
220 KV AIR BREAK SWITCH (ISOLATORS):

3.3.4 STANDARDS:
Sl. No.
Standards
Description
1.
IS: 9921
Specification
for
A.C.
Disconnectors
(Isolator) and earth switch.

2.
IS: 2544
Insulators.
3.3.5 OTHER CONSIDERATIONS

The isolator shall be provided on structure. The height shall be such that the line terminal shall be 4600
mm above top of the finished ground level / gravel level of the outdoor switchyard.
The isolator shall be three phase manually gang operated, horizontal, double break type with turn and
twist type moving blades and with gang operated vertical break earth blades having suitable short time
current rating. The isolators shall be equipped with hot dip galvanized channel iron base, post type
insulator suitable for pedestal type mounting self-aligning copper or copper ally, heavily tinned high
pressure contacts. The shape of the contacts shall be such as to avoid pitting caused of earthing blades
and contacts shall be the same as those of main switch and moving contacts respectively. Cross
sectional area of earthing blades and contacts shall not be less than 50% of cross sectio nal area of main
blade and contacts. The earthing blades shall have the same short circuit current rating (thermal and
dynamic) as that of main switch.
The insulator shall be made of homogeneous and vitreous porcelain of light mechanical and dielectric
strength. It shall have sufficient mechanical strength to sustain electrical and mechanical loading. All
moving parts shall be suitably balanced so that the switch operates smoothly and is thoroughly co ntrolled
at all stages of closing or opening movements without vibration or shock. Means shall be provided on all
devices for taking up the lost motion in opening mechanism and for adjusting the travel each blade
independently. The isolator shall remain in position in case of heavy shock due to earthquakes.
Isolator shall be provided with manually operated mechanism, gang operated through crank and
reduction gear for main switch and level / hand on the operating shaft for earth switch. The isolator shall
be operated with minimum force and ease. The operating mechanism shall provide quick, simple and
effective operation. The operating mechanism shall be suitable to hold the main switch and earth switch
in closed or opened position at any circumstances. Operating mechanism shall be equipped with four
numbers of NC and four numbers of NO contacts and separate and reliable auxiliary switches exclusively
for inter locking and protection scheme.
Separate operating box shall be provided for earth switch Provision for electro mechanical locking for
open or close position of earth switch shall be provided. Auxiliary switches indication circuit and provision
for electrical interlocking shall be provided in the control circuit of earth switch.
Following interlock shall be provided:
1.
Interlock between isolator and associated circuit breaker so that isolator may be operated only
when the breaker is open.

2.
Electro-mechanical interlock is provided between earth switch and main switch so that the
operation of the earth switch is possible only when the isolator is in open position.
3.3.5.1 EARTHING:
Flexible copper connections shall be provided between rotating earth blads and the frame which shall
have a cross section at least 50 mm and shall be tinned or suitably treated against corrosion.
The frame of each disconnect earthing switch shall be provided with two reliable earthing terminals for
connectors to the purchasers earthing conductor/flat so also clamping screw suitable for carrying
specified short time current. Flexible ground connections shall be provided for connecting operating
handle to the earthing flat. The diameter of clamping screw shall be at least 12 mm. The connecting point
shall be marked with earth symbol.
3.3.5.2 TECHNICAL PARAMETERS:
The principle technical parameters of the isolators are given below:
Sl. No.
Technical Parameter
Requirement
i)
Rated frequency (Hz)
50Hz
ii)
System neutral earthing
Earthed
iii)
No. of phase (poles)
iv)
Temp. rise
As per relevant IS/IEC publication
v)
Rated voltage
As per requirement
vi)
Type of disconnect (AB)
Double break center pole rotating
vii)
Rated normal current (Amps)
As per requirement
viii)
Short time current (KA)
25
ix)
Special requirement
a.
Earthing blades shall be capable to

discharge the trapped charge of the
line.
b.
Isolator main switch shall be required

to make or break the line charging
current when no significant change in

voltage occurs the isolating distance
on account of make or breaker.
x)
Basic Insulation level

i) Lighting
impulse
withstand
As per design
voltage to earth.
ii) Rated power freq. Withstand
voltage to earth.
As per design
xi)
Min. creepage distance
As per design
xii)
phase to phase spacing for As per design

installation
xiii)
Height of center line of terminal
As per design
pad above ground level

3.3.5.3 INSTRUMENT TRANSFORMERS:
The insulation of the instrument transformer shall be so designed that the internal insulation shall have
higher electrical withstand capability than the external insulation.
The dielectric withstand values specified in this specifications shall be for fully assembled instrument
transformer.
The porcelain housing shall be of a single piece construction without any joint or coupling. The vertical
clearance of porcelain housing shall be at least 450mm.
Insulating oil required for first filling of the instrument transformers shall be cov ered in suppliers scope of
supply. The oil shall meet the requirements of latest IS: 335.
The instrument transformers shall be vacuum filled with oil after processing and thereafter hermetically
sealed to eliminate breathing and to prevent air and moisture from entering the tanks.
The instrument transformers shall be complete with all fittings, drain and sampling valves, earthing
terminals, terminal box etc., and shall withstand satisfactorily dielectric test voltage corresponding to
basic insulation level.
Instrument transformers provided with nitrogen cushion for compensation of oil volume variation shall be
provided with prismatic type oil sight window at suitable location so that the oil level is clearly visible with
naked eye to an observer standing at ground level. If metal bellow is used for the above purpose a
ground glass window shall be provided to monitor the position of metal below.
For compensation of variation in volume of the oil due to temperature variation nitrogen cushion or
stainless steel bellows shall be used. Rubber diaphragms shall be permitted for this purpose.
Metal tanks for instrument transformers shall be provided with two separate earthing terminals for bolted
connection by 50 x 8 mm flats for connection to station earth.
Instrument transformers shall provided with suitable lifting arrangement to lift the entire unit. Lifting
arrangement (lifting eye) shall be positioned in such a way so as to avoid any damage to the porcelain
housing or the tanks during the process of lifting for installation / transport. The general arrangement
drawing shall show clearly the lifting arrangements provided such as lifting type guide etc.
3.3.5.4 CURRENT TRANSFORMERS
3.3.5.5 STANDARDS
Sl. No.
Standards
Description
1.
IS: 2705
Current transformers
2.
IS: 2099
Specification for bushing for alternating

voltages above 10000v
3.
IS: 3347
Specification
for
porcelain
transformer
bushing,
OTHER CONSIDERATIONS:
The 220 KV current transformers shall be provided on the structure. The height of the structure shall be
such that the line terminal shall be 4500 mm, ground level/gravel level.
The C.T. Secondary terminals shall be brought out in a weatherproof terminal box.
The terminal box shall be provided with a removable gland plate and glands. Polarity shall be invariably
marked on each primary and secondary terminal. Facility shall be provided for short circuiting and
grounding of the C.T. secondary terminals inside the terminal box.
The cable glands shall be suitable for 1100 volts grade. PVC sheathed multi core 6 Sq.mm. s tranded
copper conductor PVC cable. The terminal box shall be dust vermin proof.
The C.T. characteristics shall be such as to provide satisfactory performance for burdens ranging from
25% to 100% or rated burden over a range of 10% to 100% or rated current in ease of relaying CTs.
3.3.5.6 TECHNICAL SPECIFICATIONS:

Current transformer shall be as per Technical Specifications given below:
Sl.
ITEM
No.
1.
Type of C.T./Installation
220 KV
Single phase /dead tank/outdoor/oil filled
& hermetically sealed.
2.
Type of mounting
CT mounting structure
3.
Suitable for system
50 Hz
4.
Method of earthing the system to be Effectively earthed (solidly grounded)

connected
5.
Rated continuous terminal current (A)
120% of the rated primary current
6.
Acceptable limit or temperature rise As per IS: 2705

above specified ambient temperatures
for continuous operation at rated current.
7.
Core purpose
Protection /metering
8.
Rated insulation class (KV rms)
220 KV
9.
3 Sec. Insulation level (KVP)
170
10.
1 min. dry power frequency withstand 70

voltage primary (KV rms)
11.
Power frequency over voltage withstand
As per Clause 7.4 & 7.5 of IS: 2705 (Part
requirement for secondary winding (HV I) 1981

rms)
12.
Minimum creepage distance of porcelain 25 mm per KV

housing (mm)
13.
Rated short time current (KA rms)
14.
Core details
25
a.
Core No.1
Differential protection for TR =-0
b.
Core No.2
Metering
c.
Core No.3
Back up protection
d.
Core No.4
Nil
3.3.6 POTENTIAL TRANSFORMERS:

3.3.6.1 STANDARDS
Sl. No.
Standards
Description
1.
IS: 3156
Potential trans formers
2.
IS: 2099
Specification for bushing for alternating

voltages above 10000v
3.
IS: 3347
Specification
for
porcelain
transformer
bushing,
3.3.6.2 TECHNICAL SPECIFICATIONS
The potential transformers shall be as per technical specification given below:
Sl. No.
1.
ITEM
Type
220 KV
Single phase /outdoor type/oil filled &
hermetically sealed.
2.
Type of mounting
VT mounting structure
3.
Rated voltage factor
1.5 for 30 seconds
4.
Core details and purpose
Core I protection, Core II metering
5.
Class of accuracy
Metering 0.5 Protection 0.3
6.
Voltage ratio
As per requirement
7.
Rated voltage (KV rms)
As per requirement
8.
Basic insulation level (KVP)
As per requirement
9.
One minute dry power frequency

withstand voltage (KV rms)
As per requirement -
Primary terminal
Secondary terminal
10.
Min. creepage distance (Min.)
As per requirement
11.
Burden (VA)
As per requirement
Core I
As per requirement
Core II
3.3.6.3 OTHER CONSIDERATIONS:
The 220 KV potential transformers shall be provided on the structure.
The height of the structure shall be such that the line terminal shall be 4500 mm.
The PT secondary terminals shall be brought out in a weatherproof terminal box.
The H.R.C. fuses meant for protection of secondary windings shall also be located in the terminal box.
The terminal box shall be provided with removable gland plate and glands suitable for 1100 volts grade,
PVC insulated, PVC sheathed multi core 2.5 sq.mm standard copper cable. The terminal box shall be
dust and vermin proof, polarity shall be
invariably marked on each potential transformer at the secondary terminals in the terminal box.
The N-end of primary shall be connected to earth through a link which can be removed for testing
purpose.
3.4
LIGHTNING ARRESTOR:
3.4.1 STANDARDS:
Sl. No.
Standards
Description
a)
IS: 3070
Lighting arresters for alternating current systems
b)
IEC 99
Lighting arresters for alternating current systems
c)
IS: 5621
Insulators

The I.A shall be provided on structure. The height shall be such that the live terminal shall be 4600 mm
above top of the finished ground level/gravel level of the 220 KV outdoor switchyard.
Lighting arrester shall be equipped with surge counter, and insulating base. Arrester shall ensure
endurance for discharging multiple stroke long duration discharges switching surges. The arrester units
shall be perfectly, scaled to prevent atmospheric senses.
3.4.3 TECHNICAL PARAMETERS:
The lighting arresters shall be as per specification given below:
Sl.
ITEM
No.
1.
Type
220 KV
Variac type lighting Arrestor (Thyrite
Magna Valve) Station Class
2.
Installation
Outdoor
3.
Nominal System Voltage
220 KV
4.
System Highest Voltage
As per design
5.
Rated Voltage of Arrestor
As per design
6.
Rated Frequency
50 Hz
7.
No. of Phases
8.
System Neutral Earthing
Effectively earthed system
9.
Nominal discharge current
10 KA
Sl.
ITEM
No.
10.
Maximum line to earth voltage
220 KV
Not exceeding 80% of highest system
voltage
11.
Mounting
Pedestal
12.
Equipment to be protected
Power transformers 220 KV switchgear
13.
Maximum 1.2/50 impulse spark over As per design

voltage (KV peak)
14.
Whether over head shield wire on Shall be provided

switchyard equipment is provided
3.5
220 KV SWITCHYARD CONTROL PANEL:
3.5.1
STANDARDS:
Sl.
No.
Standard
Description
1.
IS: 3427
Metal enclosed SW Gr & Cont. Gr (for V > 1 KV & < 71 KV)
2.
IS: 8623
Factory built assemblies of Sw.Gr.& Cont. Gr. (V < 650)
3.
IS: 2147
Degree of protection by enclosure for LV Sw. Gr. & Cont. Gr.
4.
IS: 3231
Protective relays
5.
IS: 1248
Electrical Indicating Instruments
6.
IS: 722
Integrating AC electric meters
7.
IS: 8686
Alarm enunciators
8.
IS: 9224
HRC fuses
9.
IS: 375
Marking and arrangement for switch gear bus bars main connections
and auxiliary wring.
10.
IS: 8686
Specification for static relays
11.
IS: 5082
Wrought aluminum and alloy bars, tubes, rods for Electrical purpose
12.
IS: 11353
Guide for uniform system of making terminals
13.
IS: 6875
Control Switches
14.
IS: 10118
Installation and maintenance of switch gear.

3.5.2.1 CONSTRUCTION DETAILS:
Panels shall be free standing floor mounting type and shall be of simplex design with doors at the rear.
For the control of transformer, bus sections, incoming and outgoing feeder, different vertical
compartments of control and relay panels shall be offered. All the panels shall be of same height of 2250
mm.
Panels shall be made of rigid welded structural frames, enclosed completely with smooth finished hot
rolled sheet steel of thick ness not less than 2.5 mm for front rear, side, top and bottom portions. There
shall be sufficient reinforcement to provide level surfaces, resistance to vibrate and rigidity during
transport and installation. Panels shall be completely metal enclosed and shall provide a degree of
protection not less than IP 52 in accordance with IS 2147.
Each simplex panel shall be provided with hinged full doors at the back. The doors shall be provided with
3 point locks operated by suitable handle. Bottom plates of the panels shall be provided with removable,
gland plates to allow cable entry from bottom. Design, material selection and workmanship shall be such
as to result a neat appearance both, inside and outside, with no welds, river or bolt heads apparent from
outside. Steel sheets shall be suitably treated to achieve appearance and long life.
Final painting of panels shall be done with synthetic enamel paint of light gray colour to shade No. 631 as
per IS:5 for exterior and white for interior.
3.5.2.2 WIRING, FUSES AND TERMINAL BLOCKS:
All wring shall be carried out with 1100 volts, grade, single core, multi strand, flexible copper wires with
PVC insulation conductor, size shall be 2.5 sq.m. (min) for CT circuits and 1.5 Sq.m. for other circuits.
Wiring troughs may be used for routing the cables. Wire numberings and code of wiring shall be as per
IS:375.
Terminal connectors for control wiring shall be stud type, made of brass Terminal blocks shall be of clip
on design made out of non-traceable insulating material of 1100 V grade. At least 20% spare terminals
shall be provided on each terminal block. All fuses if used, shall be HRC cartridge type, mounted on plug
on type fuse bases. Fuse bases shall have imprints of the fuse rating and voltage. No fuse shall provided
on DC ve and AC neutral. Links shall be provided for DC ve and AC netural. Bidders may alternatively
offer MCBS/MCCBS in place of fuses.
All front mounted as well as internally mounted items including fuses shall be provided with individual
identification labels. Labels shall be mounted directly below the respective equipment and shall clearly
indicate the equipment designation.
3.5.2.3 LAMP/HEATER AND EARTHING:

Each panel shall be provided with one cubicle illumination lamp controlled by door operated switch.
Space heater along with control switch shall also provided in each pane l. Both the lamp and the heater
shall be suitable for 240 volts, single phase, A.C. operation. One five amp three pin socket along with
control switch shall be provided in each panel.
Each panel shall be provided with one earth bus of size 25 x3 mm. The earth bus shall be of copper. All
metallic cases of relays, meters, instruments etc., shall be connected to this independently.
3.6
SWITCHYARD SYSTEM 220 KV SUBSTATION:
System fault level for 220 KV feeder line from KPTCI be considered as 25 KA for design purposes.
The span of the bus based on the size of conductor shall be suitable to withstand fault level.
The switchyard equipment such as CT.PT. Isolator, Bus post insulators shall have sufficient cantilever
strength to withstand fault level.
The phase to phase and phase to earth clearances shall be maintained as per the IS. All structural
supports in the switchyard shall be of hot dipped galvanized steel.
All structures shall be connected to earthing grid by at least 2 separate earth strips.
3.6.1.1 GALVANIZED STEEL STRUCTURES:
The galvanized steel structures shall be a lattice type of fabricated construction shall be hot dip
galvanized. The quality of hot dip galvanizing shall be determined sets given in IS: 728- 1959. Methods of
determination of weight, thickness and quantity of coating on galvanized articles other than wires and
sheets. All gang/drilling work shall be completed and the burrs shall be removed before putting members
for galvanizing.
The structure for each equipment shall be complete with necessary bolts, nuts washers etc., for
foundation and also for mounting of equipment.
All the structures shall be designed to withstand for the following conditions:
1.
Wind pressure in any horizontal direction of 1.5 Kg/Cm2 on 1.5 times the projected area of each
member of one face of built up column and on net area of other portions of the structure. On all the
conductors and insulators carried by the structure, the wind pressure shall be allowed at the rate stated
above 2/3 times the projected area.
2.
Gravity Loading: This will consist of the dead weight of all conductors and apparatus carried by the
structures including structures own dead weight.

3.
Tension loading: Tension in the conductor and ground wire shall not exceed 900 Kg.
4.
Factor of Safety: All structures must be designed with a minimum factor of safety of under the
maximum conditions of loading referred above, based on the yield points of the materials.
3.6.1.2 BUS BAR MATERIALS

3.6.1.2.1
CONDUCTOR:
The conductor shall be Tubular Aluminum, Bus Bar ACSR and shall confirm to relevant Indian or British
standard specification.
3.6.1.2.2
CLAMPS:
The various clamps required shall confirm to the following specifications:

The clamps shall be low grade aluminum alloy, complete with nuts, bolts, washers.
The joints between the copper terminal and ACSR conductor shall be ensured through bimetallic plates.
Sufficient contact pressure should be maintained to ensure low contact resistance but not so great as to
cause relaxation of the joints by cold flow. The design of the joint between the clamp and the conductor or
equipment terminal should be such that the pressure is maintained within the said range under all
conditions of services,
To avoid excessive local pressure, the contact pressure should be evenly distributed by use of pressure
plates or washers of adequate area and thickness.
All the edges and corners shall be rounded off to avoid corona effect due to sharpness, bimetallic joints
should be protected from the effects of electrolytic action. The resistance of the clamps shall be very low.
3.6.1.3 BUSHINGS:
The high voltage bushings used in circuit breaker, instrument transformers and other equipment covered
in these specifications, shall conform to the latest edition of British Standard Specification No.BS 223 or
equivalent Indian Standard Specification 2099. The rating of high voltage bushings shall be properly co ordinated with the ratings of equipment for which they are to be used. The bushings shall be porcelain oil
filled condenser type and shall have ample insulation, mechanical strength and rigidity for s atisfactory
operation under climatic conditions. Oil filled bushings shall be free from oil leakage and shall be provided
with suitable sight gauge to show the oil level in the bushing. Approved means shall be provided to
ensure that the correct oil level is maintained. It shall be provided with convenient means for sampling
and draining the oil. The bushing shall be designed to prevent accumulation of explosive gases and to
provide adequate oil circulation to remove internal heat. The bushings shall be so designed that there will
be no undue stress on any part due to temperature variations. Adequate means shall be provided to
accommodate expansion of the conductor.
The bushing shall be entirely free from radio disturbances when operating at voltage upto 10% above the
rated voltage and shall be free from corona effects. All bushings shall be equipped with suitable terminals
of approved type and size.
The porcelain used in construction of bushing shall be homogeneous, free from laminations, hair cracks,
cavitations and other flaws or imperfections that might be thoroughly verified, though and impervious to
moisture. The glazing of the porcelain shall be free from imperfections such as blisters and burns.
3.6.1.4 INSULATORS:
All post, suspension and tension insulators as required for switch gear and other connections shall
conform to Indian Standard Specification No.731: 1971 with latest amendment thereof. The tension and
suspension fittings (Hardware) shall be as per IS: 2486 (Part I & II) 1971.
All the insulators shall be complete with necessary hardware fittings. The suspension and tension
insulators shall be so arranged that the maximum loading on them does not exceed 200 Kg and 960 Kg
respectively.
Every suspension and tension insulator string for system shall be pro vided with arcing horns both on the
conductor and disc and at the structure and disc. The design and location of the arcing horns shall be
such that it will reduce the liability of damages to the conductors, clamps and insulator units under all
flash over conditions and it shall not present a foot hold or porch for large birds. The design of arcing
horns together with complete description and data shall be submitted to the purchaser for approval before
use.
The porcelain shall not engage directly with hard metal and where necessary, an approved yielding
material shall be interposed between the porcelain and fillings. All fixing material used shall be of
approved quality and applied in an approved manner and
shall not enter into chemical action the metal parts or cause fracture by expansion in service. Where
cement is used as fixing medium, cement thickness shall be taken to correctly center and locate the
individual parts during cementing.
The arrangements of connections and method of joining them to the apparatus shall be such that the
expansion or contraction of the connections shall be subject the associated apparatus to any stress.
Joints between bus and tee off connections shall provide ample contact surface for carrying the full rated
current of the equipment. The design of the joints and connectors shall facilitate the breaking of these
joints, when required. Special care shall be taken to avoid the possibility of any electrolyte action between
conductors, clamps and materials of the apparatus. The connector should be bimetallic wherever
necessary.
Any other minor items, forming the part and parcel of bus bar material shall be included in the scope,
though not specifically stated here.
3.6.1.5 SOAK PIT AND BURNT OIL PIT:
Soak pit shall be provided below transformers and shall be filled up with gravel such that the volume of
the cavity space left in the pit equals the transformer oil content volume.
A burnt oil pit shall be provided outside the switchyard and must be connected to each soak pit by pipe.
The soak pit shall be provided with an opening at the top cover and ladder. One pump should be provided
to remove the burnt oil. The pipe in between the soak pit and burn oil pit shall be of 150 mm size, stone
ware type and shall have slope of 1:96. The capacity of the burnt oil pit below stone ware pipe connection
shall be equal to 1.5 times the oil volume of the largest transformer.
3.7
LT CABLES:
3.7.1 STANDARDS:
Sl.
No.
Standard
Description
1.
IS: 1554
PVC insulated electric cables.
2.
IS: 8130
Conductors for insulated electric cables
3.
IS: 5831
PVC insulation and sheath of electric cables
4.
IS: 3975
Mild steel wires, strips and tapes for armouring of cables.
5.
IS: 1753
Aluminum conductors for insulated cables.

Power cable shall be of A1 conductor, whereas control and lighting cables shall be of Cu conductor. The
minimum size of A1 conductor cable shall be 4 mm2 and Cu conductor cable of 2.5 mm conductor cable
of 2.5 mm2.
Power cable sizing shall be based on the various de -rating factors recommended by cable manufacturer
rated current, temperature rise of conductor and voltage drop.
Control cable of CTs shall be based on the VA burden of CT and relays meters.
TECHNICAL PARAMETERS:
LT
PVC insulated taped PVC inner sheath and other sheath

650/1100 V grade, with multi stranded aluminum/copper
conductor armoured.
Cable Selection
Cable shall be selected considering flowing points

Current rating of the load
De-rating due to grouping of cable
Voltage drop up to 3% in cable due to cable resistance
De-rating factor due to ambient temperature
De-rating due to depth in case of buried cables
3.8
METAL ENCLOSED LT SWTICHGEAR:
3.9
STANDRAD:
Sl.
No.
Standard
Description
1.
IS: 3247
Switch gear general requirement
2.
IS: 2516
Circuit breaker
3.
IS: 8623
Factory built assemblies of Sw, Gr & Cont. Gr. (for voltages <650 V)
4.
IS: 2147
Degree of protection or enclosure of LV switch gear and control gear.
5.
IS: 1248
Electrical Indicating Instruments
6.
IS: 722
Integrating AC electric meters
7.
IS: 2705
Current Transformers
8.
IS: 3156
Voltage Transformers
9.
IS: 10118
Installation and maintenance of switch gear
10.
IS: 3231
Electric Relays
11.
IS: 8686
Specification for static relays
12.
IS: 5082
Wrought aluminum and alloy bars, tubes, rods for Electrical; purpose.
Sl.
No.
Standard
Description
1.
IS: 9431
Indoor post insulators organic material
2.
IS: 5621
Insulators
3.
IS: 11353
Guide for uniform system of marking terminals
4.
IS: 2544
Potrcelain post insulators
5.
IS: 375
Marking and arrangement for switch gear bus bar main connectors
and auxiliary wiring.
3.10
OTHER CONSIDERATIONS:
This section is applicable for all 415 V switchgears.

The switchgear shall be made out of sheet steel in compartmentalized design and shall be suitable for
bottom cable entry on rear side. The main incomer from the transformer shall be through a 3 CAYFY
Cable with suitable termination at the bottom of the switchgear. The horizontal bus bar chamber shall be
on the top whereas vertical bus bar shall be provided in bus alley at the front.
The incomer shall be provided with Moulded Case Circuit Breaker (MCCB). Additional set of NO-NC
contracts shall be provided than the required numbers.
3.11
TECHNICAL PARAMETERS:
1.
TPN bus bar details
High Conductivity A1 grade E91E for TPN bare

bus, size shall be suitable for current rating as per
requirement.
2.
Min. Clearance
Phase to phase 25 m and Phase to earth 20 m
3.
Earth Bus
50 x 6 GI strip
4.
Power freq. Withstand
As per design
5.
Short Time
50 KA (rms) for 1 second
6.
Max. temp. of bus bar
700 C
7.
Ct details
Cast resin bar primary type 1 ACT, CT ratio burden

and class as per SLD
8.
MCCB details
Rating shall be as per requirement with static

release. U/V and current limiting feature.
9.
Selector switch details
As for Ammeter with R.Y.B, OFF position VS for

Voltmeter with RY, YB, BR, OFF positions
10.
Indicating Meter details
Moving iron type 900 scale, for AM & VM AM dial

range to suit CT primary current VM dial range to
suit PT primary voltage.
Size 96 mm2 for outgoing feeder Accuracy Class
1.10 for other details refer drawings.
1.
Integrating Meter details
Train gear type, calibrated for required CT, PT ratio

Accuracy Class 1.0 for other details refer drawings.
2.
Push button details
Momentary type, 2 NO & NC contracts of ICA at

240V AC.
3.
Indicating lamp details
7 watts filament type with series resistance
4.
Control fuse details
HRC cartridge type with base and carrier.

Contractor to select rating.
5.
Miscellaneous details
Control wiring shall be with standard copper

conductor PVC insulated, 650 V grade wires of 2.5
mm2 for CT circuits and 1.5 mm 2 for other circuits.
Control terminals shall be of 10A, 1100 V grade
clip on type with din rail mounting.

CT terminal shall be provided with shorting link and
earthing facility.
Control wiring marked with ferrule No. at both
ends.
All boards shall be provided with Thermostat
controlled space heater and cubicle illumination.
3.12
BATTERY CHARGER CUM DCDB:
3.12.1 STANDARDS:
Sl.
No.
1.
Standard
IS: 8320
Description
General requirements and methods of tests for lead acid storage
batteries.
2.
IS: 1651
Stationary cells and batteries lead acid type with tubular positive
plates.
3.12.2 BATTERIES:
3.12.2.1 OTHER CONSIDERATIONS:
The batteries to be supplied are to be rated against the estimated load currents as to be calculated by the
Bidders as per IEEE and Battery manufactures guideline. The supplier shall verify adequacies of
capacities offered for the specified load currents and the necessary Battery Ampere Hour calculatio ns
shall be furnished by the tenderers along with the bid.
3.12.2.1.1 CONSTRUCTIONAL FEATURES:
The battery shall be lead acid scaled in type suitable for indoor application and shall conform to IS 1651.
Offered battery capacity shall be derated for site conditions specified.
The plant positive plates shall be cast solid in pure lead in one piece and shall have adequate mechanical
strength. It shall be electrochemically formed and shall be capable of operating under normal operating
conditions without buckling or cracking.
The containers shall be made of hard rubber, glass, lead lined wood, plastics, or fiber reinforced plastics
(FRP).
The vent plug shall be of the anti splash type, preferably with more than one hole, and shall allow the
gases to escape freely but shall effectively prevent acid particles or spry from coming out on removal, it
shall permit drawing of the electrolyte samples, servicing and checking.
Inter cell and inter tier connectors shall be of lead plated copper.
Terminal posts shall be designed to accommodate external bolted connections conveniently and
positively. Each terminal post shall have two boltholes of the same diameter. The bottom hole shall be
used to terminate the inter cell connection. All the metal parts of the terminals shall be of lead or lead
coated type. Bolts, heads and nuts, except seal nuts, shall be hexagonal and shall be lead covered. The
junction between terminal posts and cover, and between cover and container shall be properly scaled to
prevent any seepage of electrolyte.
The electrolyte shall be battery grade sulphuric acid conforming to relevant standards. Required quantity
of electrolyte for firs, filling with 10% extra shall be supplied in non- returnable containers.
3.12.2.1.2 ACCESSORIES:
The battery sets shall be completed with accessories. Following minimum accessories shall be provided.
Battery racks
Porcelain insulators rubber pads.
Set of inter cell, inter tier and inter bank connectors as required for the complete installation.
Electrolyte for first filling + 10% extra.
Accessories for testing and maintenance
One
One
One
Three
Three
Two
Two
Two
Two
One Set
:
:
:
:
:
:
:
3.0, +3 volts DC V6ltmeter with suitable leads for measuring cell

voltage.
Hydrometer for measuring specific gravity of electrolyte in steps
of 0.005.
Filler hole thermometer fitted with plug and cap and having
specific gravity correction scale.
Pocket thermometers.
Acid resisting funnels
Acid resisting jugs adequate capacity
Rubber aprons
Rubber globes
Cell lifting straps
Terminals and cable boxes with glands for connecting cabler as
required. 10% spare connectors, vent plugs, nuts and bolts, set.
3.12.2.1.3 BATTERY RACKS:

Battery racks shall be constructed from good quality teak wood and painted with two coats of approved
acid resist ant paint. The rack shall be rigid, free standing type and free from warp and twist.
3.12.2.1.4 VENTILATION:
The battery shall operate satisfactorily over the entire range of temperature indicated .
3.12.2.1.5 MARKINGS:
Each cell shall be marked with following in a permanent mapper.
Cell number
Type of positive plate
All capacity at 10 hour rate
Type of container
Manufacturers name
Month and year of manufacture.
3.12.3 BATTERY CHARGER:
The charger shall be float cum boost type. The charger in float mode shall supply float charging current
of battery. In boost mode the charger shall charge the fully discharged battery in 8 hours.
The charger shall have individually adjustable float I boost modes, over load and over voltage surge
suppresser.
On the power input side 3 Ph, 415 V, 63 A MCCB shall be provided. The battery shall be connected
through a MCCB/MCB rated for battery short circuit current. The DC output voltage during float charging
shall be stabilized with + 1% of the set DC bus voltage for the input AC voltage variation of + 10%
frequency variation of + 5% and DC load variation from 0-100%. The ripple content shall be within 3% of
DC nominal output voltage.
The setting of the output DC bus voltage shall be adjustable between + 10% of nominal rated voltage.
The load limiting feature of the float charger should be designed for short time over load to take care of
testing of lamps.
All printed circuit boards shall be plug in type, interlocked to prevent insertion in a wrong slot. Each card
shall have LED indication on its front plate to indicate normal condition.
The boost charge voltage and current settings shall be adjustable between 70% to 100% of maximum
boost charge voltage and between 30 to 100% of maximum boost charging current.
All components shall be clearly marked and all wiring colour coded and tagged.
All power and control wiring shall be done with 1.1 KV grade stranded copper conductor and shall be
adequately sized. Minimum size of control wiring shall be 1.5 mm2 and power wiring 4mm2. Ground
terminals with isolating links shall be provided. Following minimum protections shall be provided for the
charger.
Charger goes into current limit mode if battery any or charger current exceed the set value.
Charger trips if
Input u/v or DC o/v condition is sensed
Instantaneous DC current high is sensed.
Following alarms/indications and meters shall be provided.

a)
Ph. AC input supply ON
b)
DC ON condition
c)
Charger ON
d)
Battery on load
e)
Battery under voltage
a)
Charger failure
b)
Battery CB open
c)
Any other necessary for monitoring
d)
72 x 72 mm, AC voltmeter and ammeter with selector switches
e)
72 x 72 mm, DC voltmeter and ammeter with shunt
f)
an under voltage relay shall be provided to isolate battery from load when the cell voltage drops
below 50% of healthy cell voltage.

Suitable number of feeders shall be provided for feeding DC loads at 110-132 V.
Sub-station and Pumping station.
The MCCB shall be provided with short circuit overload release and earth fault relay. The numbers of
outgoing feeders indicated are tentative. If the system requires more feeder, the same shall be provided.
All non-current carrying metallic parts, instrument and relay cases shall be connected to earth bus bar by
2.5 mm2 stranded copper earthing conductor, green in color. Power and control terminal blocks shall be
of unbreakable polyamide material. Protective covers shall be provided over open cable terminals.
Adequate space shall be provided for termination of incoming cables.
All meters and relays shall be flush mounting type.
Panel shall be fabricated of cold rolled sheet steel of thickness not less than 2.5 mm for front and rear
equipment bearing surfaces and 2mm for sides, top and bottom portions. The panel shall be free from
undulations, dents and flaws and sufficiently reinforce to provide level surfaces, resistance to vibration
and rigidity during transportation and installation.
The perimeter of all doors, removable cover plates shall be gasketted all around with neoprene gaskets.
Ventilating louvers, if provided, shall have fine brass or GI mesh. All doors shall be provided with
concealed type hinges.
3.12.3.1
a)
PAINTINGS:
Pretreatment of all sheet steel work, including de -greasing, rust/scale removal, Phosphating and
oven drying shall be carried out as per applicable standard.

b)
The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type
zinc chromate primer. The first coat may be flash dried, while the second coat shall be stoved.
c)
After application of the primer, two coats of finishing synthetic, enamel paint shall be applied, each
coat followed by stoving. The second finishing coat shall be applied after completion of tests. The colour
of the finishing paint shall be shade 631 as per IS:5.
d)
The final finished thickness of paint film on steel shall be 100 microns.
e)
A small quantity of finishing paint shall be supplied for minor touching up required at site after the
installation of the panel.

3.13 EARTHING SYSTEM:
3.13.1 GENERAL:
-
The entire earthing system shall fully comply with Indian electricity act and rules. The contractor
shall carry out all changes desired by the electrical inspector, in order to make the installation conform to
I.E. Rules.
-
The main earth grid shall be laid at a depth of 1000 mm below Grade level. In trenches, earth strip
shall be laid along the trench. It shall be protected against mechanical damage. Joints and tappings in
the main earth grid shall be made in such a way that reliable and good electrical connections are
permanently ensured. All joints except the equipment end shall be welded. All joints buried in ground
shall be suitably protected by applying two coats of bitumen and covering with Hessian tape.
-
Conduits in which cables have been installed shall be bonded and earthed. Cable armours shall be
earthed at both ends.

-
Earth pipe electrodes shall be installed as per IS:3043. Their location shall be marked on earth pit
chamber covers.
-
The electrodes shall be tested for earth resistance by means of standard earth tester.
A water tap for continuous water supply should be provided for each earth pit.
A disconnecting facility shall be provided for individual earth pit to check earth resistance.
All electrical equipment above 230 V shall be earthed at two points and equipment 230 V and below shall
be earthed at one point.
Conductor size for connections to various equipment shall be as per the table as follows:
Equipment
Conductor Size
Motors
50 x 6 mm GI flat
Panels
50 x 6 mm GI flat
Local Control Station, Street Light Pole and its 8 SWG GI wire
junction box
All switchyard equipment
50 x 6 mm GI flat
Main earth grid
50 x 6 mm GI flat
Indoor fixtures
14 SWG GI wire
All paint, scale etc., shall be removed before earthing connections are made.
Anchor bolts or fixing bolts shall not be used for earthing connections.
3.13.2 EARTHING MATERIALS:
The earthmat shall be made up of M.S. Flats in the outdoor 220 KV switchyard and also duly connected
with the respective pump house earthmat. The earthmat risers shall be made available at the vicinity of
the foundations of the steel structures within a radius of 2m. approx. The contractors scope of earthing
work shall be as under:
i)
To interconnect the earthing terminals of equipment with eartmat, by providing a suitable M.S. Flats
for the said interconnection.

ii)
To provide the earth wire (Lightning shield wire) on the top of towers and earth mask to protect the
outdoor equipment from the strokes of lightning. The wire shall be hot dipped galvanized, grand flew,
best quality and of suitable size.
iii)
To provide the various clamps as required for fixing the earth wire on top of towers. It shall be
noted that the earthing is to be provided for each of the following apparatus.
a)
All structures and steel works, the base of all equipment and control gear etc.
b)
All metal casing on metallic coverings of the electric apparatus.
The earthing shall confirm to IS:3043. Bidder shall note that in carrying out the earthing work, no welding
of any M.S. flat shall be made on the galvanized steel structures
The quantity covered under the scope of ear thing material shall be suit the equipment lay out generally
as shown in the drawings.
3.13.3 EARTHING STATION PIPE ELECTRODE TYPE:
The pipe electrode of 40mm dia. X 3000 mm long GI pipe shall be provided. Salt and coke shall be filled
in layers of 25 mm up to one meter and balance shall be filled with loose soil. However, care shall be
taken that the earth pit does not sink. The brick chamber (600 x 600) shall be made 75 mm above
finished ground level (FGL) and shall have a heavy duty cast iron frame with hinged cover at tope for
inspection. A 40mm NB GI Watering pipe shall be provided in the pit.
3.14 LIGHTING SYSTEM:
The cabling/wiring, installation and commissioning of complete illumination system shall comply with all
currently applicable statues, regulations, fire insurance and safety codes.
Outdoor lighting shall be carried out by using 1.1KV grade four core cable. The cabling for the outdoor
lighting fixtures will be done in loop-in loop-out at respective outdoor fixture mounted junction boxes. The
indoor lighting of high by/medium bay shall be carried out by using 2 core. 2.5 mm2 copper cables. The
indoor office area wiring shall be carried @ conduits.
Outdoor cabling shall be buried in ground whereas indoor lighting wiring (cable/conduit) shall be of
exposed type.
3.14.1 GENERAL REQUIREMENTS:
Location of lighting fixtures, switches and receptacles shall be shown on the drawing and shall be
relocated if required to suit the site conditions. 5A, 3 pin and 15A, 5 pin receptacles with switches shall
be provided on the light control switch boards.
LPs shall be provided with labels indicating LP number and outgoing circuit feeder numbers.
LPS shall be provided with cable gland for incoming cable and knockouts for outgoing conduit
termination.
Cable and Conduit supports shall be provided at an interval of 300-400mm for horizontal runs and 400500mm for vertical runs.
Cables and Conduits shall be kept, wherever possible at least 300 mm away from pipes, heating devices
and other equipment.
For the purpose of calculating connected loads of various circuits, a multiplying factor of 1. 25 will be
made to the rated lamp voltage for lamp fixtures to take into account the losses in the control gear.
Contractor shall supply junction boxes, pull boxes, terminal blocks, glands conduits and accessories
(elbows, tees, bends etc.) and supporting/anchoring materials to make the installation complete.
In all types of cabling due consideration shall be given to neatness and good appearance.
The work for installation, testing and commissioning of the indoor lighting shall include the mounting of
fixtures with necessary materials, laying of cable/conduit, pulling of wires through conduit and external
earth wire providing all accessories for cable/conduit installation, including conduit fittings. Providing of
light control switch board with switches, switch board mounted 5A, 3 pin receptacles with switches etc.
3.14.2 TESTING:
Lighting installation testing shall include but not be limited to the following:
Measure the insulation resistance of each circuit without the lamps being n place. It should be not less
than 1 M ohms to earth.
Current and voltage of all the phases shall be measured at the lighting panel bus bars with all the circuits
switches on with lamps. If required, load shall be re -balanced on the three phases.
Check the earth continuity for all socket outlets. A fixed relative position of the phase and neutral
connections inside the socket shall be established for all sockets.
After inserting all the lamps and switching on all circuits minimum and maximum illumination level shall be
measured in the area with an approved industrial light meter.
3.15
LIGHTING FIXTURES:
3.15.1 STANDARDS:
No
1.
Standard
IS 1913
Description
General and Safety requirements for electric lighting
fittings.
2.
IS 1777
Industrial lighting fittings with metal reflector
3.
IS 5077
Decorative lighting outfits
4.
IS 2149
Luminaries for street lighting
5.
IS 6665
COU for Industrial Lighting

Lighting system shall be designed considering following Lux levels.
-
Pump room area
100 Lux
Maintenance bays
200 Lux
Elect. Substation/control room
250 Lux
Outdoor area 33 KV switchyard
50 Lux
In order to have higher illumination for maintenance and repairs in the substation area outlets of 16 A
SPN shall be provided for the connection of portable lamps.
No.
1.
Standard
Rated
Voltage
Description
(with
230 V +/- 10%
variations)
2.
Incoming
cable,
conduit Cable entry for HPSV, HPMV lamps, Conduit for
entry for fixtures
fluorescent tube lights
3.
Painting
Vitreous enameled reflectors for HPSV lamps
4.
Types of lamps
250 W HPSV highbay fixture
Indoor
70 W HPSV lowbay fixture
Outdoor
Single tube light fixture, vitreous enamel reflector

twin tube light fixture
No.
Standard
Description
150 W HPSV street light fixture
HPSV lamp flood light fixture
5.
Type-Outdoor Indoor
Weather proof for outdoor fixture

Commercial for Office areas and Industrial for other
areas
6.
Earthing
One Terminal Outside.
CABLING SYSTEM:
INSTALLATION:
The cables shall be laid in trenches, trays or conduits or buried in ground. Tenderer to submit cable
layout drawing for approval of KBJNL. All cables shall be carefully measured and cut to the required
length, leaving sufficient length for final connections to the equipment on both ends.
The contractor shall ascertain the exact requirement of cable, for a particular feeder, by measuring at site
along the actual finalized routed.
Cables shall be laid in complete uncut lengths from one time to equipment to another. Cables shall be
neatly arranged in the trenches, trays in such a manner, that cri ss-crossing is avoided and final take off
to the motor, switch gear is facilitated. Arrangement of cables within the trench, tray shall be the
responsibility of the contractor.
Power and control cables shall be laid on different trays in one trench. Power and cables shall be
separated by Asbestos Cement (AC) sheets. 1.1 KV grade cable may be laid on one tray.
All cables shall be identified close to their termination point by cable numbers. Cable numbers will be
punched on aluminum straps. (2mm thick), securely fastened to the cable and wrapped around it.
Underground cables shall be provided with cable markers. These cable marker posts shall be located at
every 50metres and every corner or change of direction.
All temporary ends of cables shall be protected against dust and moisture to prevent damage to the
insulation. While laying cables, the ends shall be taped with PVC tape.
Cables shall be handled carefully during installation to prevent mechanical injury to the cables. Ends of
cables leaving trenches shall be coiled and provided with protective cover until the final termination to the
equipment is completed. Where cables rise from trenches to motors, control stations, lighting panels etc.,
they shall be taken up in GI pipes (rigid, flexible) for mechanical protection up to a minimum of 600 mm
above grade level. The diameter of the GI pipe shall be at least 3 times the diameter of the cable.
Cable shall be carefully pulled through conduits to prevent damage.
If pipe sleeves installed are inadequate due to a greater number of cables being laid, then additional pipe
sleeves shall be laid. After the cables are installed and all testing is complete, conduit ends above grade
level shall be plugged with suitable weatherproof plastic compound.
Where cables pass through foundation walls or other underground structures, the necessary ducts or
openings will be provided in advance for the same.
At road crossings and other places where cables enter pipe sleeves an adequate bed for sand shall be
given.
Cables installed above grade level shall be run in trays, exposed on walls, ceilings of structures and shall
be run parallel to or at right angles to, beams, walls or columns.
The cables shall be so routed that they sill not be subjected to heat.
Cables running along with structures will be clamped by means of GI saddles and saddle bats at a
spacing of 300 mm.
Cable carrier system i.e. site fabricated ladder type cable trays and supporting steel shall be painted
before laying of cables. Painting shall have two coats of red oxide and one coat of aluminum paint.
For all outdoor buried cables a 3 meter diameter loop shall be provided at both ends before termination.
TERMINATION:
All PVC cables shall be terminated at the equipment/panel by means of double compression type brass
glands and tinned copper lugs.
All XLPE cables shall be terminated at the equipment/panel by means of HT cable termination kits.
Power cable cores shall be identified with red, yellow and blue PVC tapes.
In case of control cables, all cores shall be identifie d at both ends by their terminal numbers by means of
PVC ferrules. Wire numbers shall be as per interconnection diagram, to be furnished to the Contractor.
The cable shall be taken through an adequate size gland inside the panel or any other electrical
equipment.
Cable leads shall be terminated at the equipment terminals by means or crimped type solder less
connectors.
Crimping shall be done by hand imping/hydraulically operated tool and conducting jelly shall be applied
on the conductor. Insulation of the leads should be
TESTING OF CABLES:
Before energizing, the insulation resistance shall be measured from phase to phase and phase to ground.
3.16 HT CABLES
3.17.1 STANDARDS:
No.
Indian Standard
Description
1.
IS 7098
XLPE insulated electric cables
2.
IS 5831
PVC insulation and sheath of electric cables
3.
IS 3975
Mild steel wires, strips and tapes for armouring of cables.
4.
IS 1753
Aluminum conductors for insulated cables

The HT cable sizing shall be based on 27.0 MVA fault level at 6.6 KV. The short circuit withstand
duration shall be 1.0 Sec. Per all feeders.
i.
Voltage grade
: 6.6 KV (E) grade (Earthed System) laid from

transformer to 6.6 KV switch gear (suitable for
6.6 KV induction motors to be directly ONLINE or through soft starter started).
ii.
Impulse level
: As per IS
iii.
No. of cores
: Single Core
iv.
Nominal area of conductor
: As per requirement
v.
Conductor
: Aluminum conductor complying with the

requirements specified in IS.
vi.
Type of insulation
: Cross linked polyethylene (XLPE)
vii.
Shielding
: Conductor shielding and insulation shielding
viii.
Armoured or Unarmoured
: Armoured
ix.
Cables to be used in earthed or : Earthed System

unearthed system
3.17.4 CONDUCTOR:
The conductor shall be made from high electrical purity Aluminum of circular shape.
Conductor
construction and testing shall comply to latest IS.

3.17.5 INSULATION:
High quality XLPE insulating compound of natural colour shall be used for insulation and shall be
chemically cross linked by continuous vulcanization process. The cables shall be manufactured with dry
cure system. This shall comply to latest IS.
3.17.6 SHIELDING:
The XLPE cables shall be provided with both conductor shielding and insulating shielding. Both conductor
shielding and insulation shielding shall consist of extruded semiconductor compound.
Additional
insulation shall be provided with semiconductor tape and non-magnetic tape screen over the extruded
insulation conductor shielding.
XLPE insulation and insulation shielding shall be extruded in one
operation by a special process ensuring perfect bonding of inner and outer shielding with insulation.
3.17.7 OUTER SHEATH:
i)
A tough outer sheath of heat resisting PVC compound shall be extruded over the non-magnetic
metallic part of insulation screening. This shall confirm to latest IS. The outer sheath shall be embossed
with name of manufacture, voltage grade and year of manufacture after every 1000 mm along the length
of cable.
ii)
The outer sheath of the cable shall be provided with antirodent anti termite property.
iii)
The outer sheath of the cable shall be marked with progressive length and cable at one meter
interval at the time of manufacturing.

iv)
The outer sheath of the cable shall have fire retardant low smoke property (i.e. FRLS) and shall be
tested for IEC 332-3 category C.

3.17 MISCELLANEOUS:
3.17.1 CABLE GLANDS AND LUGS:
All cable glands shall be made out of brass and shall be of double compression type.
All cable lugs shall be of tinned copper, crimping type.
3.17.2 CABLE TRAYS:
Cable carrier system shall comprise of site fabricated ladder type cable trays made out of structural steel
and painted with two coats of red oxide primer and a final coat of enamel paint. The construction of the
cable trays shall be as per the site requirement.
3.17.3 JUNCTION BOXES/MARSHALLING BOXES:

Each equipment shall be provided with a junction box as near as possible to the equipment. In addition
one marshalling box for each by shall be provided. Junction boxes/marshalling boxes shall be fabricated
from sheet metal steel and shall be outdoor type, weather and vermin proof with hinged door and lock.
They shall be duly painted from inside the outside as per standard industrial type painting.
Each box shall have detachable gland plates for incoming and outgoing cables. Each box shall contain
adequate terminal strips for cable connections. The terminals shall be ELMAX-10 type or equivalent.
3.17.4 CIVIL WORKS IN SWITCHYARD TO INCLUDE INTERALIA:
1.
Soak pit, burnt oil pit and laying of stoneware pipes.
2.
Partition wall between transformers.
3.
Rail track, with foundations, for jack for transformer removal.
4.
All necessary foundations for structures, equipment, fence posts/door posts etc.
5.
Leveling of ground.
6.
R.C.C. cable trenches with removable pre-cast concrete cover.
7.
Gravel spreading.
TECHNICAL SPECIFICATION FOR POWER CONDUCTOR (ACSR DRAKE) FOR TRANSMISSION

LINES
SCOPE
STANDARDS
PRICIPAL PARAMETERS
TESTS
INSPECTION
QUALITY ASSURANCE PLAN
PACKING AND FORWARDING
TEST PROCEDURES
SURFACE CONDITION TEST

UTS TEST ON STANDARD CONDUCTOR
CORONA EXTINCTION VOLTAGE TEST
RADIO INTERFERENCE VOLTAGE TEST
DC RESISTANCE TEST ON STRANDED CONDUCTOR
STRESS STRAIN TEST
CHEMICAL ANALYSIS OF ZINC
CHEMICAL ANALYSIS OF ALUMINIUM AND STEEL
VISUAL AND DIMENSIONAL CHECK ON DRUMS
VISUAL CHECK FOR JOINTS, SCRATCHES ETC.
DIMENSIONAL CHECK OF STEEL AND ALUMINIUM STRANDS
CHECK FOR LAY-RATIOS OF VARIOUS LAYERS
GALVANIZING TEST
TORSION AND ELONGATION TESTS ON STEEL STRANDS
BREAKING LOAD TEST ON WELDED ALUMINIUM STRAND
TECHNICAL SPECIFICATION FOR POWER CONDUCTOR (DRAKE ACSR) FOR TRANSMISSION

LINES
Scope:
4.1
This specification provides for design, manufacture, engineering, inspection and testing before
dispatch, packing and delivery F.O.R. (destination) of aluminum conductors steel reinforced (ACSR) for
overhead transmission purposes specified herein.
The conductor shall conform in all respects to high standards of engineering, design, workmanship and
latest revisions of relevant standards at the time of offer and purchaser shall have the power to reject any
work or material, which in his judgment is not in full accordance therewith.
Standards:
4.2 Except as modified in this specification they shall conform to the following Indian Standards, which
shall mean latest revisions, amendments thereof. Equivalent International and Internationally recognized
standard to which some of these standards generally correspond are also listed below:
3
4
Indian
Standards
IS: 209
IS: 398
Part-I to Part-V
(As relevant)
IS: 1778
IS: 1521
IS: 2629
IS: 2633
IS: 4826
IS: 6745
IS: 1841
10
IS: 5484
11
IS: 6754
12
C-49 CSA
No.
1
2
International
Standards
Specification for zinc
BS: 3436
Specification for aluminum conductors for IEC: 209 BS: 215
overhead transmission purpose
(Part-II)
Title
Reels and Drums for Bare Conductors

Method of Tensile Testing of steel wire
Recommended practice for Hot Dip
Galvanizing of Iron and Steel
Method of Testing Uniformity of coating of
zinc coated Articles
Galvanised coating on round steel wire
Method of Determination of weight of zinc
coating of zinc coated Iron and Steel
Articles
EC grade Aluminum rod produced by rolling
(second Revision)
EC grade Aluminum rod produced by
continuous casting and rolling (first revision)
Methods of determination of weight of zinc
coating of zinc coated Iron and steel
Articles.
Specification for Drake ACSR
BS: 1559
ISO/R89
ASTM A-472 729

BS: 443
The standards mentioned above are available from:

Reference Abbreviation
BS
IEC/CISPR
BIS
ISO
NEMA
Name and Address

British Standards, British Standards Institution, 101, Pentonvile
Road,
N-19-ND UK
International Electro-technical Commission, Bureau Central de
la Commission, Electro Technique International, 1 Rue de
verembe, Geneva, SWITZERLAND
Bureau of Indian Standards, Manak Bhavan, 9, Bahadur Shah
Zafar Marg, New Delhi-110 001 INDIA
International Organization for Standardization, Danish Board of
Standardization, Danish Standardizing Sraat, Aurehoegvej-12,
DK-2900, Heelprup, DENMARK
National Electric Manufacture Associate, 115, East 44 th Street,
New York NY 10017 U.S.A
Canadian Standards Assn.

CSA
However, in an event where the Bidder offers ACSR conductor conforming to standards equivalent to or
better than the above, the salient points of comparison between the standards adopted and the s tandards
quoted herein shall be detailed in relevant schedule. Two copies of authenticated English version of such
standards shall be furnished along with the offer.
Principal Parameters:
4.3
The details of conductor are tabulated below:

Stranding and wire diameter
Number of Strands Steel Centre.

I Steel Layer
I Al. Layer
II Al. Layer
Sectional area of aluminium
(Sq.mm)
Total sectional area (Sq.mm)
Overall diameter (mm)
Approximate weight (kg/km)
200C
Calculated D.C resistance at

(ohm/km)
Minimum UTS (Kg)
Modulus of Elasticity (Kgs/Sq.cm x
106)
26/4.442 mm
Aluminium 7/3.45
mm Steel (Drake)
1
6
10
16
30/2.79 mm
Aluminium 7/2.79
mm Steel (Drake)
(Not applicable)
1
6
12
18
26/2.5 mm
Aluminium 7/1.9
mm Steel (Coyote)
(Not applicable)
1
6
10
16
402.8
183.4
131.7
468.40
28.13
226.2
19.53
151.6
15.86
1623.5
844
521
0.0715
0.1589
0.2214
14175
7950
4625
0.773
0.787
0.773
The details of aluminium strand are as follows:

Minimum breaking load of strand before
stranding (Kg)
Minimum breaking load of strand after
stranding (Kg)
Maximum DC resistance of strand at
200C (ohm/km)
The details of steel strand are as follows:
Minimum breaking load of strand before
stranding (Kg)
Minimum breaking load of strand after
stranding (Kg)
Minimum weight of zinc coating
(gm/sq.m
262
105
88
249
100
84
1.842
4.700
5.671
1251
819
403
1188
778
383
259
230
210
General Technical Requirement:

4.4 The conductor shall be suitable for satisfactory operation under the tropical climatic conditions
given in the project synopsis.
Physical constants of materials:
Physical constants for Hard-drawn Aluminium.
Resistivity: The resistivity of aluminium depends upon its purity and its physical condition. For the
purpose of this specification the maximum value permitted is 0.028264 Ohm.sq .mm/mt 200C, and this
value has been used for calculation of the maximum permissible value of resistance.
NOTE: It is not intended to check the resistivity from the measured values of resistance.
Density: At a temperature of 200C the density of hard drawn aluminium has been taken as 2.703 g/cubic
cm.
Constant-Mass Temperature Co-efficient of Resistance: At a temperature of 200C the constant-mass
temperature co-efficient of resistance of hard drawn aluminium measured between two potential points
rigidly fixed to the wire, the metal being allowed to expand freely.
Co-efficient of linear expansion: The coefficient of linear expansion for hard drawn aluminium at 00C has
been taken as 0.004/0C has been taken as 23.0 x 10-6/0C. This value holds good for all practical
purposes over the range of temperature from 00C to highest safe operating temperature.
Physical constant for Galvanised steel wires:
Density: At a temperature 200C, the density of galvanised steel wire is to be taken as 7.80 g/cm3.
Co-efficient of Linear Expansion: In order to obtain uniformity in calculations a value of 11.5 x 10 -6/0C
may be taken as the value for the co-efficient of Linear Expansion of galvanized steel wires used for the
cores of steel-reinforced aluminium conductors.
Materials:
The conductors shall be manufactured from EC grade aluminium rod suitably hard -drawn on wire drawing
machines. The aluminium rods used shall comply with IS: 1841 and IS: 5484. The mechanical and
electrical properties of aluminium wire shall comply with the requirements given in relevant standard.
Galvanised steel wire shall be drawn from high carbon steel rods produced by either acidic or basic openhearth process, electric furnace process or basic oxygen process. The mechanical and electrical
properties of wire shall comply with the requirements given in relevant standard. The chemical
composition of high carbon steel wire is given below for guidance only.
Element
Percentage Composition
Carbon
0.50 to 0.85
Manganese
0.50 to 1.10
Phosphorous
Not more than 0.035
Sulphur
Not more than 0.045
Silicon
0.10 to 0.35
The zinc used for galvanising shall be electrolytic high-grade zinc not less than 99.95% purity. It shall
conform to and satisfy all the requirements of IS: 209 Galvanizing may be done by hot process. Natural
grease may be applied between the layers of wires.
NOTE: Lithium soap grease corresponding to Grade-II of IS: 7623 (Specification for lithium soap greases)
is suitable for such application.
Freedom from Defects:
The wires shall be smooth and free from all imperfections such as spills, splits, slag inclusion, die marks,
scratches, pittings, blow-holes, projections, looseness, overlapping of strands, chipping of aluminium
layers etc and all such other defects, which may hamper the and mechanical/ electrical properties of the
conductor. Special care should be taken to keep away dirt, grit etc during stranding.
Wire sizes:
Nominal size:
The aluminium and galvanised steel wires for the stranded conductor covered by this standard shall have
diameters specified in clause 3.1. The diameter of the steel wires shall be measured over the zinc
coating.
Tolerances on normal size:
Aluminium Wires: A tolerance of + 1% is permitted on the nominal diameter of conductor respectively.
Galvanized steel earthwire: A tolerance of + 2% is permitted on the nominal diameter.
NOTE: In order to maintain the circularity of the wires the tolerance allowed in 4.6.2.1 and 4.6.2.2 shall
apply to both the measurements at right angles taken at the same cross -section as per Clause 2.2 of
IS:398 (Part-II) (Second Revision with Amendments 1 to 30).
Joints in Wires:
Aluminium Wires: No joints shall be permitted in the aluminium wires in the outermost layer of the ACSR
Conductor. Joints in the inner layers are permitted, in addition to those made in the base rod or wire
before final drawing, but no two such joints shall be less than 15 meter apart in the complete stranded
conductor. Such joints shall be made by cold pressure butt-welding.
NOTE: Joints are not permitted in the outermost layer of the conductor in order to ensure a smooth
conductor finish and reduce radio interference levels and corona losses on the extra high voltage lines.
Galvanized steel wires: There shall be no joints except those in the base rod or wire before final drawing,
in steel wires forming the core of the steel-reinforced aluminium conductor.
NOTE: Joints are not permitted in the steel wires after final drawing in order to avoid reduction in the
breaking strength of the conductor that may occur as a result of failure of the joints.
Stranding:
The wires used in the construction of galvanised steel reinforced aluminium conductor shall before
stranding, satisfy all the relevant requirements of this specification.
The lay ratio of the different layers shall be within the limits given in the following tables:
LAY RATIO OF ALUMINIUM CONDUCTORS,
GALVANISED STEEL-REINFORCED
(Drake, Lynx and Coyote)
ACSR DRAKE
Steel Wire
Aluminium
10 Wire layer
16 Wire layer
ACSR LYNX
Steel Wire
Aluminium
12 Wire layer
18 Wire layer
COYOTE ACSR
Steel Wire
Aluminium
10 Wire layer
16 Wire layer
Maximum
Minimum
28
18
14
16
10
10
30
20
21
14
14
11.25
30
20
21
14
14
11.25
NOTE: For the purpose of calculation, the mean lay ratio shall be taken as the arithmetic mean of the
relevant minimum and maximum values given in this table.
In all constructions, the successive layers shall have opposite directions of lay, the outermost layer being
right-handed. The wires in each layer shall be evenly and closely stranded.
In conductors having multiple layers of aluminium wires, the lay ratio of any aluminium layer shall not be
greater than the lay ratio of the aluminium layer immediately beneath it.
Standard Length:
The standard length of the Conductor shall be in Standard leng th of 1500 meters for DRAKE However,
the bidder is at to offer a higher standard length. A tolerance of +5% on the standard length offered by
the bidder shall be permitted. All lengths outside this limit of tolerance shall be treated as random
lengths.
Random lengths will be accepted provided no length is less than 70% of the standard length specified
and the total quantity of such random lengths shall not be more than 5% of the total quantity ordered.
Bidder shall also indicate the maximum single length, above the standard length, he can manufacture in
the guaranteed technical particulars. This is required for special stretches like river crossing etc. The
purchaser reserves the right to place orders for the above length on to the extent of 10% of the total
ordered quantity the same terms and conditions applicable for the standard lengths during the pendency
of the contract.
Tests:
4.5 The type, acceptance, routine tests and tests during manufacture shall be carried out on the
conductor. For the purposes of this clause:
4.5.1 Type tests shall mean those tests, as per IS, which are to be carried out to prove the design,
process of manufacture and general conformity of the material to this specification. These tests shall be
carried out on samples prior to commencement of commercial production against the order. The Bidder
shall indicate his schedule for carrying out these tests in the offer.
Acceptance Tests shall mean those tests, which are to be carried out on samples taken from each lot
offered for predespatch inspection, for the purposes of acceptance of that lot.
Routine Tests shall mean those tests, which are to be carried out on each strand/spool/length of the
conductor to check requirements, which are likely to vary during production.
Tests during manufacture shall mean those tests, which are to be carried out during the process of
manufacture by the supplier to ensure the desired quality of the end product to be supplied by him.
The norms and procedure of sampling for these tests will be as per the Quality Assurance Programme to
be mutually agreed to by the supplier and the purchaser as per relevant clause of General Conditions of
Contract.
The standards and norms to which these tests will be carried out are listed against them. Where a
particular test is a specific requirement of this specification, the norms and procedures of the test shall be
as specified in Annexure-II or as mutually agreed to between the supplier and the purchaser in the
Quality Assurance Programme.
For all type and acceptance tests, the acceptance values shall be the values guaranteed by the bidder in
the Guaranteed Technical Particulars, Part-II of his proposal or the acceptance value specified in this
specification, whichever is more stringent for that particular test.
Type tests:
The following type tests shall be conducted once on each sample/samples of conductor for every 500 KM
of production from each manufacturing facility.
UTS test on Stranded Conductor: Ref. Test Procedure
Corona extinction voltage test (dry)
:- do-
Radio interference voltage test (dry)
:- do-
DC resistance test on stranded

Conductor
:- do-
Stress-strain Test
:- do-
Acceptance Tests:
Visual and dimensional check on: Ref. Test Procedure
Drum
Visual check for joints, scratches :
Etc. and lengths of conductor
- do -
Dimensional check on steel and :

Aluminium strands
Check for lay ratios of various
- do :
Layers
- do -
Galvanizing test on steel strands :
- do -
Torsion and Elongation test on :
- do -
Steel strands
Breaking load test on steel and :
Aluminium strands
- do -
Wrap test on steel and aluminium:

Strands
- do -
DC resistance test on aluminium :

Strands
- do -
UTS test on welded joints of
Aluminium strand
- do -
NOTE: All the above tests except test mentioned at (j) shall b e carried out on aluminium and steel
strands after stranding only.
Routine Tests:
Check to ensure that the joints are as per specification.
Check that there are no cuts etc on the strands.
All acceptance tests as mentioned in Clause 5.3 above shall be carried out on each coil.
Tests during Manufacture:
Chemical analysis of zinc used : Ref. Test Procedures
For making galvanising
Chemical analysis of aluminium :
- do -
Used for making aluminium strands

Chemical analysis of steel used :
- do -
For making steel strands

Testing Expenses:
The testing charges for the type tests specified shall be indicated separately in the prescribed schedule.
The Bidder shall indicate the type test charges for each type test separately. In case the same are not
mentioned then the charges are deemed to have been included in the quoted rates of materials.
In case of failure in any type test, the Bidder is either required to modify the design of the material or
repeat the particular type test three times successfully at his own expenses. The decision of the
purchaser in this regard shall be final and binding. The type tests are to be conducted irrespective of
whether the same have been conducted earlier or not.
Bidder shall indicate the laboratories in which he proposes to cond uct the type tests. He shall ensure that
the tests can be completed in these laboratories within the time schedule guaranteed by him in the
appropriate schedule.
The entire cost of testing for the acceptance and routine tests and tests during manufacture specified
herein shall be treated as included in the quoted unit price of conductor, except for the expenses of the
inspector/ purchasers representative.
The prices quoted by the bidder towards conductance of type test shall be taken into consideration fo r bid
evaluation.
Additional Tests:
The purchaser reserves the right of having at his own expenses any other test(s) of reasonable nature
carried out at suppliers premises, at site, or in any other place in addition to the aforesaid type,
acceptance and routine tests to satisfy himself that the material comply with the specifications.
Sample Batch for type testing:
The supplier shall offer at least three (3) drums for selection of samples required for conducting all the
type tests.
The supplier is required to carry out all the acceptance tests successfully in the presence of purchasers
representative before dispatch.
Test Reports:
Four copies of type test reports shall be furnished to the Purchaser within one month of conducting the
tests. One copy will be returned duly certified by the purchaser to the supplier within three weeks
thereafter and on receipt of the same supplier shall commence with the commercial production of the
conductor.
Four copies of acceptance test reports shall be furnished to the purchaser. One copy will be returned,
duly certified by the Purchaser and only thereafter shall the conductor be despatched.
All records of routine test reports shall be maintained by the supplier at his works for periodic inspection
by the purchaser.
All test reports of tests conducted during manufacture shall be maintained by the supplier. These shall be
produced for verification as and when required for by the purchaser.
Test Facilities:
The following additional test facilities shall be available at Suppliers works:
Calibration of various testing and measuring equipment including tensile testing machine resistance
measurement facilities, burette, thermometer, barometer etc.
Standard resistance for calibration of resistance bridges.
Finished conductor shall be checked for length verification and surface finish on separate rewinding
machine at reduced speed (variable from 8 to 16 metres per minute). The rewinding facilities shall have
appropriate clutch system and free of vibrations, jerks etc with transverse layering facilities.
Inspection:
4.6 The Purchasers representative shall at all times be entitled to have access to the works and all
places of manufacture where conductor shall be manufactured and the representative shall have full
facilities for unrestricted inspection of the suppliers works raw materials and process of manufacture for
conducting necessary tests as detailed herein.
The supplier shall keep the purchaser informed in advance of the time of starting and of the progress of
manufacture of conductor in its various stages so that arrangements can be made for inspection.
No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected
and tested, unless the inspection is waived off by the purchaser in writing. In the later case also, the
conductor shall be dispatched only after satisfactory testing for all tests specified herein has been
completed.
The acceptance of any quantity of material shall in no way relieve the supplier of any of his
responsibilities for meeting all requirements of the specification, and shall not prevent subsequent
rejection if such material is later found to be defective.
At least 5% of the total number of drums subject to minimum of two in any lot put up for inspection, shall
be selected at random to ascertain the length of conductor by following method:
At the works of the manufacturer of the conductor, the conductor shall be transferred from one drum to
another at the same time measuring its length with the help of a graduated pulley & Cyclometer. The
difference in the average length thus obtained and as declared by the Supplier in the packing list shall be
applied to all the drums if the conductor is found short during checking.
Quality Assurance Plan:
4.7 The Bidder shall invariably furnish following information along with his offer, failing which his offer
shall be liable for rejection.
Statement giving list of important raw materials names of sub -suppliers for the raw materials, list of
standards according to which the raw materials are tested, list of tests normally carried out on raw
materials in presence of Bidders representative, copies of test certificates.
(i) above in respect of bought out material.
ii) Information and copies of test certificates as in
iii) List of manufacturing facilities available.
iv) Level of automation achieved and list of areas where manual processing exists.
v) List of areas in manufacturing process, where stage inspections are normally carried out for quality
control and details of such tests and inspections.
vi) List of testing equipments available with the Bidder for final testing of equipment specified and test
plant limitation, if any, vis--vis the type, special, acceptance and routine tests specified in the relevant
standards. These limitations shall be very clearly brought out in schedule of deviation from specified test
requirements.
4.7.1 The supplier shall within 30 days of placement of order submit following information to the
purchaser.
List of raw materials sub-suppliers selected from those furnished along with offer.
Type test certificates of the raw material.
Quality Assurance Plan (QAP) with hold points for Purchasers inspection. The quality assurance plan
and Purchasers hold points shall be discussed between the Purchaser and supplier, before the QAP is
finalized.
The supplier shall submit the routine test certificates of raw material at the time of routine testing on the
conductor.
Packing & Forwarding:
4.8 The Conductor shall be supplied in non-returnable strong wooden drums provided with lagging of
adequate strength, and displacement during transit, storage and subsequent handling and stringing
operations in the field. The drums shall generally conform to IS: 1778-except otherwise specified
hereinafter.
The drums shall be suitable for wheel mounting and for jetting off the conductor under a minimum
controlled tension of the order of 5 KN.
The Bidder should submit the proposed drum drawings along with the bid. However, the same shall be in
line with the requirements as stated herein. After placement of the Letter of Award, the supplier shall
submit four copies of fully dimensioned drawing of the drum he wished to supply, for Purchasers
approval before taking up manufacturing of Conductor. After getting approval from the purchaser,
supplier shall submit 30 more copies of the approved drawing to Purchaser for further distribution and
field use at Purchasers end.
All wooden components shall be manufactured out of seasoned softwood free from defects that may
materially weaken the component parts of the drums. Preservative treatment for anti -termite/anti-fungus
(Aldrime/Aldruse) shall be applied to the entire drum with preservatives of a quality, which is not harmful
to the conductor.
The flanges shall be of two/three ply construction with each ply at right angles to the other and nailed
together. The nails shall be driven from the inside face flange, punched and then clenched on the outer
face. The tolerance in thickness of each ply shall be + 3 mm only. There shall be at least 3 nails p er
plank of ply with maximum nail spacing of 75 mm. Where a slot is cut in the flange to receive the inner
end of the conductor, the entrance shall be in the line with the periphery of the barrel.
The wooden battens used for making the barrel of the conductor shall be of segmental type. These shall
be nailed to the barrel supports with at least two nails. The battens shall be closely butted and shall
provide a round barrel with smooth external surface. The edges of the battens shall be rounded or
chamfered to avoid damage to the conductor.
Barrel studs shall be used for construction of drums. The flanges shall be holed and the barrel supports
slotted to receive them. The barrel studs shall be threaded over a length on either end, sufficient to
accommodate washers, spindle plates and nuts for fixing flanges at the required spacing. Barrel studs
should be tack welded with the nuts after tightening.
Normally, the nuts on the studs shall stand protrude of the flanges. All the nails used on the inner surfac e
of the flanges and the drum barrel shall be countersunk. The ends of barrel shall generally be flushed
with the top of the nuts.
The inner cheek of the flanges and drum barrel surface shall be painted with a bitumen-based paint.
Before reeling, cardboard or double corrugated or thick bituminized waterproof bamboo paper shall be
secured to the drum barrel and inside of flanges or the drum by means of a suitable commercial adhesive
material. The paper should be dried before use. Medium grade Kraft paper shall be used in between the
layers of the conductor. After reeling the conductor, the exposed surface of the outer layer of conductor
shall be wrapped with thin polythene sheet across the flanges to preserve the conductor from dirt, grit and
damage during transportation and handling and also to prevent ingress of rain water during
storage/transport.
A minimum space of 125 mm shall be provided between the inner surface of the external protective layer
and outer layer of the conductor.
Each batten shall be securely nailed across grains as far as possible to the flange edges with at least 2
nails per end. The length of the nails shall not be less than twice the thickness of the battens. The nails
shall not protrude above the general surface and shall not have exposed sharp edges or allow the
battens to be released due to corrosion.
Outside the protective layer, there shall be minimum of two binders consisting of hoop iron/galvanized
steel wire. Each protective layer shall have two recesses to accommodate the binders.
The conductor ends shall be properly sealed and secured with the help of U-nails on one side of the
flanges. The end securing shall be done by taking out at least 500 mm of steel core on either end by Unails. The composite conductor shall be hinged by use of galvanized steel wire/ aluminium wire at three
locations at least 75 mm apart or more covered with PVC adhesive tape so as to avoid loosening of
conductor layers in transit and handling.
Only one length of conductor shall be wound on each drum.
Marking:
Each drum shall have the following information stenciled on it in indelible ink along with other essential
data:
Contract/Award letter number.
Name and address of consignee.
Manufacturers name and address.
Drum Number.
Size of conductor.
Length of conductor in meters.
Gross weight of drum with conductor.
Weight of empty drum with lagging.
Arrow marking for unwinding.
TEST PROCEDURES
Surface Condition Test:
A sample of the finished conductor having a minimum recommended length of 5 meters with compression
type dead and clamps compressed on both ends in such a manner as to permit the conductor to take its
normal straight line shape, shall be subject to a tension of 50% of the UTS of the conductor. The surface
shall not depart from its cylindrical shape nor shall the strands move relative to each other so as to get
out of place or disturb the longitudinal smoothness of conductor. The measured diameter at any place
shall be not less than the sum of the minimum specified diameters of the individual aluminium and steel
strands.
UTS Test on Stranded Conductor:
Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor
of minimum 5-meter length suitably compressed with dead end clamps at either end. The load shall be
increased at a steady rate up to specified 50% of UTS and held for one minute. The circles drawn shall
not be distorted due to Relative movement of strands. Thereafter the load shall be increased at a steady
rate to the minimum UTS specified in clause 3.1 (h) and held for one minute. The applied load shall then
be increased until the failing load is reached and the value recorded.
Corona Extinction Voltage Test:
One sample of conductor of 5-meter length shall be strung. Incase of twin conductor, two samples shall
be arranged with the actual sub-conductor spacing between them. This sample assembly when
subjected to power frequency voltage shall have a corona extinction voltage of not less than 176 kV (rms)
for 220 KV system line to ground under dry condition. There shall be no evidence of corona on any part
of sample when all possible sources of corona are photographed in a darkened room. The test shall be
conducted without corona control rings. The voltage shall be corrected for standard atmospheric
conditions.
Radio Interference Voltage test:
Under the conditions as specified in (2) above, the conductor samples shall have a radio interference
voltage level below 1500 micro volts at one MHz when subjected to 50 Hz AC voltage of 1.1 times
maximum line to ground voltage under dry condition. This test may be carried out with corona control
rings and arcing horns.
D.C. Resistance test on Stranded Conductor:
On a conductor sample of minimum 5-meter length two contact clamps shall be fixed with a predetermined bolt torque. The resistance shall be measured by a Kelvin double bridge by placing the
clamps initially zero meter and subsequently one meter apart. The test shall be repeated at least five
times and the average value recorded. The value obtained shall be corrected to the value at 200C as per
Clause No.12.8 of IS: 398 (Part-V). The resistance corrected at 200C shall conform to the requirements
of this specification.
Stress-Strain Test:
4.9 This test is contemplated only to collect the creep data of the conductor from the supplier. A
sample of conductor of minimum 10-meters length shall be suitably compressed with dead end clamps.
Test set-up:
The test sample shall be supported in a trough over its full length and the trough adjustment so that the
conductor will not be lifted by more than 10 mm under tension. This shall be ascertained by actual
measurement.
The distance between the clamp and the sleeve mouth shall be monitored with calipers during the test to
ensure that, after the test, it does not change by more than 1 mm + 0.1 mm from the value before the
test.
The conductor strain shall be evaluated from the measured displacements at the two ends of the gauge
length of the sample. The gauge reference targets shall be attached to the clamps, which lock the steel
and aluminium wires together. Target plates may be used with dial gauges or displacement transducers
and care shall be taken to position the plates perpendicular to the conductor. Twisting the conductor,
lifting it and moving it from side-to-side by the maximum amounts expected during the test should
introduce no more than 0.3 mm error in the reading.
Test Loads for complete conductor.
The loading conditions for repeated stress-strain tests for complete conductor shall be as follows:
1-KN load shall be applied initially to straighten the conductor. The load shall be removed after
straightening and then the strain gauges are to be set at zero at zero tension.
For non-continuous stress-strain data, the strain readings at 1 KN intervals at lower tensions and 5 KN
intervals above 30% of UTS shall be recorded.
The sample shall be reloaded to 50% of UTS and held for 1 hour. Readings are to be noted after 5, 10,
15, 30, 45 and 60 minutes during the hold period. The load shall be released after the hold period.
Reloading up to 70% of UTS shall be done and held for 1 hour. Readings are to be noted after 5, 10, 15,
30, 45 and 60 minutes. The load shall then be released.
Reloading up to 85% of UTS shall be done and held for 1 hour. Read ings are to be noted after 5, 10, 15,
30, 45 and 60 minutes and then the load shall then be released.
Tension shall be applied again and shall be increased uniformly until the actual breaking strength is
reached. Simultaneous readings of tension and elong ation shall be recorded up to 90% of UTS at the
intervals described under Clause 6.3.5.
Test Loads for Steel Core only:
The loading conditions for repeated stress-strain tests for the steel core of ACSR shall be as follows:
The test shall consist of successive application of load applied in a manner similar to that for the complete
conductor at 30%, 50%, 70% and 85% of UTS.
The steel core shall be loaded until the elongation at the beginning of each hold period corresponds to
that obtained on the complete conductor at 30%, 50%, 70% and 85% of UTS respectively.
Stress Strain Curves:

The design stress-strain curve shall be obtained by drawing a smooth curve through the 0.5 and 1-hour
points at 30%, 50% and 70% of UTS loadings. The presence of any aluminium slack that can be related
to any observed extrusion entering the span from the compression dead ends shall be removed from the
lower ends of the design curves. Both the laboratory and design stress -strain curves shall be submitted
to the Purchaser along with test results. The stress-strain data obtained during the test shall be corrected
to the standard temperature i.e. 200C.
Chemical Analysis of Zinc:
Samples taken from the zinc ingots shall be chemically/spectrographically analyzed. The same shall be
in conformity to the requirements stated in this specification.
Chemical Analysis of Aluminium and Steel:
Samples taken from the Aluminium ingots/coils/strands shall be chemically/spectrographically analyzed.
The same shall be in conformity to the requirements stated in this specification.
Visual and Dimensional Check on drums.
The drums shall be visually and dimensionally checked to ensure that they conform to the requirements
Visual Check for Joints, Scratches etc:
Conductor drums shall be rewound in the presence of the inspector. The inspector shall visually check
for scratches, joints, etc and that the conductor generally conforms to the requirements of this
specification.
Dimensional check of steel and aluminium strands:
The individual strands shall be dimensionally checked to ensure that they conform to the requirements of
this specification.
Check for Lay-ratios of various Layers:
The lay-ratios of various layers shall be checked to ensure that they conform to the requirements of this
specification and clause No.9.4 & 9.5 of IS-398 (Part-V).
Galvanizing Test:
The test procedure shall be as specified in IS: 4826. The material shall conform to the requirement of this
specification.
Torsion and Elongation Tests on Steel Strands.
The test procedures shall be as per clause No.12.6.1 and 12.6 of IS:398 (Part -V). In torsion test, the
number of complete twists before fracture shall not be less than 18 on a length equal to 100 times the
standard diameter of the strand. In case test sample length is less or more than 100 times the standard
diameter of the strand, the minimum number of twist will be proportionate to the length and if number
comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the
elongation of the strand shall not be less than 4% for a gauge length of 200 mm.
Breaking load test on welded Aluminium strand:
Two Aluminium Wires shall be welded as per the approved quality plan and shall be subjected to tensile
load. The welded point of the wire shall be able to withstand the minimum-breaking load of the individual
strand guaranteed by the supplier.
TECHNICAL SPECIFICATION FOR GROUND WIRE (7/3. 15mm)
SCOPE
STANDARDS
MATERIALS
SIZES AND CONSTRUCTIONS
LENGTHS AND JOINTINGS
TEST AND TEST CERTIFICATE
PACKING AND MARKING
SAG AND TENSION CHARTS
TECHNICAL SPECIFICATIONS FOR GROUNDWIRE (7/3.15mm)

6.1
SCOPE:
This Specification provides for the manufacture, testing before despatch supply and delivery of 7/3.15mm
ground wire 1100 NEWTON/Sq.mm quality (grade 3 as per IS 12776 of 1989 for the purpose of earthing
and protection of power transmission lines as per the particulars given in Appendix I attached. The
ground wire shall consist of standard galvanised steel wires. The other applicable standards are IS209/2979,
IS-1521/1972, IS-1755/1961, IS-1778/1961,
IS-2633/1972, IS-4826/1979, IS-6745/1972,
IS-5714/1979, IS-6594/1977, IS-1766/1983,
IS-182/1972.
6.2
STANDARDS:
The ground wire shall comply in all respects with the latest edition of IS 12776/1989 (with latest
amendments).
6.3
MATERIALS:
The materials offered shall be of best quality and workmanship. The steel wire (strands) shall be
manufactured from steel produced by the suitable process. The steel wire shall not contain sulphur and
phosphorous exceeding 0.05% each.
The steel wire shall be evenly and uniformly coated with Zinc complying with IS-209/1979 specification for
Zinc (revised)-99.99% grade and zinc coating shall conform to heavy type coating as per IS -4826/1979
including latest amendments, IS-2633/1972 and IS-6745/1972. The individual wires after galvanising
shall be smooth, free of inequalities, spills or splits before stranding.
6.4
SIZES AND CONSTRUCTION:
The sizes and physical properties of the ground wire shall be as given in Appendix-I. The lay of the
strands shall be of lengths given in the appendix and the wires shall be so stranded together that when
an evenly distributed pull is applied at the end of completed strands, each wire will take an equal share of
the pull.
6.5
LENGTHS AND JOINTINGS:
The ground wire may be supplied in the standard length of 2 Kms. However, random lengths of ground
wire up to a minimum of 10 (ten) percent may be allowed.
The length of strand, which may be supplied without joints. In the individual wires comprising it, depends
on the lengths of wire, which may be carried by the bobbin in a normal stranding machine. The normal
lengths of strands which shall be supplied without joints in individual wires, excluding welds made in the
rod before drawing shall be as given in Appendix-I. The lengths may be exceeded by agreement
between the manufacturer and Owner. Joints are not permitted either in the individual strand wires or in
completed strand.
Each coil shall be warranted to contain no weld joints or splice. The wire shall be free from scale,
irregularities, imperfections, flaws, splits and other defects. The zinc coating shall be smooth even and
bright.
6.6
TEST AND TEST CERTIFICATE:
Samples from each lot shall be tested for ascertaining the confo rmity to the requirements of the ground
wire, specified herein. The coils selected shall be tested for lengths of the lay joints. The lot shall be
declared conforming to the requirements of these characteristics if all the coils are found satisfactory.
One test specimen from each wire of the strand shall now be drawn from every selected coil and
subjected to tensile test, ductility test and coating test. One test specimen of the completed strand shall
now be drawn from every selected coil and subjected to tensile strength. The lot shall be declared
conforming to the requirements of these characteristics if all the test specimen satisfy the relevant
requirement.
All the coils of the galvanised strand of the same grade, diameter, and construction, manufac tured under
similar conditions shall be grouped to constitute one lot.
6.6.1
CHEMICAL ANALYSIS:
One sample shall be drawn from the lot for chemical analysis. Unless otherwise agreed to between the
owner and the supplier, the chemical analysis shall be carried o ut.
6.6.2
TENSILE TEST:
The wire when tested in accordance with the IS-1521 or any one-gauge length of 100 mm, shall
have the minimum-breaking load of strand as specified in Appendix-I, shall be as follows. The tensile
strength of the finished strand shall not be less than 95% of the aggregate of the single wires.
6.6.3
DUCTILITY TEST:
The wire shall be subjected to wrapping test in accordance with IS-1755. When wrapped eight
times round its own dia and on being subsequently straightened, the wire shall not break o r split.
6.6.4
COATING TEST:
The uniformity of zinc coating shall be tested as per IS-2633. The wire shall withstand the
number of dips specified in Appendix-I or as per latest edition of IS-4826 and IS-6745/1972.
6.6.5
TOLERANCE ON WIRE DIAMETER:
The tolerance shall be +0.06 and 0.03 in millimeter as per clause 6.1 of IS-12776/1989.
6.6.6
CHEMICAL ANALYSIS:
Shall be conducted on a sample drawn from each lot as per clause 8.1.4 of IS-2141/1979.
6.6.7
ACCEPTANCE TEST:
The acceptance tests shall be conducted as per the scale of sampling specified in standard IS12776/1989.
Samples from each lot shall be tested for ascertaining the conformity to the requirements of this
specification. The number of coils to be selected shall be in accordance with Clause -10 of the of IS
12776/1989. The lot shall be declared in conformity with the requirements of the following tests are
satisfied. The length of the test sample shall be not less than 5 (five) metres.
Length and lay of joints.
Ductility Test.
Tolerance on wire diameter.
Tensile and Elongation test.
Galvanising test.
Electrical resistance as per BS 182 1972 and
BS 5714 1979.
The above acceptance tests should be conducted in the presence of the Purchasers representative.
Three copies of manufacturers tests certificate shall b e submitted by the contractor to the owner for
approval immediately after such tests have been conducted on the G.S. strands and the wire. No
separate charge shall be payable for these type and acceptance tests.
The owner reserves the right to inspect the material at manufacturers works before despatch.
6.7
PACKING AND MARKING:
The ground wire shall be supplied in non-returnable reels or drums of non-perishable or treated wood
conforming to IS-1778/1961 Specification for reels and drums for the same wires. Each coil shall be
provided with a label fixed firmly on the inner part of the coil bearing the following information.
a) Trade mark, name if any.
b) Name of the manufacturer.
c) Type of wire-size and length of wire.
d) Net weight of the wire.
e) Tare weight and
f)
6.8
No. of lengths on the reel or drum.

SAG AND TENSION CHARTS:
The successful tenderer shall submit seven copies of stringing charts for earth wire showing initial and
final sags and tensions for various temperatures and spans. One set of chart shall be in ink or tracing.
APPENDIX I
Details of ground wire (1100 Newton/Sq.mm quality) grade 3 as per
IS-12776/1989.
1. Stranding and wire diameter: 7/3.15mm
2. Single wire before stranding
a) Diameter
Nominal : 3.15mm
Maximum: +3.23mm
Minimum : - 3.07mm
b)Minimum breaking load: 8.57 KNf

3.
Lay length
i.
Maximum
: 265 mm
ii. Minimum
: 123 mm
4.
Minimum breaking load of
Stranded wire
5.
Percentage elongation at
break on complete strand

6.
: Min.4%
Minimum ultimate tensile
strength of individual strand

7.
: 1100 N/Sq.mm
Nominal overall diameter of
stranded wire
8.
9.
: 58.45 KNf
: 9.45mm
Zinc coating
a)
Duration and No. of dips
: 1. Min dip 3.
b)
Weight of coating
: 260 Gms/Sq.mm
Normal length without joint or weld in the same wire: 1000 Metres
TECHNICAL SPECIFICATION FOR DISC INSULATORS FOR USE ON TRANSMISSION LINES

(120KN & 90KN EMS)
7.1
SCOPE:
7.1.1 This specification provides for design, manufacture, engineering, inspection and testing before
dispatch, packing and delivery F.O.R. (destination) DISC INSULATORS / LOG ROD INSULATORS as
per technical requirements furnished in this specification. These insulators are to be used in suspension
and tension insulator strings for suspension and anchoring of conductors on EHV transmission towers of
KPTCL.
7.1.2 The insulators shall conform in all respects to high standards of engineering, design, workmanship
and latest revisions of relevant standards at the time of offer and purchaser shall have the power to reject
any work or material which, in his judgment, is not in full accordance therewith.
7.2
STANDARDS
7.2.1 Except as modified in this specification, the disc insulators shall conform to the following Indian
standards which shall mean latest revisions and amendments. Equivalent International and
Internationally recognized standards to which same of these standards generally correspond are also
listed below:
Sl.
No.
1
2
3
Indian
Standard
IS: 206
IS: 209
IS:731
IS:2071
Part(I)
Part (II)
Part(III)
IS:2121
5
Part (I)
Title
Method for chemical analysis of slab zinc
Specification for Zinc
Porcelain insulators for overhead power lines
with the nominal voltage greater than 1000 V.
Method of High voltage Testing

Specification of Conductors and Earth-wire
Accessories for Overhead Power lines
Armour Rods, Binding-Wires and Tapes for
conductors
International standard
BS:3436
BS:137 (I&II)
IEC:274
IEC:383
Sl.
No.
6
Indian
Standard
IS:2486
Part (I)
Part (II)
Part (III)
7
8
9
IS:2629
IS: 2633
Title
Specification for Insulator fittings for overhead

power lines with a nominal voltage greater
than 1000V
General Requirements and Tests
Dimensional Requirements
Locking Devices
Recommended practice for hot dip
galvanization for iron and steel
Testing for Uniformity of Coating of Zinc
Coated Articles
BS:3288
IEC:120
IEC:372
IS0/R 947 and

IS0/R 272
IEC:305
IS0/R 68-1969 R 26-1963,
R262-1969 and R 965-1969
IS:3138
Hexagonal bolts and nuts
10
11
IS:3188
IS:4218
Dimensions for Disc Insulators

Metric Screw Threads
12
IS:6745
13
IS:8263
14
IS:8269
Determination of weight of zinc coating on zinc

coated iron and steel articles
Methods of RIV Test of HV Insulators
IEC:437
NEMA Publication
No.107/1964 CISPR
Methods for switching impulse test on HV IEC: 506
insulators
Thermal Mechanical performance test and IEC:575
mechanical performance test on string
insulator units.
Long rod insulators
IEC-433
15
16
IEC
7.2.2 The Standards mentioned above are available from:

Reference
Abbreviation
BS
IEC/CISPR
IS
ISO
NEMA
Name and Address

British Standards, British Standards institution, 101, Pentonvile Road, N-19, ND,
UK
International Electro technical Commission Bureau Central de la Commission
Electro Technique International 1, Rue de verembe Geneva Switzerland
Bureau of India Standards, Manak Bhavan, 9, Bahadur Shah Zafar Marg, New
Delhi 110 001 India
International Organisation for standardization
Danish Board of Standardization ,Dansk Standardisering Street,
Aurehoegvej 12 DK 2900
DENMARK
National Electric Manufactures Association,155, East 44 th Street, New York, NY
10017 USA.
7.2.3 Insulators conforming to any other international standard s are also acceptable provided always that
such standards are equivalent to or better than the corresponding standards specified in 2.1 above
However in such an event the salient points of Comparison between the standards adopted and the
standards quoted herein shall be detailed in the appropriate schedule. Two copies authentic English
version of such standards shall be submitted along with the offer.
7.3
PRINCIPAL PARAMETERS:
7.3.1
Sl.
No.
Details of disc Insulators:
Type of String
Size of disc
insulator
(mm)
Minimum
creepage
distance
of each disc
(mm)
No. of
Standard
discs
Electro-mechanical
Strength of
Insulator string in
KN
255x145
320
90
-do-
-do-
2x7
2x90
255x145
-do-
320
-do-
8
2x8
90
2x90
220 KV
01
02
03
04
7.3.2
Single
Suspension
Double
Suspension
Single Tension
Double Tensile
The insulator strings shall consist of standard discs for a three phase. 50 HZ, effectively earthed
220 or 110 or 66KV transmission system in a moderately polluted atmosphere. The discs shall be cap
and pin, ball and socket type.
The Size of disc insulator, minimum creepage distance, the number to be used in different type of
strings, their electromechanical strength and mechanical strength of insulator string along with hardware
shall be as follows:
7.4
GENERAL TECHNICAL REQUIREMENTS:
7.4.1 PORCELAIN:
The porcelain used in the manufacture of the shells shall be ivory white, nonporous, of high dielectric,
mechanical and thermal strength, free from internal stresses, blisters, laminations, voids, foreign matter,
imperfections or other defects which might render it in any way unsuitable for insulator shells. Porcelain
shall remain unaffected by climatic conditions, ozone, acid, alkalis, zinc or dust. The manufacturing shall
be by the wet process and impervious character obtained by through versification.
7.5
PORCELAIN GLAZE:
Surface to come in contact with cement shall be made rough by stand glazing. All other exposed
surfaces shall be glazed with ceramic materials having the same temperature co -efficient of expansion as
that of the insulator shell. The thickness of the glaze shall be uniform throughout and the colour of the
glaze shall be brown. The glaze shall have a visible luster and smooth on surface and be capable of to
satisfactory performance under extreme tropical climatic weather conditions and prevent ageing of the
porcelain. The glaze shall remain under compression on the porcelain body throughout the working
temperature range.
7.6 METAL PARTS:
7.6.1 CAP AND BALL PINS:
Ball pins shall be made with drop forged steel and caps with malleable cast iron. They shall be in one
single piece and duly hot dip galvanized. They shall not contain parts or pieces joined together, welded,
shrink fitted or by any other process from more than one piece of material. The pins shall be of high
tensile steel, drop forged and heat-treated. The caps shall be cast with good quality black heart
malleable, cast iron and annealed. Galvanizing shall be by the hot dip process with a heavy coating of
zinc of very high purity. The bidder shall specify the grade, composition and mechanical properties of
steel used for caps and pins.
7.6.2 SECURITY CLIPS:
The security clips shall be made of phosphor bronze or of stainless steel.
7.6.3 FILLER MATERIAL:
Cement to be used, as a filler material shall be quick setting, fast curing port-land cement. It shall not
cause fracture by expansion or loosening by contraction. Cement shall not react chemically with metal
parts in contact with it and its thickness shall be as small and as uniform as possible.
7.7
7.7.1
MATERIAL DESIGN AND WORKMANSHIP:

GENERAL:
i.
All raw materials to be used in the manufacture of these insulators shall be subject to strict raw
materials quality control and to stage testing / quality control during manufacturing stage to ensure the
quality of the final end product. Manufacturing shall conform to the best engineering practices adopted in
the field of extra high voltage transmission. Bidders shall therefore offer insulators as are guaranteed by
them for satisfactory performance on Transmission Lines.
ii.
The design, manufacturing, process and material control at various stages be such as to give
maximum working load, highest mobility, best resistance to corrosion, good finish, elimination of sharp
edges and corners to limit corona and radio interference voltages.
7.7.2 INSULATOR SHELL:
The design of the insulator shells shall be such stresses due to expansion and contraction in any part the
insulator shall not lead to deterioration. Shells with cracks shall be eliminated by temperature test
followed by mallet test. Shells shall dried under controlled conditions of humidity temperature.
7.7.3 METAL PARTS:

i.
The Pin and cap shall be designed to transmit the mechanical stresses to the shell by compression
and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and
outer surfaces concentric and of such design that it will not yield or distort under loaded conditions. The
head portion of the pinball shall be suitably designed so that when the insulator is under tension the
stresses are uniformly distributed over the pinhole portion of the shell. The pinball shall move freely in
the cap socket either during assembly of a string or during erection of string or when a string is placed in
position.
ii.
Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes and rough edges. All
metal surfaces shall be perfectly smooth with no projecting parts or irregularities which may cause
corona. All load bearing surfaces shall be smooth and uniform so as to distribute the lo ading stresses
uniformly. Pins shall not show any microscopically visible cracks, inclusions and voids.
7.7.4 GALVANISING:
All ferrous parts shall be hot dip galvanized in accordance with IS:2629. The zinc to be used for
galvanizing shall conform to grade Zn 99.5 as per IS-209. The zinc coating shall be uniform, smoothly
adherent, reasonably bright, continuous and free from impurities such as flux, ash, rust strains, bulky
white deposits and blisters. Before ball fittings are galvanized, all die flashing on the shank and on the
bearing surface of the ball shall be carefully removed without reducing the designed dimensional
requirements.
7.7.5 CEMENTING:
The insulator design shall be such that the insulating medium shall not directly engage with hard metal.
The surfaces of porcelain and coated with resilient paint to offset the effect of difference in thermal
expansions of these materials. A zinc sleeve measuring 5mm thick and 20mm length shall be provided
on the pin as shown in the drawing Section-XII.
7.7.6 SECURITY CLIPS (LOCKING DEVICES):
The security clips to be used as locking device for ball and socket coupling shall be R shaped hump type
to provide for positive locking of the coupling as per IS:2468 (Part-IV). The legs of the security clips shall
allow for spreading after installation to prevent complete withdrawal from the socket. The locking device
shall be resilient, corrosion resistant and of sufficient mechanical strength. There shall be no possibility of
the locking device to be displaced or be capable of rotation when placed in position and under no
circumstances shall it allow separation of insulator units and fittings. W type security clips are also
acceptable. The hole for the security clip shall be countersunk and the clip shall be of such desi gn that
the eye of the clip may be engaged by a hot line clip puller to provide for disengagement under energized
conditions. The force required for pulling the clip into its unlocked position shall not be less than 50N (5
Kg) or more than 500 N (50 Kg).
7.8
BALL AND SOCKET DESIGNATION:
The dimensions of the balls and sockets for 90KN discs shall be of 16mm and for 120KN discs shall be of
20mm designation in accordance with the standard dimensions state in IS:2486 (Part II).
7.9
DIMENSIONAL TOLERANCE OF INSULATOR DISCS:
It shall be ensured that the dimensions of the insulators are within the limits specified below:
a. diameter of Disc (mm)
Standard
255
120 kN Disc
90 kN Disc
Maximum
266
255
Minimum
244
266
244
b. Ball to Ball spacing between discs (mm)

Standard
120 kN Disc
90 kN Disc
145
145
Maximum
Minimum
149
141
149
141
7.10 INTERCHANGEABILITY:
The insulators inclusive of the ball and socket fit shall be of standard design suitable for use with ware
fittings of any make conforming to relevant standards.
7.11 CORONA AND RIV PERFORMANCE:
All surfaces shall be even, smooth, without cuts, sions or projections. No part shall be subject to
excessive localized pressure. The metal parts and lain shall not produce any noise generating corona at
all operating conditions.
7.12 SUITABILITY FOR LIVE LINE MAINTENANCE:
The insulators shall be compatible for use wit line or live line maintenance technique that usual hot line
operations can be out with ease, speed and safety.
7.13 FREEDOM FROM DEFECTS:
Insulators shall have none of the following defects:
i.
Ball pin shake
ii.
Cementing defects near the pin like small blow holes, small hair cracks, lumps, etc.
iii.
Sand fall defects on the surface of the insulator.
7.14 INSULATOR STRINGS:

7.14.1 TYPE AND RATING:
The insulator strings shall be formed with standard discs described in this specification for use on 3
phase, 220/110/66KV, 50 Hz effectively earthed systems in an with pollution level as indicated in projec t
synopsis atmosphere. Suspension insulator strings for use with suspension / tangent towers are to be
fitted with discs of 90 KN EMS rating while tension insulator strings for use with Anchor / Tension towers
are to be fitted with discs of 120/90 KN EMS rating.
7.14.2 STRING SIZE:
The size of the disc insulator, the number to be used in different types of strings, their Electro -mechanical
strength and minimum nominal creep age distance shall be as given in clause 3.1.2.
7.15 STRING CHARACTERISTICS:
Suspension
110KV
550
i.
Lightning Impulse withstand voltage
(dry) KV peak.
ii.
Power frequency withstand voltage (wet)
230
KV r.m.s.
iii.
Corona extinction voltage KV (rms.
iv. Max. RIV for complete string including
corona rings, arcing horns, clamps etc, at 1.1
times maximum line to ground voltage (microvolts)
v.
Mechanical failing load for each sting
90
KN.
vi. No deformation load for each string Kgf.
vii. Max. voltage across any disc.
13%
The characteristic of the complete sting shall be as follows:
Tension
110KV
550
230
-
90
13%
7.15.1 Insulator units after assembly shall be concentric coaxial within limits as permitted by Indian
standards
7.15.2 The string design shall be such that when units coupled together there shall be contact between
shell of one unit and metal of the adjacent unit.
7.16 TECHNICAL DESCRIPTION OF PORCELAIN LONG ROD INSULATORS.
7.16.1 DETAILS OF PORCELAIN LONG ROD INSULATORS:
7.16.1.1 The Insulator string shall consists of standard long rod insulators with normal sheds for three
phase 50 Hz, effectively earthed 220/110/66kv transmission system in a lightly/medium polluted
atmosphere. The insulators shall be long rod type with Ball & Socket connection.
7.16.1.2 Insulator shall have normal sheds/alternate sheds with good self-cleaning properties. Insulator
shed profile, spacing projection etc. shall be strictly in accordance with the recommendations of IEC-815
7.16.1.3 Supplier quoting for long rod insulators made of electro porcelain shall also supply intermediate
ball pins and intermediate arcing horns along with long rod insulators.
7.16.1.4 The prices of these items shall be considered as included in the price of long rod insulators.
7.16.1.5 The size of long rod insulator, minimum creep age distance, the number to be used in
different type of strings, their electromechanical strength and mechanical strength of insulator string along
with hard ware shall be as follows.
Sl No
Line
KV
Type of String
Single Suspn
220KV Single Tension
1.
/110kv Double Suspn
Double Tension
7.16.2 STRING CHARACTERSTICS:
Length of the
string with long
rod ins.(Cap to
Cap) (mm)
1015
1160
1015
1160
No.of
Min.
individual
Creep age
units /
distance
string
2240
1X1
2560
1X1
2240
2X1
2560
2X1
EMS of
Insulator
(KN)
90
90
90
90
The Characteristics of the complete string with long rod insulators shall be as follows.
Sl No
Particulars
Lightning Impulse withstand voltage (dry)
1
KV peak
Power frequency withstand voltage (wet)
2
KV rms
3
Corona extinction voltage KV (rms)
Max. RIV for complete string including
corona rings, arcing horns, clamps etc., at
4
1.1 times maximum line to ground voltage
(micro-volts)
7.17 GENERAL TECHNICAL REQUIREMENTS:
220 KV
550
230
-
7.17.1 PORCELAIN
The porcelain used in the manufacture of the shells shall be ivory white, nonporous, of high dielectric,
mechanical and thermal strength, free from internal stresses, blisters, laminations, voids, foreign matter,
imperfections or other defects which might render it in any way unsuitable for insulator shells. Porcelain
shall remain unaffected by climatic conditions, ozone, acid, alkalis, zinc or dust. The manufacturing shall
be by the wet process and impervious character obtained by through verification.
7.17.2 PORCELAIN GLAZE:
Surface to come in contact with cement shall be made rough by stand glazing. All other exposed
surfaces shall be glazed with ceramic materials having the same temperature co-efficient of expansion as
that of the insulator shell. The thickness of the glaze shall be uniform throughout and the color of the
glaze shall be brown. The glaze shall have a visible luster and smooth on surface and be capable of to
satisfactory performance under extreme tropical climatic weather conditions and prevent ageing of the
porcelain. The glaze shall remain under compression on the porcelain body throughout the working
temperature range.
7.17.3 METAL PARTS:

7.17.3.1 CAP AND BALL PINS:
zinc of very high purity. The bidder shall specify the grade, composition and mechanical properties of
steel used for caps and pins.
7.17.3.2 METAL PARTS:
i.
The Pin and cap shall be designed to transmit the mechanical stresses to the shell by compression
and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and
outer surfaces concentric and of such design that it will not yield or distort under loaded conditions. The
head portion of the pinball shall be suitably designed so that when the insulator is under tension the
stresses are uniformly distributed over the pinhole portion of the shell. The pinball shall move freely in
the cap socket either during assembly of a string or during erection of string o r when a string is placed in
position.
ii.
Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes and rough edges. All
metal surfaces shall be perfectly smooth with no projecting parts or irregularities which may cause
corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses
uniformly. Pins shall not show any microscopically visible cracks, inclusions and voids.
7.17.3.3 SECURITY CLIPS:
The security clips shall be made of phosphor bronze or of stainless steel.
7.18 FILLER MATERIAL:
Cement to be used as a filler material shall be quick setting, fast curing port-land cement. It shall not
cause fracture by expansion or loosening by contraction. Cement shall not react chemically with metal
parts in contact with it and its thickness shall be as small and as uniform as possible.
7.19 MATERIAL DESIGN AND WORKMANSHIP:
7.19.1 GENERAL:
i.
All raw materials to be used in the manufacture of these insulators shall be subject to strict raw
materials quality control and to stage testing / quality control during manufacturing stage to ensure the
quality of the final end product. Manufacturing shall conform to the best engineering practices adopted in
the field of extra high voltage transmission. Bidders shall therefore offer insulators as are guaranteed by
them for satisfactory performance on Transmission Lines.
ii.
The design, manufacturing, process and material control at various stages be such as to give
maximum working load, highest mobility, best resistance to corrosion, good finis h, elimination of sharp
edges and corners to limit corona and radio interference voltages.
7.20 INSULATOR SHELL:

The design of the insulator shells shall be such stresses due to expansion and contraction in any part the
insulator shall not lead to deterioration. Shells with cracks shall be eliminated by temperature test
followed by mallet test. Shells shall dried under controlled conditions of humidity temperature.
7.21 METAL PARTS:
i) The Pin and cap shall be designed to transmit the mechanical stresses to the shell by compression and
develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer
surfaces concentric and of such design that it will not yield or distort under loaded conditions. The head
portion of the pinball shall be suitably designed so that when the insulator is under tension the stresses
are uniformly distributed over the pinhole portion of the shell. The pinball shall move freely in the cap
socket either during assembly of a string or during erection of string or when a string is placed in position.
ii) Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes and rough edges. All metal
surfaces shall be perfectly smooth with no projecting parts or irregularities which may cause co rona. All
load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly.
Pins shall not show any microscopically visible cracks, inclusions and voids.
7.22 GALVANISING:
All ferrous parts shall be hot dip galvanized in accordance with IS:2629. The zinc to be used for
galvanizing shall conform to grade Zn 99.5 as per IS-209. The zinc coating shall be uniform, smoothly
adherent, reasonably bright, continuous and free from impurities such as flux, ash, rust strains, bulky
white deposits and blisters. Before ball fittings are galvanized, all die flashing on the shank and on the
bearing surface of the ball shall be carefully removed without reducing the designed dimensional
requirements.
7.22.1 CEMENTING
The insulator design shall be such that the insulating medium shall not directly engage with hard metal.
The surfaces of porcelain and coated with resilient paint to offset the effect of difference in thermal
expansions of these materials. A zinc sleeve measuring 5mm thick and 20mm length shall be provided
on the pin as shown in the drawing Section-XII.
7.23 SECURITY CLIPS (LOCKING DEVICES):
The security clips to be used as locking device for ball and socket coupling shall be R shaped hump type
to provide for positive locking of the coupling as per IS:2468 (Part-IV). The legs of the security clips shall
allow for spreading after installation to prevent complete withdrawal from the socket. The locking device
shall be resilient, corrosion resistant and of sufficient mechanical stre ngth. There shall be no possibility of
the locking device to be displaced or be capable of rotation when placed in position and under no
circumstances shall it allow separation of insulator units and fittings. W type security clips are also
acceptable. The hole for the security clip shall be countersunk and the clip shall be of such design that
the eye of the clip may be engaged by a hot line clip puller to provide for disengagement under energized
conditions. The force required for pulling the clip into its unlocked position shall not be less than 50N
(5Kgs) or more than 500 N (50 Kgs).
7.24 BALL AND SOCKET DESIGNATION:

The dimensions of the balls and sockets for 90KN Long Rod shall be of 16mm and for 120KN Long Rod
shall be of 20mm designation in accordance with the standard dimensions state in IS:2486 (Part II)
7.25 DIMENSIONAL TOLERANCE OF INSULATOR UNITS:
It shall be ensured that the dimensions of the insulators are within the limits specified below:
+ (0.04d + 1.5)mm when d<300mm
+ (0.025d+6)mm when d>300mm
Where d being the dimensions in millimeters for diameter, length or creep age distance as the case may
be.
However, no negative tolerance shall applicable for creep age distance.
7.26 INTERMEDIATE BALL PIN DESIGNATION
The dimensions of the intermediate ball pin shall be in accordance with standard dimension stated in IEC
471
The long rod insulator with ball and socket connection shall be of standard design suitable for use with
the hardware fittings of any make conforming to relevant IS/IEC standards.
7.28 TESTS:
7.28.1 The following tests shall be carried out on the insulator string and unit insulators.
7.28.2 TYPE TESTS:
This shall mean those tests, which are to be carried to prove the design, process of manufacture and
conformity of the material and product with the insulator of this specification. These tests shall be
conducted on representative number of samples prior to commence of commercial production. The
bidder shall indicate his schedule for carrying out these tests.
7.28.3 ACCEPTANCE TESTS:
This shall mean these tests, which are to be carried on samples taken from each lot offered for pre dispatch inspection for the purpose of acceptance of the lot
7.28.4 ROUTINE TEST:
This shall mean those tests, which are to be carried out on each insulator to check the requirements are
likely to vary during production.
7.28.5 TESTS DURING MANUFACTURE:
Stage tests during manufacture shall mean those, which are to be carried out during the process of
manufacture to ensure quality control such that the product is of the designed quality conforming to intent
7.28.6 TEST VALUES:

For all type and acceptance tests, the acceptance values shall be the value guaranteed by the Bidder in
the guaranteed technical particulars or the acceptance value specified in this specification or the relevant
standard whichever is more stringent for that particular test.
7.28.7 TEST PROCEDURES AND SAMPLING NORMS:
The norms and procedure of sampling for the above tests shall be as per the relevant Indian standard or
other internationally accepted standards. This will be discussed and mutually agreed to between the
supplier and purchaser before placement of order. The standards and norms according to which these
tests are to be carried out are listed against each test. Where a particular test is a specific requirement of
this specification, the norms and procedure for the same shall be as specified in annexure IV attached
hereto or as mutually agreed to between the supplier and the purchaser in the Quality Assurance
program.
7.28.8 TYPE TESTS:
The following type tests shall be conducted on a suitable number of individual discs, components,
materials or complete strings.
7.28.8.1
On unit Disc Insulators:
a) Verification of dimensions
: IS:731
b) Thermal mechanical Performance test
: IEC:575
c) Power frequency voltage withstand and flashover (i) dry (ii) wet
:BS:137
d) Impulse voltage withstand
IEC:383
Flashover test (dry)
e) Visible Discharge test (dry)
: IS:731
f)
: IS:8263
RIV test (dry)

7.28.8.2
On Porcelain Long Rod Insulator unit.
g) Verification of dimensions
: IEC -383
h) Thermal mechanical Performance test
: IEC:575
i)
Power frequency voltage withstand and flashover (i) dry (ii) wet
: IEC-383
j)
Impulse voltage withstand Flashover test (dry)
: IEC:383
k) Visible Discharge test (dry)
: IS:731
l)
: IS:8263
RIV test (dry)
7.28.8.3 On the complete insulator string with hardware fittings:

a) Power frequency voltage withstand
test with coronaBS
:137(Part-I)
control rings and under wet condition

b) Switching surge voltage withstand
condition (400KV only):
test under wet

:
c) Impulse voltage withstand test under dry condition.
:IEC:383
d) Impulse voltage flashover test under dry condition
e) Voltage distribution test
f)
: As per this Specification
Corona and RIV test under dry condition
g) Mechanical strength test
h) Vibration
7.28.8.4 On the complete porcelain long rod insulator string with hardware fittings:
i)
Power frequency voltage withstand
test with
corona control rings and under wet condition

j)
:IEC-383
Switching surge voltage withstand test under wet condition

(400KV only)
k) Impulse voltage withstand test under dry condition.

l)
Impulse voltage flashover test under dry condition
:IEC:383
:
m) Voltage distribution test
n) Corona and RIV test under dry condition
: As per this Specification
o) Mechanical strength test
p) Vibration
7.28.8.5
All the type tests given under clause No.6.8.1 shall be conducted on Single
suspension and Double tension Insulator strings along with hardware fittings.
7.28.9.1
For Disc Insulators:

a) Visual Examination
: IS:731
b) Verification of Dimensions
: IS:731
c) Temperature cycle test
:IS:731
d) Galvanizing test
e) Mechanical performance test
: IEC:575
f)
:IEC: 372
Test on locking device for ball and socket coupling :

Eccentricity test (As per this
specification)
h) Electro mechanical strength test

g) Puncture test
7.28.9.2
: IS:731
:
For Porcelain Long rod Insulator:
a) Visual examination
: As per IEC 383
b) Verification of dimensions
: As per IEC 383
c) Temperature cycle test
: IS:731/IEC-383
i. Galvanizing test
ii. Mechanical performance test
: IEC:575
iii. Test on locking device for ball and socket coupling: IEC: 372
d) Eccentricity test As per this specification/IEC 383
e) Electro mechanical strength test
i. Puncture test
:IS:731/IEC 383
:
ii. Porosity test
:
:
7.28.10 ROUTINE TEST :

7.28.10.1
7.28.10.2
7.28.11
For Disc Insulators:

a) Visual Inspection
: IS:731
b) Mechanical Routine Test
c) Electrical Routine Test
: IEC:383
For Porcelain Long rod Insulators:

d) Visual Inspection
: IS:731/IEC 383
e) Mechanical Routine Test
f)
: IEC:383
Electrical Routine Test
TESTS DURING MANUFACTURE:
On all components as applicable

a) Chemical analysis of zinc used for galvanizing
b) Chemical analysis, mechanical and metallographic test and :

magnetic particle inspection for malleable castings.
c) Chemical analysis, harness test and magnetic
Specification
:As
Particle inspection for forgings

d) Hydraulic Internal pressure test on shell
e) Crack detection test for metal parts
per
the
7.28.12
ADDITIONAL TEST:
The purchaser reserves the right for carrying out any other tests of a reasonable nature at the works of
the supplier or at any other recognized laboratory / research institute in addition to the above mentioned
type, acceptance and routine tests at the cost of the purchaser to satisfy that the materials complies with
the intent of this specification.
7.28.13 CO-ORDINATION FOR TESTING:
For insulator strings, the supplier shall arrange to conduct testing of their disc insulators with the
hardware fittings to be supplied to the Purchaser by other suppliers. The supplier is also required to
guarantee overall satisfactory performance of the disc insulator with the hardware fittings.
NOTE:
In respect of electrical test on a complete string consisting of insulators and hard wares guarantee of
values and responsibility of testing shall be with hardware manufacturer for RIV, corona and voltage
distribution test and with insulator manufacturer for all other tests.
7.28.14
TEST CHARGES AND TEST SCHEDULE:
7.28.14.1
TYPE TESTS:
The disc insulators offered shall be fully type tested as per this specifications. The bids offering Disc
Insulators not type tested will be rejected. These tests must not have been conducted earlier than five
years from the date of bid opening. In case the equipment of the type and design offered has already
been type tested, the bidder shall furnish four sets of type test reports along with the offer. In case the
type tests are conducted earlier than five years all type tests as per the relevant standards shall be
carried out by the successful bidder in the presence of purchasers representative at free of cost. The
purchaser reserves the right to demand repetition of any or all the type tests in the presence of his
representatives. For this purpose, the bidder may quote relevant rates for carrying out each type test.
The prices quoted by the bidder towards conductance of type test shall be taken into consideration for bid
evaluation. For any change in the design / type already type test and the design / type offered against
this specification the purchaser reserves the right to demand repetition tests without any extra cost.
7.28.14.2
ACCEPTANCE AND ROUTINE TESTS:
All acceptance and Routine tests as stipulated here shall be carried out by the supplier in the
presence purchasers representative.
7.28.14.3
Immediately after finalization of the programme of type / acceptance / routine testing, the
supplier shall give sufficient advance intimation to the Owner, enable him to depute his representative for
witness the test.
7.28.14.4
For type tests involving tests on a complete insulator string with hardware fittings, the
Purchaser will advice the supplier of the hardware fittings to provide the necessary fittings to the place of
the test.
7.28.14.5
In case of failure of the complete string in any type tests, the manufacturer whose
product has failed in type tests, shall get the tests repeated at his cost. In case of any dispute,
assessment of the Purchasers to the items that has caused the failure in any of the type tests shall be
final and binding.
7.29 INSPECTION:
7.29.1 i. Purchaser and its representative shall at a times be entitled to have access to the works and to
all places of manufacture where insulators are manufactured and the supplier shall afford all facilities to
them for unrestricted inspection of the works, inspection of materials, inspectio n of manufacturing process
of insulators for conducting necessary tests and specified herein.
ii. The supplier shall keep the Purchaser informed in advance of the time of starting and progress
of manufacture of insulators in various stages so that arrangements could be made for inspection.
iii. No material shall be dispatched from its point of manufacture unless the material has been
satisfactorily inspected and tested.
iv. The acceptance of any quantity of insulators shall in no way relieve the supplier of his
responsibility for meeting all the requirement of this specification and shall not prevent subsequent
rejection, if such disc insulators are later found to be defective.
7.29.2 IDENTIFICATION MARKING:
7.29.2.1 Each disc insulator shall be legibly and indelibly marked with the trademark of the supplier, the
year of manufacture, the guaranteed combined mechanical and electrical strength in Kilo -Newton
abbreviated by KN to facilitate easy identification and proper use.
7.29.2.2 The marking shall be on porcelain for porcelain insulators. The marking shall be printed and
not impressed and the same shall be applied before firing.
7.29.3 Quality assurance plan:
7.29.3.1 The bidder hereunder shall invariably furnish following informations along with his offer, failing
which the offer shall be liable for rejection.
i.
Statement giving list of important raw materials, names of sub -suppliers for the raw materials, list of
standard, according to which the raw materials are tested, list of tests, normally carried out on raw
material in presence of Bidders representative, copies of test certificates.
ii.
Information and copies of test certificates as in (i) above in respect of bought out material.
iii.
List of manufacturing facilities available.
iv.
Level of automation achieved and list of areas where manual processing exists.
v.
List of areas in manufacturing process, where stage inspections are normally carried out in quality
vi.
Special features provided in the equipment to make it maintenance free.
vii. List of testing equipment available with the Bidder for final testing of equipment specified and test
standards. These limitations shall be very clearly b rought out in schedule of deviations from specified
test requirements.
7.29.3.2 The supplier shall within 30 days of placement of order submit the following information to the
owner.
i.
List of raw materials and the names of sub-suppliers selected from those furnished along with the
offer.
ii.
Type test certificates of the raw material and bought out accessories.
iii. Quality assurance plan (QAP) with hold points for purchasers inspection. The QAP and
purchasers hold points shall be discussed between the Owner and the supplie r before the QAP is
finalised.
The supplier shall submit the routine test certificates of bought out items and raw material at the time of
routine testing of the finalized insulator.
7.30 Documentation:
7.30.1 The bidder shall furnish full description and illustrated catalogues of insulators offered along with
the offer.
7.30.2 TEST REPORTS:
i.
Four copies of type test reports shall be furnished to the purchasers within one month conducting
the tests. One copy will be return duly certified by the purchasers to the supplier within three weeks
there afterwards and receipt of the same supplier shall commence with the commercial production of the
concern material.
ii.
Four copies of acceptance test reports shall furnished to the purchasers. One copy will returned,
duly certified by the purchasers and only there after shall the materials be dispatched.
iii. All records of routine test reports shall maintained by the supplier at his works for periodic
inspection by the purchasers.
iv. All test reports of tests conducted during manufacture shall be maintained by the supplier. These
shall be produced for verification as and when requested for by the purchaser.
7.31 PACKING & FORWARDING:
i.
All disc insulators shall be packed in strong seasoned wooden crates. The gross weight of the
crates along with disc insulators shall not normally exceed 200 kg. to avoid handling problem. Suitable
lifting lugs shall be provided on the crates in order to facilitate handling by cranes.
ii.
The packing shall be of sufficient strength to withstand rough handling during transit, storage at site
and subsequent handling in the field.
iii.
Suitable cushioning, protective padding, Dunn age or spacers shall be provided to prevent damage
or deformation during transit and handling.
iv.
All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and avoid the possibility of goods being lost or wrongly dispatched on account of faulty
packing and faulty or illegible markings. Each wooden case / crate shall have all the markings stenciled
on it in indelible ink.
Annexure-A
TEST DETAILS
8.1
TESTS ON COMPLETE STRING WITH HARDWARE FITTINGS:
8.1.1 VOLTAGE DISTRIBUTION TEST:

The voltage across each insulator unit shall be measured by sphere gap method. The result obtained
shall be converted into percentage and proportionate correction be applied as to give a total of 100%
distribution. The voltage across any disc shall not exceed the values given in clause4-12.1
8.1.2 CORONA EXTINCTION VOLTAGE TEST (DRY):
The sample assembly when subjected to power frequency voltage shall have a corona extinction voltage
of not less than the value specified at clause 4.12.1 (iv) under dry condition. There shall be no evidence
of corona on any part of the sample when all possible source of corona are photographed in a darkened
room.
8.1.3 RIV TEST (DRY):
Under the conditions as specified in (2) above, the insulator string along with complete hardware fittings
shall have a radio interference voltage level below 500 micro volts at one MHz when subjected to 50 Hz
AC voltage of 1.1 times maximum line to ground voltage under dry condition. The test procedure shall be
in accordance with IS:8263/IEC:437
8.1.4 MECHNICAL STRENGTH TEST:
The complete insulator string along with its hardware fitting excluding arcing horn corona
controlling/grading ring and suspension assembly/dead end assembly shall be subject to a load equal to
50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at steady rate to
68% of the minimum UTS specified. The load shall be held for five minutes and then removed. After
removal of the load, the string components shall not show any visual deformation and it shall be possible
to disassemble them by hand. Hand tools may be used to remove cotter pins and loosen the nuts
initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further
increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should
occur during this period. The applied load shall then be increased until the failing loads reached and the
value recorded.
8.1.5 VIBRATION TEST:
The suspension string shall be tested in suspension mode and tension string in tension mode itself in
laboratory span of minimum 30 meters. In the case of suspensions string a load equal to 600 Kg. S hall
be applied along with the axis of the suspensions string by means of turn buckle. The insulators string
along with hardware fittings and two sub conductors throughout the duration of the test vibration dampers
shall not be used on the test span. Both the sub-conductors shall be vertically vibrated simultaneously at
one of the resonance frequencies of the insulator string (more than 10HZ) by means of vibration inducing
equipment. The amplitude of vibration at the antipode point nearest to the string shall be measured and
the same shall not be less than 120.4 being the frequency of vibration. The insulator strings shall be
vibrated for five million cycles then rotated by 90 deg and again vibrated for 5 million cycles without any
failure, after the test the disc insulators shall be examined for looseness of pins and cap or any crack in
the cement. The hardware fittings shall be examined to fatigue fatter and mechanical strength test.
There shall be no deterioration of properties of hardware components and disc insulators after the
vibration test. The insulators shall be subjected to the following tests as per relevant standards.
Test
%age of units to be tested

Disc.
a.
b.
Long Rod
Temperature cycle test followed by

mechanical performance test.
60
100
Puncturetest
40
(for porcelain insulator only)

8.2
ON DISC INSULATOR UNITS/PORCELAIN LONG ROD UNITS (As applicable):
8.2.1 Steep Wave Front Test (For Disc Insulator only):

Test following test shall be performed on 10 insulator units in case of disc insulators selected at random
from the lot offered for selection of sample for type test.
a.
Each insulator unit shall be subjected to five successive positive and negative impulse flashovers
with a wave having minimum effective rate of rise of 2500 KV per micro seconds.
b.
Each unit shall then be subjected to three dry power frequency voltage flashovers.
Acceptance Criteria:
An insulator shall be deemed to have met the requirement of this test if, having bee n successfully
subjected to the ten impulse flashovers, the arithmetic mean of the three subsequent dry/power
frequency voltage flashover values equals or exceeds 95% of the rated dry power frequency flashover
voltage.
An insulator shall be deemed to have failed to meet the requirement of above testing if,
a)It has not flash over when the oscillogram or peak voltage indicator shows a marked reduction in
voltage.
or
b)Any one of the subsequent three dry power frequency voltage flashover value is less than 80% of
the value specified.
Failure of any one unit either in the steep wave front or subsequent low frequency voltage test shall
cause for testing on double number of units.
8.2.2 Polarized Light Inspection (only for Glass Disc Insulator):

The disc insulator shall be held over a polarized light source and the stress lines viewed thereon. There
shall be no uneven stress distribution in the toughened glass insulators. This shall be carried out on
100% glass shells.
8.2.3 Hydraulic Internal Pressure Test on Shells (only for Disc Insulator):
The test shall be carried out on 100% shells before assembly. The details regarding test will be as
discussed and mutually agreed to by the Supplier and Purchaser in Quality Assurance Programme.
8.2.4 Thermal Mechanical Performance Test:
Thermal Mechanical Performance Test shall be performed in accordance with IEC-60383-1 Clause 20
with the following modifications:
1) The applied mechanical load during this test shall be 70% of the rated electromechanical
or mechanical value.
2) The acceptance criteria shall be
a)X greater than or equal to R + 35.
Where
X = Mean value of the individual mechanical failing load.
R = Rated electro-mechanical/mechanical failing load.
S= Standard deviation.
b)The minimum sample size shall be taken as 20 for disc insulator units and 5 units for long rod units.
c) The individual electromechanical failing load shall be at least equal to the rated value. Also
puncture shall not occur before the ultimate fracture.
8.2.5 Electromechanical/Mechanical Failing load Test:
This test shall be performed in accordance with clause 18 and 19 of IEC 383 with the following
acceptance.
i) X greater than or equal to R + 35
Where
X = Mean value of the individual mechanical failing load.
R = Rated electro-mechanical/mechanical failing load.
S= Standard deviation.
ii) The minimum sample size shall be taken as 20 for disc insulators units and 5 for long rod units.
However, for larger lot size, IEC591 shall be applicable.
iii) The individual electro-mechanical failing load shall be at least equal to the rated value. Also electrical
puncture shall not occur before the ultimate fracture.
8.2.6 Residual Strength Test (For Disc Insulators only):

The above test shall be performed as per clause 4.4 and 4.5 of IEC 797 preceded by the temperature
cycle test, on both glass and porcelain disc insulators. The Sample size shall be 25 and the evaluation of
the results and acceptance criteria shall be as per clause No.4.6 of IEC:797.
8.2.7 IR Measurements:
IR Measurement shall be carried out by the instrument operating at 1 KV DC. IR value when measured
under fair weather condition, shall not be less than 50 M-ohm.
8.2.8 Impact Test:
The Impact test shall be carried out in accordance with ANSI-C-29.2 Clause 8.2.8 with the following
modification.
The breaking point of the pendulum shall be so adjusted that, when released the copper nose will strike
the outer rim of the shell or the most protruded rim of the shell squarely in direction parallel to the axis of
the unit and towards the cap.
The test specimen shall receive an impact of 7 N-m for 120 kN Disc & 10N-m for 160 kN Disc releasing
the pendulum.
8.3
TESTS ON ALL COMPONENTS (As applicable)
8.3.1 CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING:

Sample taken from the zinc ingot shall be chemically analyzed as per IS:209. The purity of zinc shall not
be less than 99.95%.
8.3.2 TEST FOR FORGINGS:
The chemical analysis hardness tests and magnetic particle inspection for forgings will be as per the
international/recognized procedures for these tests. The sampling will be based on heat number and
heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the
supplier and purchaser in quality assurance programme.
8.3.3 TEST ON CASTINGS:
The Chemical analysis mechanical and metallographic tests and magnetic particle inspection for castings
will be as per the internationally recognized procedures for these tests. The samplings will be based on
heat number and heat treatment batch. The details regarding test will be as discussed and mutually
agreed to by the supplier and purchaser in quality assurance programme.
8.3.4 HYDRAULIC INTERNAL PRESSURE TEST ON SHELLS:
The test shall be earned out on 100% shells before assembly. The details regarding test will be as
discussed and mutually agreed to by the suppliers and purchaser in quality assurance prog ramme.
8.3.5 THERMAL MECHNICAL PERFORMANCE TEST:
The thermal mechanical performance test shall be carried out on minimum 15 number of disc insulators
units as per the procedure given in IEC 575. The performance of the insulator unit shall be determined
by the same standard.
8.3.6 ECCENTRICITY TEST:

The insulator shall be vertically mounted on a future using dummy pin and socket. A vertical scale with
horizontal slider shall be used for the axial run out. The pointer shall be positioned in contract with the
bottom of the outermost petticoat of the disc. The disc insulators shall be rotated with reference to the
fixture and the slider shall be allowed to move up and down on the scale but always maintaining contact
with the bottom of the outer most petticoats. After o ne full rotation of the disc the maximum and minimum
position the slider has reached on the scale can be found out. Difference between the above two
readings shall satisfy the guaranteed value for axial run out.
Similarly using a horizontal scale with veridical slider the radial run out shall be measured. The slider
shall be positioned on the scale to establish contact with the circumstance of the disc insulator and disc
insulator rotated on its future always maintaining the contact. After one full rotation of the disc the
maximum and minimum position the slider has reached on the scale can be found out. Difference
between the above two readings shall satisfy the guaranteed value for axial run out.
8.3.7 CRACK DETECTION TEST:
Crack detection test shall be carried out on each ball and pin before assembly of disc unit. The supplier
shall maintain complete record of having conducted such tests on each and every piece of ball pin. The
bidder shall furnish full details of the equipment available with him for crack test and also indicate the test
procedure in detail.
TECHNICAL SPECIFICATION FOR SILICON RUBBER COMPOSITE INSULATORS

FOR USE ON TRANSMISSION LINES
(120KN & 90KN EMS)
9.1
SCOPE:
9.1.1 This specification provides for design, manufacture, engineering, inspection and testing before
dispatch, packing and delivery F.O.R. (destination) of SILICON RUBBER COMPOSITE as per technical
requirements furnished in this specification. These insulators are to be used in suspension and tension
insulator strings for suspension and anchoring of conductors on EHV transmission towers of KPTCL.
9.1.2 The insulators shall conform in all respects to high standards of engineering, design, workmanship
and latest revisions of relevant standards at the time of offer and purchaser shall have the power to reject
any work or material which, in his judgment, is not in full accordance therewith.
The materials covered here under this specification shall be supplied complete in all respects, including
all components, fittings and accessories which are necessary or are usual for their efficient performance
and satisfactory maintenance under the various operating and atmospheric conditions. Such parts shall
be deemed to be within the scope of the Contract, whether specifically included or not in the Specification
or in the Contract Schedules. The Supplier shall not be eligible for any extra charges for such fittings, etc.
9.2
PRE- QUALIFYING REQUIREMENT:
The bidders should be original manufacturer of the Silicon Rubber composite insulators and shall have all
the facilities to manufacture 90KN & 120KN and higher Size of Composite long rod insulators. Traders
are not eligible for the tenders offered by KPTCL.
9.3
STANDARDS
9.3.1 Except as modified in this specification, the SILICON RUBBER COMPOSITE insulators shall
conform to the following Indian standards which shall mean latest revisions and amendments.
Equivalent International and Internationally recognized standards to which same of these standards
generally correspond are also listed below:
Sl.
No.
Indian
Standard
International Electro-technical Vocabulary
1
2
3
IS: 206
IS: 209
5
6
Title
IS:2071
Part(I)
Part (II)
Part(III)
IS:2121
Method for chemical analysis of slab zinc

Specification for Zinc
Composite insulators for A.C. Overhead
power lines with the nominal voltage greater
than 1000 V.
Method of High voltage Testing
Specification of Conductors and Earth-wire
IEC 60050 Chapter 471
Insulators
BS:3436
IEC:61109-1992
IEC:60060-1 - General definition&
test requirements.
IEC:60060-2 Measuring
systems.
Sl.
No.
Indian
Standard
Part (I)
IS:2486
Part (I)
Part (II)
Part (III)
IS:2629
IS: 2633
10
IS:3138
11
IS:3188
12
IS:4218
13
IS:6745
14
IS:8263
15
IS:8269
16
17
18
19
20
IEC
Title
Accessories for Overhead Power lines

Armour Rods, Binding-Wires and Tapes for
conductors
Specification for Insulator fittings for IEC: 575
overhead power lines with a nominal voltage
greater than 1000V
General Requirements and Tests
BS:3288
Locking Devices
IEC:6020
IEC:60372
Recommended practice for hot dip ISO:1459
galvanization for iron and steel
ISO:1460
ISO:1461
Testing for Uniformity of Coating of Zinc
Coated Articles
Hexagonal bolts and nuts
IS0/R 947 and
IS0/R 272
IEC:60305- Characteristics of
insulator units for O/H lines with
nominal Voltage above 1000
Volts.
IS0/R 68-1969 R 26-1963, R2621969 and R 965-1969
Determination of weight of zinc coating on BS: 443-1969
zinc coated iron and steel articles
ISO:1460
IEC:60437
NEMA Publication
No.107/1964 CISPR
Methods for switching impulse test on HV IEC: 60506
insulators
Thermal Mechanical performance test and IEC: 60575
mechanical performance test on string
insulator units.
Long rod insulators
IEC-433
Salt Fog Pollution Voltage Withstand Test.
IEC-60507
Residual strength of string Insulatur Units of IEC- 60797
Glass Or Ceramic Material for Over head
lines after Mechanical damage of the Dielectric.
Guide for the Selection of insulators in IEC- 60815
Sl.
No.
Indian
Standard
Title
respect of polluted conditions.

Tests for insulators of Ceramic materials or IEC-60363.Part-1-Ceramic &
Glass for Over head lines with a nominal Glass Units for a.csystemVoltage greater than 1000V.
Definitions, Test methods &
acceptance criteria.
& Part 2- Insulator strings and sets
for a.c system.
Instruments & Software used for IEC :61083-1
measurement in high Voltage Impulse test
Requirements of Instrumrnts
Impulse Puncture testing in air for Ceramic IEC- 61211.
or Glass or Composite insulator for O/H lines
with nominal voltage greater than 1000v.
21
22
23

Reference
Abbreviation
BS
IEC/CISPR
IS
ISO
NEMA
Name and Address

British Standards, British Standards institution, 101, Pentonvile
Road, N-19, ND, UK
International Electro technical Commission Bureau Central de la
Commission Electro Technique International 1, Rue de verembe
Geneva Switzerland
Bureau of India Standards,
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi 110 001 India
International Organisation for standardization
Danish Board of Standardization
Dansk Standardisering Street,
Aurehoegvej 12 DK 2900
DENMARK
National Electric Manufactures Association
155, East 44th Street, New York,
NY 10017 USA.
9.3.3 Insulators conforming to any other international standards are also acceptable provided always that
such standards are equivalent to or better than the corresponding standards specified in 2.1 above
However in such an event the salient points of Comparison between the standards adopted and the
standards quoted herein shall be detailed in the appropriate schedule. Two copies authentic English
version of such standards shall be submitted along with the offer.
9.4 SERVICE CONDITIONS:
Composite Insulators are to be for lines located near thermal power stations using Coal, near sea coast
which are getting polluted by certain deposits from the sea, salt deposits in the water vapour from cooling
towers, coal dust & cement/fly ash. The lines covered under this contract are to run in plains / undulating
hilly terrain (Western Ghats)/coastal areas/Polluted areas in the vicinity of Cement factories,of Karnataka
and shall be suitable for the hot and humid tropical climatic conditions prevailing in the State. These are
furnished here below:
a) Peak ambient day temperature in still air 500C.
b) Minimum night temperature 100C.
c) Average maximum ambient day temperatures.
i.
June to January 350C.
ii. February to May 450C.

d) Relative humidity maximum 90 % in coastal area; minimum 10 % in the Western Ghats and
plains.
e) Maximum rainfall 200 mm in the plains/6000 mm in the coastal areas and the Western Ghats.
f)
Average number of rainy days:- 120 between April and November.
g) Average number of thunderstorm days/annum 50 between April and November.

h) Altitude above Mean Sea level MTr..
i.
Varying from 0 to 250 m in the coastal areas.
ii. Varying from 250 to 1000 m in the plains.

iii. 500 m in the Western Ghats.
i)
Maximum wind speed.

i. 39 m/sec in the coastal areas, the Western Ghats and the plains of northeastern Karnataka (
Bidar, Gulbarga & Raichur).
ii. 33 m/sec in the plains of northwestern and southern Karnataka.
j) Seismic level i.e Earthquake Accelaration.

a) Horizontal Seismic Co-efficient
(acceleration )- g (Zone 5).
b) a) Horizontal Seismic Co-efficient
(acceleration )- g (Zone 5).
9.5
BASIC TECHNICAL PARAMETERS OF THE LINES:
A) Electrical System Data:

a) System Voltage (kV rms)
110
b) Maximum Voltage (kV rms)
123
c) Lightning impulse withstand voltage (dry

& wet) (kVp)
550
d) Power frequency withstand voltage (wet)

(kVp)
230
e) Power frequency withstand voltage (dry)

(kVp)
265
f)
Short circuit level (KA)/duration
B) Line Data:
i) Conductor:
a. Name
b. Conductor per phase
c.Spacing between the conductors of same
phase (Vertical) mm
a) Configuration
25/1 Sec
ACSR
DRAKE
Single
ACSR
DRAKE
Single
ACSR
COYOTE
Single
3100
3100
2100
i.
Single Circuit
Right angled
Triangle
ii.
Double Circuit
Vertical
b) Minimum ultimate tensile strength (kg)

c) Conductor tension at 320C without
external load
i.
Initial unloaded tension
Right angled
Right angled Triangle
Triangle
Vertical
Vertical
7950
7950
4625
35%
25%
35%
25%
35%
25%
C) Galvanized Steel Earthwire Ground Wire):

a) Size (strands and wire diameter)
7/3.15
(mm)
7/3.15
7/3.15
ii.
Final unloaded tension
b) Location of earth wire

c) System of Grounding
d) Progressive shielding angle
e) Isokeraunic level
f) Tensile load in each earth wire
One continuous earth wire to run horizontally on the

top of the towers and conductors
Solidly
Solidly
Solidly earthed
earthed
earthed
300
300
300
50
50
50
The tension of earth wire & power conductor are so
co-ordinated such that the earth wire Sag shall not
be more than 90% of the corresponding Sag of
power conductor under still air condition for the
entire specified temperature range.
D) Towers:
a) Span length in metres:
b) Wind span in meters
c) Wind Load (Kg/sq.m)
d) Suspension Towers
Tension Towers
E) Insulators:
a)
320
352
130
320
352
130
150,
275
302
130
20
300,
600
Type of Insulators
SILICON RUBBER COMPOSITE INSULATOR
b) Lightning protection to insulator
Arcing horns both on the conductor side and cross

arm side
9.6
PRINCIPAL PARAMETERS:
9.6.1 Details of Silicon Rubber Composite Insulators:

GENERAL REQUIREMENT
The design, manufacturing, processes, tolerances and inspection of composite insulators shall
confirm to the following.
Language and units:
i.
All correspondence, literature, drawings and markings shall be in the English language.
ii. Dimensioning shall be in the SI (Metric System) units. Manufacturer should mention the standard
adopted for Dimensioning & tolerance principals considered for design.
iii. The insulator shall consist of standard module for a three phase. 50 HZ, effectively earthed 220 or
110 or 66KV transmission system in a moderately polluted atmosphere. The insulator shall be therefore
suitable for satisfactory operation under the tropical climatic conditions listed in the relevant clause. The
applicable design particulars of the insulator to be used on these lines are furnished in the System
particulars.
iv. The end fitting of the Composite Insulators shall be shall be ball and socket type with necessary
coupling arrangement such that the Pin shall move freely in the sockets but they do not get disengaged
while in service under various operating and atmospheric conditions. The length and other dimensions
should be such that it should be substituted by other conventional type Porcelain insulators. The
Composite Insulator Units shall have Ball fitting on the line side and Socket fitting on the tower side.
The insulator shall be suitable for being installed in air supported on suspension insulator hardware or
anchored through tension insulator hardware at the power cross arm of single circuit, double circuit or
multi-circuit line towers , as such it should be substitution for the conventional porcelain insulators.
v. The insulators shall have sheds of open aerodynamic profile with good self cleaning properties.
Insulator shed profile, spacing, projection etc shall be strictly in accordance with the recommendations of
IEC:60815.
vi.
The color of housing material shall be Dark Brown , uniform and consistent.
vii. The insulator shall be designed to withstand high pressure (3800KPa)/ (550psi) water washing from
a 6mm diameter nozzle from a distance of 3 meter between nozzle to Polymer insulator,
viii. The track resistance of the material used in the manufacture of housing and weather sheds shall
meet the requirements of IEC 587 class 1A4.5 or 1B4.5.
ix. The end fittings shall be free from defects like pitting, scaling, laps, folds. Cracks, shrinks, blow
holes. Burrs or rough edges etc. The fittings shall be attached to the core through crimping process
(controlled compression technique) and shall be designed to transmit the mechanical load to the core and
develop uniform and consistent mechanical strength of insulators. The metal surfaces shall be perfectly
smooth with no projecting parts or irregularities which may cause Corona .Ball pins shall not show any
microscopically visible cracks. inclusions and voids. The end fittings shall not contain parts of pieces
joined together, welded, shrink fitted or manufactured by any other process from more than one piece of
material.
x. The ball and socket fittings shall be designed to transmit the mechanical stresses to the core and
develop uniform mechanical strength in the insulator . The socket shall be circular with the inner and
outer surfaces Concentric and of such design that it will not yield or distort under loaded conditions. The
ball shall move freely in the socket either uring assembly of a string or during erection of a string or when
a string is placed in position.
xi. The Design, manufacturing Process and material control ay various stages shall be such as to give
maximum working load, highest mobility. best resistance to corrosion, good finish, elimination of sharp
edges and corners to limit Corona and Radio interference voltages. The design of the insulator string
shall be such that all the stresses due to expansion or contraction in any part of the insulator under rapid
temperatures fluctuation, which may be created due to variation in the loads or fault of any nature , while
in service shall not lea to any type of deterioration. Flat surfaces and corners shall not be allowed and
shall be completely rounded off.
xii. All raw materials to be used in the manufacture of insulators shall be subject to strict raw material
quality Control and to stage testing during manufacturing stage to ensure the quality of the final end
product. Manufacturing shall conform to the best engineering practices adopted in the field of extra high
voltage transmission. Bidders shall therefore offer insulators as are guaranteed by them for satisfactory
lifetime performance on transmission lines.
xiii. For reference the Size of conventional Disc insulator, Section length of insulator , minimum
creepage distance, the number to be used in different type of strings , their electromechanical strength
and mechanical strength of insulator string along with hardware shall be as indicated in Table-1 and
Table-2.
TABLE:1
Sl.
No.
01
02
03
04
Type of String
220 KV
Single
Suspension
Double
Suspension
Single Tension
Double Tensile
Size of disc
insulator
(mm)
Minimum
creepage
distance of
each disc
(mm)
No. of
Standard
discs
Electro-mechanical
Strength of Insulator
string in KN
255x 145
320
13
90
255x145
255x145
-do-
-do320
-do-
2x13
15
2x15
2x90
120
2x120
ELECTRICAL STRING CHARACTERISTICS FOR DISC INSULATOR STRING:

TABLE -2
i. Lightning Impulse withstand
voltage (dry) KV peak.
1050
550
325
1050
550
325
ii. Power frequency withstand

voltage (wet) KV r.m.s.
460
230
140
460
230
140
176
176
500
500
120
90
90
120
90
90
13%
13%
13%
13%
13%
13%
iii. Corona extinction voltage KV (rms)

iv. Max. RIV for complete string including
corona rings, arcing horns, clamps etc, at
1.1 times maximum line to ground
voltage (micro-volts)
v. Mechanical failing load for each sting
KN.
vi. No deformation load for each string
Kgf.
vii. Max. voltage across any disc.
XIV. Section length of Silicon rubber Composite insulator string, minimum creepagre distance required,
no. of units per string & EMS of each unit is tabulated in Table -3.
TABLE-3
Line
KV
No
Type of String
Single Suspn
220k
Section length
of insulator
( Soket to Ball pin)
(mm)
1885
Min.
Creepage
distance
No.of Standard
individual
units / string
EMS of
Insulator
(KN)
4160
90
Single Tension
2030
4800
120
Double Suspn
1885
4160
1X2
90 x 2
Double
2030
4800
1X2
120 x 2
Tension
Note: The section length of insulators mentioned above is the required length of insulator corresponding
to equivalent length of disc insulator string. The bidder may offer insulator varying in length with that
mentioned above. However, in such a casr the total length of string including hardware fittings shall be
within the maximum and minimum limits specified in the drawing (inclusive of tolerances on hardware and
insulator) attached to this specification.
9.6.2 STRING CHARACTERISTICS:
The Electrical String Characteristics of the complete string with long rod insulators shall be as tabulated in
Table 4.
TABLE-4
Sl No
Particulars
220 KV
Lightning Impulse withstand voltage (dry) KV peak
1050
Power frequency withstand voltage (wet) KV rms
460
Corona extinction voltage KV (rms)
176
Max. RIV for complete string including corona

rings, arcing horns, clamps etc., at 1.1 times
maximum line to ground voltage (micro-volts)
500
9.6.3 DRAWINGS:
9.6.3.1 The General arrangement drawings 220KV, strings mentioned above are enclosed at the end
of this specification. These drawings are attached only for the information
and guidance of the
manufacturer.
9.6.3.2 The manufacturer shall furnish outline drawing of the insulator and component drawing of end
fittings, Corona control ring indicating all dimensions. All drawings shall be neatly arranged and all
drafting and lettering shall be standard and legible. Dimensions shall be in SI units . The drawings shall
give the following information.
1) The bill of material indicating quantity, nature grade and reference standard of the material used for
various parts,
2) Technical details like Section length of insulator, dry arcing distance, creepage distance, ball and
socket designation, identification mark on the insulator.
3) Mechanical characteristics like specified mechanical load (SML) , Routine test load (RTL) and weight
of insulator.
4) Electrical characteristics like One minute Power fre quency withstand voltage under dry and wet
conditions, lightening impulse withstand voltage. Switching surge impulse withstand voltage. Corona
inception and extinction voltage.
5) After award of contract the bidder shall submit 3 sets of drawings to CEE (P&C) , Kaveri Bhavan ,
Bangalore, giving details as mentione above for scrutiny and approval. Once the drawings have been
approved no alteration or modification will be carried put without prior approval of the purchaser.
9.6.4
GALVANIZING:
All ferrous parts shall be hot dip galvanized in accordance with IS: 2629/ASTM A 153 to resist corrosion.
The Zinc to be used for galvanizing shall conform to grade Zn 98 (purity = 99.95%) of IS:209. The Zinc
coating shall be uniform,smooth, reasonably bright continous and free from impurities such as flux, ash,
rush stains, bulky white deposits and blisters. Before ball fittings are galvanized , all die flashing on the
shank and on the bearing surface of the shall be carefully removed without reducing the designed
dimensional requirements,
The Galvanised end fittings shall withstand 4 one minute dips in standard CuSO4 solution as per IS:
2633. The mass of Zinc coating shall not be less than 610gm/m 2 (86 micro m)
9.7
SPECEFIC TECHNICAL REQUIREMENTS:

DESIGN, WORKMANSHIP AND MATERIAL REQUIREMENT
9.7.1 GENERAL:
It is not the intent to specify completely herein all details of design and construction of the insulators
involved. However, the insulator shall conform, in all respects to the highest standards of Engineering an
workmanship and shall fulfill the anticipated performance in a manner acceptable to the purchaser who
will interpret the meaning of drawings and specifications and shall have the power to reject any material
which in his judgment. are not in full accordance therewith.
9.7.2 Design:
Silicon rubber Composite insulator shall be designed to meet the high quality, safety and reliability
capable of withstanding a wide range of system and environmental conditions mentioned in section 3,4
& 5 above. Composite insulators shall consists of Three Parts, at least two of which are insulating parts:a) Core- the internal insulating part designed to ensure the mechanical characteristics.
b) Housing the external insulating part which provides the necessary creepage distance and protects
the core from weather. A shed provided in the housing is a projecting part of the housing intended to
increase the creepage distance.
c) Metal end fittings - intended to transmit the mechanical load.
9.7.2.1 Core:
The core shall be glass-fibre reinforced epoxy resin rod (FRP) of high di-eletric and mechanical strength.
Both, glass fibre and Epoxy resin matrix material shall be optimized in the FRP rod. Process used for
manufacturing should yield a uniform material structure and optimum control and regulation of the qualityinfluencing parameters such as homogeneity and uni-directionality of the glass fibre across the cross
section of the rod. Glass fibers with low content in alkalies shall be boron free Eglass or Boron free
Electrically corrosion resistance(ECR) glass. Use of resin with hydrolysis trend due to water penetration
should be prevented i. e. matrix of the FRP rod shall be Hydrolysis resistant. Suitability of Epoxy matrix
as well as interface between matrix and fibres is to be considered as design parameter to prevent brittle
fracture. The FRP rod should be void free and shall be manufactured through Pultrusion process and
shall not be of draw forming process.
9.7.2.2 Housing:
The core of the composite insulator shall be completely covered by a continuous housing consisting of a
seamless sheath & -weathershed of silicon rubber compound. For moulding of entire weather shed
structure on to the rod, a one shot moulding process or extruded process shall be employed to avoid
multiple interfaces i.e. the housing shall consist of one piece of housing using injection moldings principle
consisting of seamless silicon rubber sheath with sheds to cover the entire core, to protect the rod against
environmental influences like Hydrolysis, U.V radiations, Corona & Ozo ne degradation, nd also to
external Pollution and humidity. The interface between the housing and the Fiber reinforced glass rod
shall be chemically bonded to prevent contaminations and moisture ingress. The strength of the bond
shall be greater than the tearing strength of composite insulating material used. The manufacturer shall
follow non-destructive technique (N.D.T) to check the quality of jointing of the housing interface with the
core. The technique being followed with detailed procedure and sampling shall be furnished along with
the bid. Hardware i. e. metal fittings may be installed on the rod prior to moldings of the shed controlling
moldings lines. The base polymer shall be 100% Silicon Rubber prior to the addition of reinforcing fillers.
The housing and weather sheds shall have Silicon contents of minimum of 30% to 40% by weight. The
Shore A hardness of Silicon rubber used in the manufacture of housing and weather sheds shall not be
less than 60.
The thickness of compounding material on core should be minimum 3 mm. The weather-sheds of the
insulators shall be of alternate shed profile. The weather shed shall be vulcanized to the sheath
(extrusion process) or molded as part of the sheath (injection moulding process) and free from
imperfections. The vulcanization for extrusion process shall be at high temperature and for injection
moulding shall be at high temperature and high pressure. Any seams/ burrs protruding axially along the
insulator, resulting from the injection moulding process shall be removed completely without causing any
damage to the housing. The track resistance of housing and shed shall be class 1A 4,5 according to IEC
60587. Manufacturer should furnish a description of its Quality Assurance Programme including
fabrication, testing and inspection for any material (i.e. rubber), components(i.e. rod) or hardware (i.e. end
fittings). If the manufacturer has got fabricated or manufactured components of insulator by others, the
same should also be included.
Manufacturing methods and material composition documentation will be a part of Technical Bid to be
submitted along with offer. Insulator should have hermetically sealed structure in which the housing
material is molded to cover the interface between the end fittings and the FRP rod. This seal should
never be broken during testing or otherwise.
9.7.2.3 End fittings:
The composite insulators shall be socket and ball type with the necessary coupling arrangement
such that pin shall move freely in the cap socket either during assembly of a insulators or during erection
of insulators or when a insulators is placed in position but do not get disengaged while in service under
various operating and atmospheric conditions.
The socket & ball type metal end fittings shall be designed to transmit the me chanical stresses to
the to the core & the end fittings by compression and develop uniform mechanical strength in the
insulator Material and methods used in the fabrication of metal parts shall be selected to provide good
toughness and ductility. Metal end fittings shall be made from a quality malleable cast iron or forged steel
with high tensile quality and shall be hot dipped galvanized in accordance with IS 2629 & ASTM A -153.
zinc of very high purity. The dimensions of the end fittings of insulato rs shall be in accordance with the
standard dimensions stated in IEC:60210/IS:2486-Part-II.
The attachment to the FRP rod shall be performed with a symmetrically controlled crimping method
control by acoustic method such as Co-axial Compression process that compresses the metal radially
onto the rod without damage to the individual rod fiber or resin matrix or causing crack the rod, while
providing a strength equal to or greater than the defined and specified ultimate strength to the insulator.
The manufacturer shall have in-process Aquostic emission arrangements to ensure that there is no
damage to the core during crimping. The verification shall be in-process and done on each insulator. The
Compression technique used shall make the insulator fittings relatively insensitive to dynamic stresses
which, for example, are caused by conductor vibrations. The interface point of the housing and the metal
end fittings shall be sealed by a flexible silicon elastomeric , metastable compound or Silicone alloy
compound sealant. The system of attachment of the end fittings to the rod shall provide superior sealing
performance between housing and metal connection. The sealing must be humidity proof and durable
with time.
The material used in fittings shall be corrosion resistant. Nominal dimensions of the pin, ball and
socket interior shall be in accordance with the standard shown at Clause No. 2.0 of this Specification. No
joints in ball & socket will be allowed. Outer portion of ball or socket should be Zinc sleeved with minimum
99.95% purity of electrolytic high grade Zinc. Before ball fittings are galvanized, all die flashing on the
shank and on the bearing surface of the ball shall be carefully removed without reducing the designed
dimensional requirements.
The bidder shall specify the grade, composition and mechanical properties of steel used for fittings.
The surface shall not crack or get chipped due to ageing effect under normal and abnormal service
conditions or while handling during transit or erection.
The design of the fittings and the insulators shall be such that there is no local corona formation or
discharges likely to cause the interference to either sound or vision transmission.
9.7.2.4 INTERPHASE ZONES:
Every insulator has, depending on the design and manufacturing process, various inter face zones
between the individual components of the insulator, as well as within the composite material, the RBGF
or FRP rod. In all the zones the best possible bonding must be achieved at the interface surface of the
materials being bonded so that no voids are created which can lead to the occurrence of partial
discharges in service, causing ageing and damade to the insulation. As silicon does not readily bond to
other substrates, the composite surface shall be sprayed evenly with a primer on a silicon basis before
the silicone weathershed is poured. In this way no additional layer is formed between the reinforced
epoxy resin rod and the silicon weathershed. The process should be such that, from both an electrical
and a mechanical view no problems concerning interface surfaces and intermediate layers should occur.
In load transfer area, the metal fittings shall be given silicon covering. This will ensure and
guarantee insulators resistance to hydrolysis at the ends for a long period so that no moisture is able to
penetrate into the insulator and which otherwise leads to the well known negative effects on the fiber
glass rod.
9.7.2.5 SECURITY CLIPS (LOCKING DEVICES):
The security clips to be used as locking device for ball and socket coupling shall be R shaped
hump type to provide for positive locking of the coupling as per IS:2486 (Part -IV)/ IEC: 60372. The legs
of the security clips shall allow for spreading after installation to prevent complete withdrawal from the
socket. The locking device shall be resilient, corrosion resistant and of sufficient mechanical strength.
There shall be no possibility of the locking device to be displaced or be capable of rotation when placed in
position and under no circumstances shall it allow separation of insulator units and fittings. W type
security clips are also acceptable. The hole for the security clip shall be countersunk and the clip shall be
of such design that the eye of the clip may be engaged by a hot line clip puller to provide for
disengagement under energized conditions. The force required for pulling the clip into its unlocked
position shall not be less than 50N (5 Kg) or more than 500 N (50 Kg).
9.7.2.6 GRADING RINGS:
Grading rings shall be provided when system voltages are equal to or greater than 220 KV. For 220
KV transmission, grading ring is to be provided at energized end only.
All grading rings and brackets shall be designed as an integral part of the insulator assembly with a
positive mounting system that allows mounting in only one position. The design of the grading ring shall
be such that ring can only be mounted with its orientation towards the weather sheds for maximum RIV
and corona control. Grading rings shall be designed in such a manner that the rings can be readily
installed and removed with hot line tools without disassembling any other part of the insulator assembly.
The size and placement of the metallic grading rings shall be designed to eliminate dry band
arcing/Corona cutting/ exceeding of permissible electrical stresses of material in the vicinity of the end
fittings and shield the end fittings preventing Corona inception at 115% of the nominal line to ground
voltage. The supplier shall furnish calculations along with the proposed placement and design of corona
ring in support of the above.
Grading ring height (is the distance from the end of the end fitting to the top of corona ring) should
be so selected that maximum field minimizes & uniformly distributed along the insulator. Manufacturer
should provide reports of successful electrical field modeling testing for the specific insulator design. The
EFM should be three dimensional with results containing drawing depicting the electric field in various
colors, each of a different voltage level. The result of this study should show that the voltage field
surrounding the composite insulator is optimum along the entire length of insulator, with the effected hot
end of the insulator being a critical location. The threshold at which corona may or may not be present
should be defined as a figure in kV/mm for the designed insulator.
9.8
VERIFICATION OF HOUSING MATERIAL
The manufacturer should provide written verification about housing material, for which base polymer shall
be 100% Silicon Rubber prior to the addition of reinforcing fillers considered will provide satisfactory
performance in the particular environment mentioned atCl.No.3 & 4.
It shall meet following requirements :
Be homogenous, impermeable, with no fissures, bubbles and strange materials inc lusions.
Be designed in order to avoid formation of localized discharges and to prevent interfaces humidity
penetration.
Be resistant to corona, UV radiation, ozone, atmospheric contamination, water penetration and
power arcs.
9.9
BALL AND SOCKET DESIGNATION
The dimensions of the Ball and Socket shall be 16mm designation for 90KN and 20mm designation for
120KN insulators in accordance with the standard dimensions stated in IEC: 60120/IS:2486(Part-II)
9.10 DIMENSIONAL TOLERANCE OF COMPOSITE INSULATORS:
The tolerance on all dimensions e.g. diameter, length and creepage distance shall be allowed as follows:
(0.04 d + 1.5) mm. when d = 300 mm.
(0.025 d + 6) mm. when d > 300 mm.
Where d being the dimensions in millimeters for diameter, length or creepage dis tance as the case may
be. However, no negative tolerance shall be applicable to creepage distance.
The composite insulators including the ball socket connections shall be standard design suitable for use
with the hardware fittings of any make conforming to relevant Indian standards.
The length and other dimensions should be such that it should be substituted by other conventional type
Porcelain insulators.
9.12 SUITABILITY FOR LIVE LINE MAINTENANCE
The insulators shall be compatible for use wet line or live line maintenance technique that usual hot line
operations can be carried out with ease, speed and safety.
9.13 CORONA AND RI PERFORMANCE:

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to
excessive localized pressure. The insulator and metal parts shall be so designed and manufactured that it
shall avoid local corona formation and not generate any radio interference beyond specified limit under
the operating conditions.
9.14 WORKMANSHIP:
1.1 All the materials shall be of latest design and conform to the best engineering practices adopted in
the high voltage field. Bidders shall offer only such insulators as are guaranteed by them to be
satisfactory and suitable for continued good service in Powe r Transmission lines.
1.2 The design, manufacturing process and material control at various stages shall be such as to give
maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of
sharp edges and corners to limit Corona and Radio interference..
1.3 The design of insulators shall be such that stresses due to expansion and contraction in any part of
the insulator shall not lead to deterioration.
1.4
The core shall be sound and free from cracks and voids that may adversely affe ct the insulators.
1.5 Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and shall be free
from defects and excessive flashing at parting lines.
1.6 Metal end fittings surfaces shall be uniform, perfectly smooth with no projecting parts or
irregularities, without sharp edges or corners which may cause corona and shall be free of cracks,
seams, air holes, blow holes and rough edges , flakes, slivers, slag, shrinkage defects and localized
porosity. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses
uniformly. Pins shall not show any microscopically visible cracks, inclusions and voids. End fittings
should be effectively sealed to prevent moisture ingress, effectiveness of sealing system must be
supported by test documents.
1.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of Zinc equivalent
to 610gm/sqm or 87 micrn thickness and shall be in accordance with the requirements of IS:2629/ISO
1461(E) . The zinc to be used for galvanizing shall conform to grade Zn 99.5 as per IS-209. The zinc
coating shall be uniform, smoothly adherent, reasonably bright, continuous and free from impurities such
as flux, ash, rust strains, bulky white deposits and blisters. The galvanized metal parts shall be
guaranteed to withstand at least four successive dips each lasting for one (1) minute duration under the
standard Preece test. The galvanization shall be carried out only after any machining.
9.15 MARKINGS:
Each Composite insulator shall be legibly and indelibly marked with the following details as per IEC
61109.
a.
Name or trademark of the manufacturer.
b.
Voltage and Type.
c.
Month and year of manufacturing.
d.
Minimum failing load / guaranteed mechanical strength in
work KN to facilitate easy
identification.
e.
kilo Newton followed by the
Country of manufacturer.
9.16 PACKING:
All insulators shall be packed in strong corrugated box of minimum 7 ply duly platted or wooden crates.
The gross weight of the crates along with the material shall not normally exceed 100 kg to avoid hackling
problem. The crates shall be suitable for outdoor storage under wet climate during rainy season. The
packing shall be of sufficient strength to withstand rough handling during transit, sto rage at site and
subsequent handling in the field. Suitable cushioning, protective padding, or Dunn age or spacers shall
be provided to prevent damage or deformation during transit and handling. All packing cases shall be
marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of
goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. Each
wooden case / crate corrugated box shall have all the markings stenciled on it in indelible ink.
The bidder shall provide instructions regarding handling and storage precautions to be taken at site.
9.17 INSPECTION, TESTS AND STANDARDS:
9.17.1
INSPECTION:
Inspection includes the performance of acceptance, type and design tests. KPTCL reserves the right to
carry out design and type tests to check conformity of the material with the proto type unit previously
approved.
Inspection includes the performance of acceptance, type and design tests. KPTCL & KBJNLreserves the
right to carry out design and type tests to check conformity of the material with the proto type unit
previously approved.
KPTCL reserves the right to attend the tests and perform inspections in any stage of the supply,
appointing its inspectors and following the approved manufacturing schedule. Inspection and tests
scheduled to happen during manufacture shall have their dates informed to KPTCL at least 10 days in
advance.
The manufacturer shall assure KPTCLs & KBJNL inspector the right to being fully acquainted with
installations and apparatus, check calibrations, be present at the tests, check results and in case of
doubt, perform new inspections and claim the repetition of any test.
9.17.2
TESTS:
Insulators offered shall be manufactured with the same configuration & raw materi als as used in the
insulators for which Design & type test reports are submitted. the manufacturer shall submit a certificate
for the same . The desgn and type test reports submitted shall not be more than five years old.
No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected,
tested, and necessary dispatch instructions are issued in writing, except for the cases where waiver of
inspection is granted by competent authority of the Purchaser, and even in this case also written dispatch
instructions will be issued. Any dispatches before the issue of Dispatch Instructions in writing will be liable
for rejection and non-acceptance of the materials by the consignee.
The acceptance of any quantity of material shall in no way relieve the Bidder of any of his responsibilities
for meeting all requirements of the specification, and shall not prevent subsequent rejection if such
material is later found to be defective.
The sample taken from any numbers of crates for carrying out any type of
tests will be to the suppliers account.
9.17.3
The following tests shall be carried out on the composite insulators.
9.17.3.1 DESIGN TEST:

The design tests are intended to verify the suitability of the design, materials and method of manufacture
(Technology),i.e., to prove the design, process of manufacture and conformity of the core material,
housing material, core assembly (core & end fittings), interfaces and connections of sample insulators
and product with the insulator of this specification. These tests shall be conducted on representative
number of samples prior to commence of commercial production. The bidder shall indicate his schedule
for carrying out these tests. When a composite insulator is submitted to the design tests the resul ts shall
be considered valid for the whole class of insulators which are represented by the one tested and having
the following characteristics.
Same materials for the core and sheds and same methods of attachment.
Same material of the fittings ,the same design and the same method of attachment.
* Same or greater layer thickness of the shed material over the core (including a sheath where
used)
same or smaller ratio of the highest system voltage to insulation length.
* same or smaller ratio of all mechanical loads to the smallest core diameter between fittings
highest system voltage to insulation length.
* same or greater diameter of the core.the tested composite insulator shall be identified by a
drawing giving all the dimensions with the manufacturing tolerances. Subsequently, if there are
small variations in the design data of not more than 15% for characteristics marked with *, the
design tests shall not be repeated.
9.17.3.2 PROTO TYPE or TYPE TESTS:
This shall mean those tests, which are to be carried to ve rify the main characteristics of a composite
insulator , which depend mainly on its shape and size. Type tests shall be applied to composite
insulators, the class of which has passed the design tests. They shall be repeated only when the type or
material of the composite insulator is changed.
9.17.3.3 ACCEPTANCE /SAMPLING TESTS:
The sampling tests are for the purpose of verifying other characteristics of composite insulators, including
those which depend on the quality of manufacture and on the materials used. This shall mean these tests
which are to be carried on insulator samples taken at random from each lot offered for pre -dispatch
inspection for the purpose of acceptance of the lot
9.17.3.4 ROUTINE TEST:

The aim of these tests is to eliminate composite insulators with manufacturing defects. This shall mean
those tests, which are to be carried out on each insulator offered for acceptance to check the
requirements are likely to vary during production.
9.17.3.5 TESTS DURING MANUFACTURE:
Stage tests during manufacture shall mean those which are to be carried out during the process of
manufacture to ensure quality control such that the product is of the designed quality conforming to intent
9.17.3.6 TEST VALUES:
For all type and acceptance tests, the acceptance values shall be the value guaranteed by the Bidder in
the guaranteed technical particulars or the acceptance value specified in this specification or the relevant
standard whichever is more stringent for that particular test.
9.17.3.7 TEST PROCEDURES AND SAMPLING NORMS:
The norms and procedure of sampling for the above tests shall be as per the relevant Indian standard or
other internationally accepted standards. This will be discussed and mutually agreed to between the
supplier and purchaser before placement of order. The standards and norms according to which these
tests are to be carried out are listed against each test. Where a particular test is a specific requirement of
this specification, the norms and procedure for the same shall be as specified in annexure IV attached
hereto or as mutually agreed to between the supplier and the purchaser in the Quality Assurance
program.
9.17.4
DESIGN TESTS:
The design test are performed only once and results are recorded in a test report as per IEC 1109 latest
edition. Each part of the four tests enlisted can be performed independently on new test specimens when
appropriate. The composite insulator of a particular design will be qualified only when all insulator or test
specimens pass the design tests, in the given sequence defined as under clause 5.1,5.2,5.3 and 5.4 of
IEC 1109 an as per Annexure- A,C & D of IEC:61109.
The summary of this tests.
Sl No
Description of the Type Test
Relevant standard/ test procedure.
Tests on interface and connections of As per clause 5.1 of IEC 61109 1992 and
metal fittings
as per Annexure-D of IEC 61109..
Test specimens and preliminary tests.
As per clause 5.1.1 of IEC 61109 1992.
Dry Power frequency tests
Pre-stressing.
Sudden load release test.
As per clause 5.1.3.1 of IEC 61109 1992.
Thermal- mechanical test
Water immersion test
Sl No
Verification tests.
Visual examination
Steep-front impulse Voltage test.
As per clause 5.1.4.2. of IEC 61109

1992.
Dry Power frequency Voltage test.
Assembled Core loadtime test:
As per clause 5.2 of IEC 61109 1992 and

as per Annexure A & D of IEC:61109
Test Specimens
Mechanical Load test
Determination of average failing load of the As per clause 5.2.2.1 of IEC 61109 1992.
core of the
4.
assembled insulator,
Control of slope of the strength-time curve of As per clause 5.2.2.2 of IEC 61109 1992.
the insulator.
Test of Housing : Tracking and erosion As per clause 5.3 of IEC 61109 1992 and
as per Anexxure-D of IEC 61109..
test & Multi stress test :
Test Specimens.
Test procedure.
Test conditions.
Evaluation of the tests.
Tests for the core material

Dye penetration test.
As per clause 5.4 of IEC 61109 1992 and

as per Anexxure-D of IEC 61109..
Test specimens
Performance of the test
Acceptance criterion.
Water diffusion test
As per clause 5.4.2 of IEC 61109 1992
Test Specimens
As per clause 5.4.2.1 of IEC 61109 1992
Prestressing
As per clause 5.4..2.2 of IEC 61109 1992
Voltage test
As per clause 5.4.2.3 of IEC 61109 1992
Flammability test
As per clause 5.5 of IEC 61109 1992
Test Specimens.
Evaluation of the tests.
Additionally following tests shall be carried out or reports for the tests shall be submitted after award of
contract.
1) Pollution test for composite insulator as per IEC-507.
2) Power arc test.
3) Brittle facture test.
4) Radio interference test.
5) Torsion withstand test for insulators whose coupling do not give total rotational freedom.
9.17.5
TYPE TESTS:
One insulator type is Electrically defined by arcing distance, creepage distance, Shed inclination, Shed
diameter and shed spacing. The Electrical type test shall be performed only once on the insulator
satisfying the above criteria for one type and shall be performed with arcing devices, if they are an
intergral part of the insulator type.
The Electrical type tests shall be repeated only when one or more of the above characteristics is
changed.
One insulator type is Mechanically defined by the Core diameter and the method of attachment of the
metal fittings. The mechanical type tests shall be performed only once on insulators satisfying the above
criteria for each type. They shall be repeated only when one or both of the above characteristics is
changed.
Unless otherwise agreed, a tolerance of
(0.04 d + 1.5) mm. when d < or = 300 mm.
(0.025 d + 6) mm. when d > 300 mm with a maximum of 50mm.
is allowed on all dimensions for which specific tolerance are not
dimension in millimeter).
requested ( d being the
Following Type tests shall be conducted on the complete Long Rod Composite insulator with Hardware
Fittings
No
1

ELECTRICAL TESTS:
Dry Lightning Impulse voltage withstand
test
As per IEC 61109 (Clause 6.1) Test procedure

according to clause and sub clauses
7,9,10,14,15.1,15.2, 17,18.1.2, 18.2,19 and 20
of IEC 383.
Wet Power frequency test
As per IEC 61109 (Clause 6.2) Test procedure
according to clause and sub clauses
7,9,12,13,14,15.1,17,18.1.2, 18.2,19 and 22 of
IEC 383.
Wet Switching impulse withstand Voltage As per IEC 61109 (Clause 6.3) Test procedure
test
according to clause and sub clauses 7,9,11,
13,14,15.1,17,18.1.3, 18.2,19 and 21 of IEC
No

383.
Mechanical Tests
Mechanical Load- time test
Long time mechanical withstand
Short time mechanical withstand
As per IEC 61109 (Clause 6.4) Annexure -A

and as per amendment of IEC:6110-9 1995
Clause 6.4
Radio interference test
Chemical composition test for Silicon

content
Brittle fracture resistance test Annexure-A
Ageing test under operating Voltage Annexure C of IEC 61109
simulating weather conditions (Accelerated
Ageing Test of 5000 hours)
Power frequency voltage withstand test with -IEC:383-1993
corona control rings/grading ring and arcing
horns under wet condition
d) Vibration test
-IEC:383-1993-Annexure-A
7
8
10
11
As per IEC 61109 (Clause 6.5) amendment -1

1995
12
Recovery of Hydrophobic test
-Annexure-A
All the above type test shall be conducted on Single I suspension and
Double tension insulator along with hardware fittings.
i) Grading device test
ii) Electrical Field Modeling test(EFM)
The bidder shall submit type test reports as per IEC 61109 along with the bid Additional type tests
required if any shall be carried out by the manufacturer, after award of contract for which no additional
charges shall be payable. In case, the tests have already been carried out, the manufacturer shall submit
reports for the same.
9.17.6
Sample Tests ( Acceptance Tests)
When specified on a purchase order, sample tests shall be performed as per ANSI C29.11& IEC:611091992.
Sl No
Verification of Dimensions
Clause 7.2 of IEC:61109
Verification of Locking System-applicable Clause 7.3 of IEC:61109

only in the event ball and socket insulators
is specified.
3.
Verification of tightness of the interface Clause 7.4 of IEC:61109
Sl No
between end fittings and insulator housing

4.
Mechanical Load test: Verification of the Clause 7.4 of IEC:61109 and as per
specified Mechanical Load (SML)
amendment of IEC:61109 1995
clause 7.4
5.
Galvanizing Test
Clause 7.5 of IEC:61109
If any one insulator or metal part fails to comply with the sampling tests, Re -testing procedure shall be as
per Clause 7.6 IEC:61109.
9.17.7
Routine Tests:
The following tests shall be performed on every insulato r produced as

per IEC:61109-1992.
(a) Identification of the Composite insulators: Each insulator shall be marked with the name or trade mark
of the manufacturer and the year of manufacture. In addition, each insulator shall be marked with the
Specified Mechanical Load(SML). These markings shall be legible and indelible.
(b) Mechanical Test: Every insulator shall withstand at ambient temperature a tensile load equal to or
greater than its Routine Test Load (50% of the Specified Mechanical Load) for a peri od not less than 10
seconds
(c) Visual Examination: Every insulator shall be examined to insure its conformance to the manufacturers
drawing as per Clause 8.2 of IEC:61109. Superficial polymer surface defects of an area less than 25
square millimeters (total area not to exceed 0.2% of total insulator surface area) and depth less than 1
mm shall be acceptable.
9.17.8
Additional Tests
The Purchaser reserves the right of getting done any other test(s) of reasonable nature carried out at
Purchaser's premises, at site, or in any other place in addition to the aforesaid type, acceptance and
routine tests to satisfy himself that the material comply with the specifications. In such case all the
expenses will be to Suppliers account.
The owner also reserves the right to conduct all the tests mentioned in this specification at his own
expense on the samples drawn from the site at suppliers premises or at any other test centre. In case of
evidence of non-compliance, it shall be binding on the part of the supplier to prove the compliance of the
items to the technical specifications by repeat tests or correction of deficiencies or replacement of
defective items, all without any extra cost to the owner.
9.17.9
Tests during Manufacturing:
Following tests shall also be carried out during manufacturing on all components as applicable and
the reference standards according to which the test shall be conducted are as follows.
Sl No
Particulars of tests
Raw material Inspection
Silicon Rubber
Reference standards
Sl No
Reference standards
Tensile strength & Elongation
ASTM D 412
Tear strength
ASTM D 624
Hardness
ASTM D2240
Resistance to track and erosion
IEC-60587
Di-electric strength
ASTM D 149
Silicone content test
Between 30% to 40%
Resistance to weathering and UV
ASTM G 53-93
Limiting Oxygen index
ASTM D 2863
FRP rods
1
Dimensions
As per drawing
Dye penetration test
As per Cl. 5.4.1 of IEC 61109
Water absorption test
ASTM 570
Water diffusion test
As per Cl. 5.4.2 of IEC 61109
Hardness test ( Barcol)
ASTM D 2583
% of Glass content,
ASTM D 2584
Brittle fracture resistance test & Flexural

test, inter laminar shear & tensile
strength of FRP
Bonding Agent
Appearance and specific gravity
Acceptance norms 0.836 to

0.880
Galvanized condition
1
Visual inspection & Dimension
IS:2486
Uniformity of Zinc coating
Thickness of coating by Electrometer
Chemical analysis of Zinc used for As per IS: 209

galvanization(Purity of Zinc)
Ball end Fittings(Forged steel)
Failing Load test, Yield strength test bar, As per IS:1608

Tensile strength to test bar, Hardness
test
IS:2486 Part II
Sl No
3
Reference standards
Chemical analysis, hardness tests and As per IS: 1608 & IS:3703
magnetic particle inspection for forging.
Socket end fittings
Tensile test, Elongation , Hardness
`Chemical
analysis,
metallographic
particle
test
inspection
As per IS: 14329 & IS: 1865.
mechanical, As per IS 3703

and
magnetic
for
malleable
castings.
Security Clip
1
As per IEC 60372 Cl.12
Resistance to bending test, Hardness & As per IEC 60372 Cl.13

Chemical analysis
Corona Ring
Chemical analysis
In process Inspection
Visual inspection of Prime application
Should be uniform on the entire

rod
Gauge checking for alignment after

crimping
SML check after crimping
50% of SML for 10 %
Sample Batch For Type Testing

The bidder shall offer material for sample selection for the type testing only after Quality Assurance Plan
approved by the General Manager Procurement. The Bidder shall offer at least 10% of the ordered
quantity or 300 nos. whichever is higher, for selection of samples required for conducting all the type
tests.
The Bidder is required to carry out all the acceptance tests successfully in the presence of Purchaser's
representative before dispatch of the selected sample to the testing laboratory for type test.
9.18 TEST REPORTS
9.18.1 Copies of type test reports shall be furnished in at least two (2) copies along with one original.
One copy shall be returned duly certified by the Purchaser only after which the material already inspected
i.e. the materials manufactured for selection of sample for type test, shall be dispatched on receipt o f
Dispatch Instructions from the CEE(P&C),KPTCL, Kaveri Bhavan, Bangalore
9.18.2 Record of routine test reports shall be maintained by the Bidder at his works for periodic
inspection by the purchasers representative.
9.18.3 Test Certificates of test during manufacture shall be maintained by the Bidder. These shall be
produced for verification as and when desired by the Purchaser.
9.19 TEST FACILITIES
The following additional facilities shall be available at Supplier's works:
a)
Calibration Reports from Government approved testing laboratory of various testing and measuring
equipment including tensile testing machine, resistance measurement facilities, burette, thermometer,
barometer etc.
b)
Finished insulator shall be checked for dimension verification and surface finish separately.
c)
The bidder should have all the routine and acceptance testing facilities, in house in accordance
with IEC:383 & 61109.
Manufacturers of foreign origin shall, in addition to the above, also have arrangements in India,
either at works of their authorized representative/licenses or in the NABL lab. like CPRI, IISC, ERDA etc.
for conducting sampling test in accordance with IEC : 383 & 1109.
9.20 QUALITY ASSURANCE PLAN
9.20.1 The bidder shall invariably furnish following information along with
his offer shall be rejected.
his offer, failing which
i)
Statement giving list of important raw materials, proposed to be used in the manufacture of the
insulator against this Specification, names of sub suppliers for the raw materials, list of standards
according to which the raw materials are tested, list of tests normally carried out on raw materials in
presence of Bidder's representative as routine and / or acceptance during production and on finished
goods, copies of test certificates.
ii)
Information and copies of test certificates as in (i) above in respect of bought out accessories.
iii)
List of manufacturing facilities available.
iv)
Level of automation achieved and lists of areas where manual processing exists.
v)
List of areas in manufacturing process, where stage inspections are normally carried out for quality
vi) List of testing equipment available with the Bidder for final testing of Insulator specified. In the case
if the Bidder does not possess all the Routine and Acceptance testing facilities the tender will be rejected.
vii) The Purchaser reserves the right for factory inspection to verify the facts quoted in the offer. If any
of the facts are found to be misleading or incorrect the offer of that Bidder will be out rightly rejected and
he may be black listed.
viii)
Special features provided to make it maintenance free.
ix)
Bidder shall also submit the Field Quality Plan (FQP) along with Technical Bid.
9.20.2
The bidder shall also submit following information to the purchaser along with the technical Bid. .
i) List of raw materials as well as bought out accessories, and the name of suppliers of raw materials as
well as bought out accessories.
ii) Type test certificates of the raw material and bought out accessories.
iii) Quality assurance plan (QAP) with hold points for purchaser's inspection.
9.20.3
The Bidders shall submit the routine test certificates of all the bought out items, accessories etc.
9.21 DOCUMENTATION
9.21.1 Two sets of type test reports, duly approved by the Purchaser shall be submitted by the Bidder,
before commencement of supply. A copy of acceptance and routine test certificates, duly approved by the
purchaser shall accompany the dispatch consignment.
9.21.2 The bidder shall submit the drawings in triplicate for the offered insulators well within the
commencement period for approval. The manufacturing of the insulator shall be strictly in accordance
with the approved drawings and no deviation shall be permitted without the written approval of the
Purchaser. All manufacturing and fabrication work in connection with the insulator prior to the approval of
the drawing shall be at suppliers risk.
9.21.3 Approval of drawings etc. by the purchaser shall not relieve the Bidder of his responsibility and
liability for ensuring correctness and correct interpretation of the latest revision of applicable standards,
rules and codes of practices. The insulator shall conform in all respects to high standards of engineering,
design, workmanship and latest revisions of relevant standards in vogue on the day of opening of the
Technical Bid and purchaser shall have the power to reject any work or material which in his judgment is
not in full accordance therewith.
9.21.4 In case the bidders offers Silicon rubber composite insulators tested and supplied to other utilities
, and are in service, the following additional information shall be furnished along with the bid.
1. The certificates of Type test as specified conducted within 5 years from the date of enquiry.
2. Performance report from the utilities for satisfactory performance of the Composite insulator for
at least Three years.
3. List of similar past orders executed for insulator for the last 5 years period.
4. Quality assurance plan in prescribed proforma.
9.22 DRAWINGS
All the bidders have to submit the drawings for Composite long rod (Silicon Rubber) insulator along with
the crates to be utilised for packing of the insulator, for the numbers specified in this Tender Specification
along with the offer. In the event of an order the successful bidder shall submit the drawings stated above
in triplicate for approval during the commencement period to CEIG , CEE (P&C), KPTCL, HESCOM &
KBJNL Kaveri Bhavan, Bangalore.
The set of approved drawings shall be submitted in soft copy in Auto CAD format.
9.23 DEVIATIONS
9.23.1 Any deviation to this tender Specification will be out rightly rejected. All the Bidders have to
submit this specification duly authenticated without any alterations, additions etc. on each page along
with the Technical Bid. Any offer without this will be out rightly rejected.
9.24 MAINTENANCE:
The insulator shall be capable of high pressure washing at a maximum nozzle pressure of 550psi. The
insulators offered shall be suitable for employing Hot Line Maintenance Techniques with required speed,
ease and safety.
ANNEXURE-A
10.1 Tests on Complete Strings with Hardware Fittings.
10.1.1 Mechanical Strength Test
The complete insulator string along with its hardware fitting excluding arcing horn, corona control ring
grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of
the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of
the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of
the load, the string components shall not show any visual deformation and it shall be possible to
disassemble them by hand. Hand tools may be used to, remove cotter pins and loosen the nuts initially.
The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased
at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during
this period. The applied load shall then be increased until the failing load is reached and the value
recorded.
10.1.2 Vibration Test
The suspension string shall be tested in suspension mode and tension string in tension mode itself in
laboratory span of minimum 30 Meters. In the case of suspension string a load equal to 60 0 kg shall be
applied along the axis of the suspension string by means of turn buckle. The insulator string along with
hardware fittings and two sub-conductors (each tensioned at 43 KN shall be secured with clamps. The
system shall be suitable to maintain constant tension on each sub-conductors throughout the duration of
the test. Vibration dampers shall not be used on the test span. Both the sub -conductors shall be vertically
vibrated simultaneously at one of the resonance frequencies of the insulators string (more than 10 Hz) by
means of vibration inducing equipment. The peak to peak displacement in mm of vibration at the
antinodes point, nearest to the string, shall be measured and the same shall not be less than
1000/fwhere is the frequency of vibration in cycles/sec. The insulator string shall be vibrated for not less
than 10 million cycles without any failure. After the test the insulators shall be examined for looseness if
pins and cap or any crack in the cement. The hardware shall be examined for loos eness, fatigue failure
and mechanical strength test. There shall be no deterioration of properties of hardware components and
insulators after the vibration test. The insulators shall be subjected to the following tests as per relevant
standards :
a) Temperature cycle test followed by mechanical performance test.
10.1.3 Salt -fog pollution withstand test
This test shall be carried out in accordance with IEC-60507. The salinity level for composite long rod
insulators shall be 80 Kg / m3 NACL.
10.2 Composite Long rod Insulator Units
10.2.1 Brittle Fracture Resistance Test.
Assembled core load time test with container that contains in-HNO3 concentric acid this is applied at the
naked rod. The rod should be held at 80% of SML for the duration of the test. The rod should not fail
within the 96 hour test duration.
10.2.2
Recovery of Hydrophobicity Test
(1) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface to dry and
spray with water. Record the HC classification. Dry the sample surface.
(2) Treat the surface with corona discharges to destroy the hydrophobicity. This can be done utilizing a
high frequency corona tester. Holding the electrode approximately 3 mm from the sample surface slowly
move the electrode over an area approximately 1 x 1. Continue treating this area for 2-3 minutes,
operating the tester at maximum output.
(3) Immediately after the corona treatment, spray the surface with water and record the HC classification.
The surface should be hydrophilic with an HC value of 6 to 7. If not, dry the surface and repeat the corona
treatment for a longer time until an HC of 6 or 7 is obtained. Dry the sample surface.
(4) Allow the sample to recover and repeat the hydrophobicity measurement at several time intervals.
Silicone rubber should recover to HC 1 HC 2 within 24 to 48 hours, depending on the material and the
intensity of the corona treatment.
10.3 Test on All components (As applicable).
10.3.1
Chemical Analysis of Zinc used for Galvanizing.
Samples taken from the zinc ingot shall be chemically analyzed as per IS 209-1979. The purity of zinc
shall not be less than 99.95%.
10.3.2
Tests for Forgings.
The chemical analysis hardness tests and magnetic particle inspection for forgings will be as per the
internationally recognized procedures for these tests. The sampling will be based on heat number and
heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the
Supplier and Owner in Quality Assurance Programme.
10.3.3
Tests on Castings.
The chemical analysis, mechanical and metallographic tests and magnetic, article inspection for castings
will be as per the internationally recognized Procedures for these tests. The samplings will be based on
heat number and heat treatment batch. The details regarding test will be as discussed and mutually
agreed to by the Supplier and Owner in Quality Assurance Programme.
10.4 Grading device test:
10.4.1 In addition to the electrical design tests, for 220 KV & above class insulator design with
applicable grading device test, similar to the following
described test: Grading devices shall be tested using a mechanical shaker with at least a one inch stroke
at the grading device and a frequency of no less than three cycles per second for duration of 2,000,000
cycles. Movement shall be along the long axis of the insulator. The grading device shall be attached to
the shaker in a vertical position. The test shall be considered successful if no movement is detected in the
ring with respect to the insulator and there is no physical damage to the grad ing device and the
attachment assembly.
The manufacturer should provide with documentation that the insulator design with applicable grading
devices will minimize or eliminate corona discharge activity under wet and dry conditions.
10.5 Power Arc Test:

10.5.1 Three insulators having any one design of end fittings shall be tested for power arc endurance
while tensioned horizontally at 3000lb. An arc shall be initiated across the insulator by means of a Copper
shorting fuse wire. The arc shall burn 15 to 30 cycles and its current magnitude is determined by amperetime product(IxT) equal to a minimum of 150kA cycles. Each insulator is only acceptable if there is no
exposure of the core, no mechanical separation of the insulator, and no cracks in the housing (As per
IEC61467-1997)
GUARANTEED TECHNICAL PARTICULARS FOR SILICON RUBBER HOUSED COMPOSITE
INSULATORS
(To be furnished by the bidder and submitted with the offer. Entering
lead to rejection of offer.)
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
GTP PARTICULARS
GENERAL
Manufacturers name, address &
country.
Bidders name, address & country
Size & designation of Ball &
Socket(mm)
Standard to which Ball & socket will
conform
Section length of insulator (mm)
No. of units per string
Number of weather sheds per
unit.(nos)
Material
of
housing
and
weathershed
Creepage distance of insulator in
mm.
Dry arc distance (mm)
Specified Mechanical Load (SML)
of insulator in KN
ELECTRICAL
Dry Power frequency withstand
Voltage (KV rms)
Wet Power frequency withstand
Voltage (KV rms)
Positive
Lightning
Impulse
withstand Voltage under Dry
condition (KVp)
Duplicate/overwritten data may
SUSPENSION TYPE
TENSION TYPE
COMPOSITE INSULATOR COMPOSITE INSULATOR
220 KV
220 KV
No
15
16
17
18
19
20
21
22
GTP PARTICULARS
Negative
Lightning
Impulse
withstand Voltage under Dry
condition (KVp)
Dry Power frequency Flash over
Voltage (KV rms)
Wet Power frequency Flash over
Voltage (KV rms)
Positive Lightning Impulse Flash
over Voltage under Dry condition
(KVp)
Negative Lightning Impulse Flash
over Voltage under Dry condition
(KVp)
Maximum RIV including CC rings,
Arcing horns, Clamps etc. at 1.1
times maximum Corona inception
Voltage (KV rms) line to ground
voltage ( micro volts)
Corona extension Voltage (KV rms)
Whether details regarding method
of fixing end fitting to FRP rod,
method of detecting harmful cracks
on FRP rod during crimping and
method of manufac turing are
enclosed.
SUSPENSION TYPE
TENSION TYPE
COMPOSITE INSULATOR COMPOSITE INSULATOR
TECHNICAL SPECIFICATIONS FOR ACCESSORIES FOR ACSR CONDUCTORS

SCOPE
STANDARDS
MATERIALS
GENERAL REQUIREMENTS
TESTS
SUBMISSION OF DRAWINGS
INSPECTION
PACKING
PART-IIB
SECTION-VII
TECHNICAL SPECIFICATION FOR ACCESSORIES FOR ACSR CONDUCTORS
11.1 SCOPE:
This specification covers, design, manufacture, testing at manufacturers works, supply and delivery of
midspan compression joints, preformed armour rods, vibration dampers, repair sleeves, P.G.Clamps for
the power conductor specified. The equipment required shall be complete with all components which are
necessary or useful for their efficient performance and satisfactory maintenance.
11.2 STANDARDS:
The fittings and accessories shall comply in all respects with the latest edition of relevant IS Specification
or any other equivalent authoritative standard. Except as modified by this specification, the conductor
accessories to be supplied shall conform to the latest addition with amendments and revisions thereof the
following Bureau of Indian Standards (IS) and British Standards (BS) specifications.
IS 2486
IS 2486 (Part-I) 1977
IS 2486 (Part-II) 1974
IS 2486 (Part-III) 1974
IS 2486 (Part-IV) 1981
IS 2121
IS 2121 (Part-I) 1981
IS 2121 (Part-II) 1981
IS 1363 (Part-I) 1984
IS 1363 (Part-II) 1984
IS 1363 (Part-III) 1984
IS 1363
IS 1367
IS 1367 (Part-I) 1980
IS 1367 (Part-II) 1979
IS 1367 (Part-III) 1979
IS 6639 1972
IS 2633 1972
IS 2629 1966
IS 209 1979
IS 9708 1980
IS 1327 1966
Insulator fittings for overhead power lines of 3.3 kV and above.

General Requirements and tests (First Revision with Amendment
No.1)
Dimensional Requirements (First Revision)
Locking devices
Tests for locking devices
Conductors and Earthwire Accessories for overhead power lines
Armour rods, binding wires and tapes for conductors
Mid span joints and repair sleeves for conductors.
Hexagon head bolts (Second Revision with Amendment No.1)
Hexagon head screws (Second Revision with Amendment No.1)
Hexagon nuts (Second Revision with Amendment No.1)
Hexagon head bolts, screws and nuts
Technical supply conditions for threaded steel fasteners
Introduction and general information (Second Revision)
Product grades and tolerance (Second Revision)
Mechanical properties and test methods for bolts, screws and studs
with full leadability (Second Revision)
Hexagon bolts for steel structures (Amendments 1 & 2
Methods of testing uniformity of coating on zinc coated articles (First
Revision)
Recommended practice for hot dip galvanizing of Iron and Steel
Zinc (Third revision)
Stockbridge vibration dampers for overhead power lines
Method of determination of mass of tin coating on tinplate (Second
revision)
IS 4826 1979
IS 1573 1976
IS 8263 1976
Hot dipped galvanized coatings on round steel wires (First Revision

with Amendment No.1)
Electroplated coatings of zinc on Iron & Steel (First revision)
Method of radio interference tests on high voltage insulators
IS 10162 1982
Spacers and spacer dampers for twin horizontal bundle conductors

Carbon steel forging for general engineering purposes (Second
IS 2004 1978
Revision)
General instructions and testing procedures specific requirements for
BS 970 (Part-I) 1983
carbon and carbon Manganese alloy and stainless steels
Conductor accessories and hardwares conforming to any other national or international standards are
also acceptable. However, in such an event, the salient points of comparison between the standards
adopted and deviations schedule in section BPS with an authentic English version of such standards.
11.3 MATERIAL:
The materials offered shall be complete in all respects and of best quality and workmanship. The
materials in the manufacturer of accessories viz. malleable iron and forged steel depending on the type of
application for which the accessories are used shall be corrosion resistant and mechinable. The
composition of aluminium alloys used shall be made available to the owner if required for verification.
11.4 GENERAL REQUIREMENTS:
All parts of fittings shall be suitable for use in atmospheric cond ition indicated elsewhere in the
specification inherently resistant to atmospheric corrosion or be suitably protected against corrosion both
during storage and in service.
All ferrous metal parts except those made of stainless steel shall be protected by hot dip galvanizing.
Spring washers shall be electro galvanized.
All castings shall be free from blowholes and other casting defects such as cracks etc. The surface shall
be as smooth as possible.
The tension joints shall be so designed that strength of complete joints shall not be less than 95% of the
minimum breaking load of the conductor under tension.
In case of rods, wire or tape no joints shall be permitted except those in the base rod or wire before final
drawings.
11.5 MID Span Compression Joints for Power Conductor:
This shall be suitable for jointing the two ends of the power conductor. The joint shall have a conductivity
of an equivalent length of the conductor. The joint shall not permit slipping of, damage to or failure of the
complete conductor or any part thereof at a load of not less than 95% of the ultimate tensile strength of
the conductor. The electrical resistance of the joint after installation shall not exceed 75% of the
measured resistance of the equivalent length of the conductor.
The components of the joint shall consist of steel and Aluminium sleeves for joint compression of the
steel core conductors and aluminium conductors respectively. The steel sleeve shall not crack or fail
during compression. The steel sleeve shall be hot dip g alvanized. The Aluminium sleeve shall be
manufactured and extruded out of EC grade Aluminium with a purity of not less than 99.5%. Tapered
Aluminium filler plugs shall be provided at the line of demarcation between compression and non compression zone.
The dimensions and dimensional tolerances of this mid span compression joint shall be as per relevant
ISS.
11.6 Repair Sleeves for Power Conductor:
Repair sleeves to be used shall be for repairing the conductor when a few strands of the Aluminium
conductor in the outermost layer are damaged with scratches, kinks abrasions, nicks or cuts. They shall
be of the compression type. The sleeve shall be manufactured and extruded out of EC grade Aluminium
having a purity of 99.5%. The sleeve shall be in two halves with a seat provision for sliding of the keeper
piece. The edges of the seat as well as of the keeper piece shall be so rounded that the conductor
strands are not damaged during installation. The outer body of the sleeve shall be smooth even and with
rounded off edges.
The compressed conductor with the repair sleeve shall not permit damage or failure of the conductor at a
load of not less than 95% of the ultimate tensile strength of the conductor. The electrical resistance of the
repaired portion of the conductor shall not exceed 75% of the measured resistance of an equivalent
length of the conductor.
The dimensions and dimensional tolerances of the repair sleeves shall be as per relevant ISS.
11.7 Vibration Dampers for Power Conductor:
The vibration dampers shall be of the stock bridge 4R type for being used at all suspension and tension
points at each and every span to damp out the vibrations of the conductors to the level specified
hereinafter. These shall conform to the relevant ISS.
The clamp of the vibration damper shall be made of aluminium alloy. It shall be capable of supporting the
damper during installation and prevent damage or chafing of the conductor during erection or continued
operation. The clamp shall have sufficient grip to maintain the damper in position on the conductor
without damaging the strands or causing premature fatigue of the conductor under the clamp. The
groove of the clamp body and clamp cap shall be smooth, free of projections grit or other materials, which
could cause damage to the conductor when the clamp is installed. Clamping bolts shall be provided with
self-locking nuts and designed to prevent corrosion of the threads or loosening during service.
The messenger cable of the damper shall be made of high strength steel with a minimum strength of 136
kg/mm. It shall be preformed and post formed in order to prevent subsequent drop of weights and to
maintain consistent flexural stiffness cable while in service. The messenger cable shall be suitably and
effectively sealed to prevent corrosion.
The damper mass shall be made of hot dip galvanized mild steel/cast iron or a permanent mould cast
zinc alloy. All castings shall be free from defects such as cracks, shrinkage, inclusions and blowholes
etc. The inside and outside surfaces of the damper masses shall be smooth.
The damper assembly shall be electrically conductive to reduce radio interference.
The vibration damper shall be capable of being installed and removed from energized line by means of
hot line technique. In addition, the clamp shall be capable of being removed and reinstalled on the
conductor at the design torque without shearing or damaging of bolts, nuts or cap screws.
The vibration analysis of the system with and without damper, dynamic characteristic of the damper shall
have to be submitted by the Bidder along with the bid. The technical particulars for vibration analysis and
damping design of the 220-kV/220 KV/66 kV systems.
The bidder recommend the number of vibration dampers of the type offered by them and their points of
fixation for spans of 250 M, 400 M and up to 600 Metres in steps of 50 Meters.
11.8 Preformed Armour Rods:
These shall conform to the relevant Drawings. Suitable aluminium alloy shall be used for the
manufacture of preformed armour rods. The armour rods shall be marked in the centre with black paint.
No joint shall be permitted in the individual rods.
11.9 P.G. Clamps:
Forced wedge type clamps shall be used for giving jump connections at anchor point. All the bolts,
nuts and washers should be hot dip galvanized.
11.10 TESTS:
All tests shall be conducted in accordance with latest edition of IS 2121/IS 9708. The following shall
constitute the tests. Type test certificates of recent origin (not older than 5 years) for having conducted
the tests should be furnished along with the quotation. In case the test certificates are older than 5 years,
then the contractor shall conduct the same afresh at his own cost.
I. Type tests:
For Mid Span compression joints and repair sleeves.
Visual examination.
Dimensional verification.
Failing load test.
Electrical resistance test.
Heating cycle test.
Galvanizing test.
For Preformed Armour Rods.
Visual examination.
Verification of dimensions.
Tensile strength test.
Slip strength test.
Bend test.
Resilient test.
Vibration dampers:
Visual examination.
Verification of dimension.
Resonance frequency test.
Fatigue test.
Mass pull off test.
Dynamic characteristic test.
Damping efficiency test.
Clamp slip test.
Torque test.
Galvanising electroplating test.
Magnetic power loss test.
Radio interference voltage test.
P.G. Clamps:
Failing load test.
II. Acceptance Tests:
Following Acceptance tests shall be conducted as per IS 2121 /IS 9708 and any other relevant standards
in the presence of the Purchasers representative.
Mid span compression joints and repair sleeves.
Visual examination.
Failing load test.
Galvanising test.
Armour rods.
Visual examination.
Tensile strength test.
Electrical resistance.
Slip strength test.
Vibration dampers.
Visual examination.
Resonance frequency test.
Fatigue test.
Mass pull off test.
Galvanizing/electroplating test.
P.G. Clamps: As per the relevant ISS.
III. Routine tests:
i)
Mid span compression joints and repair sleeves, armour rods, vibration dampers, spacers and
dampers.
Visual examination.
Galvanisation test:
Galvanised parts shall be tested in accordance with latest edition of relevant IS.
11.11 SUBMISSION OF DRAWINGS:
Drawings equivalent to the number of consignees plus six extra for each item have to be
submitted for approval before commencement of supply. Supplies shall not be commenced before
approval of drawings. Non-submission of drawing/receipt of approval shall not be linked with delivery
schedule. Delivery schedule should be adhered to.
The drawing shall be complete in all respects. Detailed dimensions shall be furnished in each of the
drawings. Full specification of the equipment such as material weight, tensile strength, tolerance,
chemical composition etc shall be incorporated in each drawing.
Any defects noticed in the manufacture of the equipment during inspection or after receipt at destination
have to be promptly set right by the contractor free of all cost to the owner.
11.12 INSPECTION:
The owners representative shall have access to the manufacturers works for purposes of
inspection during the manufacture of the equipment.
11.13 PACKING:
All accessories shall be supplied in strong wooden case all packages shall be marked on the sides as
follows:
a)
Name and designation of the consignee.
b)
Ultimate destination as required by the Owner.
TECHNICAL SPECIFICATION FOR GROUND WIRE ACCESSORIES

SCOPE
STANDARDS
MATERIALS
GENERAL REQUIREMENTS
MATERIAL DESIGN AND WORKMANSHIP
BID DRAWINGS
TESTS
TECHNICAL SPECIFICATION FOR GROUND WIRE ACCESSORIES

12.1 SCOPE:
This specification covers design, manufacture, testing at manufacturers works, supply and delivery of
accessories for the ground conductor. The details of the conductors for which these accessories are
required have been given under the specifications for Ground wire elsewhere in the specifications. The
equipment required shall be complete with all components which are necessary or usual for their e fficient
performance and satisfactory maintenance and shall be as per the enclosed drawings.
The accessories/Hardware suitable for 7/3.15 GSS ground wire shall comprise of the following:
i)
Mid span compression joint.
ii)
Flexible copper earth bonds.
iii)
Vibration dampers.
iv)
Suspension clamp.
v)
Tension clamp.
vi)
P.G. Clamps.
vii)
Repair sleeves.
12.2 STANDARDS:
The fittings and accessories shall comply in all respects with relevant Indian Standard Specification, IS
2121-1962 and IS 2486 with latest amendments. The Indian Standards wherever mentioned in this
specification shall mean only the latest edition of the relevant standards including latest amendments.
12.3 MATERIALS:
The materials offered shall be of best quality and workmanship. The materials employed in the
manufacture of accessories viz-malleable iron and forged steel etc. On the type of application for which
the accessories are used shall be corrosion resistant and mechinable.
12.4 GENERAL REQUIREMENTS:
12.4.1 All parts of fittings shall be suitable for use in atmospheric conditions given in Part-I (General) of
Technical Specifications and shall be inherently resistant to atmospheric corrosion or be suitably
protected against corrosion both during storage and in service.
All ferrous metal parts except those made of stainless steel shall b e protected by hot dip
galvanizing. Spring washers shall be electro galvanized.
The threads in nuts and in tapped holes shall be cut after galvanizing and shall be well lubricated or
greased. All other threads shall be cut before galvanizing. The bolt threads shall be under cut to take
care of the increase in diameter due to galvanising and if required should be return after galvanizing.
All castings shall be free from blowholes and other casting defects such as cracks.
The tension joints shall be so designed that when installed they withstand at least 95% of the
minimum-breaking load of the ground wire.
Fittings intended to connect conductors of two dissimilar metal shall be designed to avoid harmful
bimetallic corrosion when erected in accordance with conductor accessories manufacturers
recommendations.
All fittings shall be so designed that the effects of vibration both on the conductor and the fitting
itself are minimized.
12.4.2 Mid span compression joint for ground wire conductor:
i)
The mid-span compression joint for Ground wire conductor is to be used for jointing of two lengths
of galvanized steel stranded (GSS) earthwire of size 7/3.15 mm and of 110 Kgs/ sq.mm tensile strength.
ii)
The joint sleeve shall be made of high strength mild steel tubes with aluminium sleeves and shall
be easily compressible with a 100 tonne capacity hydraulic compressor. The mild steel shall conform to
IS:226 grade, 58A grade or equivalent thereof. The clamp shall not permit slipping of damage to or
failure of the complete earth wire or any part thereof at a load of not less than 95% of the ultimate tensile
strength of the earthwire. The joint shall have conductivity more than the conductivity of an equivalent
length of earthwire. The dimensions of the joint shall be as per drawing enclosed.
12.4.3 Flexible Copper Earth Bond:
The flexible copper-earthing bond shall be made of tinned flexible copper cable of size 37/7/0.417 with
9.81 mm dia and copper area equivalent to 34 Sq.mm. The tinning shall be as per relevant Indian
Standard. The length of copper cable shall not be less than 500 mm. Two tinned copper connecting lugs
shall be press jointed to the either ends of the flexible copper cable. The complete assembly shall also
include one 16 mm dia 40 mm. 10hs HRH M.S. bolt hot dip galvanized with nut and lock washer.
12.4.4 Vibration Damper for Ground Wire Conductor:
i)
Vibration dampers of stock bridge 4R type be used at all suspension and tension points on each
overhead ground wire in each span to damp out the vibrations of the ground wire to the specified level as
stated hereinafter.
ii)
The clamp of the vibration damper shall be made of aluminium alloy. It shall be capable of
supporting the damper during installation and prevent damage or chafing of the earthwire during erection
or continued operation. The clamp shall have sufficient grip to maintain the damper in position on the
earthwire without damaging the strands or causing premature fatigue of the earthwire under the clamp.
The groove of the clamp body and clamp cap shall be smooth, free of projections, grit or other materials,
which could cause damage to the earthwire when the clamp is installed.
iii) The messenger cable of the vibration damper shall be made of high strength steel with a minimum
strength of 136 Kg/mm and performed in order to prevent subsequent drop of weights in service. The
number of strands in the messenger cable shall be 19. Clamping bolts shall be provided with self-locking
nuts designed to prevent corrosion of the threads or loosening during service. The messenger c able
shall be suitably and effectively sealed to prevent corrosion.
iv) The damper mass shall be made of hot dip galvanized mild steel/cast iron or a permanent mould
cast zinc alloy. All castings shall be free from defects such as cracks shrinkage, inclusions and
blowholes etc. The inside and outside surfaces of the damper masses shall be smooth.
v)
The vibration damper shall be capable of being installed and removed from an energized line by
means of hot line techniques. In addition, the clamp shall be capable of being removed and reinstalled
on the earthwire at the design torque without shearing or damaging of bolt and nuts or cap screws.
vi) The vibration analysis of the system with and without damper, dynamic characteristic of the damper
shall have to be submitted by Bidder along with the bid. The vibration analysis and damping design shall
be suitable to the 220-kV/110-kV/66 kV system now offered for construction.
vii) The Bidder shall recommend the number of vibration dampers of the type offered by them and their
point of fixation for spans of 250 Metres to 600 Metres at an interval of 50 Metres.
12.4.5 Suspension Hardware for Ground Wire Conductor:
i)
These are to be used for suspending the ground wire conductor at all tangent/suspension towers
and shall be suitable for supporting the G.S.S. earthwire of size 7/3.15 mm.
ii)
The suspension clamps shall conform to IS 2486-1971 and shall have adequate area of support for
the earthwire. The groove of the clamp shall be smooth, finished in an uniform circular or oval shape and
shall slope downwards in a smooth curve to avoid edge support and hence to reduce the intensity of
bending moment on the earthwire.
iii) There shall be no sharp points in the clamps coming in contact with earthwire. There shall not be
any displacement in the configuration of the earthwire strands nor shall these be unduly stressed in final
assembly.
iv) The clamping piece and the clamp body shall be clamped by at least two U bolts of size not less
than 10 mm with 3-mm thick lock washers on each of its limbs. Suspensio n clamp shall be provided with
inverted type of U bolts. One limb of the U bolt shall be long enough to accommodate the lug of the
flexible copper bond.
v)
The suspension clamp shall be of the Trunion type or envelope type.
vi) The complete assembly of the suspension clamp shall be guaranteed for slip strength and
Mechanical test as per clause 5.4.1 and 5.5.1 of ISS 2486 Part-I 1971.
12.4.6 Tension Hardwares for Ground Wire Conductor:
i)
These tension hardwares are to be used at all tension towers for anchoring the 7/3.15-mm
galvanized steel earthwire (ground wire). The hardware assembly shall comprise of Bolted
type/compression type of tension clamp and two D shackles. The tension clamp is to be attached to the
horizontal strain plate of the tower body by means of a D shackle.
ii)
These clamps shall give adequate area of support without any slip to the ground wire under normal
working tension and vibration conditions.
iii) The complete tension hardware assembly shall be so designed as to avoid undue bending in any
part of the clamp and shall not produce any hindrance to the movements of the clamp in horizontal and
vertical direction.
iv) The slip strength of tension clamp assembly shall not be less than 95% of the ultimate strength of
the ground wire. The ultimate strength of the clamp and individual components shall not be less than that
of ground wire.
12.5 MATERIAL, DESIGN AND WORKMANSHIP:
12.5.1 General:
i)
All the equipments shall be of the latest design and shall conform to the best modern engineering
practice adopted in the field of extra high voltage engineering. The bidder shall offer only such equipment
as are guaranteed for satisfactory and suitable performance of 220 KV transmission lines.
ii)
The design, manufacturing process and quality control of all the materials shall be such as to give
maximum factor of safety, maximum possible working load, highest mobility, elimination of sharp edges
and corners to limit corona and radio interference best resistance to corrosion and a good finish.
12.5.2 Galvanising:
i)
All ferrous parts including steel components, bolts, nuts and washers etc shall be hot dip
galvanized after all machining has been completed. Nuts may, however be tapped (threaded) after
galvanizing. Spring washers shall be electro-galvanized. The bolt threads shall be undercut to take care
of increase in diameter due to galvanizing. Galvanizing shall be done in accordance with IS -2629 and
shall satisfy the tests mentioned in IS 2633. Bolts and nuts and washers shall withstand four dips while
spring washers shall withstand three dips. Other galvanized materials shall be guaranteed to withstand
at least six dips each lasting one minute under the standard preece test for galvanizing.
ii)
The zinc coating shall be perfectly adherent, of uniform thickness, smooth, reasonably bright,
continuous and free from all imperfections such as flux, ash, rust stains, bulky white deposits and blisters.
The zinc used for galvanizing shall be of grade Zn 99.95 as per IS 209.
12.5.3 Castings:
i)
All ferrous and aluminium alloy castings, shall be free of all internal defects, shrinkages, inclusions,
blow holes, cracks etc.
ii)
All castings shall be smoothly and evenly finished by machining, buffing etc., so as to eliminate
sharp ends, edges, abrasions and projections. No surface area of the accessories and hardware in
contact with the conductors in any manner either during erection or during continuous operation. The
surface in contact with the conductor shall not cause any abnormal electrical or mechanical stresses
during normal working and operating conditions.
12.5.4 Current Carrying Parts:
i)
All current carrying parts shall be so designed and manufactured that the contact resistance is
reduced to a minimum.
ii)
The design of metal parts and their mating surfaces in contact with power conductors shall be such
as to prevent corrosion of the contact surface and to maintain good electrical contact under all operating
conditions.
12.5.5 Metal parts of ground wire hardware:

i)
The suspension clamp shall be of malleable cast iron or forged steel. The tension clamp shall be
made of forged steel/malleable cast iron with aluminium sleeves conforming to IS-2486 or of a grade or
equivalent thereof.
ii)
D shackles, clevis U bolts, cotter pins and other components shall be manufactured from drop
forged steel conforming to IS 2004/1978 or equivalent there of.
iii) Bolts, nuts and washers shall be as per IS 1367 and shall be of reputed makes such as GKW,
TATA brands etc.
iv)
All split pins shall be of stainless steel.
12.5.6 Interchangeability:
All components like design shall be interchangeable.
12.5.7 Compression Markings:
i)
Die compression areas shall be clearly marked on components, which are to be pressure
compressed such as Mid-span compression joints and tension hardwares. The marking shall be an
etched inscription with the words COMPRESS FIRST on components, which are meant for continuous
die compression. Where components are designed for in termiltent die compressions, the compression
and non-compression zones shall bear etched inscription such as COMPRESS ZONE and NONCOMPRESSION ZONE distinctly with etched arrow signs indicating the direction of compression and
knurled marks showing the end of the zones.
ii)
All inscriptions etched on metal shall be distinct, legible and shall not wear out in the course of
normal handling.
12.6 BID DRAWINGS:
i)
The bidder shall furnish along with the bid the dimensional drawings of all accessories and
hardwares.
ii)
These drawings shall include the following information.
a)
Dimensions.
b) Tolerances on dimensions.
c) Material designation used for different components with reference to standards.
d) Fabrication details such as welds, finishes and coatings.
e) Catalogue or part numbers for each component and the total assembly with bill of materials.
f)
Identification marking.
g) Weight of individual components and total assembled weight.

iii)
The assembly drawings shall include the following:
a) Brief installation instructions.

b) Design installation torque for the bolt or cap screw.
c) Withstand torque that can be applied to the bolt or cap screw without failure of components or parts
thereof.
d) Compression dies number with recommended compression pressure.
e) Relevant technical details of significance.
12.7 TESTS:
All tests shall be conducted in accordance with IS 2121-1962 and IS-2486. Tests are divided groups viz.
type tests, sample tests and routine tests. Details of tests have been given under the respective fittings.
12.7.1 Type Tests:
Type tests are normally made once and unless otherwise agreed test certificates giving the results of the
appropriate type tests made on not less than three fittings identical in all essential details with those to be
supplied are regarded as evidence of compliance. All the type test certificates of recent origin not older
than 5 years as on Bid opening date conducted in a reputed laboratory shall be furnished along with the
Bid. In case the type test reports are older than 5 years the contractor shall conduct the type tests on his
own cost before commencement of mass production.
12.7.2 Sample Test:
Sample tests are not applicable when the order is for less than one hundred identical fittings. The
number of samples shall be the nearest whole number to one half of one percent of the batch offered for
inspection. If these samples meet the test requirements, the batch is deemed to comply with the
standard. In the event of a sample not meeting the requirement, twice the original no. of new samples
shall be tested. If all these new samples meet the test requirement, the batch is deemed to comply with
the standard but if any fails to do so, the batch is deemed not to comply with the standard.
12.7.3 Routine Test:
Those shall be applied to every fitting unless mentioned otherwise.
12.7.4 Acceptance Test:
These are tests carried out on samples taken from a lot for the purpose of acceptance of the lot.
12.7.5 The following shall constitute the type tests, routine tests and acceptance tests as contemp lated
in the relevant ISS.
I.
Mid span compression joint for Ground wire, Repair Sleeves and vibration damper for ground wire:
The type tests, acceptance tests and routine tests shall be the same as that for mid span compression
joint for ACSR conductor and vibration dampers ACSR conductor respectively. However, following type
tests are not applicable for earth wire accessories:
i) Mid Span compression joint for earth wire.
a) Heating Cycle test.
ii) Vibration dampers:
a) Magnetic power loss test.
12.7.6 The tests to be carried out on other hardware/accessories are as follows:
II.
Flexible copper bond:
Type test:
Slip strength test.
Acceptance test: i) Visual examination ii) Dimensional verification and iii) Slip strength test.
The Routine tests shall be as per the relevant ISS.
III.
Suspension hardware and tension hardware for ground wire:
i) Type tests:
a) Slip strength test.
b) Mechanical tests.
c) Verification of dimensions.
d) Galvanizing/electroplating test.
e) Visual examination test.
ii) Acceptance tests:
a) Verification of dimensions.
b) Galvanizing Test.
c) Mechanical Test.
iii) Routine Test;
a) Visual examination test.
b) Routine mechanical test.
All the above tests shall be carried out in accordance with the latest edition of IS 2121, IS 2486, IS 2263,
IS 8263.
iv) P.G. Clamps:
The type test and routine test shall be
a)
Failing load test and any other test specified in the latest ISS.
TECHNICAL SPECIFICATION FOR INSULATOR HARDWARE FOR TRANSMISSION

LINES
13.1 SCOPE:
13.1.1 This specification provides for design, manufacture, inspection and testing before dispatch
packing and delivery F.O.R. (destination) of hardware fittings required for 220KV & 66KV transmission
line insulator strings as per the requirement furnished in Bid proposal sheets. The hardware shall be
suitable for the type of insulator Viz., Porcelain Disc insulator or Long rod insulator n or Silicon rubber
composite insulator in all respect.
13.1.2 The hardware shall conform in all respects to high standards engineering, design, workmanship
and latest revision of relevant standards at the time of offer and purchaser shall have the power to reject
any work or material which, in his judgment, is not is full accordance therewith.
13.2 STANDARDS:
13.2.1 Except as modified in this, the hardware fittings shall conform to the following Indian Standards,
which shall mean latest revisions and amendments thereof. Equivalent International and Internationally
recognized standards to which these standards generally correspond are also listed below.
No.
1
2
Indian
Standard
IS:206
IS:209
IS:731
IS:1570
(Part-I)
IS:1573
IS:2004
IS:2071
IS:2121
IS:2486
10
Part-I
Part-II
Part-III
IS:2629
Title
Methods for Chemical Analysis of Slab Zinc
Specification for zinc
International
Standard
BS:3436
BS:137 (I&II)
Porcelain insulators for overhead power lines with a
IEC:274
nominal voltage greater than 1000 V
IEC:383
Schedules for wrought steels for general
engineering purposes (amendment No.1&3)
Steel specified by tensile and/ or yield properties
Electroplated coatings of zinc on iron and steel
Carbon Steel forging for general engineering
purposes
Methods of High Voltage Testing
Specification of conductor and Earthwire
Accessories for overhead power lines
Specification for Insulator fittings for overhead
Power lines with a nominal voltage Greater than
1000 V
General Requirements & tests
BS:3288
IEC:120
Locking Devices
IEC:372
Recommended practice for Hot Dip Galvanisation
No.
Indian
Standard
Title
for Iron and Steel
Testing for Uniformity of coating of zinc coated
articles
11
IS:2633
12
IS:3138
Hexagonal Bolts and Nuts
13
14
IS:3188
IS:4172
15
IS:4206

Dimensions for heads of bolts and screws
Dimensions for nominal lengths and thread length
for screws and studs (with amendment No.I)
16
IS:4218
17
18
IS:6603
IS:6639
19
20
21
22
23
International
Standard
ISO/R 947
ISO/R 272
IEC:305
and
ISO/R-68-1969
R-26-1963,
R-262-1969 &
R-965-1969
Stainless steel bars and flats

Hexagonal bolts for steel structures
ISO/R-2/2-1968
Determination of weight of zinc coating on zinc
IS:6745
coated Iron and Steel articles
IS:7814
Phosphor Bronze sheet, strip and foil
BS:2870
IEC:437
NEMA
IS:8263
Publication
CISPR
IS:8269
Method for switching impulse test on HV Insulators
IEC:506
ASTM-D-1171 & ASTM-D-573

Reference Abbreviation
BS
IEC/CISPR
IS
ISO
NEMA
Name and Address

British Standards, British Standards Institution, 101, Pentonvile Road, N19-NO UK.
International Electrotechnical Commission Bureau Central de la
commission Electro Technique International, 1, Rue de Verembe
Geneva, SWITZERLAND
Bureau of Indian Standards, Manak Bhavan, 9, Bahadur Shah Zafar
Marg, New Delhi-110 001, INDIA
International Organization for Standardization, Danish Board of
Standardization Aurehoegvej-12 DK-2900 Helleprup DENMARK
National Electric Manufacturers Association 155, East 44 th Street New
York, NY USA, 10017
13.2.3 Hardware fittings conforming to any other or International Standards are also acceptable
provided always that such standards are equivalent to or better than the corresponding standards
specified in 2.1 above. However in such an event the salient points of comparison between the
standards adopted and the standards quoted herein shall be detailed in the appro priate schedule two
copies at authentic English version of such standards shall be submitted the offer.
13.3 PRINCIPAL PARAMETERS:
13.3.1 DETAILS OF HARDWARE FITTINGS:
13.3.1.1 The hardware fittings shall be as per the specification drawings for hardware fittings attached
herewith.Hardware fittings shall be suitable for single/double suspension insulator strings and
single/double tension insulator strings for 220 KV & 66KV transmission lines.
13.3.1.2 Each hardware fitting shall be supplied complete in all respect and shall include all components
indicated in the specification drawings.
13.3.2 INSULATOR STRING CHARACTERISTICS:
Sl.
No.
Characteristics
No. of standard discs
2
3
4
5
6
7
Single/Double
tension
220
KV
1x13
2x13
Single/Double
tension
220
KV
1x15
2x15
Size of each disc (Dia x

-----------------------255 x 145----------------------
height)
Power frequency withstand voltage (wet) kV 460
460
rms
Lightning impulse with
1050
1050
stand voltage (dry) (kVp)
Power frequency with
510
510
stand voltage (dry) kVp
Mechanical failing load 120/
120/
(KN)
240
240
Pollution
------------------Refer Part-III----------------------
13.4 GENERAL TECHNICAL REQUIREMENTS:

13.4.1 DIMENSIONS OF INSULATOR STRING ALONG WITH HARDWARE FITTING:
13.4.1.1 Fabrication drawings shall be prepared by the supplier.
13.4.1.2 The dimensions shall be suitably selected by the supplier while preparing the fabrication
drawings.
13.4.1.3 The fabrication drawings shall be submitted to the purchaser for scrutiny and approval.
13.4.1.4 Dimensional tolerances as per relevant ISS only shall be allowed.
13.4.2 CORONA AND RI PERFORMANCE:

Sharp edges, scratches on all the hardware fittings shall be avoided. All surfaces must be clean, smooth,
without cuts and abrasions or projections. The Bidder must give suitable assurance about the
satisfactory corona and radio interference performance of the materials offered by him.
13.4.3 BALL AND SOCKET FITTINGS:
The dimensions of the ball and socket shall be of 16 mm & 20 mm designation for suspension and
tension string respectively in case of 220 KV line assembly in accordance with standard dimensions
stated in IS:2486 (Part-II).
13.4.3.1 BALL FITTINGS:
Ball fittings shall be made of class IV steel as per IS:2004 or steel of equivalent grade forged in one
piece. They shall be normalized to achieve the minimum breaking strength specified on the respective
drawings. Before galvanization of ball fittings, all die flashing on the shank and on the bearing surface of
the ball shall be carefully removed without reducing the dimensions below the requirements.
13.4.3.2 SOCKET FITTINGS:
Socket fittings shall be made of class-IV steel as per IS: 2004 or steel of equivalent grade and shall be
forged in one piece. They shall be normalized to achieve the minimum breaking strength specified on the
respective drawings.
13.4.3.3 DIMENSIONS AND TOLERANCES:
13.4.3.3.4 The dimensions and tolerances of pin balls and socket ends shall conform to IS:2486, PartII and shall be checked by the gauge therein after galvanizing.
13.4.3.3.5 The pinballs be checked with the applicable GO gauges in at least two directions, one of
which shall be across the line of die flashing, and the other 900C to this line. NO GO gauges shall not
pass in any direction.
13.4.3.3.6 The bearing surfaces of balls and machined sockets, before galvanizing shall not have
surface roughness more than 250 micron.
13.4.3.3.7 The bearing surface of socket ends shall be uniform about the entire circumference without
depressions or high spots. The internal contour of the socket ends shall be concentric with the axis of
fittings. The axis of the bearing surface of socket ends shall be coaxial with the axis of fittings with no
appreciable tilting.
13.4.3.4 SECURITY CLIPS FOR SOCKET FITTINGS:
13.4.3.4.1 Socket fittings shall be provided with R-shaped security clip in accordance with IS:2486
(Part-III) to provide positive locking against unintentional dise ngagement of socket from the ball of the
insulator. The security clip shall be humped to maintain the clip in the locked position and shall have both
prongs spread to prevent complete withdrawal from the socket. The clip end shall not project outside the
recess of socket when the clip is in locked position.
13.4.3.4.2 The hole for the security clip shall be on the side of the socket opposite to the socket
opening. The hole for the clip shall be counter sunk. The clip eye shall be of such design that the same
may be engaged by a hotline clip puller to provide for disengagement under energized conditions.
13.4.3.4.3 The force required to pull the clip to its unlocked position shall not be less than 50 N or more
than 500 N.
13.4.3.4.4 The security clip shall be made of stainless steel of type AISI 302 or 304 or phosphor bronze
as per IS:7814.
13.4.4 YOKE PLATE/LINK PLATE:
13.4.4.1 The yoke plate/link plate shall be made of mild steel plate as per IS:226 or equivalent
standards. Shearing/cutting of the plates shall be clean without drawn or ragged edges. If the plates are
flame cut, mechanical guides shall be used. It shall be ensured that the grain flow of the yoke plate shall
be in the direction of the tensile load.
13.4.4.2 Holes shall be cylindrical, clean cut and perpendicular to the plane of the material. The
periphery of the holes shall be free from burrs.
13.4.4.3 All the corners and edges should be rounded off with a radius of at least 3 mm.
13.4.5 ARCING HORNS:
13.4.5.1 Arcing horns shall be provided on the line side as well as tower side of various locations. It
may be essential to reduce the insulation near the substation ends up to a length of 1.6 KM on either side
in order to arrive at a good coordinated design. The spark gap shall be so spaced as to ensure effective
operation under actual conditions. The range settings and dry, wet and impulse flashover values shall be
as given in the tender. The arcing horns shall be provided with two bolts instead of one bolt to fix it to the
main laviwave in order to prevent it from sliding or tilting.
13.4.6 SAG ADJUSTMENT DEVICE:
Not applicable.
13.4.7 SUSPENSION ASSEMBLY:
13.4.7.1 The suspension assembly shall be suitable for AAAC MOOSE conductor in case of 220 KV
lines,
13.4.7.2 The suspension assembly shall include one armour - grip suspension clamps except for pilot
insulator string for which one/two suitable envelope type suspension clamps shall be used.
13.4.7.3 The suspension clamp along with standard preformed armour rods set shall be designed to
have maximum mobility in any direction and minimum moment of inertia so as to have minimum stress on
the conductor in the case of oscillation of the same.
13.4.7.4 The suspension clamp along with standard preformed armour rods set shall have a slip
strength between 20 to 29 KN.
13.4.7.5 The suspension assembly shall be smooth without any cuts, grooves, abrasions, projections
ridges or excrescence which might damage the conductor.
13.4.8 ARMOUR GRIP SUSPENSION CLAMP (AGS):
Clause not used as this is not proposed to be used.
13.4.9 AGS PREFORMED ARMOUR RODS:

13.4.9.1 The AGS Preformed Armour rod set suitable for AAA MOOSE conductor (as the case may be)
shall be used to minimize the stress developed in the conductor due to different static and dynamic loads
because of vibration due to wind, slipping of conductor from the suspension clamp as a result of
unbalanced conductor tension in adjacent span and broken wire conditions. It shall also withstand power
arcs, chafing and abrasion from suspension clamp and localized heating effect due to resistance losses
of the conductor.
13.4.9.2
The performed armour rod set shall have right hand lay and the inside diameter of the hole
shall be less than the outside diameter of the conductor to grip the same tightly. The surface of the
armour rod when fitted on the conductor shall be smooth and free from projections, cuts and abrasions
etc.
13.4.9.3
The pitch length of the rods shall be determined by the Bidder but shall be less than that of
the conductor layer of AAA MOOSE conductor and the same shall be accurately controlled to maintain
uniformity and consistently reproducible characteristic wholly independent of the skill of linemen.
13.4.9.4
The length and diameter of each rod shall be as per the drawing enclosed. The tolerance in
length of the rods in completed set should be within 13 mm between the longest and shorter rod. The
ends of armour rod shall be parrot billed.
13.4.9.5
The number of armour rods in each set shall be twelve. Each rod shall be marked in the
middle with paint for easy applications on the line.
13.4.9.6
The armour rod shall not lose their resilience even after applications.
13.4.9.7
The conductivity of each rod of the set shall not be less than 40% of the conductivity of the
International Annealed copper Standard (IACS).
13.4.10 ENVELOPE TYPE SUSPENSION CLAMP:
13.4.10.1 The seat of the envelope type suspension clamp shall be smoothly rounded and suitably
curved at the ends. The lip edges shall have rounded head. There shall be at least two U-bolts for
tightening of clamp body and keeper pieces together. Hexagonal bolts and nuts with split-pins shall be
used for attachment of the clamp. The clamp body and keeper piece shall be cast out of aluminium alloy
of type LM-6 or equivalent.
13.4.11 DEAD END ASSEMBLY:
13.4.11.1
The dead end assembly shall be suitable for TWIN AAA MOOSE conductor.
13.4.11.2 The dead end assembly shall be of compression type with provision for compressing jumper
terminal at one end for 220 KV lines. The Bidder may offer compression type as an alternative. The
angle of jumper terminal to be mounted should be 300 with respect to the vertical line. The area of
bearing surface on all the connections shall be sufficient to ensure positive electrical and mechanical
contact and avoid local heating due to I2R losses. The resistance of the clamp when compressed on the
conductor shall not be more than 75% of the resistance of equivalent length of conductor.
13.4.11.3 Die compression length shall be clearly marked on each dead end assembly designed for
continuous die compressions and shall bear the words COMPRESS FIRST suitably inscribed near the
point on each assembly where the compression begins. It shall bear identification marks
COMPRESSION ZONE and NON-COMPRESSION ZONE distinctly with arrow marks showing the
direction of compressions and knurling marks, showing the end of the zones. Tapered aluminium filler
plugs shall also be provided at the line of demarcation between compression and non-compression zone.
The letters, number and other markings on the finished clamp shall be distinct and legible. The
dimensions and dimensional tolerances of the cross section of aluminium and steel dead ends shall be as
per the specification drawings.
13.4.11.4 The assembly shall not permit slipping of, damage to or failure of the complete conductor or
any part thereof at a load less than 95% of the minimum UTS of the conductor i.e. 153 KN.
13.4.11.5 The outer sleeve shall be made out of EC grade aluminium. The steel sleeve shall be made
of mild steel rod.
13.4.12 BALANCING WEIGHTS:
13.4.12.1 The balancing weights shall be made of cast iron/machined mild steel and consist of four
weights weighing 50 Kg each. The balancing weights shall be connected to the yoke plate of pilot
suspension string by means of eye bolt and shackle arrangement. The bottom weight shall be provided
with recess to shield the ends of eyebolts.
13.4.13 FASTENERS:
13.4.13.1 All fasteners shall conform to IS:6639. All fasteners except spring washer shall be hot dip
galvanized. All bolts and nuts shall have hexagonal heads, the heads being forged out of solid truly
concentric, and square shank, which must be perfectly straight.
13.4.13.2 Fully threaded bolt shall not be used. The length of the bolt shall be such that the threaded
portion shall not extend into the place of contact of the component parts.
13.4.13.3 All bolts shall be threaded to take the full depth of the nuts and threaded enough to permit the
firm gripping of the component parts but not further. It shall be ensured that the threaded portion of the
bolt protrudes not less than 5 mm and not more than 10 mm when fully tightened.
13.4.13.4 Flat washers and spring washers shall be provided wherever necessary and shall be of
positive lock type. Thickness of washers shall conform to IS:2016. Spring washers shall be of
rectangular cross section.
13.4.13.5 To obviate bending stress in bolt, it shall not connect aggregate thickness more than three
times its diameter.
13.4.13.6 Bolts may have either rolled or cut threads. Nuts may be threaded after galvanizing to ensure
clean threads but bolts shall not be threaded or re -threaded after galvanizing. Nut threads shall be
tapped oversize to closely fit those of the galvanized bolt, with no unnecessary looseness but free
enough to permit the nut to be turned freely with fingers over the entire threaded length.
13.4.14
FORGED COMPONENTS:
Forged components other than those covered in the clauses mentioned herein above shall be made out
of class-IV steel as per IS:2004 or equivalent.
The items shall be normalized to achieve the required tensile properties. The forged components shall
not have sharp corners and edges so as to affect corona and RIV performance.
13.4.15
MATERIALS:
The materials of the various components shall be as specified in clauses mentioned herein above.
However, components made of alternative materials giving equivalent or better performance shall also be
considered. The Bidder shall indicate the material proposed to be used for each and every component of
hardware fittings stating clearly the class, grade or alloy designation of the material and the reference
standards. However, the critical dimensions of components shall not be changed in relation to selection
of different material.
13.4.16
GALVANISING:
13.4.16.1 Galvanizing shall satisfy the tests mentioned in IS:2633. No material shall be galvanized until
all shop operations have been completed except that the nuts may be threaded and oiled after
galvanizing. Minimum weight of zinc coating shall be 300 g/sq.m for fasteners and 600 g/sq.m for all
other hot dip galvanized articles.
13.4.16.2 Fasteners shall withstand four dips while spring washers shall withstand three dips each of
one minute duration in the standard preece test. Other galvanized material shall withstand minimum six
dips each of one minute duration in the standard preece test.
13.4.16.3 The zinc coating shall be perfectly adherent, of uniform thickness , smooth reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky white deposits and blisters.
13.4.16.4 The zinc used for galvanizing shall be grade 99.95% as per IS:209.
13.4.17 WORKMANSHIP:
13.4.17.1 All the hardware fitting shall conform to the best modern practices adopted in the extra high
voltage field.
13.4.17.2 The manufacturing process and quality control of all the materials shall be such as to give
maximum possible working load, highest mobility, elimination of sharp edges and corners to limit corona
and radio-interference, best resistance to corrosion and a good finish.
13.4.17.3 Castings shall be uniform without sharp edges or corners, free from all defects like shrinkage,
inclusion, blowholes, cracks etc. Pressure die-casting shall not be used for casting of components with
thickness more than 5 mm.
13.4.17.4 Forgings shall be uniform in quality and condition, without sharp edges or corners, free from
cracks, flakes or seams, laps, slag, silvers, scabs, rolled -in scale and fissures.
13.4.17.5 All current carrying parts shall be so designed and manufactured that contact resistance is
reduced to minimum.
13.4.17.6 No item shall have sharp ends or edges, abrasions or projections and cause any damage to
the conductor in any way during erection or during continuous operation, which would produce high
electrical and mechanical stresses in normal working. The design of adjacent metal parts and mating
surfaces shall be such as to prevent damage of the contact surface and to maintain good electrical
contact under service conditions.
13.4.17.7 All fasteners shall have suitable corona free locking arrangement and shall not loosen under
vibration conditions.
13.4.17.8 Welds shall be clean, sound, smooth uniforms without overlaps, properly fused and
completely sealed. There shall be no cracks, voids, incomplete penetration, incomplete fusions;
undercutting or inclusions. Porosity shall be minimized so that mechanical properties of the aluminium
alloys are not affected. All welds shall be properly finished as per good engineering practices.
13.4.18 MARKINGS:
Each component of hardware shall be marked with the trademark of the supplier. Marks shall be forged
or stamped with a steel die before galvanizing. The marks shall be distinct, durable, and conspicuous.
13.4.19 BID DRAWINGS:
13.4.19.1 The Bidder shall furnish insulator string drawings along with component drawings in
accordance with specifications.
13.4.19.2 The Bidder shall furnish fabrication drawings with all additional dimensions along with the
critical dimensions specified in the specifications/ISS.
13.4.19.3 Material specifications, details of applicable standards and heat treatment details shall also be
furnished.
13.4.19.4 The details of manufacturing process also shall be furnished along with the component
drawings.
13.4.19.5 The details of trademark to be provided on the components shall also be furnished.
13.5 TESTS:
The following tests shall be carried out on the hardware fittings.
13.5.1 TYPE TESTS:
These are those tests, which are to be carried out to prove the design, process of manufacture and
general conformity of the material in accordance with the specifications. The Contractor shall furnish type
test certificates not older than 5 years. In case the same is older than 5 years then these tests shall be
carried out on samples prior to commencement of commercial production against this specification at his
own cost. The bidder shall indicate his schedule for carrying out these tests.
These are those tests, which are to be carried out during inspection prior to despatch for the purpose of
acceptance of that lot.
13.5.3 ROUTINE TESTS:
These are those tests, which are to be carried out on each hardware fitting to check the requirements,
which are likely to vary during production.
13.5.4 TEST DURING MANUFACTURE:
Tests during manufacture shall mean those tests, which are to be carried out during the process of
manufacture by the Bidder to ensure quality control such that the end product is of the designed quality
conforming to the intent of this specification.
13.5.5 TESTING VALUES:

For all type and acceptance tests, the acceptance values shall be those value guaranteed by the bidder
in the Guaranteed Technical Particulars or the acceptance values specified in the relevant standard
whichever is more stringent for that particular test. The norms and procedures of sampling for these tests
will be as per the Quality Assurance Programme to be mutually agreed to by the supplier and the
purchaser.
The standards and norms to which these tests will be carried out are listed against them. Where a
particular test is a specific requirement of this specification, the norms and procedures of these shall be
as specified in Annexure-III of this volume or as mutually agreed to between the supplier and the
purchaser in the Quality Assurance Programme.
13.5.6 TYPE TESTS:
The following type tests shall be conducted on a suitable number of individual compone nts, materials or
complete strings.
13.5.11.5 On the complete insulator string with hardware fittings (Please also refer Clause 5.10.3)
a) Power frequency voltage withstands test with arcing horns.
BS:137
(Part-I)
b) Switching surge voltage withstands test under wet condition
IEC:383
c) Impulse voltage withstands test under dry condition
IEC:383
d) Impulse voltage flashover test under dry condition
IS-731/1971
e) Voltage distribution test

f)
Mechanical strength test for complete string
g) Vibration test
NOTE: For electrical tests, the insulator string shall be mounted on a simulated tower.
13.5.11.6 On Suspension Hardware Fittings only.
a) Mechanical test
IS-2486 (Part-I)
b) Clamp slip strength for AGS clamp
As
per
Specification
c) Clamp slip strength Vs torque test for suspension clamp

13.5.11.7 On Tension Hardware Fittings Only:
a) Electrical resistance test for dead end assembly
b) Heating Cycle test for dead end assembly
IS:2486
(Part-I)
this
c) Slip strength test for dead end assembly

d) Mechanical tests
13.5.11.8 All the type tests given under clause No.5.6.1 above shall be conducted separately on
Single/Double Suspension and Single/Double tension insulator string along with hardware fittings.
13.5.11.9 The tests specified under clause No.5.6.1 (e) and (f), that is, the voltage distribution test and
corona/RIV (Dry) test shall also be conducted on single suspension pilot insulator string along with
hardware fittings.
13.5.7 ACCEPTANCE TESTS/SAMPLE TESTS:
13.5.7.1 On both suspension and tension hardware fittings:
a) Visual examination
b) Verification of dimensions
c) Galvanizing test/Electroplating
d) Mechanical strength test of welded joint
e)Mechanical strength test for corona control rings/grading rings
f) Test on locking devices for ball and socket coupling
IS:2486
(Part-I)
IS:2486
(Part-I)
As per Specification
BS: 3288 (Part-I)
IEC: 372(2)
13.5.7.2 ON SUSPENSION HARDWARE FITTINGS ONLY:

a) Clamp slip strength Vs. Torque test for suspension clamp
b) Shore hardness test of elastomer cushion for AG
suspension clamp
As per specification
c) Band test for armour rod set

d) Resilience test for armour rods set
IS:2121
(Part-I
e) Conductivity test for armour rods set
13.5.7.3 ON TENSION HARDWARE FITTINGS ONLY:

a)
Slip strength test for dead end assembly on Neoprene
b)
Ozone test
c)
Heat Resistance test
IS:2486
(Part-I)
13.5.8 ROUTINE TESTS:

a) Visual Inspection
b) Proof Load test
IS:2486 (PART-I)
As
per
the
specification
13.5.9 TEST DURING MANUFACTURE:

On all components as applicable:
a) Chemical analysis of Zinc used for galvanizing
b) Chemical analysis, hardness tests, grain size, inclusion
per
rating
and
magnetic particle
inspection for As
specification
forgings/castings
the
c) Chemical analysis, and proof load test fabricated hardware
13.5.10 TEST CHARGES AND TEST SCHEDULE:

13.5.10.1 TYPE TESTS:
The Hardware offered shall be fully type tested as per the relevant standards. The bids offering
equipment not type tested will be rejected. These tests must not have been conducted earlier than five
years from the date of bid opening. In case the equipment of the type and design offered has already
been type tested, the bidder shall furnish four sets of the type test reports along with the offer. In case
these type tests are conducted earlier than five years all the type tests as per the relevant standards shall
be carried out by the successful bidder in the presence of purchasers representative at f ree of cost. The
purchaser reserves the right to demand repetition of some or all the type tests in the presence of his
representatives and these shall be conducted at no extra cost to owner. For any change in the
design/type already type tested and the design/type offered against this specification, the purchaser
reserves the right to demand repetition of tests without any extra cost.
13.5.10.2 ACCEPTANCE AND ROUTINE TESTS:
All acceptance and routine tests as stipulated in the relevant standards shall be carried out by the
supplier in presence of purchasers representative.
13.5.10.3 For type test, which involve the tests on the complete insulator string along with hardware
fittings, the primary responsibility of conducting test lies with the disc insulator supplier. However, the
hardware supplier shall make all the necessary hardware fittings for testing available to the insulator
supplier at the place of testing and do all the associated co -ordination work in this regard. In respect of
electrical tests on the complete insulator string consisting of insulators and hardwares for RIV, Corona
and voltage distribution test and with insulator manufacturer for all other tests.
In case of any failure during testing, the cause of failure shall be thoroughly investigated by the supp lier in
association with purchasers engineers. In case it is established that the cause of failure is due to some
defects in manufacturing process or in the material itself, then the re -testing shall be carried out by the
supplier
13.5.10.4 without any extra cost to purchaser. However, if it is established that the failure is due to
deficiency in design itself, then the design will be suitably modified by the supplier. After incorporating the
modification suggested, re-testing is to be carried out. In the latter case, the re-resting charges will be
paid as per the rates quoted in the appropriate schedule of Bid Proposal Sheet for that particular test. In
case of any dispute, the assessment of the purchaser as to what is the cause of failure shall be final and
binding.
13.5.10.5 Supplier shall indicate the laboratories in which it is proposed to conduct the type tests.
Supplier shall also ensure that the tests can be completed in these laboratories, within the time schedule
guaranteed, by him in the appropriate schedule of Bid Proposal Sheet.
13.5.10.6 The entire cost of testing for acceptance and routine tests and tests during manufacture
specified herein shall be treated as included in the quoted unit price of hardware fittings, except for the
expenses of the Inspector/Purchasers representative.
13.5.10.7 Immediately after finalization of the programme of type/acceptance/routine testing, the
supplier shall give sufficient advance intimation to the purchaser, to enable to depute his representative
for witnessing the tests.
13.5.11 SAMPLE BATCH FOR TYPE TESTING:
13.5.11.1 The supplier shall offer at least three times the quantity of materials required for conducting all
the type tests for sample selection.
13.5.11.2 Before sample selection, the supplier shall be required to conduct all the acceptance tests
successfully in presence of purchasers representative.
13.5.12 ADDITIONAL TESTS:
13.5.12.1 The purchaser reserves the right of having at his own expenses and other test (s) of
reasonable nature carried out at suppliers premises, at site, or in any other place in addition to the
aforesaid type, acceptance and routine tests to satisfy that material comply with the specifications.
13.5.12.2 The Purchaser also reserves the right to conduct all the tests mentioned in this specification at
his own expense on the samples drawn from the site at suppliers premises or at any other test center. In
case of any failure, it shall be binding on the part of supplier to replace that particular lot completely,
without any extra cost to the purchaser.
13.6 INSPECTION:
i) The Purchaser shall have access at all times to the works and all other places of manufacture, where
the hardware fittings and its components are being manufactured and the supplier shall provide all
facilities for unrestricted inspection of the suppliers works, raw materials, manufacture of all the
accessories and for conducting necessary tests as detailed herein.
ii) The supplier shall keep the purchaser informed in advance of the time of starting and of the progress of
manufacture of accessories in its various stages so that arrangements could be made for inspection.
iii) No material shall be despatched from its point of manufacture unless the material
satisfactorily inspected and tested.
has
been
iv) The acceptance of any quantity of accessories shall in no way relieve the supplier of his responsibil ity
for meeting all the requirement of this specification and shall not prevent subsequent rejection if such
hardware fittings later found to be defective.
13.7 QUALITY ASSURANCE PLAN:
7.1 The bidder shall invariably furnish the following information along with his offer, failing which the
offer shall be liable for rejection.
i) Statement giving list of important raw materials, names of sub -suppliers for the raw materials, list of
standards according to which the raw materials are tested, list of tests normally carried out on raw
material in presence of Bidders representative, copies of test certificates.
ii) Information and copies of test certificates as in (i) above in respect of bought out materials.
iii) List of manufacturing facilities available.
iv) Level of automation achieved and list of areas where manual processing exists.
v) List of areas in manufacturing process, where stage inspections are normally carried out for quality
vii) List of testing equipment available with the Bidder for final testing of equipment specified and test
standards. These limitations shall be very clearly brought out in schedule of deviations from specified
test requirements.
7.2 The supplier shall within 30 days of placement of order, submit the following information to the
purchaser:
i) List of raw material as well as bought out accessories and the names of sub -suppliers selected from
there furnished along with the offer.
ii) Type test certificates of the raw material and bought out accessories.
iii) Quality Assurance Plan (QAP) with hold points for purchasers inspection. The QAP and hold points
shall be discussed between the Purchaser and the Supplier before the QAP is finalized.
7.3
The supplier shall submit the routine test certificates of bought out items and raw materials at the
time of routine testing of the fully assembled hardware fittings.
13.8 DOCUMENTATION:
13.8.1
i) The bidder shall furnish along with the bid the dimensional drawings of all types of
hardware fittings:
ii) These drawings shall include the following information:
a)Dimensions.
b)Tolerance on dimensions.
c) Material designation used for different components with reference to standards.
d) Fabrication details such as welds, finishes and coatings.
e) Catalogue or part numbers for each component and the total assembly with bill of materials.
f) Identification marking.
g) Weight of individual components and total assembled we ight.
iii) The assembly drawings shall include the following:
a)
Brief installation instructions.
b)
Design installation torque for the bolt or cap screw.
c) Withstand torque that can be applied to the bolt or cap screw without failure of components or parts
thereof.
d) Compression die number with recommended compression pressure.
c)
Relevant technical details of significance.
13.8.2
TEST REPORTS:
i) Four copies of type test reports shall be furnished to the purchaser within one month of conducting the
tests. One copy will be returned duly certified by purchaser to the supplier within three weeks there
afterwards and on receipt of the same supplier shall commence with the commercial production of the
concerned material.
ii) Four copies of acceptance test reports shall be furnished to the purchaser. One copy will be returned
duly certified by the purchaser and only there after shall the materials be despatched.
iii) All records of routine test reports shall be maintained by the supplier at his works for periodic
inspection by the purchaser.
iv) All test reports of tests conducted during manufacture shall be maintained by the supplier. These shall
be produced for verification as and when requested for by the purchaser.
13.9 PACKING AND FORWARDING:
i) All hardware fittings shall be packed in suitably sized strong and weather resistant wooden
cases/crates. The gross weight of the packing shall not normally exceed 200 Kg to avoid handling
problems. Suitable lifting lugs shall be provided on the crates in order to facilitate handli ng by cranes.
ii) Suitable cushioning, protective padding or spacer shall be provided to prevent damage to or
deformation of the hardwares during transit and handling.
iii) All identical items shall be despatched to destination duly assembled and packed. Bolts, nuts,
washers, cotter pins, security clips and split pins etc. shall be packed duly installed and assembled with
the respective parts and suitable measures shall be taken to prevent their transit loss.
iv) Each component part shall be legibly and indelibly marked with the trademark of the supplier and year
of manufacture.
v) All packing cases shall be marked legibly and correctly so as to ensure their safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty or
eligible markings. Each wooden case/crate shall have all the markings stenciled on it in indelible ink
DETAILS OF TESTS
14.1 VOLTAGE DISTRIBUTION TEST:
The voltage across each insulator unit shall be measured by sphere gap method. The result obtained
shall be converted in to percentage and proportionate correction applied so as to give a total of 100%
distribution. The voltage distribution across any disc shall not exceed the values specified in clause 3.2.
14.2 CORONA EXTINCTION VOLTAGE TEST:
The sample assembly when subjected to 50 Hz Power frequency voltage shall have a corona extinction
voltage of not less than the value specified in clause 3.2 under dry condition. These shall be no evidence
of corona on any part of the sample when all possible sources of corona are photographed in a darkened
room.
14.3 RIV TEST:
Under the conditions as specified under (2) above, the insulator string along with the complete hardware
fittings shall have a radio interference voltage level below 500 micro-volts at one MHz when subjected to
50 Hz AC voltage of 1.1 times the maximum line to ground under dry condition. The test procedure shall
be in accordance with IS: 8263.
14.4 MECHANICAL STRENGTH TEST FOR COMPLETE STRING:
The complete insulator string along with its hardware fittings excluding arcing horn, corona control
rings/grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to
50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to
67% of the minimum UTS specified. This load shall be held for five minutes and then removed. After
removal of the load, the string component shall not show any visual deformation and it shall be possible
to disassemble them by hand. Hand tools may be used to remove cotter pins and loosen the nuts
initially. The string shall then the reassembled and loaded to 50% of UTS and the load shall be further
increased at a steady rate till the specified minimum UTS is reached and held for one minute. No fracture
should occur during this period. The applied load shall then be increased until the failing load is reached
and the value recorded.
14.5 VIBRATION TEST:
The suspension string shall be tested in suspension mode and tension string in tension mode i tself in a
laboratory span of minimum 30 meters. In the case of suspension string a load equal to 6 KN shall be
applied along the axis of the suspension string by means of a turnbuckle. The insulator strings along with
hardware fittings and two sub-conductors tensioned at 45 KN shall be suitably secured. The system shall
be suitable to maintain constant tension on each sub -conductor throughout the duration of the test.
Vibration dampers shall not be used on the test span.
Both the sub-conductor shall be vertically vibrated simultaneously at one of the resonance frequencies of
the insulator string above 10 Hz by means of vibration inducing equipment. The amplitude of vibration at
the anti-node nearest to the insulator string shall be measured and the same shall not be less than
+120/f, being the frequency of vibration. The insulator string shall be vibrated for 5 million cycles then
rotated by 900 and again vibrated for 5 million cycles without any failure. After the test, the disc insulators
shall be examined for fatigue and mechanical strength. There shall be no deterioration of properties of
hardware components after the vibration tests.
14.6 GALVANISING TEST:
The test shall be carried out as per clause No.5.9 of IS: 2496 (Part-I) except that both uniformity of zinc
coating and standard preece test shall be carried out and the results obtained shall satisfy the
requirements of this specification.
14.7 MECHANICAL STRENGTH TEST FOR WELDED JOINT:
The welded portion of the component shall be subjected to a load of 2000 Kgs for one minute.
Thereafter, it shall be subjected to die-penetration/ultrasonic test. There shall not be any crack at the
welded portion.
14.8 CLAMP SLIP STRENGTH VS TORQUE TEST AND CLAMP SLIP FOR AGSC
LAMP/ENVELOPE TYPE SUSPENSION CLAMP:
The suspension clamp shall be vertically suspended by means of a flexible attachment. A suitable length
of ACSR conductor shall be fixed in the clamp. The clamp slip strength at various tightening torque shall
be obtained by gradually applying the load at one end o f the conductor. The clamp slip strength vs.
torque curve shall be drawn. The above procedure is applicable only for free center type suspension
clamp. For AG suspension clamp only clamp slip strength after assembly shall be found out. The clamp
slip strength at the recommended tightening torque shall be more than 20 KN but less than 29 KN.
14.9 SHORE HARDNESS TEST OF ELASTOMER CUSHION FOR AGS ASSEMBLY:
The shore hardness at various points on the surface of the elastomer cushion shall be measured by a
shore hardness meter and the shore hardness number shall lie between 65 to 80.
14.10 PROOF LOAD TEST:
Each component shall be subjected to a load equal to 50% of the specified minimum tensile strength.
The load shall be held for one minute and then removed. After re moval of the load the component shall
not show any failure or permanent deformation.
14.11 CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING:
Samples taken from the zinc ingot shall be chemically analyzed as per IS: 209. The purity of zinc shall
not be less than 99.95%.
14.12 TEST FOR FORGING CASTING AND FABRICATED HARDWARE:
The chemical analysis, hardness test, grain size, inclusion rating and magnetic particle inspection for
forging, casting, radio-graphical inspection for items made of aluminium alloys, chemical analy sis and
proof load test for fabricated hardware and ductility test on tensile test specimen shall be as per the
internationally recognized procedures for these tests. The sampling will be based on heat number and
heat treatment batch. The details regarding test and acceptance criteria will be as per the Quality
Assurance Programme agreed upon.
TECHNICAL SPECIFICATIO FOR STUB SETTING AND CASTING OF

FOUNDATIONS
TESTING OF SOIL
EXCAVATION
SETTING OF STUBS
MIXING, PLACING, COMPACTING OF CONCRETE AND REINFORCEMENT
BACK-FILLING AND REMOVAL OF STUB TEMPLATE
CURING
BENCHING
PROTECTION OF TOWER FOOTING
MEASURING OF BACK FILLING
EARTHING
TECHNICAL SPECIFICATION FOR STUB SETTING AND CASTING OF

FOUNDATIONS
15.1 Testing of soil:
The Contractor shall be required to undertake soil tests at approved tower locations in the manner
specified in and submit report and recommendations thereof as specified under the said clauses for the
design of foundations. The Contractor shall also furnish soil resistivity values to the Owner along the line
alignment. The Contractor shall furnish final foundation design for approval to the Engineer based on the
soil investigations carried out and on approval thereto such foundations shall be cast.
15.2 Excavation:
15.2.1 Except as specifically otherwise provided, all excavation for footings shall be made to the lines
and grades of foundation. The excavation walls shall be vertical and pit dimensions shall be such as to
allow a clearance of not more than 150 mm on all sides from the foundation pad. All excavation shall be
protected so as to maintain timbering, shoring or casing, if necessary. Any sand, mud, silt or other
undesirable materials, which may have accumulated in the excavation, shall be removed by the
contractor before placing concrete.
15.2.2 The soil to be excavated for tower foundations shall be classified as under:
a) Normal soil soil removable by means of ordinary pick axes and shovels.
b) PS : Where sub soil water is encountered between 0.75 mtr and 1.5 mtr depth below ground level
c) Wet: Where sub-soil water in encountered within 1.5 mtr or more below ground level. Presence of
surface water will be treated as wet soil.
d) FS : Where sub-soil water in encountered within 0.75 mtr below ground level
e) Black Cotton: Where the soil is clayey type, not necessarily black in colour which shrinks when dry,
swells when wet resulting in differential movement extending to a maximum depth of about 3.5 mtr below
ground level
f) Soft/fissured rock: Lime stone, laterite, hard englomerate or other soft or fissured rock to be
quarried or split with crowbars, wedges or pickaxes. If required, light short blasting may be resorted to,
for loosening the material, but this will not in way entitle the material to be classified as hard rock.
g) Hard rock: Any rock excavation other than specified under soft/fissured rock above for which blasting,
drilling, chiseling are required. The unit rate quoted for hard rock excavation shall include all costs of
blasting, drilling chiseling and services thereof.
15.2.3 Where soil at a tower foundation is of composite nature, classification will be according to the
type of soil, which is predominant in the footing and the rate for the same will apply for the predominant
soil foundation. However, for excavation, the payment shall be made for different soils as per soil
encountered at the time of excavation but limited to the lowest of the following:
i)
Payment calculated based on the volume of different
types of soils encountered at the time of
excavation at their respective rates and excavated volumes as per actuals (i.e. strata wise).
ii)
Payment calculated based on the type of soil for which foundation is classified considering the
applicable ceiling volume for that particular soil indicated in the Purchase Order as quoted by the Bidder
and its applicable rate.
iii) Payment calculated based on the type of soil for which foundation is classified considering the
design volume of excavation for that particular soil and its applicable rate.
The decision of the Engineer shall be final and binding with reference to the classification of soils.
15.2.4 No extra charge shall be admissible for the removal of the fallen earth in the pit, when once
excavated, shoring and timbering as approved by authorized representative of the Board shall be
admissible when the soil condition is so bad that there is likelihood of accident due to the falling of earth.
15.2.5 Where rock is encountered, the holes for tower footings shall preferably be drilled, but where
blasting is to be resorted to as an economy measure, it shall be done with utmost care to minimize the
use of concrete for filling up the blasted area. All necessary precautions for handling and use of blasting
materials shall be taken. In cases where unnecessarily large quantities are excavated/blasted, resulting
in placement of large volumes of concrete no extra payment is allowed. In case where drilling is done,
the stubs may be shortened suitably with the approval of the Engineer.
15.2.6 The contractor shall supply requisite blasting material and be responsible for the purpose of
storage and use of this material. The unit rates quoted shall include all cost of blasting drilling chiseling
and services thereof.
15.2.7 The foundation design for different soils shall be as given by the owner.
15.2.8 The excavation volumes for each type of tower footing shall be estimated assuming the facing of
surrounding earth as vertical keeping a distance of 150 mm clearance from the extreme edge of the base
slab of the footing for all types of foundations except hard rock and fissured rock where the undercut type
of foundation is provided.
15.3 Setting of stubs:
15.3.1 The stubs shall be set correctly in accordance with the approved method at the exact location
aligned precisely to correct levels with the help of stub setting template and leveling instruments. Stubs
shall be set in the presence of owners representative only and contractor shall sufficiently intimate in
advance to the Owners representative for such presence.
15.3.2 Setting of stubs shall be approved by the Owners representative.
15.3.3 The following tolerances shall be applicable in case of position of foundation as a whole with
reference to the tower position as spotted on the survey chart:
Type of Tower
Suspension or Intermediate
Section or Tension (Set at
bi-section of deviation angle
Out of alignment
0.50
From centre line

of route
+ 25 mm
From transn.
Centre line
+ 25 mm
0.50
+ 25 mm
+ 25 mm
15.3.4 The Owner may get certain foundations such as well type or pile type constructed through other
agencies. However, the contractor shall be required to set the s tubs for the same and coordinate his
work with the other agencies accordingly.
15.4 Mixing, Placing, Compacting of Concrete and Reinforcement:

i) The concrete shall be mixed in a mechanical mixer. However, in case of difficult terrain hand mixing
may be permitted at the discretion of the Engineer. The water for mixing concrete shall be fresh, clean
and free from oil, acids and alkalis. Saltish or brackish water shall not be used.
ii) Mixing shall be continued until there is uniform distribution of material and the mix is uniform in colour
and consistency, but in no case the mixing shall be done for less than two minutes. Normally, mixing
shall be done close to the foundation, but where this is not possible mixing may be resorted to at the
nearest convenient place. The concrete shall be transported from the place of mixing to the place of final
laying/placing as rapidly as practicable by methods, which shall prevent the segregation or loss of any
ingredient. The concrete shall be placed and compacted before setting commences.
iii) The concrete shall be laid in 150 mm layers and consolidated well so that the cement cream works
up to the top and no honey-combing is left in the concrete. However, in case of difficulty terrain, manual
compaction may be permitted at the discretion of site Engineer. After concreting the chimney portion to
the required height, the top surface should be finished smooth with a slight slope towards the outer edge,
to drain off any rain water falling on the coping, and making ingress in to the stub angle.
iv) In wet locations, the site must be kept completely de -watered, both during the placement of concrete
and for 24 hours thereafter. There should be no disturbance on concrete by water during this period.
v) The formwork shall be removed 24 hours later after concreting or after the concrete has fully set. If
the concrete surface is found to be defective on removal of the formwork, the damage shall be required
with rich cement and sand mortar to the satisfaction of the Engineers representative before the
foundation pits are back filled.
vi) The concrete volume and dimensions of the foundation shall be as per approved drawings.
Measurement of concrete volume shall be in cubic metres and shall be worked out to the second decimal
place.
vii) Steel required for reinforcement of foundations shall be provided for by the contractor. No payment
will be made for wire required for binding the reinforcement, chairs, bolsters and spacers, as the cost of
these is deemed to be included in the unit rate quoted for reinforcement.
viii) The payment for foundations shall be restricted to the ceiling volumes or design volumes whichever
is lower.
15.5 Back-filling and removal of stub template:
i) Following the opening of the form work and removal of shoring and timbering, if any, back -filling shall
be started, after repairs, if any, to the foundation concrete, Back -filling shall normally be done with the
excavated soil, unless it consists of large boulders/stones, in which case the boulders shall be broken to
a maximum size of 80 mm. At such locations where borrowed earth is required for back filling, this shall
be done by the Contractor at his own cost, irrespective of lead.
ii) The back-filling materials should be clean and free from organic or other foreign materials. The earth
shall be deposited in maximum 200 mm layer, leveled, wetted and tamped properly before another layer
is deposited. Care shall be taken that the back filling is started from the foundation ends of the pits,
towards the outer ends. After the pits have been back-filled to full depth, the stub template may be
removed.
iii) The back filling and grading shall be carried to an elevation of about 75 mm above the finished
ground level to drain out water. After back-filling a 50 mm high earthen embankment (Bund) shall be
made along the sides of the excavated pits and sufficient water will be poured in the back -filled earth for
at least 24 Hours.
15.6 Curing:
The concrete after setting for 24 hours shall be cured by keeping the concrete wet continuously for a
period of 10 days after laying. The pit may be back filled with selected earth sprinkles with necessary
amount of water for a period of 24 hours and thereafter both the back filled earth and exposed chimney
top shall be kept wet for the remainder of the prescribed time of 10 days. The unc overed concrete
chimney above the back-filled earth shall be kept wet by providing empty cement bags dipped in water
fully wrapped around the concrete chimney for curing and ensuring that the bags are kept wet by the
frequent pouring of water on them.
15.7 Benching:
When the line passes through hilly/undulated terrain, for a few tower locations it may be required to level
the ground for casting of tower footings on same elevations. All the activities related to make the required
area of ground in same elevation for casting of foundation, shall be termed as benching work. Benching
work shall include cutting of excess earth and removing the same to a suitable point of disposal as
required by the Owner. Benching shall be resorted to only after getting specific approval from the Owner.
Volume of the earth to be cut shall be measured before cutting and got approved from the Owner. This
volume of earth shall be considered for the purposes of payment against the head of benching work. The
Bidders are requested to quote unit rates for this work in the price schedules.
15.8 Protection of tower footing:
i) Special measures are required for protection of tower footings located close to or in nallahs, river
streambeds, etc. and subject to approval by the Engineer. The work includes all necessary stone
revetment, concreting, earth filling above ground level, providing suitable revetment or galvanized wire
netting and meshing packed with boulders. The contractor shall furnish recommendations for providing
protection at such locations. The Bidders are required to furnish unit rates for such protective works in
the price schedules. The unit rates shall be applicable with actual quantities of revetment and extra
excavation work done if any.
ii) On ordinary flat ground, the stubs shall be set with their tops above ground level as per design and
given a coping but not marking up of plinths shall be required. Where the ground surface is irregular, the
foundation shall be finished off in a substantial and permanent way forming a plinth by side cutting,
building a suitable stone revetment or in case of rock foundations by building up with cement, as desired
by the Engineer.
The quantity of excavated earth obtained from a particular location shall generally be utilized in back filling work in protection of tower footing of same location, unless it is unsuitable for such purpose. In the
later case, the back filling shall be done with borrowed earth of suitable quality irrespective of lead and lift
and consolidated at no extra cost to the owner.
The provisional quantities for protections work to foundations are furnished in respective schedule of Bid
Proposal Sheets. The unit rates shall also be applicable for adjusting with the actual quantities for
protection works done.
No separate rates shall be allowed for borrowed earth and the Contractor shall make his own
arrangements for procurement of borrowed without any extra cost.
15.9 Measurement of back filling:
The volume of back filling shall be considered equal to that of the excavation. This als o applies to any
earthwork embankments to be provided over the foundation to the design drawings.
15.10 Earthings:
Each tower shall be earthed after the foundation has been cast. For this purpose, earth strips shall be
fixed to the stub during concreting of the chimney and taken out horizontally below the ground level. The
earth strip shall be provided on the leg with step bolts.
The footing resistance of all towers to earth shall not exceed the values specified in IS -3043-1966 after
earthing and tower erection but before stringing of the overhead ground wire. In case the resistance
exceeds the specified value, multiple pipe earthing or counterpoise earthing shall be adopted in
accordance with the following procedure, but without interfering with the foundation concrete even though
the earth strip/counterpoise lead remains exposed at the tower end. The connection in such case shall
be made with the existing lattice member holes on the leg just above the chimney top.
Pipe earth: The installation of the pipe earthing shall be in accordance with IS 5613.
Counterpoise earth: Counterpoise earth consists of four lengths of galvanized steel stranded wires, each
fitted with a lug for connection to the tower leg at one end. The wires are connected to arch of the legs
and taken radially away from the tower and embedded horizontally 450 Mtr. below ground level. The
length of earth wire is normally limited to 15 mtr. but may be increased if the resistance requirements are
not met. The size of the galvanized steel strand ed wire may be taken equal to sizes of the earth
conductor. The counterpoise type earthing of tower shall be in accordance with IS 5613.
TECHNICAL SPECIFICATION FOR ERECTION OF TOWER SUPER

STRUCTURE, STRINGING AND INSTALLATION OF LINE MATERIALS
AND COMMISSIONING
GENERAL
ERECTION OF SUPER STRUCTURE
TREATMENT OF JOINTS
ASSEMBLY
INSULATOR HOISTING
INSTALLATION OF POWER CONDUCTOR AND EARTHWIRE
FIXING OF CONDUCTOR AND EARTHWIRE ACCESSORIES
SAFETY PRECAUTIONS
FINAL CHECKING, TESTING AND COMMISSIONING
TECHNICAL SPECIFICATION FOR ERECTION OF TOWER SUPER STRUCTURE,

STRINGING AND INSTALLATION OF LINE MATERIALS AND COMMISSIONING:
16.1 General:
The details of the scope of erection work shall include the cost of labour, and tools and plants like tension
stringing equipment and all other incidental expenses in connection with erection and stringing work.
The contractor shall be responsible for transportation of all materials to the site, proper storage and
preservation at their own cost till such time the erected line is taken over the Owner. Similarly the
Contractor shall be responsible for transportation, proper storage, safe custody, loss or damage of all
materials for incorporation in the lines and shall maintain and render proper account for all such materials
lost or damaged during storage and erection.
The Contractor shall set up required number of stores along the line and the exact location of such stores
shall be discussed and agreed to between the contractor and the owner.
If any defects are found in case of hot-dip galvanized members, the members if acceptable to Owner
shall be repaired by applying zinc rich protection paint
16.2 Erection of Super Structure:
The towers shall be erected on the foundations not less than 14 days after concreting or till such time that
the concrete has acquired full strength. The towers are erected as per the erection drawings furnished by
the manufacturers. To facilitate, erection, each tower member shall be marked to correspond with a
number shown in the erection drawing. The steel is first delivered to the tower location and is placed in
such a manner as to be accessible for erection. Any damage to the steel and injuring of galvanizing shall
be avoided. No member shall be subjected to any undo over stress during erection.
The erection of tower may be carried out by any of the following methods generally followed:
i)
Built up method or piece meal method.
ii)
Section method.
iii)
Any other approved advanced method.
16.3 Treatment of Joints:

Before starting assembly, the surfaces shall be cleaned and applied with a coat of zinc rich paint, if
required.
16.4 Assembly:
16.4.1 Irrespective of the method followed for the erection of towers, the points mentioned below shall
be observed:
a)
Straining of the members shall not be permitted for bringing them in to position. It may, however,
be necessary to match hole positions at joints and to facilitate this, tommy bars not more than 450 mm
long may be used.
b) Before starting erection of an upper section the lower section shall be completely braced and all
bolts fitted in accordance with approved drawings.
c)
All plan diagonals relevant to a section of tower shall be placed in position before assembly of
upper section is taken up.
d) All bolts shall have their nuts facing outside of the tower for horizontal or nearly horizontal bolt
connections and downwards for vertical bolt connection. The bolt positioning in assembled towers shall
be as per IS-5613, Part-II, Section-2, 1976.
e) The cross arms be assembled on ground and the top cross arm shall be lifted first, followed by the
middle and bottom cross-arms. The tips shall be fully tightened before lifting them in to position, such
bolts which are not accessible for tightening by ordinary tommy spanners, may be tightened with the help
of box or ratchet ring spanner.
f)
The towers shall be fitted with Number plates, danger plates, phase plates, circuit plates and anti climbing devices as described elsewhere in the specifications.
g) All the blank holes, if any left after complete erection of the tower are to be filled up by bolts and
nuts of correct size.
16.4.2
Tightening & punching of Bolts & Nuts:
All nuts shall be tightened properly using correct size spanners. Before tightening it shall be seen that
filler washers and placed in relevant gaps between members, bolts of proper size and length are inserted
and one spring washer has been inserted under each nut. In case of step bolts the spring washer shall
be placed under the outer nut. The tightening shall progressively be carried on from the top downwards,
care being taken that all bolts at every level are tightened simultaneously. It may be better to employ four
persons, each covering one leg and the face to his left.
The threads of bolts projecting outside nuts shall be punched at three positions on the diameter to ensure
that the nuts are not loosened in course of time. If during tightening a nut is found to be slipping or
running over the bolt threads, the bolt together with the nuts shall be changed out right. All the bolts and
nuts in all joints up to the level of bottom cross arm from the tower base shall be tack welded after final
tightening. After welding cold galvanized paint having at least 90% Zinc content shall be applied to the
welded portion. AT least two coats of the paint shall be applied. The cost of welding and paint incl uding
application of paint shall be deemed to be included in the erection price.
In addition to tack welding of nuts with bolts, as described above, the Contractor can also propose some
alternative arrangements like use of epoxy adhesive which can serve the purpose of locking the nut
permanently with the bolt and thus preventing pilferage of the tower members.
In case the Bidder offers some alternative to tack welding as stated above, the Bidder shall have to
furnish all the technical parameters of the same , to facilitate the owner to technically evaluate its
acceptability. However, the evaluation of the tender shall be done based on the tack welding only.
16.5 Insulator Hoisting:
16.5.1 The string shall be fixed on the tower just prior to the stringing of conductors, but only after the
towers have been fully assembled, bolt/nuts tightened as per the requirements of the technical
specification. Damaged insulators and fittings, if any, shall not be employed in the assemblies. Before
hoisting all insulators shall be cleaned in a manner that may not spoil or injure or scratch the glaze of the
porcelain and in no case any oils shall be used for the purpose. Security clips shall be in position for the
insulators before hoisting.
16.5.2 Arcing horns or grading rings, shall be placed along the line on suspension, and facing upwards
on tension insulator string assemblies. The yoke arrangements shall be horizontal for tension, and
longitudinal for suspension strings. Torque wrench shall be used for fixing various line materials and their
components like suspension clamps for conductor and earthwire, etc. wherever recommended by the
manufacturer of the same.
16.6 Installation of power conductor and earthwire:
16.6.1 General:
The erection of conductors shall be done in 4 stages as follows:
a)
Delivery of conductors at site
b)
Running out (also called paying out) and stringing
c)
Tensioning and sagging, and
d)
Clipping-in.
Delivery of conductors at site:

16.6.1.1 The standard length contained in all the drums supplied against the line requirement shall be
noted down and the drums shall be batched 3 drums in a batch.
16.6.1.2
At every dumping site, two such batches shall be dumped.
16.6.1.3 While deciding the place of dumping, due consideration shall be made of the particular
standard length of the batch, extra length consumed on account o f sag, damaged ends of the conductor
in the drum, inclined spans, etc. The points noted under the Clause Tensioning and Sagging of
conductors in this section shall as well be borne in mind so that the planning for dumping of the drums
would not be disturbed, once it is finalized.
16.6.1.4 All drums in dilapidated condition shall be discarded and the conductor shall be rewound on
new drums before use. In case of the drums with only the lagging damaged, use may be made of
turntables holding the drums on vertical rotational axis, for running out.
16.6.2 Running out:
16.6.2.1 Whatever the method employed for running out the conductors, care shall be taken that the
conductors do not touch or rub against ground or objects which would cause scratches or damages to the
strands. The conductors shall be run out of the drums from the top (and not from the bottom) in order to
avoid damage due to checking. The conductors shall be pulled out evenly in preference to pulling out a
complete section of one wire. The conductor immediately after running out, shall be raised at the
supports to a level as that of the clamp and placed into the running blocks or the aerial rollers.
16.6.2.2 The running blocks shall be of diameter not less than the internal barrel diameter of the drum
as given in the IS: 1778-1961. In case such blocks are not avail able, the blocks shall be provided with
two small pulleys, which shall enable the conductor to form a curve of minimum equivalent diameter. The
groove of the pulley shall be of the design that the seat is semi-circular and larger than the diameter of
the conductor and it does not slip or rub against the sides. The groove shall be lined with hard rubber or
neoprene to avoid damage to conductor and shall be mounted on well-oiled bearings.
16.6.2.3 The running blocks shall be suspended in manner to suit the design of cross arms. All running
blocks, especially those at the tensioning end, shall be fitted with cross arms with sacking wrapped over
the steel work and under the slings to avoid damage to the slings as well as to the protective surface
finish of the steel work. In case suspension, light angle or section towers are used for termination of
stringing operations for longer periods they shall be suitably guyed. Normally, suspension towers shall
not be used even for temporary terminations, if this becomes necessary, these shall well guyed and steps
taken to avoid damage. The drums shall be provided with suitable breaking device to avoid loose running
out and to prevent kinking of the conductors. The conductor shall continuously be observed for loose, or
broken strands or any other damage. When approaching the end of a drum length, at least three coils
shall be left when the stringing operations are stopped. These coils shall be removed carefully and if
another length is required to be run out, a joint shall be made according to the recommendation of the
manufacturers. Normally, the joint shall be compression joint done with hydraulic compressor.
16.6.2.4 Repairs to conductors, if necessary, shall be carried out during the running out operations, with
repair sleeves. Repairing of conductor surface shall be done only in case of minor damage, scuff marks
etc keeping in view both electrical and mechanical safe requirements. The final conductor surface shall
be clean, smooth and without any projections, sharp points, cuts, abrasions etc.
16.6.2.5 Conductor splices shall be so made that they do not crack or get damaged in the stringing
operation. The contractor shall use only such equipments/methods during conductor stringing which
ensures complete compliance in this regard.
16.6.2.6 Derricks shall be used where roads, rivers, canals, telephones or over head power lines,
railway premises, fences or walls have to be crossed during stringing operations. It shall be ensured that
normal services are not interrupted or damage caused to property. Shutdown shall be obtained when
working at crossing of overhead power lines, and railways (electrified or otherwise).
16.6.2.7 The sequence of running out shall be from top downwards, that is the earth conductor shall be
run out first, followed by top, middle and bottom power conductors in succession. Unbalances of loads
on towers shall be avoided as for as possible. The sequence of running out shall be from top to
downwards i.e., the earthwire shall be run out first, follo wed by the conductors in succession. Unbalance
of loads on towers shall be avoided as far as possible. Outer phases of line conductor shall be strung
before the stringing of the middle phase is taken up. B & C type towers are not designed for one side
stringing. Therefore, proper guying arrangement shall be made for B & C type of towers during stringing
on one section while the other section is strung. The contractor shall forward detailed proposals along
with calculation for guying for approval by the engineer. Proper tools and instruments shall be made
available to the Engineer by the contractor for checking the tension in the guy wires. All the expenditure
on account of the above work is deemed to be included in the bid price.
16.6.2.8 The proposed 220 KV/110KV /66 KV Transmission line may run in parallel for certain distances
with existing 220 KV, 220 KV & 66 kV lines which may remain energized during the of dangerous voltage
build up due to electromagnetic and electrostatic coupling in the pulling wire conductors and earth wires,
which although comparatively small during normal operations could be the contractors responsibility to
take adequate safety precautions to protect his personnel and others from this potential danger.
16.6.3 Stringing of the conductor and earthing:

The bidder shall give complete details of the stringing methods, which he proposes to adopt. Before the
commencement of stringing, the contractor shall submit stringing charts for the conductors and earthwire
showing the initial and final sags and tensions for various temperatures and spans, along with equivalent
spans in the lines for approval by the Engineer.
16.6.4 Jointing:
i)
All joints on the earthwire and conductor shall be of compression type, in accordance with the
recommendations of the manufacturer for which all necessary tools and equipment like compressors,
dies, etc. shall have to be arranged for by the contractor. Each part of the joint shall be cleaned by wire
brush to make it free of rust or dirt etc. and properly greased before the final compression is done with the
compressors.
ii)
All joints or splices shall be made at least 30 meters away from the structures. No joints or splices
shall be made in spans crossing over main roads, railways, small rivers etc. Not more than one joint per
sub-conductor shall be allowed in one span. The compression type fittings used shall be of self-centering
type. Care shall be taken to mark the conductors to indicate when the fitting is centered properly. During
compression or splicing operation the conductor shall be handled in such a manner so as to prevent
lateral or vertical bearing against the dies. After pressing the joints, the aluminium sleeve shall have all
corners rounded, burrs and sharp edges removed and smoothened.
iii) To avoid damage to the joint during sagging operation, the contractor shall use a suitable protector
with mid-span compression joints in case the joints have to be passed over pulley blocks/aerial rollers.
The size of the sleeve of the pulley shall be such that the joint with pro tector can be passed over it
smoothly.
16.6.5 Sagging-in-operation:
i)
The conductors shall be pulled up to the desired sags and left in running blocks for at least one
hour after which the sag shall be rechecked and adjusted, if necessary, before transferring the
conductors from the running blocks to the suspension clamps. The conductors shall be clamped within
36 hours of sagging in.
ii)
The sag shall be checked in the first and the last span of the section in case of sections up to eight
spans and in one intermediate span also for sections with more than eight spans. The sag shall also be
checked when the conductors have been drawn up and transferred from running blocks to the insulator
clamps.
iii) The running blocks, when suspended from the transmission structure fo r sagging shall be so
adjusted that the conductors on running blocks will be at the same height as the suspension clamp to
which it is to be secured.
iv) At sharp vertical angles, the sags and tensions shall be checked on both sides of the angle, for
equality of tension. All suspension insulator assemblies shall normally assume a vertical position when
the conductor is clamped.
16.6.6 Tensioning and sagging of conductors:

The tension insulator sets, complete with clamped conductors, shall be hoisted at the ends remote from
the tensioning points. The running blocks at the tensioning end shall be fitted on the cross -arms with
tension end with sacking wrapped under the slings.
The mid-span tension joints shall be placed to ensure the following:
a)
No joints shall be placed within 15 mtr of the conductor support.
b) There shall be no joints in important crossing spans, except where the spans are longer than the
standard conductor length on the drums: and
c)
There shall be not more than one joint per conductor in a span.
The tensioning and sagging shall be done in accordance with the approved stringing charts prepared
form the data and relevant specifications of the line. Initial stringing chart for conductor and final string
charts for earth wire shall be employed for the purpose. Both sags and tension may checked if
considered necessary, but checking on sag only shall also be considered sufficient. The sag shall
preferably be checked in a span lying approximately in the middle of the relevant section, such span
being as near the length of the ruling span for the section as practicable. Dynamometers shall be
employed for measuring tension in the conductor and earth wire. The Dynamometers employed shall be
periodically calibrated with standard dynamometer.
Tensioning and sagging operations shall be carried out in calm weather when rapid changes in
temperature are not likely to occur.
16.6.7 Clipping-in:
Clamping the conductors in positioning, armouring at supports
placing of the dampers
and spacers, etc. shall be done in
accordance with the recommendations of the
manufacturer or field
personnel or both.
The jumper at the section and angle towers shall be formed to parabolic shape to ensure minimum
clearance requirements. Pilot suspension insulator strings shall be used where necessary to restrict
jumper swing.
Fasteners on all fittings and accessories shall be secured in position, the security clip also properly
opened and sprung in to position.
16.7 Fixing of conductor and earthwire accessories:
All conductor and earth wire accessories shall be installed by the contractor as per the design
requirements and respective manufacturer instructions within 24 Hours of the conductor/earthwire
clamping. While installing the conductor and earthwire accessories proper care shall be taken to ensure
that the surfaces are clean and smooth and no damage shall occur at any part of the accessories.
16.8 Safety Precautions:
16.8.1 All conductors shall be temporarily earthed in an effective manner at every section point. Such
temporary earth shall be removed after stringing of the entire line is over and before testing and
commissioning of the line.
16.8.2 The jumps provided for the conductors at the anchor towers shall be of adequate length to satisfy
the live metal clearances as indicated in the drawings enclosed.
16.8.3 Final checking, testing and commissioning: After completion of works, final checking of the line
shall be done by the contractor to ensure that all the foundation works, tower erection, and stringing are
done strictly in accordance with the intent of the specifications. All the works shall be thoroughly
inspected keeping in view, the following main points:
a)
Sufficient back-filled earth laying over each foundation pit is adequately compacted.
b)
Concrete chimneys and their coping are in good pointed conditions.
c)
All tower members are correctly used, strictly in accordance with the approved drawing and are
free of any defects or damage whatsoever.
d)
All bolts are properly tightened and punched.
e) The stringing of the conductors and earthwire has been done as per the approved sag and tension
charts and desired clearances are clearly available.
f)
All conductor and earth wire accessories are properly installed.
g) All other requirements to complete the work like fixing of danger plates; phase plates, number
plates, ant climbing devices, aviation signals (wherever required) etc are properly installed.
h)
The line insulation is tested by the contractor by providing his own equipment, personnel, etc to the
satisfaction of the Engineer.
i)
The line is tested satisfactorily for commissioning purpose following clearance given by the
electrical inspectorate and KPTCL in this behalf.
16.9 Final Checking, Testing and Commissioning:
After completion of works, final checking of the line shall be done by the contractor to ensure that all the
foundation works, tower erection and stringing are done strictly in accordance with the intent of the
specifications. All the works shall be thoroughly inspected keeping in view, the following main points:
a)
Sufficient back-filled earth laying over each foundation pit is adequately compacted.
b)
Concrete chimneys and their coping are in good pointed conditions.
c)
All tower members are correctly used, strictly in accordance with the approved drawing and are
free of any defects or damage whatsoever.
d)
All bolts are properly tightened and punched.
e) The stringing of the conductors and earthwire has been done as per the approved sag and tension
charts and desired clearances are clearly available.
f)
All conductor and earthwire accessories are properly installed.
g) All other requirements to complete the work like fixing of danger plates, phase plates, number
plates, anti-climbing devices, aviation signals (wherever required) etc., are properly installed.
h)
The line insulation is tested by the Contractor by providing his own equipment, personnel, etc., to
the satisfaction of the Engineer.
i)
The line is tested satisfactorily for the commissioning purpose following clearance given by the
electrical inspectorate and KPTCL in this behalf.
TECHNICAL SPECIFICATION FOR 220 / 123/ 72.5 / 36 KV

SF - 6
CIRCUIT BREAKERS FOR 220KV/6.6KV
SUB-STATIONS
VOLUME II(A)
TECHNICAL SPECIFICATION
FOR 220/ KV 123KV / 72.5KV / 36KV SF6 CIRUIT BREAKERS FOR VARIOUS SUB-STATIONS OF
KPTCL GRID
SECTION 4(A) : CHAPTER CIRCUIT BREAKER
Clause No.
1.0.0
2.0.0
3.0.0
4.0.0
5.0.0
6.0.0
7.0.0
8.0.0
9.0.0
10.0.0
11.0.0
12.0.0
13.0.0
14.0.0
15.0.0
16.0.0
17.0.0
18.0.0
Particulars
Scope
Service Conditions
Standards
Principal Parameters
Technical Requirements
Tests
Inspection
Quality Assurance Plan
Experience for Participating in Tenders
Performance Guarantee
Documentation & Drawings
Test Reports
Packaging & Forwarding
Supervision of Erection, Testing &
Commissioning
Training of Engineers
Recommended Spares
Schedules
List of Annexures
VOLUME II(A)
Section 4(A) (Circuit Breakers)
TECHNICAL SPECIFICATION FOR 220 KV / 123KV / 72.5KV / 36KV SF6 CIRUIT BREAKERS FOR
VARIOUS SUB-STATIONS OF KPTCL GRID
17.1 SCOPE
17.1.1 This specification covers design, manufacture, assembly, testing at manufacturers works /
testing laboratories before supply, inspection, packing and delivery of outdoor type circuit breakers,
erection and commissioning of circuit breakers of rated insulation class of 220 KV , 123kV, 72.5kV and
36kV. The Circuit Breakers shall be of sulphur hexafluoride (SF6) type and shall be complete with all the
accessories and auxiliary equipments and mounting structures required for their satisfactory operation in
various sub-stations of KPTCL grid.
17.1.2 It is not the intent to specify completely here in all the details of design and construction of the
circuit breaker. However, the breaker shall conform, in all respects to high standards of engineering,
design and workmanship as listed in clause No. 3.0. It shall be capable of performing in continuous
commercial operation up to the suppliers guarantee in a manner acceptable to the purchaser who will
interpret the meanings of drawings and specifications and shall have power to reject any work or material
which, in his judgment, is not in accordance therewith. The circuit bre aker offered shall be complete with
all components necessary for its effective and trouble free operation. Such components shall be deemed
to be within the scope of suppliers supply, irrespective of whether those are specifically brought out in
this specification and / or in the commercial order or not.
17.2 SERVICE CONDITIONS
17.2.1 Environmental Conditions :
The circuit breakers and accessories to be supplied against this specification shall be suitable for
satisfactory continuous operation under the following tropical conditions.
a) Maximum ambient air temperature [Deg. C]
50
b) Minimum ambient air temperature [Deg. C]
c) Average daily ambient air temperature [Deg. C]
30
d) Relative humidity [%]
10 to 100
e) Average rainfall per annum [mm]
1000-3000/5000
f) Maximum altitude above mean sea level [Mtrs] -
1000
g) Maximum wind pressure [Kg. / Sq. M]
150
h) Isoceraunic level [stormy days per year]
46
i) Seismic level [horizontal acceleration]
0.3g
j)
Moderately hot and humid tropical climate, conducive to rust and fungus growth.
17.2.2 AUXILIARY POWER SUPPLY

The Rating, quality and location of electrical supply system that will be made available by the purchaser
for operation of the circuit breaker are described below. The auxiliary electrical equipments provided by
the tenderer for specified operation of the circuit breaker, shall be suitable for operation on the same.
17.2.2.1 Ratings :
i) For power devices (like drive motors)
415V, 3 phase, 4 wire, 50 Hz neutral grounded AC

supply
ii) For AC Control & Protective devices, lighting 240V, single phase, 2 wire, 50 Hz, AC supply with
fixtures, space heaters and f.h.p. motors
one point grounded.
iii) For DC alarm, control and protective devices 2 wire ungrounded DC supply from batteries &
battery charger.
i) 110V DC for 110, 66 & 33KV Sub-Stations.
ii) 220V DC for 220kV Sub-Station
The ripple content in the DC supply from the
battery charger will be less than 2%
17.2.2.2 Variation :
The above supply systems may have variations as follows :
1) AC supply voltage variation
+10% to 30%
2) Frequency variation
+5%
3) DC supply voltage variation
+10% to 20%
17.3 STANDARDS:
17.3.1 The circuit breakers shall conform to the latest revision and amendments of standards as given
below :
Sl. No.
1
2
3
Standard ref. No.

IS : 117
IS : 325
IS : 2099
IEC :60137
IS : 2147
IS : 2629
IS : 3247
7
8
IS : 4379
IS : 5561
IS : 7311
10
IS : 13118
Title
Ready mixed paints, brushings, finishing etc.,
Specification for 3 phase induction motor
High voltage porcelain bushing
Degree of protection provided for enclosures for low voltage
switch gear and control gear
Recommended practice for hot dip galvanizing of iron and steel
General requirement of switch gear and control gear for voltages
not exceeding 1000V
Identification of contents of industrial gas cylinders
Electrical power connectors
High pressure cylinder in which SF6 gas is transported and
stored at site.
Specification for HV AC circuit breakers
Sl. No.
13
14
15
16
17
Standard ref. No.

CIGRE
working
group report No.
13-02-1973
Indian
electricity
rules
IEC : 62271-100
IEC :60060
IEC : 71 Part I & II
IEC : 60270
IEC : 60376
18
IEC : 60694
19
IEC 60427
11
12
Title
Switching over-voltages in EHV and UHV systems with special
reference to closing and re-closing transmission lines.
Specification for AC circuit breakers

High voltage test techniques
Insulation coordination, terms, definitions, principles and rules
Partial discharge measurements
Specification and acceptance of new supply of SF6
Common clauses for high voltage switchgear and control gear
controls.
Synthetic testing of high voltage alternating current circuit breaker
17.3.2 Equipments meeting with the stipulations of equivalent IEC, ANCI, CSA, DIN standards, which
ensure equal or better quality than the standards listed above shall also be acceptable. In such a case
the bidder should submit along with his offer, two copies of such standards in authentic English
translation, if the language of the standard is other than English. In case of dispute, the stipulations in the
English translation, submitted by the bidder, shall prevail. Further, in the event of the conflict between the
stipulations of the standard adopted by the bidder and the corresponding Indian standard specifications,
the stipulation of Indian standards specification shall prevail.
The breakers shall conform to the specific Technical requirements specified here under:
Sl.
Item
Requirements
No.
1
Rated voltage of the breaker (KV rms)
123
72.5
36
2
Nominal system voltage (KV)
110
66
33
3
Highest system voltage (KV)
123
72.5
36
4
System frequency
-----------50 Hz --------------
5
System Neutral grounding
-----effectively earthed------
6
Continuous current rating (A) (at site conditions)
1250 1250 1250
7
Installation (Indoor / Outdoor)
---------Outdoor -------------
8
Type of breaker
---------SF6 ------------------
9
Mounting
On hot dip galvanized steel support structure
or on the operating mechanism box, as the
case may be, to be supplied by the bidder.
10 Number of poles
3
3
3
11 Type of operation
Three Three Three
single single single
poles
poles
poles
gang
gang
gang
Sl.
No.
12
13
14
15
16
17
18
19
20
21
22
23
i.
Item
operated operated operated

Phase to phase spacing in the switchyard i.e.,
preferred inter pole spacing for breaker (in mm) 2000/ 2700
2000
1500
Required ground clearance from the lowest live
part of the breaker from the ground level(mm).
(If both the terminals are not in the same
horizontal plane then the above mentioned
4600
4250
4000
heights are to be reckoned for lower terminal)
Height of concrete plinth above ground level
300
300
300
(mm)
Minimum height of the lowest part of the
2500
2500
2500
support insulator from ground level (mm)
Operating mechanism
spring operated / semi pneumatic /
pneumatic refer clause 5.12
Type of tripping
Trip free
Auto re-closing duty
Three
Three Three
phase phase phase
Rated operating duty cycle
0-0.3 seconds CO-3-minutes CO-as per
IEC-62271-100
First pole to clear factor
1.5
1.5
1.5
Max. closing time (ms)
150
150
150
Max. total break time at rated breaking capacity
60
60
60
(ms)
1.2 / 50 micro second impulse withstand
voltage:
to earth (KVP)
550
325
170
550
325
170
ii.
Across open contacts:
i.
(Impulse on one terminal and power frequency

voltage on opposite terminal (KVP))
One minute power frequency withstand voltage
(KV rms)
Max. radio interference voltage (micro volts)
Rated breaking current capacity:
Line charging at rated voltage (A)
24
25
26
Requirements
ii.
Small inductive current (A)
iii.
Cable charging at rated voltage (A)

Note:- The rated cable charging breaking
current for circuit breakers used for switching
under ground cables shall be confirmed by the
bidder
iv.Short Circuit current
230
140
---
---
31.5
10
70
--10
0.5 to 10 without switching over voltage

exceeding 2.0 PU.
140
31.5
1sec
40KA
1 Sec
125
31.5
1 sec
50
25
1sec
Sl.
No.
27
28
29
Item
a)A.C Component (KA rms)

corresponding to minimum opening time as
For stations in Bangalore
per IEC-62271-100
b) Percentage D.C component
Rated short circuit making current capacity (KA
78.75
78.75
62.5
peak)
Permissible limits of temperature rise
Refer clause No. 5.11.0
Max. acceptable difference in the instants of
closing / opening of contacts:
i.
Within a pole (ms)
------10
10
10
ii.
30
31
32
33
Requirements
Between poles (ms)
Minimum creepage distance of support

3075
1815
900
insulator (mm)
Rating of auxiliary contact
10A at 110 volts D.C
Breaking capacity of auxiliary contacts
2A D.C with the circuit time constant not less
than 20 ms.
Noise level at base and up to 50 meters
140 db(max)
17.5 Technical requirement:

17.5.1 General
17.5.1.1 Circuit breaker offered shall be sulphur hexafluoride (SF6) type of 220 KV , 123KV, 72.5KV &
36KV rating. SF6 gas shall serve as the quenching medium and insulation between open contacts of the
circuit breakers
17.5.1.2 Similar parts of the breaker, especially the removable ones, shall be freely interchangeable
without the necessity of any modification at site.
17.5.1.3 The circuit breaker shall comprise of three identical single pole units.For 220 KV , 123KV,
72.5KV & 36KV circuit breaker the type of operation shall be three single poles gang operated suitable for
three pole re-closing. These units shall be linked together electrically /pneumatically/mechanically
complete in all respects.
Complete circuit breaker with all the necessary items for successful operation shall be supplied, including
but not limited to the following.
a)
Breaker assemblies with bases, support structures for Circuit Breaker as well as for individual
control cabinet/central control cabinet and foundation bolts for main structure as well as individual control
cabinet / central control cabinet (except concrete foundations), terminals and operating mechanism.
b) Compressed SF6 gas, Pneumatic system complete including compressors, tanks, piping, fittings,
valves and controls and necessary supports for inter-pole piping for pneumatic systems.
c)
One central control cabinet for each breaker with all the required electrical devices mounted therein
and the necessary terminal blocks for termination of inter-pole wiring.
d)
Instruments, gauges and other devices for SF6 gas pressure, pneumatic pressure supervision.
e) All necessary Parts to provide a complete and operatable circuit breaker installation such as main
equipment, terminal, control parts, connectors and other devices, whether specifically called for herein or
not,
17.5.1.4 The circuit breaker shall be designed for three pole re-closing for 220 KV , 123KV, 72.5KV and
36KV rating with an operating sequence and timing as specified in clause 4.0 Principal Parameters".
17.5.1.5 The support structure of circuit breaker as well as that of control cabinet shall be hot dip
galvanized.
17.5.1.6 Circuit Breaker shall be suitable for hot line washing.
17.5.1.7 Facility for up-rating:
The design of the breaker shall be such that it should be possible to up -rate the rupturing capacity of the
breakers at a later date either by adding additional interrupter assemblies or parallel resistors, etc. the
supplier should highlight in his offer, the special features available for up -rating the breakers offered.
17.5.2 CONTACTS:
17.5.2.1 All making and breaking contacts shall be sealed free from atmosphe ric effects. Contacts shall
be designed to have adequate thermal and current carrying capacity for the duty specified and to have a
life expectancy so that frequent replacements due to excessive burnings will not be necessary. Provision
shall be made for rapid dissipation of heat generated by the arc on opening.
17.5.2.2 5.2.2 Main contacts shall be first to open and the last to close so that there will be little contact
burning and wear. If arching contacts are used they shall be first to close and the last to open. Tips of
arching contacts and main contacts shall be silver plated or made of superior material like graphite or
tungsten alloy.
17.5.2.3 5.2.3 Any device provided for voltage grading to damp oscillations or to prevent re -strike prior
to the complete interruption of the circuit or to limit over voltages on closing shall have a life expectancy
comparable to that of the breaker as a whole.
17.5.2.4 5.2.4 Breakers shall be so designed that when operated within their specified rating, the
temperature of each part will be limited to values consistent with a long life of the material used. The
temperature shall not exceed that indicated in IEC-56 under specified ambient conditions.
17.5.2.5 5.2.5 Contacts shall be kept permanently under pressure of SF6 gas. The gap between the
open contacts shall be such that it can withstand at-least the rated phase to ground voltage continuously
at zero gauge pressure of SF6 gas due to its leakage.
17.5.2.6 If multi-break interrupters are used these shall be so designed and augmented that a uniform
voltage distribution is developed across them. Calculations/ test reports in support of the same shall be
furnished along with the bid. The thermal and voltage withstands of the grading elements shall be
adequate for the service conditions and duty specified.
17.5.2.7 5.2.7 The inside operating rod or insulated fiber glass connecting rods wherever used, shall be
sturdy and shall not break during the entire life period of the breaker. The insulated rods shall have anti tracking quality towards electrical stresses.
17.5.3 PORCELAIN HOUSING:

5.3.1 The porcelain housing for the interrupter shall be of a single piece construction without any joint. It
shall be made of homogeneous, vitreous porcelain of high mechanical and dielectric strength. Glazing of
porcelain shall be of uniform brown or dark brown colour with a smooth surface arranged to shed away
rain water or condensed water particles (fog).
17.5.4 SUPPORT INSULATORS:
17.5.4.1 In the live type tank construction, the tank containing SF6 gas and interrupters which is at the
potential of the circuit to which circuit breaker is connected when the breaker is in service, shall be
insulated from earth by providing suitable support insulators.
17.5.4.2 The basic insulation level of the external insulator supports shall be 550KV for 123KV, 325KV
for 72.5KV and 170KV for 36KV system and shall be suitable for installation in contaminated atmosphere.
The porcelain used shall be homogenous and free from cavities or other flaws. They shall be designed to
have ample insulation, mechanical strength and rigidity for satisfactory operation under conditions
specified above. All bushings of identical ratings shall be interchangeable. The puncture strength of the
bushings shall be greater than the flashover value.
The bushings shall be entirely free from radio disturbances when operating at a voltage up to 10% above
rated voltage and also be free from external and internal corona.
17.5.5 ADDITIONAL REQUIREMENTS:
a)
The Circuit breakers shall be single pressure type and shall utilise puffer cylinder for interrupting
circuit currents. Each SF6 circuit breaker pole shall be provided with its own self obtained gas system.
The design and construction of the circuit breaker shall be such that there is no possibility of gas leakage
and ingress of moisture. There should not be any condensation of SF6 gas on the internal insulating
surface of the circuit breaker.
b) All gasketted surfaces shall be smooth, straight and reinforced, if necessary to minimize distortion
and to make a tight seal, the operating rod connecting the operating mechanism to the arc chamber (SF6
media) shall have adequate seals, Double-0-ring seals and test holes for leakage test of the internal seal
shall be provided on each static joint.
c)
In the interrupter assembly there shall be an absorbing product box to eliminate SF6 decomposition
products and moisture. The material used in the construction of the circuit breakers shall be fully
compatible with SF6 gas.
d)
The SF6 gas density monitor shall be adequately temperature compensated.
The density monitor shall meet the following requirements.

i.
It should be possible to dismantle the density monitor for checking / replacement without draining
the SF6 gas by using suitable interlocked non-return couplings.
ii.
It shall damp the pressure pulsation while filling the gas in service so that the flickering of the
pressure switch contacts does not take place.
iii.
A pressure indicator shall also be supplied.
e) Means for pressure relief shall be provided in the gas chamber of circuit breaker to avoid the
damages or distortion during occurrence of abnormal pressure increase or shock waves generated by
internal electric fault arcs. The position of vent, diaphragms and pressure relief devices shall be arranged
so as to minimize dangers to the operations in the event of gas or vapour escaping under pressure.
f)
Facility shall also be provided to reduce the gas pressure within the breaker to a value not
exceeding 8millibars within 4 hours or less. Each circuit breaker shall be capable of withstanding this
degree of vacuum without distortion or failure of any part.
g) Sufficient SF6 gas shall be provided to fill all the circuit breakers installed. In addition to this 20% of
the total gas requirement shall be supplied as spare requirements.
h)
Provisions shall be made for attaching an operation analyzer after installation at site to record
contact travel, speed and making measurement of operation timings, pre -insertion timing of closing
resistor and synchronization of contacts in one pole.
17.5.6 SULPHUR HEXAFLOURIDE GAS (SF6 GAS):
a)
The SF6 gas shall comply with IEC-60376, 376A AND 376B and be suitable in all respects for use
in the switch gear under the worst operating conditions.
b) The high pressure cylinders in which the SF6 gas is shipped and stored at site shall comply with
requirements of the following standards and regulations :
IS: 4379
Identification of the contents of industrial gas cylinders
IS: 7311
Seamless high carbon steel cylinders for permanent and
high pressure liquefiable gases.

The cylinders shall also meet Indian Boiler regulations.
17.5.6.1 The SF6 gas shall have the following characteristics :
Sl.
Particulars
No.
1.
Physical properties
2.
Density at 20C and 1 bar
3.
4.
Electric strength
Compatibility
5.
Toxic impurities
Characteristics
Colourless. odourless, non-toxic and nonflammable
6.08 grams/ litre
2 times that of Nitrogen
Up to temperature of about 180C its compatibility with
material used in electrical construction shall be similar to
that of Nitrogen.
SF6 gas shall comply with the requirements of the test
as per clause 22 of IEC : 487 1971.
Impurity or group
Maximum permitted
of impurities
concentration % by
Mass
CF4
0.05%
Oxygen + Nitrogen (Air)
0.05%
Water
15PPm
Acidity expressed
Sl.
No.
Particulars
Characteristics
as HF
Hydrolysable fluorides
expressed as HF
Oil Content
1.0ppm
substantially
free from oil
There shall be no traces of carbon or carbon oxides
what so ever in the gas.
Preferred size of cylinders
10 and 40 liters
Test pressure of cylinder
According to gas cylinder rules 1981 and to comply with
IS : 7285-1974.
Maximum filling ratio for tropical According to gas cylinder rules 1981 and to comply with
country
IS : 7285 1974
6.
7.
8.
9.
0.3ppm
TESTS :
a)
Toxicity test
b)
Water
content
condensation temperature
and
Clause No.22 of IEC :60376 1974

Clause Nos. 23, 24, 25 and 26 of IEC :60 376B 1974
Clause Nos. 27, 28, 29, 30 and 31 of IEC :60 376

1976.
c)
Carbon tetra fluoride oxygen
Clause Nos. 32,33,34,35,36 and 42 of IEC : 60376
and nitrogen contents
1976
Clause Nos. 38, 39,40,41 and 42 of IEC :60376 1976
d)
Hydrolysable
Section 13 of IEC60 376A - 1973
Fluoride content.
e)
Acidity
f)
Oil content
17.5.6.2 The gas shall be non-flammable, nontoxic, odourless, inert and thermally stable and shall have
a high specific heat to enable quick removal of the heat produced by the arc.
17.5.6.3 The deterioration or decomposition of the SF6 gas due to arcing should be practically negligible
and even when decomposed it should recombine immediately to form the original SF6 gas within an
extremely short time such as one micro-sec.
17.5.7 a) SF6 breaker shall be so designed that upon loss of pressure the gap between open contacts
shall be adequate to withstand at least the rated voltage at atmospheric pressure of gas.
b)
Bidder shall clearly bring out in his offer, the precautions to be taken in the use of SF6 breaker.
c)
Following features shall be provided for monitoring of SF6 gas in the
breaker:
1)
SF6 gas density meter with two potential free contacts of suitable rating. One of these contacts
shall be used for annunciation of low density. The other contact shall be used by the bidder to ensure
breaker lockout in the event of low SF6 gas pressure. The successful bidder shall furnish a chart showing
relation between pressure and density of SF6 gas, as well as settings for alarm and lockout.
2)
Suitable pressure gauges shall be provided for SF6 gas, pneumatic air, hydraulic oil as applicable.
Gauge dials shall be clearly visible with naked eye to an observer standing on ground.
3)
Adequate number of pressure switches, shall be provided for monitoring pressure of SF6 gas. The
pressure switches shall be provided with sufficient number of potential free NO & NC contacts for
purchaser's use in control, protection and alarm circuits.
d)
For 220 KV , 123KV, 72.5KV and 36KV CBs common gas system with pressure gauge, density
monitor, gas filling port, piping between poles should be provided.
17.5.8 DUTY REQUIREMENTS:
17.5.8.1 Recovery voltage and power factor:
The circuit breaker shall be capable of interrupting rated power with recove ry voltage equal to the rated
maximum line to line service voltage at rated frequency and at a power factor not exceeding 0.15.
17.5.8.2 Re-striking voltage:
a)
The circuit breaker shall be totally re-strike free under all duty conditions, opening resistors shall
not be used.
b) The measures adopted for ensuring proper operation at high rate of rise of re -striking voltage and
for limiting the actual voltage values across the breakers shall be described in the tender. The type,
characteristics and rating of the resistor used if any to shunt the breaker contacts and of the auxiliary
switching devices used for interrupting the resistor current shall be clearly stated.
17.5.8.3 The circuit breaker shall meet the duty requirements for any type of fault or fault location, for
line and cable charging and dropping when used on an effectively grounded system and perform make
and break operations as per stipulated duty cycles satisfactorily.
17.5.8.4 The circuit breaker shall be capable of :
i)
Interrupting the steady and transient magnetizing current of 220 KV , 123kV & 72.5kV class upto
20/31.5 MVA Power Transformers and 36KV class 5MVA Power Transformers.
ii)
Interrupting line charging current and cable charging current as given in Clause 4.0 "Principal
parameters" of this specification.
The circuit breaker shall be designed so as to be capable of interrupting line charging and cable charging
currents without undue rise in the voltage on the supply side and without any re -strike and without
showing signs of undue stress. The guaranteed over vo ltage which will not be exceeded while
interrupting the line charging current and cable charging current as specified in IEC 62271-100 (having
a time constant not less than 0.1Sec.) shall be indicated in the tender.
The over voltage caused while interrupting the above charging currents, shall preferably not exceed the
designed switching over voltage specified in table IX of IEC 62271-100.
The results of the tests along with copies of the oscillographs, conducted to prove the ability of the
breakers to interrupt these and lower line charging current values shall be furnished with the tender.
iii)
Clearing short line faults:
Clearing short line faults (Kilometric faults) with source impedance behind the bus equivalent to
symmetrical fault current specified.
The interrupting capacity of the breaker for Kilometric faults (short line faults) shall be the same as the
rated capacity. The details of tests conducted for proving the capabilities of the breaker under Kilometric
fault conditions shall also be stated in the tender.
The 220 KV , 123/72.5 kV breaker shall have the capacity to interrupt capacitor bank of 220 KV ,
123/72.5kV, 20/30 MVAR capacity connected back to back without exceeding the switching over voltage
specified in IEC -62271-100, The breaker shall also have rated capacitor bank inrush making current as
specified in IEC -62271-100.
iv) Breaking inductive currents of 0.5 to 10A without switching over voltage exceeding 2.0 p.u. as
given in clause 4.0 Principal Parameters"
v)
The breaker shall be capable of satisfactory operation even under conditions of phase opposition
that may arise due to faulty synchronizing. The maximum power which the breakers can satisfactorily
interrupt under phase opposition shall be stated in the tender.
17.5.8.5 The critical current, which gives the longest arc duration at lock out pressure of extinguishing
medium and the arc duration shall be indicated.
17.5.8.6 The breaker shall satisfactorily withstand the high stresses imposed on them during fault
clearing, load rejection and re-energisation of lines with trapped charges. The breaker shall also
withstand the voltage specified in clause 4.0 "Principal Parameters" of this specification.
17.5.9 TOTAL BREAK TIME :
17.5.9.1 The "Total Break Time" as specified in Clause 4.0 "Principal Parameters" of this sec tion shall
not be exceeded under any of the following duties:
i)
Basic short circuit Test duties as per IEC 62271-100 (with TRV as per I EC 62271-
ii)
Short line fault L90, L75 (with TRV as per IEC 62271-100).
17.5.9.2 The Bidder may please note that there is only one specified break time of the breaker which
shall not be exceeded under any duty conditions specified such as with the combined variation of the trip
coil voltage, (70-110%) pneumatic / arc extinguishing medium pressure etc., while furnishing the p roof for
the total break time of complete circuit breaker, the Bidder may specifically bring out the effect of non simultaneity between contacts within a pole or between poles and show how it is covered in the
guaranteed total break time.
17.5.9.3 The values guaranteed shall be supported with the type test reports.
17.5.10 INSULATION OF CIRCUIT BREAKER:
17.5.10.1 The insulation to ground, the insulation between open contacts and the insulation between
phases of the completely assembled circuit breaker shall be capable of withstanding satisfactorily
dielectric test voltages corresponding to the basic insulation level as specified in Clause 4.0 "Principal
Parameters"
17.5.10.2 If SF6 gas is utilized for insulating purposes across open contacts, the insulation strength of
the break at the lowest permissible pressure and at atmospheric pressure shall be stated.
17.5.11 LIMITS OF TEMPERATURE RISE:
The temperature rise on any part of equipment shall not exceed the maximum temperature rise specified
below under the conditions specified in test clauses. The permissible temperature rise indicated is for a
maximum ambient temperature of 50 deg C. If the maximum ambient temperature rises, permissible
values shall be reduced accordingly.
Nature of the part of the
material and of the dielectric
Maximum permissible
temperature (deg. C)
Values of Temperature rise at a

max. air temperature not
exceeding 50deg C
75
90
25
40
80
30
105
105
90
55
55
40
90
90
90
40
40
40
90
105
40
55
1) Contacts (see note-3) Bare

Copper and
Bare copper alloy
- In air
-
In
SF6
(Sulphur
Hexafluoride)
-
In oil
Silver coated or nickel coated

(see note-4)
- in air
-
in SF6
in oil
Tin coated (see note 4 & 5)

- in air
-
in SF6
in oil
2. Connections, bolted or the

equivalent (see note-6)
Bare copper, bare copper alloy
or Aluminum alloy
-in air
-in SF6
-in oil
100

exceeding 50deg C
50.
115
115
100
65
65
50
105
105
100
55
55
50
See Note- 7
See Note- 7
90
40
105
See Note 7
55
See Note 7
5. Oil for oil switching devices

(See Notes 10 & 11)
90
40
6. Metal parts acting as springs
See Note 12

Silver coated or nickel coated
-in air
-in SF6
-in oil
Tin coated
-in air
-in SF6
-in oil
3. All other contacts or
connections made of bare
metals or coated with other
materials
4. Terminals for the connection
to external conductors by
screws or bolts(see note-8)
-bare
-silver, nickel or tin coated
-other coatings
Maximum permissible
See Note 12
7.Material used as insulation

and metal parts in contact with
insulation of the following
classes (See Note 9)
-Y
(for
materials)
non-impregnated
- A (for materials immersed in

oil or impregnated )
-E
-B
-F
-Enamel
:
oil
base
-synthetic in air
-H
-C
8. Any part of metal or
90
40
100
50
120
130
155
100
120
180
See Note 13
100
70
80
105
50
70
130
See Note 13
50

Maximum permissible

exceeding 50deg C
insulating materials in contact

with oil, except contacts.
NOTES :
1)
According to its function, the same part may belong to several categories as listed in table. In this
case the permissible maximum value of temperature and temperature rise to be considered are the
lowest among the relevant categories.
2)
Care shall be taken to ensure that no damage is caused to the surrounding Insulating material.
3)
When contact parts have different coating, the permissible temperature and temperature rises shall
be those of the part having the lower value permitted in table.
4)
The quality of the coated contacts shall be such that a layer of coating material remains at the
contact area :
a)after making and breaking test (if any):
b)after short time withstand current test:
c) after the mechanical endurance test ;
According to the relevant specification for each equipment. Otherwise, the contacts shall be regarded as
"bare".
5)
For fuse contacts, the temperature rise shall be in accordance with IEC publications on High
Voltage Fuses.
6)
When connection parts have different coatings, the permissible temperature rises shall be those of
the parts having the higher value permitted in table.
7)
When materials other than those given in table are used, their properties shall be considered,
notably in order to determine the maximum permissible temperature rises.
8)
The values of temperature and temperature rise are valid even if the conductor connected to the
terminals is bare.
9)
The following classification of insulating materials is in accordance with IEC - 85.
Class-Y: Insulation consists of materials or combinations of materials such as cotton, silk and paper when
suitably impregnated. Other materials may be included in this class if by experience or accepted tests
they can be shown to be capable of operation at Class-Y temperature.
Class - A: Insulation consists of materials or combinations of materials such as cotton, silk and paper
when suitably impregnated or coated or when immersed in a dielectric liquid such as oil. Other materials
or combination of materials may be included in this class if by experience or accepted tests they can be
show to be capable of operation at Class - A temperatures.
Class - E : Insulation consists of materials which by experience or accepted tests can be shown to be
capable of operation at Class - E temperatures.
Class -B : Insulation consisting of materials or combinations of materials such as mica, glass fiber,
asbestos, etc., with suitable bonding substances. Other materials or combinations of materials, not
necessarily inorganic, may be included in this class if by experience or accepted tests they can be shown
to be capable of operation at Class - B temperatures.
Class - F : Insulation consists of materials or combinations of materials such as mica, glass fiber,
asbestos with suitable bonding substances. Other materials or combinations of materials not necessarily
inorganic, may be included in this class if by experience or accepted tests they can be shown to be
capable of operation at Class - F temperatures.
Class - H : Insulation consists of materials such as siliconed elastomer and combination of materials such
as mica, glass fiber, asbestos etc., with suitable bonding substances such as appropriate silicone resin.
Other materials or combination of materials may be included in this class if by experience or by accepted
tests they can be shown to be capable of operation at Class - H temperatures.
Class - C ; Insulation consists of materials or combination of materials such as mica, porcelain, glass and
quartz with or without an inorganic binder. Other materials or combinations of materials may, be included
in this class if by experience or accepted tests they can be shown to be capable of operation at
temperatures above the Class-H limit. Specific materials or combinations of materials in this class will
have a temperature limit, which is dependent upon their physical chemical and electrical properties.
10)
At the upper portion of the oil.
11) Special consideration should be given when low flash point oil is used in regard to vaporization and
oxidation.
12)
The temperature shall not reach a value where elasticity of the material is impaired.
13)
Limited only by requirement to any damage to surrounding parts.
17.5.12 OPERATING MECHANISM AND ASSOCIATED EQUIPMENTS

17.5.12.1 The circuit breaker shall be designed for electrical local as well as remote control. In addition
there shall be provision for local mechanical control (emergency trip).
17.5.12.2 The operating mechanism shall be of spring charging type (both for closing and opening
operation) or semi pneumatic operation type in which closing operation is of spring charging type and
opening operation is by pneumatic type or pneumatic type for both opening & closing operations. The
mechanism shall be adequately, designed for the specified tripping and re-closing duty. The entire
operating mechanism control circuitry, individual breaker compressor unit, hydraulic pump, spring
charging motor etc., as required, shall be housed in an outdoor type, steel enclosure. This enclosure shall
conform to the degree of protection IP-55 of IS-2147 and shall be suitable for mounting on a separate
concrete plinth.
17.5.12.3 All working parts in the mechanism shall be of corrosion resistant material. All bearings which
require greasing shall be equipped with pressure grease fittings.
17.5.12.4 The design of the operating mechanism shall be such that it shall be practically maintenance
free. The guaranteed number of years of maintenance free operation, the number of full load and full
rated short circuit current breaking operations without requiring any maintenance or overhauling shall be
clearly stated in the tender bid. As far as possible, the need for lubricating the operating mechanism shall
be kept to the minimum and eliminated altogether, if possible.
17.5.12.5 The operating mechanism shall be anti-pumping and trip free, for all method of closing
operations i.e., electrical, mechanical, pneumatic, semi-pneumatic type and hydraulic type. There shall be
no rebounds in the mechanism and it shall not require any critical adjustments at site. Operation of the
power operated closing device, when the circuit is already closed, shall not cause damage to the circuit
breaker or endanger the operator. Provision shall be made for attaching an operation analyzer to facilitate
testing of breaker at site.
17.5.12.6 a)
A mechanical indicator shall be provided to show open and close position of
17.5.12.7 the breaker. It shall be located in a position where it will be visible to a man standing on the
ground level with the mechanism housing closed. An operation counter shall also be provid ed in the
central control cabinet.
b) All the control knobs, manual spring charge etc., shall be easily approachable on-ground level. The
height of these locations should be not more than 2000 mm from ground level.
17.5.12.8 The supplier shall furnish detailed operation and maintenance manual of the mechanism
along with the operation manual for the circuit breaker.
The detailed drawing indicating all the individual parts of the breakers and control mechanism duly
marking parts number shall be furnished.
17.5.12.9 SEMI - PNEUMATIC OPERATING MECHANISM:
Pneumatic type operating mechanism for tripping and spring charging type operating mechanism for
closing.
A)
Closing operation:
i.
Closing operation is made by closing spring. When the closing signal energises the closing coil, the
trigger is released and the closing spring closes the breaker.
ii.
The spring operating mechanism shall have adequate energy stored in the operating spring to
close and latch the circuit breaker against the rated making current.
The mechanism shall be capable of performing 5CO operations.
iii. The spring charging motor shall not take more than 30secs for fully charging the closing springs
and provision shall be made for automatic charging of the closing springs as soon as they are discharged
in a closing operation. For this, the mechanism shall be such that the charging of the springs by the motor
does not interfere with the operation of the breaker.
iv. The motor shall be adequately rated to carryout a minimum of 5 close and open operations
continuously. Also provision shall be made to protect the motor against overloads.
v.
Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of the
closing springs when the breaker is already in the closed position. Provision shall also be made to
prevent a closing operation to be carried out with the spring partially charged.
vi.
Facility shall be provided for manual charging of the closing springs.
B)
Opening operation:
The opening operation is affected by compressed air. When the ope ning signal energizes the trip coil, the
latch and cam are released. Control valve is opened, which allows the compressed air and pushes down
the opening piston and effects opening of the circuit breaker. The opening piston is held against the
spring force.
a)
Circuit breakers with pneumatic operating mechanism shall be provided with individual compressed
air system with an adequate compressor motor unit, rated to meet full requirements of the respective
circuit breaker.
b) The ICU shall be complete with air piping and accessories, all stop valves, tees, pressure reducers,
etc., required for normal operation of the breaker.
c)
The compressed air mechanism shall be capable of operating the circuit breaker under all duty
conditions with air pressure immediately before operation between 85% and 105% of rated supply
pressure. The make / break time at this supply pressure shall not exceed the specified make/break time
written any values of trip coil supply voltage as specified.
d) The semi - pneumatic operating mechanism shall consist of pilot or auxiliary and main valves for
closing and opening operation of the circuit breaker. The pilot valves shall be suitable for operations
either electrically by electrical solenoids or by local control push buttons. The accessories shall include an
intake filter, stop valve, non-return valve, drain valve, breaker position indicator, auxiliary contacts,
operation counter, space heater, a set of terminal blocks, etc.
e) The operating mechanism shall also include necessary monitoring and safety interlocks such as
pressure gauges with electrical alarm contacts for low/ high pressure signals, pressure switches for low
pressure lock-out for closing, opening and auto re-closing operations and a safety valve. Local manual
control shall not be provided. The closing and auto re-closing lock-out pressure shall be such that the
breaker shall be able to open immediately after closing or re -closing operation as the case may be.
Provision shall exist for both local and remote electrical operation of the breaker. The mechanism shall be
provided with anti-pumping features.
f)
The compressed air stored in the local air receiver shall, at least, be sufficient to carry out 5CO
operations and the charging time to restore the pressure shall be sufficie ntly short to complete the rated
operating sequence viz., O-0.3See.-CO-3min-CO.
g)
Compressed Air system:

i)
Compressed air piping shall be carried out in accordance with BS : 162.
ii)
Compressor shall be oil less rotary type complete with drive motors.
iii)
Compressor shall be provided with automatic adjustable un-loading device.
iv) Compressor shall be provided with automatic start/ stop control along with hour meter to check the
running of the compressor. Supplementary manual control shall also be provided.
v). Compressor drive motor shall be 3 phase, full voltage direct-on-line starting, constant speed,
squirrel cage induction type, rated for continuous operation in the specified climatic conditions. The motor
shall be totally enclosed fan cooled type with-Class 'E' insulation. Maximum permissible temperature rise
of motor shall not exceed 65 C over an ambient temperature of 50 C measured by resistance.
h)
Air receivers:
i)
Air receivers of circuit breakers shall be capable of performing the operating duties as listed against
clause 20 of IEC Publication 652271-100.
ii)
Air receivers shall have a manhole with cover for inspection and cleaning.
iii)
Connections for air inlet and outlet, drain and relief valves on receiver shall be flanged type.
iv)
Pressure gauge & pressure switch connection shall be of the screw type.
v)
Accessories supplied along with the air receiver shall include but not be limited to the following :
a.
Suitable safety valve to relieve full compressor discharge, at a set pressure equal to 1.1 times the
maximum operating pressure.
b.
Blow off valve auto drain tap with isolating and by-pass valve.
c.
Dial type pressure gauge with isolating and drain cock and test connection and fitting for mounting
on the receiver.
d.
Isolating and drain cocks for the pressure switches.
e.
Black flange with bolts, gasket, etc., for the test connection.
vi)
Air receivers shall be hydro-statically tested to a pressure of 1.5 times the design pressure.
vii) Air receiver shall be designed in accordance with the latest edition of the ASME code for pressure
vessel-section VIII of BS : 5197. A corrosion allowance of 3.0mm shall be provided for shell and dished
ends. Receivers shall be coated on the inside face with antirust medium.
i)
Compressor control and compressed air piping :
i)
Compressor control shall be of the automatic start stop type initiated by pressure switches.
ii)
All control equipment shall be housed in a totally enclosed sheet steel cabinet. Pressure gauge and
such other indicating devices shall also be mounted on the control cabinet.
iii) In all other respect control cabinets shall be in accordance with the specification for "Control
Cabinet as per Clause No. 5.23.
iv) All compressed air piping shall be of adequate diameter, bright annealed, se amless phosphorous,
De-oxidized, non-Arsenical copper alloy or stainless steel pipe (C-106 of BS 2871- 1957).
v)
The flow capacity of all valves shall be at least 20% greater than the total compressor capacity.
vi)
All joints and connections in the piping system shall be brazed or flared as necessary.
j)
Quality of Air :
Compressed air used shall be dry and free of dust particles. Arrangement for conditioning compressed air
shall be provided as an integral part of air compressor system. Air shall condense at working pressure at
a temperature of minus 10 deg. C. Measures of achieving this shall be brought out clearly in the bid. All
instruments required for checking the quality of air shall be furnished as special tools along with the
breakers.
k)
Operating mechanism Housing:
Operating mechanism of unit compressor and all accessories shall be enclosed in a weather proof
cabinet of sheet steel construction, the thickness of which shall not be less than 3mm. Hinged doors
giving access to the mechanism at the front and sides shall be provided.
Suitable space heaters shall be mounted in the housing to prevent condensation. Heaters shall be
controlled by differential thermostat so that the cubicle temperature is always, maintained approximately
10 deg. C above the outside air temperature. On/Off switch and fuse shall be provided for the heaters.
Heaters shall be suitable for 240 V AC single phase supply. The heater leads shall be covered with
porcelain material up to sufficient length to avoid melting of insulation o f the leads.
17.5.12.10 PNEUMATIC OPERATING MECHANISM
Pneumatic operating mechanism for both closing and opening of the breaker -operations affected by
compressed air. Other details are similar to the clause Nos. 5.12.8 (B) (a) to (k) above.
NOTE: In addition to the above details the Clause No. 5.23 for specification for control cabinet is
applicable wherever necessary.
17.5.12.11 SPRING OPERATING MECHANISM :
Spring charging type operating mechanism for both closing and tripping.
Closing and opening operation :
i)
Closing operation is made by closing spring. When the closing signal energises the closing coil, the
trigger is released and the closing spring closes the breaker.
ii)
The spring operating mechanism shall have adequate energy stored in the operating spring to
close and latch the circuit breaker against the rated making current and also to provide required energy
for the tripping mechanism.
The mechanism shall be capable of performing 5CO operations.
iii) The spring charging motor shall not take more than 30 secs for fully charging the closing springs
and provision shall be made for automatic charging of the closing springs as soon as they are discharged
in a closing operation. For this, the mechanism shall be such that the charging of the springs by the motor
does not interfere with the operation of the breaker.
iv) The motor shall be adequately rated to Carryout a minimum of 5 close and open operations
continuously. Also provision shall be made to protect the motor against overloads.
v)
Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of the
closing springs when the breaker is already in the closed position. Provision shall also be made to
prevent a closing operation to be carried out with the spring partially charged.
vi)
Facility shall be provided for manual charging of the closing springs.
17.5.13
CONTROL CIRCUIT :
17.5.13.1 The close and trip circuits shall be designed to permit use of momentary contact switches
and push buttons.
The control circuit shall include the following features
i)
Two electrically independent trip circuits including two trip coils for 220 KV, 66 KV & 33 KV
breakers to operate the three poles simultaneously.
ii)
The breaker shall normally be operated by remote electrical control. Electrical tripping shall be
performed by shunt trip coils. However, provision shall be made for local electrical control. For this
purpose a local / remote selector switch and close and trip push buttons shall be provided in the breaker
central control cabinet. Remote located control switches and indicating lamps shall be provided in the
control panel by the purchaser.
iii)
Conveniently located manual emergency trip.
iv)
Anti-pumping feature.
v)
Auxiliary switches as specified elsewhere.
vi)
Independence of trip circuit from local remote selection.
vii)
Alarms, indications, monitoring equipments and interlocks as specified elsewhere.
viii) Trip circuit supervision for pre-trip as well as post-trip.

17.5.13.2 Closing coil shall operate correctly at all values of D.C voltage between 85% and 110% of
the rated control voltage and shunt trip coil shall operate correctly under all operating conditions of the
circuit breaker, up to the rated breaking capacity of the circuit breaker and at all values of D.C. control
voltage between 70-110% of rated voltage.
17.5.13.3 To safeguard against the failure of D.C. supply for control circuits, the capacitor tripping
device shall be provided. In case of D.C. supply failure the capacitor shall automatically discharge its
energy through the trip coil causing it to operate and trip, the breaker, except when the breaker is in
lockout condition due to low SF6 gas pressure.
17.5.13.4 A separate cabinet shall be provided for housing operating mechanism and control circuitry.
These control cabinets shall meet the requirements specified in clause No. 5.23.
17.5.13.5 The tenderer shall furnish along with the tender bid, detailed schematic drawings showing all
types of control, protection, monitoring schemes to be employed by the tenderer. The successful tenderer
shall be required to modify the schemes, if necessary, after discussions with the purchaser.
17.5.13.6
Auxiliary switches:
Each operating mechanism of the circuit breaker shall be provided with Cam / Snap type auxiliary
switches with ten (10) normally open and ten (10) normally closed contacts (10NO+10NC) contacts for
each breaker for 123KV, 72.5KV & 33KV rating, exclusively for the purchaser's use with continuous
current rating of 16A DC. Breaking capacity of the contacts shall be minimum 5A with circuit time
constant less than 20 milliseconds at the rated DC voltage. Normal position of auxiliary switches refers to
contact position when circuit breaker is open. There shall be provision to add more auxiliary switches at a
later date if required. Additional contacts required for pole discrepancy relay etc., should be provided
separately. The make of auxiliary switches shall be preferably of Siemens, Crompton Greaves Limited,
L&T and Alsthom make.
17.5.13.7
Alarms and Indications:
Potential free contacts shall be provided, duly wired up to the operating mechanism housing / control
cabinet for the following alarms and indications to be provided by the purchaser both on his control
panels and SCADA. To cater to this requirement, sufficient number of potencial free contacts shall be
provided.
a)
Alarms :
i)
General lockout for SF6 gas / air / oil / Nitrogen gas.
ii)
Low pressure of SF6 gas / low oil level.
iii)
Auxiliary AC / DC supply failure.
vi)
Low operating air pressure.
vii)
Low operating nitrogen / gas pressure.
b)
Indication :
i)
Breaker on / off
ii)
Spring charged
c)
Mechanical Indication:
The operating mechanism housing shall be provided with the following mechanical indication / counters
i)
Breaker on / off.
ii)
Operation counter to register the number of breaker operations.
17.5.13.8
INTERLOCKS:
It is proposed to electrically interlock the circuit breaker with Purchaser's air break isolating switches in
the switchyard in accordance with switchyard safety interlocking scheme. The details of the scheme shall
be furnished to the successful bidder. The requirement of auxiliary contacts to be pro vided in breaker
operating mechanism for successful operation of the scheme has been specified in clause 5.13.6.
17.5.14
MOUNTING:
17.5.14.1 The design and supply of support structure, required for mounting the circuit breaker in
Purchaser's switchyard, shall be in the bidder's scope. The bidder's scope shall also include foundation
bolts, nuts, plain washers, spring washers etc., necessary for the support structure. The support structure
can be lattice type or tubular type and shall be made out of hot dip galvanised steel. Wheel mounted type
support shall not be accepted. The support structure shall be installed on a concrete plinth of 300mm
height to be arranged by the Purchaser. The foundation plan for the breakers have been furnished in the
bid document. The mounting structures are to be designed suitable to foundation plans furnished. The
height of the support structure shall meet the following requirements.
i)
Vertical clearance of lowest live part as specified in clause 5.21.4.
ii)
Minimum height of 2200mm above the top of concrete plinth (This is a statutory regulation).
17.5.14.2 The circuit breaker shall be connected to adjacent equipment in the switchyard through
ACSR conductor. The maximum unsupported length of conductor on both sides of the Circuit Breaker is
10mtrs.
17.5.14.3 The loading data to be considered by the bidder for design of support structure shall include
the following:
i.
Dead weight of the circuit breaker, structure, Bus bars.
ii.
Operational steady state and impact loading.
iii.
Wind load on a circuit breaker, structure, Bus bars.
iv.
Short circuit forces.
The support structure shall be designed on the basis of applicable Indian / International standards and
codes of practice.
17.5.14.4 The foundation drilling plan shall be exactly in line with the details given in annexure. Thi s is
intended to ensure voltage class wise common foundation for circuit breaker irrespective of its make.
17.5.15
FITTINGS AND ACCESSORIES:
17.5.15.1 Following is a partial list of some of the major fittings and accessories to be furnished by
supplier in the central control cabinet. Number and exact location of these parts shall be indicated in the
bid
a)Central control cabinet in accordance with clause No.5.23 complete with
i)
Cable glands.
ii)
Local / remote changeover switch
iii)
Operation counter
iv)
Pneumatic / pressure gauges.
v)
Control switches to cut off control power supply.
vi)
MCBs / Fuses as required.
vii) The number of terminals provided shall be adequate enough to wire out all contacts and control
circuits plus 24 terminals spare for owner's use.
b)
Anti - pumping relay or anti - pumping contactor.
Pole discrepancy relay for 245KV brc)

year of manufacture.
Rating and diagram plate in accordance with IEC incorporating
17.5.15.2 Additional fittings for pneumatic & semi - pneumatically operated circuit breaker:
a)Unit compressed air system in accordance with Clause No. 5.12.8 (g).
b)
Breaker local air receivers.
c)
Pressure gauge spring loaded safety valve, pressure switch with adjustable contacts and explosion
vents.
d) Pressure switch to initiate an alarm if the pressure in the auxiliary reservoir remains below a preset
level for longer than it is normally necessary to refill the reservoir.
e) Stop, non-return and other control valves, piping and all accessories up to breaker mechanism
housing.
17.5.16
PAINTING:
17.5.16.1 All metal sheet surfaces exposed to atmosphere shall be given two primer coats of zinc
phosphate and two coats of epoxy paint with epoxy base thinner. All metal parts not accessible for
painting shall be made of corrosion resisting material. All machine finished or bright surfaces shall be
coated with a suitable preventive compound and suitably wrapped or otherwise protected. All paints shall
be carefully selected to withstand tropical heat and extremes of weather within the limits specified. The
paints shall be gray shade No. 631 of IS-5. The paint shall not scale off or wrinkle or be removed by
abrasion due to normal handling.
17.5.16.2 Paint inside the metallic housing shall be of anti-condensation type and the paint on outside
surfaces shall be suitable for outdoor installation.
17.5.16.3 All components shall be given adequate treatment of climate proofing as per IS : 3202 as to
withstand corrosive and severe service condition.
17.5.17
GALVANISING:
All ferrous parts including nuts, bolts, plain and spring washers of size M10 and above, support channels,
structures, etc., shall be hot dip galvanized to conform to latest version of IS : 2629 or any other
equivalent authoritative standard. All other fixing nuts, bolts, washers of size below M10 shall be electro
galvanized.
17.5.18
EARTHING:
The operating mechanism housing, dead tank, support structures etc., shall be provided with two
separate earthing terminals for bolted connection to 50x8mm GI flat to be provided by the purchaser for
connection to station earth mat. The connecting point shall be marked with "Earth" symbol No. 86 of IEC
publication 117-1 Part - I
17.5.19
NAME AND RATING PLATE:
17.5.19.1 Circuit breaker and its operating device shall be provided with rating plate/s made out of
Anodized Aluminum, marked with the following data. The data shall be either punched or engraved on the
plate/s.
a)
Manufacturer's name or trade mark by which he may be readily identified.
b)
Serial number and type designation of CB operating mechanism.
c)
Year of manufacture.
d)Rated Voltage.
e)Rated Lightning impulse withstand voltage.
f)
Rated Normal current.
g)
Rated short circuit breaking current.
h)
Rated Duration of short circuit.
i)
Mass of circuit breaker with support structure.
j)
Rated Auxiliary D.C. supply voltage of closing and opening devices.
k)
Rated pressure of compressed air/ gas.
l)
Rated out of phase breaking current.
m)
Rated A.C. supply voltage of auxiliary circuits.
n)
Rated Insulation level.
o)
Rated Frequency.
p)
Rated line charging breaking current and cable charging breaking current for EHV CBs.
q)
Purchase Order reference.
r)
Rated Operating sequence.
s)
Weight of SF6 gas per pole / breaker.
The ratings plates shall be installed in such positions that the same are clearly visible to a man standing
on ground.
17.5.19.2 Schematic diagram plate indicating the control circuit scheme shall be provided. The diagram
plate shall be of Anodised Aluminium plate and shall be installed in such a position that the same is
clearly visible to a man standing on ground.
17.5.20 The coils of operating devices shall be marked clearly with the catalogue number / reference
number as indicated in control wiring diagram.
17.5.21
TAKE OFF TERMINAL PADS:
17.5.21.1 Terminal pads shall be provided with silver plating of the least 25 microns thickness if these
are made of metal other than Aluminum. No such plating shall be required if the terminal pad is made out
of Aluminum. The pads shall be suitably designed to take the approximate terminal loads, specified
below.
17.5.21.2 The breaker shall be designed to withstand the rated terminal load, wind load / Earth quake
load and short circuit forces. The short circuit forces to be considered for the design shall be based on
length of bus bars consisting of conductors and phase to phase spacing shown below.
Voltage
Jumper length in mtrs.
220 KV
123 KV
72.5 KV
Max. 10 M
Max. 10 M
Max. 10 M
36 KV
Max.10 M
Size of ACSR
conductor
Drake
Drake
Drake /
Drake
Drake / Lynx
Phase to phase spacing

in mts.
220 / 110 / 66 / 33KV
Stations
2.00/2.70
2.00/2.70
Twin
2.00
1.50
17.5.21.3 The current density adopted for the design of the terminal pad shall in no case exceed
1.6A/sq. mm for copper pad and 1.0A/sq. mm for pad made of other material.
17.5.21.4 The vertical clearance of lowest live part of the breaker (i.e., not the center of the terminal
pad) from ground level (including concrete foundation plinth) shall be as given below. In no case the
height less than that indicated will be accepted.
123 KV Breaker -
4600 mm.
72.5 KV Breaker -
4250 mm
36 KV Breaker - 4000 mm
17.5.22
TERMINAL CONNECTORS:
17.5.22.1 The terminal connectors required for connecting circuit breaker to other equipments for
mounting on aforesaid terminal pad shall meet the following requirements.
a)
Terminal connectors shall be manufactured and tested as per IS: 5561.
b) All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and
corners shall be blurred and rounded off.
c)
Pad part of a clamp shall not be less than 10mm thick
d)
All ferrous parts shall be hot dip galvanized conforming to IS: 2633.
e) For bimetallic connectors, copper alloy liner of minimum thickness of 2mm shall be cast i ntegral
with Aluminum body. Current density adopted for design of pad shall be 1.6A / 1A per sq. mm for copper
/ Aluminum respectively.
f)
Flexible connectors shall be made from tinned copper.
g)
All current carrying parts shall be designed and manufactured to have minimum contact resistance.
h)
Connectors shall be designed to be corona free in accordance with the requirements stipulated in
IS : 5561.
i)
Terminal connectors shall be suitable for receiving ACSR conductors as detailed in Clause No.
17.5.21.2.
17.5.23
CONTROL CABINETS:
The Control cabinet shall conform to the following requirement.

a)
Control cabinets shall be free standing floor mounting type.
b) Control cabinets shall be sheet steel enclosed and shall be dust, water and vermin proof. Control
cabinets of the operating mechanism shall be made out of 4mm HR thick sheet steel or equivalent CR
sheet steel or 10mm thick aluminum plate or casting. There shall be sufficient reinforcement to provide
level surfaces, resistance to vibrations and rigidity during transportation and installation. Control cabinets
shall be provided with double hinged door and padlocking arrangement. The door shall be provided with
handle for opening / closing. The door hinges shall be of union joint type to facilitate easy removal a nd
the distance between hinges shall not exceed 350mm. Door shall be properly braced to prevent wobbling.
Sloping rain-hood shall be provided to cover all sides. 15mm thick neoprene or better type of gaskets
shall be provided to ensure degree of protection of at least IP : 55 as per IS 2147.
c)
Equipment and devices shall be suitable for operation on specified auxiliary AC / DC supply
system.
d) Motors rated 1KW and above being controlled from the control cabinet would be suitable for
operation on a 415V, 3 phase, 50Hz system. Fractional KW motors would be suitable for operation on a
240V, single phase, 50Hz AC supply system.
e) Push button shall be rated for not less than 16Amps, 415Volts AC or 5Amp, 230V / 110V DC with 2
NO + 2 NC contacts and shall be flush mounted on the cabinet door and provided with appropriate name
plates.
f)
For motors up to 5KW, contactors shall be direct-on-line, air break, single throw type and shall be
suitable for making and breaking the stalled current of the associated motor which shall be assumed
equal to 6.5times the full load current of the motor at 0.2 p.f. For motors above 5KW, automatic star delta
type starters shall be provided. 3 pole contactors shall be furnished for 3 phase motors and 2 pole
contactors for single phase motors. Reversing contactors shall be provided with electrical interlocks
between forward and reverse contactors. If possible, mechanical interlocks shall also be provided.
Contactors shall be suitable for uninterrupted duty and shall be of duty category class AC4 as defined in
IS : 2959. The main contacts of the contactors shall be silver-plated and the insulation class for the coils
shall be class E or better.
The dropout Voltage of the contactors shall not exceed 70% of the rated voltage.
g) Contactor shall be provided with a three element, positive acting ambient temperature
compensated, time lagged, hand reset type thermal over load relay with adjustable setting. Hand reset
button shall be flush with the front door of the cabinet and suitable for resetting with starter compartment
door closed.
h)
Single phasing preventor relay shall be provided for 3 phase motor, to provide positive protection
against single phasing.
i)
Mini starters shall be provided with no volt coils when required.
j)
Power cables will be of 1100 volt grade, standard copper conductor, PVC insulated, PVC sheathed
single steel wire armoured and PVC jacketed. All necessary cable terminating accessories such as
glands, crimp type tinned copper lugs etc. for power as well as control cables shall be included in bidder's
scope of supply. Suitable brass cable glands shall be provided for cable entry.
k)
Wiring for all control circuits shall be carried out with 1100 Volts grade PVC insulated tinned copper
stranded conductors of sizes not smaller than 2.5sq. mm. At least 10% spare terminal blocks for control
wire terminations shall be provided on each panel. The terminal blocks shall be of non-disconnecting stud
type. All terminals shall be provided with ferrules indelibly marked or numbered and these identifications
shall correspond to the designations on the relevant wiring diagrams. The terminals shall be rated for
adequate capacity, which shall not be less than 10 Amps. Terminals for receiving purchaser's cables
should be marked or numbered.
l)
Control cabinet shall be provided with 240V, 1 phase, 50Hz, 20W fluorescent lighting fixture with
On / Off switch and 240V, 1 phase, 15Amp, 3 pin socket for hand lamp, with electrical & mechanical
cover with chain.
m) Suitable strip heaters shall be provided inside cabinet with thermostat to prevent moisture
condensation. Heaters shall be controlled by suitable toggle switch of industrial quality.
n)
All AC control equipment shall be suitable for operation on 240V, 1 phase, 2 wire, 50Hz system.
o)
Items inside the cabinet made of organic material shall be coated with a fungus resistant varnish.
17.6 TESTS :
17.6.1 Type Tests :
17.6.1.1 The Circuit Breakers offered shall be fully type tested as per the relevant standards. The
equipment offered if not type tested will be rejected. These tests must have been conducted not later than
five years from the date of bid opening. In case the equipment of the type and design offered, has already
been type tested, the tenderer shall furnish four sets of the type test reports along with the offer. In case
these type tests are conducted later than five years. All the type tests as per the relevant standards shall
be carried out by the successful bidder in the presence of purchaser's representative at free of cost and
no charges shall be paid by the owner. The purchaser reserves the right to demand repetition of some or
all the type tests in the presence of his representatives even though the type test reports are less than 5
years old on the day of bid opening. For this purpose, the bidder may quote unit rates for carrying out
each type test in the relevant schedule. The prices quoted by the tenderer towards conductance of type
tests and additional tests shall be taken into consideration for bid evaluation. For any change in the
design / type already type tested and the design / type offered against this specification, the purchaser
reserves the right to demand repetition of tests without any extra cost.
17.6.1.2 The following constitute the type tests :
1)
Short circuit making and breaking tests including terminal fault tests, short line fault tests.
2)
Capacitive current tests.
3)
Small inductive current tests
4)
Mechanical endurance tests.
5)
Dry power frequency test.
6)
Wet power frequency test.
7)
Lightning impulse test,
8)
Temperature rise test.
17.6.1.3 The following additional type tests are proposed to be conducted. The type test charges for
these tests shall be quoted along with other type tests as per IEC -62271 -100 in the relevant schedule
and the same shall be included in the total bid price.
i)
Corona extinction voltage test
ii)
Out of phase closing test as per IEC-60267 and IEC-62271.
iii)
Line charging breaking current test as per IEC -62271.
iv)
Cable charging breaking current as per IEC-52271
v)
Seismic withstand test in un-pressurized condition
17.6.2 ACCEPTANCE AND ROUTINE TESTS:

17.6.2.1 All acceptance and routine tests as stipulated in IEC -62271 shall be carried out by the supplier
in the presence of Purchaser's representative.
The following constitute routine tests:
a)
Power frequency voltage withstand dry test on main circuit.
b)
Voltage withstand tests on control & auxiliary circuits.
c)
Measurement of resistance of main circuit.
d)
Mechanical operating tests.
e)
Design and visual checks.
17.6.2.2 In addition to the mechanical and electrical tests specified by IEC, the following shall also be
performed.
Speed curves for each breaker shall be obtained with the help of a suitable operation analyser to
determine the breaker contact movement during opening, closing, auto re -closing and trip-free operation
under normal as well as limiting operating conditions (control voltage pneumatic pressure etc.). The tests
shall show the speed of contacts directly at various stages of operation, travel of contacts, opening time,
closing time, shortest time between separation and meeting of contacts at break / make operation etc.
This test shall also be performed at site for which the necessary operation analyser along with necessary
transducers, cables, console, etc., shall be furnished as mandatory maintenance equipment.
17.6.2.3 Immediately after finalization of the Programme of type/ acceptance / routine testing, the
supplier shall give sufficient advance intimation to the purchaser to enable him to depute his
representative for witnessing the tests.
17.6.3 ADDITIONAL TESTS
The purchaser reserves the right for carrying out any other tests of a reasonable nature at the works of
the supplier / laboratory or at any other recognized laboratory / research institute in addition to the above
mentioned type, acceptance and routine tests at the cost of the purchaser to satisfy that the material
complies with the intent of this specification.
17.7 INSPECTION:
17.7.1 The inspection may be carried out by the Purchaser or his representative at any stage of
manufacture. The successful tenderer shall grant free access to the purchasers representative /s at a
reasonable notice when the work is in progress. Inspection and acceptance of any equipment under this
specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in
accordance with the specification and shall not prevent subsequent rejection if the equipment is found to
be defective.
17.7.2 The supplier shall keep the purchaser informed in advance, about the manufacturing
Programme so that arrangement can be made for stage inspection.
17.7.3 The purchaser reserves the right to insist for witnessing the acceptance/routine testing of the
bought out items. The supplier shall keep the purchaser informed in advance, about such testing
programme.
17.7.4 No material shall be dispatched from its point of manufacture unless the material has been
satisfactorily inspected and tested unless the same is waived by the purchaser in writing.
17.8 QUALITY ASSURANCE PLAN :
17.8.1 The tenderer shall invariably furnish following information along with his offer, failing which his
offer shall be liable for rejection. Information shall be separately given for individual type and voltage
rating of circuit breaker :
i)
Statement giving list of important raw materials, including but not limited to
a) Contact Material
b) Insulation
c) Porcelain
d) Oil
e) Sealing Material
f)
Contactor, limit switches etc., in control cabinet.
Names of sub-suppliers for the raw materials, list of standards according to which the raw-materials are
tested, list of test normally carried out on raw materials in presence of purchasers/tenderers
representative, copies of test certificates.
ii)
Information and copies of test certificates as in (i) above in respect of bought out accessories.
iii) List of areas in manufacturing process, where stage inspections are normally carried out by the
purchaser / tenderer for quality control and details of such tests and inspections.
iv)
Special features provided in the equipment to make it maintenance free.
v)
List of testing equipment available with the bidder for final testing of breakers vis --vis, the type,
special, acceptance and routine tests specified in the relevant standards. The limitations in testing
facilities shall be very clearly brought out in the relevant schedule i.e., schedule of deviations from
specified test requirements.
17.8.2 The successful tenderer shall, within 30 days of placement of order, submit following information
to the purchaser.
i)
List of raw-materials as well as bought out accessories and the names of sub -suppliers selected
from those furnished along with offer.
ii)
Type test certificates of the raw-material and bought out accessories.
iii) Quality assurance plan (QAP) with hold points for purchasers inspection. The quality assurance
plan and purchaser hold points shall be discussed between the purchaser and supplier before the QAP is
finalised.
17.8.3 The supplier shall submit the routine test certificate of bought out items and raw-material, at the
time of routine testing of the fully assembled breaker.
17.9 DOCUMENTATION AND DRAWINGS :
17.9.1 Documentation:
All drawings shall conform to relevant international standard organization (ISO) specification. All
drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in System
International Units.
17.9.2 Drawings:
The Tenderer shall furnish four sets of relevant descriptive and illustrative published
literature/pamphlets and the following drawings/documents for preliminary study.
a)
General outline drawings showing outside dimensions, shipping dimensions, weights, quantity of
insulating media, air receiver capacity and such other prominent de tails.
b) Sectional views showing the general constructional features of the circuit breaker including
operating mechanism, arcing chambers, contacts, with lifting dimensions for maintenance.
c)
Schematic diagrams of the scheme for control, supervision and re -closing.
d)
Structural drawing, design calculations and loading data for support structures.
e)
Foundation drilling plan and loading data for foundation design.
f)
Type test reports of circuit breakers.
g)
Test reports, literature and pamphlets of bought out items and raw materials.
h)
Guarantied technical particulars of circuit breakers.
17.9.3 The supplier shall, within two weeks of placement of order, submit four sets of final versions of all
the above said drawings/documents for purchasers approval. The purchaser shall communicate his
comments/approval on the drawings/documents to the supplier within reasonable period. The supplier
shall, if necessary, modify the drawings/documents and resubmit four copies of the modified drawings for
purchasers approval within two weeks from the date of purchasers comments. After receipt of
purchasers approval, the supplier shall, within three weeks, submit 20 prints duly laminated and two
good quality reproducible of the approved drawings.
17.9.4 The supplier shall furnish twenty copies of bound manual covering erection, commissioning,
operation and maintenance instructions and all relevant information and drawings pertaining to the main
equipment as well as auxiliary devices. Marked erection drawings shall identify the component parts of
the equipment as shipped to enable Engineer/Purchaser to carryout erection with his own personnel.
Each manual shall also contain one set of all the approved drawings, type test reports and as well as
acceptance test reports to corresponding consignment dispatched .
17.9.5 The manufacturing of the equipment shall be strictly in accordance with the approved drawings
and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and
fabrication work in connection with the equipment prior to the approval of the drawings shall be at the
suppliers risk.
17.9.6 Approval of drawings/documents/work by the purchaser shall not relieve the supplier of any of
his responsibility and liability for ensuring correctness and correct interpretation of the
drawings/documents for meeting the requirements of the latest revisions of applicable standards, rules
and codes of practices.
17.10 TEST REPORTS:
i)
Four copies of type test reports shall be furnished to the purchaser within one month of conducting
the tests. One copy will be returned duly certified by the purchaser to the supplier within three weeks
thereafter and on receipt of the same, supplier shall commence with the commercial production of the
concerned material.
ii)
Four copies of acceptance test reports shall be furnished the purchaser. One copy will be returned,
duly certified by the purchaser and only there afterwards shall the material be dispatched.
iii) All works of routine test reports shall be maintained by the supplier at his works for periodic
inspection by the purchaser.
iv) All test reports of tests conducted during manufacture shall be maintained by the supplier. These
shall be produced for verification as and when requested for by the purchaser.
17.11.1 The equipment shall be packed in crates suitable for vertical/horizontal transport as the case
may be and suitable to withstand handling during transport and outdoor storage during transit. The
supplier shall be responsible for any damage to the equipment during transit, due to improper and
inadequate packing. The easily damageable material shall be carefully packed and marked with the
appropriate caution symbols. Wherever necessary, proper arrangement for lifting, such as lifting hooks
etc., shall be provided. Any material found short inside the packing cases shall be supplied by supplier
without any extra cost.
17.11.2 Each consignment shall be accompanied by a detailed packing list containing the following
information:
a. Name of the consignee.
b. Details of consignment.
c. Destination.
d. Total weight of consignment.
e. Sign showing upper/lower side of the crate.
f.
Handling and unpacking instructions.
g. Bill of materials indicating contents of each package and spare materials.

The supplier shall ensure that the packing list and bill of materials are approve d by the purchaser before
dispatch.
17.12 RECOMENDED SPARES:
The tenderer shall furnish in his offer, a list of recommended spares with unit rates for each circuit
breaker that may be necessary for satisfactory operation and maintenance of the circuit breaker fo r a
period of 5 years. The Purchaser reserves the right of selection of items and quantities of these spares to
be ordered. The cost of such spares shall not be considered for tender evaluation. The unit prices should
be valid for two years from the date of issue of detail A/T.
VOLUME IIA
SECTION 4(B)
CHAPTER : CHAPTER SURGE ARRESTORS
VOLUME - IIA
SECTION 4 (B) :
CHAPTER SURGE ARRESTORS
Particulars
General
Duty requirements
Constructional features
Fittings and Accessories
Tests
Spare parts
Parameters
Testing and Commissioning
VOLUME IIA
Section 4 (B)
CHAPTER- SURGE ARRESTERS
18.1
GENERAL
18.1.1 Qualifying Requirements please refer Vol- I Section IFB.

18.1.2 The surge arresters shall conform to IEC :60099 except to the extent modified in the specification
and shall also be in accordance with requirements under section 1 and 2.
18.1.3 Arresters shall be of hermetically sealed units, self-supporting construction, suitable for mounting
on tubular / lattice type support structures to be supplied by the Contractor.
18.2 DUTY REQUIREMENTS:
a.
The surge arresters shall be of heavy - duty station class and gapless type (i.e., metal oxide type)
without any series or shunt gaps.
b.
The surge arresters shall be capable of discharging over voltages occurring during switching of
unloaded transformers and long lines.
c.
Void.
d.
96kV, 60kV, 30kV and 9kV class arresters shall be capable of discharging energy equivalent to
class 2 of IEC for 123kV, 72.5kV, 36kV and 12kV system for two successive operations.
e.
The surge arresters shall be suitable for withstanding forces as defined section - 2.
f.
The reference current of the arresters shall be high enough to eliminate the influence of grading
and stray capacitance on the measured reference voltage.
g.
The surge arresters are being provided to protect the following equipment whose insulation level
are indicated in the table give below:
Equipment to Lightning
be protected
impulse(KVp)
for 123
KV
system
1
Power
transformer
Instrument
Transformer
CB/Isolator
phase to ground
Across
open
contacts
Lightning
impulse(KVp)
for 72.5 KV
KV system
Lightning
impulse(KVp) for
36 KV system
550
325
170
550
325
170
550
325
170
----
-----
----
h.
The duty cycle of CB proposed to the installed in 123KV / 72.5KV / 36KV System is 0-0.3Sec. CO
- 3Min - CO. The surge arrester shall be suitable for such circuit breaker duties in the arrester shall be
suitable for such circuit breaker duties in the system.
18.3
CONSTRUCTIONAL FEATURES:
The feature and constructional details of surge arresters shall be in accordance with requirement
stipulated hereunder:
a)
The non - linear blocks shall be of sintered metal oxide material. These shall be provided in such a
way as to obtain robust construction, with excellent mechanical and electrical properties event after
repeated operations.
b) The surge arresters shall be fitted with pressure relief devices suitable for preventing shattering of
porcelain housing and providing path for flow of rated faults cur-rents in the event of an-ester failure.
Details shall be furnished in the bids along with quality checks.
c)
The arresters shall not fail due to arrester, porcelain contamination.
d) Seals shall be provided in such a way that these am always effective ly maintained even when
discharging grated lightning current.
e) Outer insulator shall be porcelain conforming to requirements stipulated in Section - 2 (GTR).
Terminal connectors shall conform to requirements stipulated under section - 2 (GTR).
Porcelain housing shall be so coordinated that external flashover will not occur due to application of any
impulse or switching surge voltage up to the maximum design value for arrester.
f)
The end fittings shall be made of nonmagnetic and corrosion proof material and preferably, be
nonmagnetic.
g)
The nameplate shall conform to the requirements of IEC incorporating the year of manufacture.
h)
The heat treatment cycle details along with necessary, quality checks used for individual blocks
along with insulation layer formed across each block are to be furnished. Metalizing coating thickness for
reduced resistance between adjacent discs is to be furnished with additional information schedule of bid
proposal sheets along with procedure for checking the same. Details of thermal stability test for uniform
distribution of current on individual disc is to be furnished.
i)
The manufacturer will submit data for rejection rate of ZnO blocks during manufacturing/ operation
for the past three years.
18.4
FITTINGS AND ACCESSORIES:
a)
198 KV , 96 KV / 60 KV / 30 KV / 9 kV arresters shall be complete with insulating base having
provision for bolting to flat surface of structure.
b) Self contained discharge counters, suitably enclosed for outdoor use and requiring no auxiliary or
battery supply for operation shall be provided for each single pole unit along with necessary connection.
Suitable leakage current meters should also be supplied within the same enclosure. The reading of milli ammeter and counters shall be visible through an inspection glass panel. The terminals shall be robust
and of adequate size and shall be so located that incoming and outgoing connections are made with
minimum possible bends. The design of the surge monitor shall be such that it is possible to tilt the surge
monitor downwards by an angle of up to 45 from Horizontal plane.
c)
Surge monitor consisting of Discharge counters and milli-ammeters should be suitable to be
mounted on support structure of the arrester and should be tested for IP : 55 degree of protection. The
standard supporting structure for surge arrester should be provided with a standard mounting pad, for
fixing the surge monitor. The surge monitor should be suitable for mounting on this standard mounting
pad. Also all nuts, bolts, washers etc., required for fixing the surge monitor shall have to be supplied by
the Contractor.
d) Grading / Corona rings shall be provided on each complete an-ester unit as required. Suitable
terminal connectors shall be supplied by the contractor.
18.5
TESTS:
18.5.1 Type tests : Type tested equipments shall be offered. The type test reports shall not be older than
five ( 5 ) years on the day of bid opening. The type tests are to conducted again with out any extra cost to
the owner in case the type test reports are older than five ( 5 ) years on the day of bid opening. The type
test charges are to be indicated in the schedule. The owner reserves right to insist for conducting all or a
few type tests even though the type tests are less than five (5) years old on the day, of bid opening, the
payment in such cases will be made as per the rates in the schedule.
In accordance with the requirements stipulated under section 1 & 2 the surge an-esters should have been
type tested as pr IEC / IS . They shall also be subjected to routine and acceptance tests in accordance
with IEC document. In the switching surge operating duty test, the samples shall be pre heated to 70 C
(instead of 60 C as given in IEC) prior to application of long duration surges for contamination test
procedures outlined in ANSI - 062 - 11 - 1987 may be followed until IEC brings out alternate test
procedure for the same.
The contractor shall submit type test procedures along with the bid each metal oxide block of surge
arresters shall be tested for the guaranteed specific energy capability- in addition to the routine
acceptance test as per IEC - 60099.
18.5.2 a)
Acceptance Tests :
1.
Measurement of power frequency reference voltage of the arrester units.
2.
Lightning Impulse residual voltage on arrester units (IEC clause 6.3.2).
3.
Internal lonisation or partial Discharge test.
b)
Special Acceptance Test;
1.
Thermal stability test on three sections (IEC 7.2.2)
2.
Aging & Energy capability test on blocks (Procedure to be mutually agreed)
3.
Wattloss test
c)
Routine tests :
1.
Measurement of Reference voltage
2.
Residual voltage test of arrester unit.
3.
Internal Ionization test or partial discharge test.
4.
Sealing test.
5.
Verticality checks on completely assembled surge arresters as a sample test on each lot.
d)
Test on surge monitors ;
The surge monitors shall also be connected in series with the test specimens during residual voltage and
current impulse withstand tests to verify efficacy of the same. Additional routine / functional tests with one
100 A and 10 KA current impulse, ( 8 / 20 micro sec.) shall also be performed on the surge monitor.
e)
Test on insulators :
All routine tests shall be conducted on the hollow column insulators as per IEC - 60233.
18.6
SPARE PARTS:
Bidder shall include in his proposal spare parts as mentioned in Sections - 1 & 2.
18.7
PARAMETERS :
A.
SURGE ARRESTER:
a)
Rated arrester voltage KV
b)
60
30
10KA
10KA
10 KA 10 KA
Nominal discharge
Current of 8 / 20 micro sec wave
c)
96
Minimum discharge capacity

5kJ / KV (referred to rated arrester Voltage
corresponding to minimum Discharge Characteristics
d)
Continuous operating voltage at

50 deg C KV
e)
50
25
7.5
272
175
85
---
Max. switching surge

residual voltage (1 KA) kVp
f)
81
Max. residual voltage kVp at

i) 5 KA
560 kVp
ii)10 KA nominal discharge

current (kVp)
g)
j)
650 kVp
Long duration discharge

class
i)
195
Max. steep current impulse

residual voltage at l0 kA
h)
600
test value (4/ 10 micro
100
100
100
----
second wave)
kAp
kAp
kAp
----
31.5
31.5
25
----
High current short duration
Current for pressure relief

test KA RMS
k)
Low current long duration

test value (2000 micro sec)
--------- As per IEC ------------------------------
l)
Pressure relief class
--------------A-------------------------------------
m)
Installation
Outdoor
n)
Class
Station
Station
o)
Minimum creepage
3075
1815
Terminal Connector
Drake
Lynx/
Suitable for ACSR
Drake
/Rabbit
distance for arrestor
Outdoor
Outdoor
Outdoor
Station Station
900
300
housing (mm)
p)
Coyote Coyote
Conductor Size
q)
Take Off
---------------------Vertical or Horizontal ---------------------
r)
Connection
---------------------Phase to Earth------------------------------
Note :- In isolated OR unearthed Neutral system, the voltage rating of the S.A. should be 110% of the
nominal voltage in the case of capacitor bank.
18.8
TESTING AND COMMISSIONING:
An indicative list of tests is given below. Contractor shall perform any ad ditional test based on specialties
of the items as per the Field Quality Program / Instruction of the equipment supplier or owner without any
extra cost to the owner. The contractor shall arrange all instruments required for conducting these tests
along, with calibration certificates and shall furnish the list of instruments to the owner for approval.
a)
Leakage current measurement
b)
Resistance of ground connection.
VOLUME IIA
SECTION 4(C)
CHAPTER : CHAPTER ISOLATORS
VOLUME IIA
SECTION 4 (C)
CHAPTER : CHAPTER ISOLATORS
PARTICUALRS
PART-I
SCOPE
LOCATION
SERVICE CONDITION
GOVERING SPECIFICAION
RATING AND OTHER PARTICULARS
PART II
TYPE OF DISCONNECTS.
CURRENT DENSITY.
DESIGN AND CONSTRUCTION.
PART-III
TESTS.
INSPECTION
DOCUMENTATION.
PACKING AND FORWARDING.
VOLUME - IIA
SECTION 4 (C) (ISOLATORS)
SECTION i : TECHNICAL SPECIFICATION FOR 220 KV /110kV / 60kV / 33kV
AIR BREAK ISOLATORS
PART I
19.1
SCOPE
19.1.1 This specification covers design, manufacture, testing and supply of following voltage and current
class of isolators.
a)
Void.
b)
Manually operated (i) 220 KV, 1250 Amps, (ii) 66KV, 1250Amp and (iii) 33 KV, 800 Amps
The type of mounting and the provision of earth switch shall be as follows
a)
Upright mounting type with manually operated earth switch
b)
Upright mounting type without earth switch.
c)
Under hung mounting type without earth switch.
19.1.2 The isolator shall be of the manual operated type with and without earthing switches and shal l
complete with all parts and accessories including insulator operating rods, mounting attachments,
necessary for their efficient operation.
19.1.3 The earthing blades shall be of the manually operated type are shall be complete with all parts
and accessories including mounting attachment, operating rod, operating mechanism box etc., necessary
for the efficient operation.
19.1.4 It is not the intent to specify completely herein. All details of the design and construction of
equipments, however the equipment shall confirm in all respect to high standards of engineering
mentioned in clause No. 4.0 design and workmanship and shall capable of performing in continuous
commercial operation up to the suppliers guarantee in. a manner acceptable to the purchaser, who will
interpret the meanings of drawing and specification and shall have the powers to reject any work or
material which, in his judgment, is not in accordance therewith. The equipment offered shall be complete
with all components necessary for its effective and trouble free operation along with associated
equipments, interlock, protection schemes, etc. Such components shall be deemed to be within the scope
of bidder's supply irrespective of whether those are specifica.11N, brought out in this specification and /
or the commercial order or not. All similar parts particularly removable ones shall be interchangeable.
19.1.5 1.05
19.2
The isolator shall be suitable for Local manual control.
LOCATION
19.2.1 The isolators are required at sub stations specified above, where the operating conditions i.e.,
height of live point and phase to phase dimensions, will vary quite considerably from location to location.
19.3
SERVICE CONDITIONS:
19.3.1 The 220 KV / 66 KV triple pole air break isolators are intended to be used primarily with
associated circuit breakers for sectionalizing lines, and transformers
19.3.2 The earthing blades are intended to be provided on the line/Capacitor sectionalizing isolators for
solidly ear-thing, each of the phase conductor of the line before any repair / maintenance work on the
transmission line is undertaken.
19.3.3 ATMOSPHERIC CONDITIONS
Please refer to meteorological data Annexure - II, Volume - II.
19.4
GOVERNING SPECIFICATION:
21.4.1.4 The isolator shall unless otherwise specified, generally conform the IS : 9921 (Part I to IV) - 1985,
which shall be applied in the manner altered, amended or supplemented by this specification, the latest
Indian Electricity Rules wherever applicable.
21.4.1.5 Any deviation from this specification offered to improvement performance, utility and efficiency of
equipment proposed by the bidder will be given due consideration, provided full particular with justification
thereof are furnished.
21.4.1.6 In the preparation of this specification, details have been taken from IEC 600 - 129 "alternating
current disconnects (Isolators) and earthing switches", and IS 9921 (Part-I to IV) "Specification for
alternating current disconnects (isolators) and earthing switches for voltages above 1000V .
21.4.1.7 Equipment meeting with the stipulations of equivalent IEC, ANSI, CSA, DIN standards which
ensure equal or better quality than the standards listed in Clause No. 4.05, shall also be acceptable. In
such case the bidder should submit along with this offer, two copies of such standards, in authentic
English translation, if the language of the standard is other than English. In case of dispute, the
stipulations in English translation, submitted by the bidder shall prevail. Further, in the event of conflict
between the stipulations of the standard adopted be the bidder, corresponding Indian Standard
specification shall prevail.
21.4.1.8 In this specification reference has been made to the following Indian standard and other
specifications.
i)
IS : 9921-85
Part-I, II, III & IV)
ii)
Specification for alternating current Disconnects (isolators) and

ear thing switches for voltages above 1000V.
a) IS: 2544-1973 &

b) IS : 5350-1970
Porcelain post insulators for systems with

nominal voltage greater than 1000V.
iii)
IS : 7608
Phosphor bronze wires (for general engineering purposes)
iv)
IS : 2108-1977 -
Black hard malleable iron castings
v)
IS : 1570 (Part - IQ- 1979
Carbon steel (unalloyed steels)
vi)
IS : 2071
General definitions, test requirements & test
(Part-I & ll)-1974
procedures.
vii)
IEC: 600129
Alternating current disconnects (isolators) and earthing switche s
viii)
IS : 7906
Helical compression springs
(Part-Ill)-1975
ix)
IS: 5561 1970 -
Electric power connectors
x)
IS: 996-1979
Single phase small AC and Universal electric motors.
xi)
IS: 5358-1969
Galvanizing of ferrous parts.
xii)
IS : 2633
Method of testing conformity of coating of zinc coated articles.
19.5
RATING AND OTHER PARTICULARS
19.5.1 The isolators shall be designed for the following rating and other particulars.
No.
i
Type
ii
iii
iv
v
vi
vii
viii
ix
Particualrs
110KV
manually
operated
Double
break,
upright mounting
with
the
movement of the
blade
in
a
horizontal plane
suitable
for
outdoor
installation.
No. of poles (Phases)
Three
Rated Voltage
123KV
Rated normal current
2000/1250A
Rated frequency
50 Hz
System neutral earthing
.. effectively
earthed
Rated short time withstand 31.5KA (rms) for
current of main switch and
3 secs
earth switch
Rated peak withstand current
2.5 times the
rated short time
withstand current
Rated 1.2/50 micro second
impulse withstand voltage
(peak)
66KV
manually
operated
Double
break,
upright mounting/
with
the
movement of the
blade
in
a
horizontal plane
suitable
for
outdoor
installation
Three
72.5KV
2000/1250A
50 Hz
.. effectively
earthed
31.5KA (rms) for
3 secs
33KV
manually
operated
Double break,
upright mounting
with
the
movement of the
blade
in
a
horizontal plane
suitable
for
outdoor
installation
Three
36KV
800A
50 Hz
.. effectively
earthed
25KA (rms for
3secs
2.5 times the

rated short time
withstand current
2.5 times the

rated short time
withstand
current
No.
Particualrs
a) to earth
b) across
distance
isolating
xi
Operating time of the isolator
xiii
Temperature rise
110KV
550kv
66KV
325kv
33KV
170kv
630kv
375kv
195kv
--shall not exceed --shall not exceed

10 seconds-10 seconds-Max.
Temp deg.C
Max.
Temp deg.C
--shall not
exceed 10
seconds-Max.
Temp deg.C
105
105
105
75
75
75
105
90
105
90
105
90
The temperature
shall not exceed
a value, where
the elasticity of
the materials is
impaired.
For
pure copper the
temp. limit is
75deg. C
The temperature
shall not exceed
a value, where
the elasticity of
the materials is
impaired.
For
pure copper the
temp. limit is
75deg. C
5 minutes
5 minutes
30 minutes
30 minutes
30 minutes
3075
1815
840
51
17.33
40.76
13.26
35
13.26
a. Copper contacts in air

i. Silver faced
Copper
ii. Bare copper
b. Terminal of isolator to
be connected to
external conductors
by bolts
i. Silver faced copper
ii. Bare copper
xiii
The temperature
shall not exceed
c. Metal parts acting as
a value, where
springs
the elasticity of
the materials is
impaired.
For
pure copper the
temp. limit is
75deg. C
Safe duration of over load
a. 150 % of
rated current
5 minutes
b. 120%
of
rated current
xiv
xv
Minimum creepage distance

(mm)
Rated mechanical terminal
load
a. Straight load (Kgf)
No.
Particualrs
b. Across load (Kgf)
110KV
66KV
33KV
xvi
Phase to Phase spacing for

installation(mm)
Height of center line of
terminal pad above ground
level (mm)
2000 / 2700
2000
1500
4600
4250
4000
xvii
19.5.2 The isolator will be called upon to close or interrupt the charging current drawn by bus bars,
breakers and similar equipments. The bus selectors and by pass isolators will be used to change over the
line connection from main bus bar to duplicate bus bar without the interruption of power supply, in the
event of outage of line circuit breakers. Hence isolators should be capable of closing or interrupting a
current of magnitude indicated in 5.01 (iv) above.
19.5.3 RATING AND OTHER PARTICULARS FOR EARTHINS SWITCHES:
19.5.3.1 The earthing blades shall be designed for the following rating and other particulars.
i.
Type
Manually operated, vertically
mounted, vertical air break type,

suitable for outdoor installation.
ii.
Rated Voltage
Associated with respective
123KV, 72.5KV, 36 KV rated voltage isolators.

iii.
Rated frequency
50 Hz.
iv.
No. of poles(phases)
three
v.
Rated short time withstand current a) 31.5KA (rms) for 3 secs for 123KV and 72.5 KV systems
b) 25 KA for 3 secs for 33 KV system
vi.
Rated peak withstand current
2.5 times the rated short time withstand current.
19.5.3.2 Isolators provided with ear thing blades shall have a set of contacts so as to effectively earth
the fixed contact of the isolator, when the ear thing blade is closed. The earth blade and its contacts shall
be capable of carrying the same rated peak short circuit current and the rated short time current as
applicable to the main isolator. The earth switch fixed contact shall be identical to that of main isolator
fixed contact. The moving contacts shall also be made of electrolytic copper. The ear thing of the blades
shall be effected by flexible copper blades, liberally rated to carry the full short circuit current specified in
clause 5.01 (vii viii)
19.5.3.3 The eathing blades of all poles of the isolator shall be mounted on the same shaft and shall be
operated by a single and common operating handle which shall be distinct from the one for the main
switch of the isolator. The blades of all poles shall fasten simultaneously into all fixed contacts.
19.5.4 CLEARANCE:
19.5.4.1 The clearance between live parts and ground structure shall not be less than those specified in
the IS 10118, part III, 1982. The length of break in full open position should be such that there is
absolutely, no possibility of arc over from the live parts to the de -energized parts on which any
maintenance work have to be done. The speed of opening or closing the switch shall be designed to
ensure that the arcing during the operation is reduced to the minimum.
Part - II
ISOLATORS
20.1 TYPE OF ISOLATORS :
The ISOLATORS shall be of three phase gang operated horizontal, double break type with turn and twist
type moving blades and with or without gang operated vertical break earth blades as per requirements.
20.2 CURRENT DENSITY:
Current density, to be adopted, for all parts of isolator and terminal connector shall not exceed the
following limits.
a)
Hollow tube sections
b)
Other sections and
Copper
2.0 A / Sq. mm
terminal connectors
Copper
1.6 A/Sq. mm
Aluminium
1.0 A/Sq. mm
20.3 DESIGN AND CONSTRUCTION :

20.3.1 Qualifying Requirements : Please refer Vol I, Section IFB
The full particulars of design, manufacture, template and quality control devices developed for
manufacture of the equipments - offered in respect of the following items shall be furnished with drawings
and descriptions.
i.
Contacts, material, current density etc.,
ii.
Design of contact pressure.
iii.
Contacts support and fixing arrangement on insulators
iv.
Turn and twist mechanism, clamps, locks, etc.
v.
Bearings, housing of bearing, bushes, etc.
vi.
Balancing of heights.
vii.
Coupling pipes, joints, connection adjustments.
viii
Base plates.
ix.
Down pipe, guides joints.
x.
Brass bushes and bearings at various joints
xi.
Operating mechanism, type of gear, auxiliary switch, size
and thickness of box, degree of protection. Gland plate, gland, etc.

xii.
Nuts, bolts and fasteners
xiii.
Interlocking devices
Offers without the above information or with incomplete information is liable for rejection.
20.3.2 TYPE AND CONSTRUCTION:
The design of the isolators shall be such that the switch can be changed to right or left hand control
without excessive labour and with a minimum change of parts. The live parts shall be of non-rusting, noncorroding metal. Current carrying parts shall be nonferrous. Bolts, screws and pins shall be provided with
lock washers, keys or other equipment locking facilities. Current carrying parts shall be made of copper
alloy or equivalent material. The switch shall not require lubrication of any part, at frequent intervals.
The isolator shall be suitable for mounting in upright or under hung position (with the blades moving in
horizontal plane) on steel / fabricated steel structures. The heights at which the isolators will be mounted
along with phase to phase dimensions are as per clause 5.00, Part - I. Any change in dimensions, will be
intimated to successful bidder. Necessary lengths of operating rod as required shall be supplied. The
bidder should agree to modify the base mounting detail of under hung switches depending upon the
supporting beam mounting details, if so required, by the purchaser at a later date.
20.3.3 OPERATING MECHANISM:
20.3.3.1 Void.
20.3.3.2 FOR MANUALLY OPERATED ISOLATOR:
a). Manual operating mechanism, gang operated through crank & reduction gear shall be provided for
main switch.
b) Manual operating mechanism, gang operated through a lever / handle for the operating shaft shall
be provided for earth switch.
20.3.3.3 3.03.03
The design of the operating mechanism shall. be Such that minimum energy is
required for operation and one person shall be able to operate the switch without undue effort. The
blades shall be in positive continuous control throughout tile entire cycle of operation. Suitable reduction
gear to achieve above aspects may be provided, for main switch and shall close or open with about 20
revolutions of the crank. The earth switch shall close or open by rotation of lever / handle through 90
degrees.
The operating pipes and rods shall be sufficiently rigid to maintain positive control without tension or
compression & there shall also be capable of with standing all torsional and bending stresses due to
operation of the disconnecting switch. It shall not be possible, after final adjustment has been made for
any part of the mechanism to be displaced at any point in the travel sufficiently to allow improper
functioning of the switch, when the switch is opened or closed at any speed. All holes, ill crank, linkages,
etc., having moving pins, shall be drilled to accurate fit, so as to maintain the minimum amount of slack
and lost motion. The operating mechanism and its controls shall be so designed that under no
circumstances the switch blades travel is interrupted before it reaches the fully close or open position.
The operating mechanism shall be suitable to hold the main switch or earth switch in closed or opened
position to prevent operation by gravity, wind, short circuit, seismic acceleration, vibration, shock,
accidental touching etc.
20.3.3.4 CONTROL CABINET:

The operating mechanism mid all accessories shall be enclosed in a weather, dust and vermin proof
cabinet. The control cabinet of each operating mechanism shall be made out of 12 SWG (2.64 mm thick)
steel sheet. or 10mm thick aluminum in the form plate or casting. Control cabinet shall be provided with
hinged doors along with padlocking arrangement. Sloping rain hood shall be provided to cover all sides.
15 mm thick neoprene or better type gasket shall be provided to ensure degree of protection at least IP
55 as per IS : 2147.
The motor operating mechanism / manually operating mechanism shall be mounted on the base
supporting structures or on a separate Support- structure at a height of 300 mm from the ground level.
Operating or lever for manual operation shall be at a convenient height of 1000 mm above ground level
for easy operation. The unsupported length of the operating rod shall not. exceed 3 meters. Guide
bearings shall be provided at suitable intervals. All brackets angles or other members mid accessories
necessary for fixing the operating mechanism to switch supporting structure. and the bearing for
operating rods shall be supplied. Rust proof pins and bearings of the bronze bushing, ball or roller type
shall be provided. All ball and roller bearings shall be protected from weather by means of covers and
grease retainers. Bearing pressures shall be kept low to ensure long life.
20.3.3.5 GEAR:
The disconnect may be required to operate occasionally with considerably long idle intervals. Special
care shall be taken for selection of material for gear and lubrication of gears to meet these requirements.
The gears shall be made of bronze or any other better material and lubricated for life with graphite or
better quality non-draining or non-hardening grease. complete details of components, materials, selflubricating arrangement, grade of lubricant, details of jigs, fixtures and devices used for quality check
shall be furnished in the bid.
20.3.3.6 GLAND PLATE AND GLANDS:
Removable gland plate with double compression type brass type glands shall be provided with each
operating mechanism for terminating of cables. Exact quantity of glands to be provided, shall be
intimated to the successful bidder.
20.3.3.7 AUXILIARY SWITCHES:
Each disconnect switch shall be provided with EIGHT normally closed electrically separated spare
contacts, in addition to the auxiliary contact required for its operation and indication mounted in a
weather proof, dust tight metal housing suitable for outdoor use and with necessary cable glands.
Auxiliary switch shall be provided for the grounding blades also. The auxiliary contacts, shall be made of
non-ferrous metal. The contact shall be convertible type so that normally open contact May be converted
to normally closed contact and vice versa. The auxiliary contact shall be rated at 10 Amps. at 240 V AC
and 2 Amps. at 110V DC.
The auxiliary contact shall be adjustable type to suite the following requirements ;
a)
Signaling of "Closed position" shall not take place unless the main contacts have reached a
position so that rated normal and short time current can be carried safely.
b) Signaling of "open position" shall not. take place unless the main power contacts are at a safe
isolating distance.
c)
All earthing blade assemblies shall be provided with three sets of normally open and three sets of
normally closed auxiliary switches for signaling to the control room and for interlocking with any other
equipment.
d) The auxiliary switches and auxiliary circuit shall be capable of carrying a current of atleast 10 Amps
continuously.
e) Auxiliary switches shall be capable of breaking atleast 2 A in a 110V DC circuit with a time co nstant
of not less than 20 milli seconds.
f)
Quick make and break (QMB) type auxiliary, switches shall have sharp action built in within this
switch.
g) The auxiliary switches shall be actuated by a cam or similar arrangement directly mounted on the
isolator shaft without any intermediate levers, linkages, etc., to ensure foolproof operation.
NOTE:
Potential free contacts shall be provided, duly wired up to the operating mechanism housing /
control cabinet for the following alarms and indications to be provided by the purchaser both on his
control panels and SCADA. To cater to this requirement, sufficient number of potencial free contacts shall
be provided.
20.3.3.8 WIRING AND TERMINAL BLOCK:
All wiring inside the operating mechanism cabinet shall be done with 1100V g rade PVC insulated 2.5 sq.
mm stranded copper cable as per IS : 1554 Part I Latest version. All wiring shall be provided with suitable
identifying PVC or other plastic ferrules at the end. All the terminal marking shall be indelible preferably
engraved. Separate terminal blocks of stud type for AC or DC wiring shall be provided in the cabinet. The
ends of wires shall be provided with tinned terminal spade crimped on to the wires. The wiring connected
with the heaters in the panel shall be provided with porcelain beaded insulator for a short distance from
the heater terminal. No joints shall be permitted in the wiring. All spare contacts of relays, push button,
auxiliary switches etc., shall be wired up to the terminal blocks in the mechanism box.
The fuses provided with motor and heater circuit shall be cartridge type (HRC) with suitable fittings.
The terminal block should be located to allow easy access. Terminal blocks shall be 1100 Volts grade,
clip-on type, 10 mm square or approved equivalent type and shall have 20% spare terminals. Insulating
barriers shall be provided between adjacent connections.
All relays, contactors and other electrical devices mounted in the panel shall have name plates with a
rating data and manufacturer's name, etc., Suitable identification label shall also be provided for control
switches and fuses etc., including position indications of isolator / earth switch.
20.3.3.9 LOCKING / INTERLOCKING:
The operating mechanism of the isolator shall be provided with means for being locked with padl ocks
effectively either in the closed or in the open position.
The isolators shall be provided with a suitable electrical interlock arrangement to work in conjunction with
associated circuit breakers. The arrangement shall be such as to prevent operation o f the isolator either
manually or on motor operation when the circuit breaker is in the closed position. The electrical inter
locking shall be suitable for 110V DC supply available at site.
The operation of isolator shall be possible only by means of only one device at a time, i.e., either
manually or on motor operation. Adequate means shall, however be provided to make manual operation
of isolator possible in the event of failure of auxiliary DC supply to isolator operating mechanism. Under
such contingencies also, the isolator operation shall be duly interlocked with the circuit breaker so that the
manual operation by means of the operating handle is possible only when the circuit breaker is in the
open position. The isolator mechanism box shall consist of solenoid operating device, which shall prevent
insertion of manual opening handle, when the associated circuit breaker is closed, by energizing the
solenoid through the circuit breaker auxiliary circuit.
The isolator shall be suitable for provision of castles mechanical locks / interlocks for which drawings
shall be supplied by the purchaser after placement of orders.
The interlock shall be provided along with each earth blade assembly such that operation of earth blade
assembly is possible only when the associated isolators are locked in the open position by integral lock.
The design of the earthing blade assembly shall be such as to permit use of a pad lock, for locking the
operating handle of the earthing blade assembly in the open or in the closed position.
20.3.4 CONSTRUCTIONAL FEATURES:
20.3.4.1 FIXED AND MOVING CONTACTS:
The isolator shall have heavy-duty self-aligning high pressure - contacts of modem design. The contact
shall be made of high grade, high conductivity, and heat resisting material. The main contacts s hall be
made of hard drawn electrolytic copper and the surface shall be silver plated. Arcing contacts wherever
provided shall close first and open last.
The isolators blades / arms shall be made preferably from tubular section of hard drawn electrolytic
copper having suitable diameter and shell thickness, and the contact surface shall be heavily silver
plated.
The surface of the contacts shall be liberally designed to withstand safely the -highest short circuit current
of the system as specified in the clause 05.01 (vii) - (viii) of part - I.
The male and female contact assembly and blades shall ensure
i)
Electro dynamic withstand ability during short circuit without any risk of repulsion of contacts.
ii)
Thermal with stand ability during short circuits.
iii) Constant contact pressure even when the live parts of the insulators stacks are subjected to tensile
stresses the insulators stacks are subjected to tensile stresses due to linear expansion of connected bus
- bars, flexible conductors either because of temperature variation or strong winds.
iv) Self - wiping action during closing and opening (preferably twisting type contacts). The surface shall
be wiped during closing and opening operation to remove any film, oxide coating, etc. wiping action shall
not cause scouring or abrasion of surfaces.
v)
Self - wiping ensuring smooth closing of the switch. The temperature rise of the contacts and other
current carrying parts shall not be more than 45 deg. C over an ambient air temperature of 45 deg. C,
while carrying the rated current continuously. The temperature rise due to passage of rated short-circuit
current for a period of 3 seconds shall not cause an), annealing or welding of contacts.
Fixed guides shall be provided so that proper seating of contacts will b e obtained by closing even when a
blade is out of alignment by 2.5 min or less.
All movable pars which may be in the current path shall be shunted by flexible copper conductors to
prevent breaking due to repeated bending.
Fabrication shall be made with suitable jig to avoid deviation during production. Details of size and shape
of contact, springs, back plate, fixing arrangements, design of contact pressure, life of contacts, limit of
temperature rise etc., shall be furnished along with the tender.
20.3.4.2 MOUNTING OF CONTACTS:
Fixed contacts shall be mounted on a block or channel welded to 10 mm thick M.S. plate with holes for
fixing on insulators. Slots shall be provided for marginal adjustment of height of contacts. The contacts
shall rest on a brass block and with initial tension. Suitable device shall be provided to prevent dashing.
Fabrication, welding etc. shall be done in suitable jig to avoid deviation during production.
20.3.4.3 TURN AND TWIST MECHANISM:
Turn and twist mechanism shall be provided with adequate locking to avoid opening or loosening by wind,
short circuit force etc., on moving blade. The springs shall be made out of stainless steel or phosphor
bronze or any other better material to have adequate strength and resilience and shall be encased with
grease to avoid exposure to rain. The clamps and plates be made out of at least 10 mm thick M.S. plate
or flat. Fasteners with nylock nuts shall be used wherever necessary. Vulnerable parts shall be fabricated
by tubular gas cutting and milling. The entire- mechanism shall be fabricated in suitable jig and template
to avoid deviations during production.
20.3.4.4 All lives parts shall be designed to have smooth surfaces without any sharp points, edges and
other corona producing surfaces so as to eliminate corona. at specified extinction voltage or at 1.1 x
rated voltage, if extinction voltage is not specified.
20.3.4.5 FASTNERS:
Nuts, bolts and washers of M -16 and higher size shall be hot-dip galvanized. The bolts used on tapped
holes of insulators cap shall be galvanized by centrifuge process to avoid excess deposition of zinc on
threads. Nuts, bolts and washers of less than M -16 size shall be of stainless steel when used on live
parts and nickel plated brass in other parts.
20.3.4.6 BEARINGS
The design and construction of the various bearings should embody all the features required to withstand
the climatic conditions specified to ensure dependable and effective operation, even after long period of
in action. All bearings in the current path except those specially designed as high pressure contact should
be shunted by flexible copper housing having adequate cross section.
Rotating insulator shall be mounted on a housing with bearings. The housing shall be made of gravity die
cast metal with smooth surfaces and suitably machined for seating the bearings. Two nos. of bearings
with adequate shaft diameter and distance between the bearings shall be provided to avoid wobbling
during operations. The bearings shall be of at least 75 mm internal diameter. The bearings shall be of
reputed make and lubricated for life. All other friction locations shall be provided with suitable bearings or
stainless or brass bushes. The bearings, bushes, joints, springs, etc., shall be so designed that no
lubrication shall be required during the service. Complete details of bearings, bushes housing greasing,
etc., shall be furnished with tender.
20.3.4.7 BALANCING OF HEIGHT:
Fixed insulators shall be provided with elevator base plate with four studs for balancing of height for
isolator of rated voltage of 72.5 KV and above. Thickness of plate and diameter of stud shall be at least
10 mm and 25 mm, respectively. Adequate numbers of nuts, lock nuts and washers shall be provided.
Taper washer shall be provided to match inclined surface of steel sections.
20.3.4.8 TANDEM AND DOWN PIPE:
The operating down pipe and tandem pipe shall be of heavy duty GI pipe of the following sixes (Bore dia)
for different KV class
a)
Bore dia of
110KV
66KV
33KV
Isolators
Isolators
Isolators
40mm
32mm
32mm
50mm
50mm
50mm
tandem pipe
b)
Bore dia of down operating

pipe
Further outside diameter and thickness of pipe shall be as follows as per table - 3 of IS : 1239 (Part - 1)
1990. Mild steel tubes. - Heavy.
S1.
Nominal
No.
Bore in mm
outer dia
outer dia
Maximum (mm)
Minimum(mm)
Minimum
thickness
1.
32
42.9
42
2.
40
48.8
47.9
3.
50
60.8
59.7
4.5
i.
Tandem pipe:
Two Nos. of tandem pipe shall be used for phase coupling of double break isolator. Base plate of
insulators for connection of tandem pipe shall be made out of one piece of at least 10 mm. thick MS plate.
Bolt and shackle device shall be used to connect tandem pipe to the base plate. Wherever unavoidable,
sliding clamps may be used. These clamps shall be made out of at least 10 mm thick MS plate with
four(4) nos. of nuts and bolts. A grub screw shall be provided for securing connection of tandem pipes.
ii)
The pipe shall be terminated into a suitable swivel or universal type joint between the insulator
bottom bearing an the operating mechanism to take cares of marginal angular misalignment at site. All
brackets, guides, etc., shall be mounted on the base of the isolator. Arrangement of mounting any guide,
bracket, mechanism and the base shall not be accepted, for upright mounting type isolator.
20.3.4.9 BASE :
Each pole of the isolator shall be provided with hot dip galvanized rolled steel base provided with holes
for mounting bolts and designed for mounting on a steel structure. The bases shall be rigid and self
supporting and shall require the guying or cross bracing between phases other than the supporting
structure. The composite frame of the base shall be made of channel of following minimum sizes.
i)
125 x 65 x 6 / 8 mm for 220 KV isolators.(twin channel)

ii)
100 x 50 x 6 / 8 mm for 66KV isolators(twin channel)
iii)
150 x 75 x 6 / 8 mm. For 33 KV isolators(single channel)
Fabrication, welding etc. shall be done by suitable jig, power press, and templates to avoid deviations
during production. Details and dimensions of sections, jig, templates and device used for production of
the base shall be furnished with tender. The necessary galvanized bolts and nuts for fixing the bases to
the structure shall be in scope of supply.
20.3.5 EARTHING SWITCH:
One earthing switch per pole forming an integral part of the line disconnecting switch and manually
operated shall be supplied wherever called for in the schedule of requirements. The earthing switch shall
match with main switch. The earthing switch shall be designed for the rating as indicated in 5.03.01 of
Part - I. A suitable flexible braided connector shall be provided on the hinge end of the earthing blade for
connection to ground bus. The earthing blade shall be operated by a separate mechanism, but shall be
mechanically inter looked with the disconnecting switch so that the grounding blade can be closed only
when the disconnecting switch is open and vice versa. If possible similar interlock shall be provided with
the bypass isolator. Alternatively electrical interlock between the grounding switch and by pass isolator
shall be offered.
20.3.6 INSULATORS:
20.3.6.1 The isolator shall be provided with solid core insulators.
a)
These shall be of single unit to be used for220 KV , 110KV, 66KV and 33KV systems. The
dimensions and other parameters unless otherwise specified shall generally conform to IS - 5350-Part-11
& IEC60273.
b) The cylindrical type post insulators shall be of solid core type. Insulators of similar type shall be
interchangeable. The mechanical strength class for outdoor cylindrical post insulators shall be of strength
class 6, corresponding mechanical strength in tension, compression and torsional shall be as per IS :
53550 Part - II. When operated at maximum system voltage, there shall be no electrical discharge.
Shielding rings, if necessary shall be provided.
c)
The parameters of the insulators required shall conform to IS : 0350 - Part - II - 1973 or IEC60 273.
The dimensions, pitch circle diameter, no. of bolts, size of bolt holes, etc., shall conform to the
parameters detailed in IS : 5350 Part - II 1973 or IEC 273.
In the case of 220 KV,110KV, 66KV and 33KV system the cylindrical post insulator shall consist of single
unit only.
d) The insulator shall be provided with a completely galvanized steel base designed for mounting on
the support. The base and mounting arrangement shall be such that the insulator shall be rigid and self
supporting and no guying or cross bracing between phase shall be necessary.
20.3.6.2 The price of the isolators shall include the cost of insulators which shall be quoted separately.
The porcelain used for the manufacture of the insulators shall be homogenous, free from laminations and
other flaws or imperfections that might effect the mechanical or dielectric. quality and shall be thorough
vitrified, tough and impervious to moisture. The glazing of the porcelain shall be uniform brown colour,
with a smooth surface arranged to shade away rain water and free from blisters, burns and other similar
defects. Insulators of the same rating and type shall be interchangeable.
The porcelain and metal parts shall be assembled in such a manner and with such materials that any
differential thermal expansion between the metal and porcelain parts throughout the operating
temperature range will not loosen the parts or electrical strength or rigidity. The assembly shall not have
excessive concentration of electrical stress in any section or across leakage surfaces. The cement used
shall not give rise to chemical reaction. with metal fittings. The insulator shall be suitable for water
washing by rains or artificial means in service conditions. Further the insulators to be supplied shall be of
high- quality and should not result in mismatch and misalignment of stacks during erection and operation.
Each cap shall be of a high grade cast iron or malleable steel casting or steel forging. Cap and base
insulators shall be interchangeable with each other. The insulator shall conform to the requirement of the
latest edition of IS : 2544, or any other equivalent standard. The bidder should furnish the characteristics
of insulators.
20.3.6.3 All the ferrous metal part shall be hot dip galvanized smoothly as per IS : 3638 (as amended up
to date), IS : 2623 or any other equivalent authoritative standard. The material shall be galvanized on ly
after shop operations upon it have been completed. The metal parts be for galvanization should be
thoroughly cleaned of any paint, grease, rust, scales or alkalies or any foreign deposit which are likely to
come in the way of galvanization process. The metal parts coating shall withstand minimum four one
minute dips in copper sulphate solution as per IEC - 168.
The insulator unit shall be assembled in a suitable jig to ensure correct positioning of the top and bottom
metal fittings relative to one another. The phases of the metal fitting shall be parallel and at right angle to
the axis of the insulator and corresponding holes in the top and bottom metal fittings shall be in a vertical
plane containing the axis of the insulator.
It shall be sole responsibility of the supplier to carry out thorough inspection and quality, checks on the
insulators at the insulator supplier works before offering the insulators for purchaser's inspection.
20.3.7 ACCESSORIES:
The accessories to be provided on the insulator shall includ e but not to be limited to the following:
20.3.7.1 Position Indicators :
A position indicator to show whether the isolator is in ON or OFF position.
20.3.7.2 Counter Balance Springs
Counter balance springs, cushions, etc., shall be provided to prevent impact at the end of travel both on
opening and closing of isolator. The springs shall be made of durable and non-rusting type alloy.
20.3.7.3 NAME PLATE:
Isolators, earthing switches and their operating devices shall be provided with their nameplate. The
nameplate shall be weather proof and corrosion proof. It shall be mounted in such a position that it shall
be visible in the position of normal service and installation. It shall carry the following information.
a)
ISOLATORS:
Karnataka Power Transmission Corporation Limited & P.O. No.
Name of Manufacturer.
Designation type
Serial number
Rated voltage
Impulse withstand voltage to earth.
Rated current.
Rated short time current.
Rated maximum duration of short time current.
Rated short time current peak.
Rated mechanical terminal load.
Weight.
b)
EARTHING SWITCH
Designation type
Serial number
Rated voltage
Rated short time current.
Rated maximum duration of short time current.
Rated mechanical terminal load.
Weight.
c)
OPERATING DEVICE
Designation type
Rated voltage
Rating
Weight.
Reduction gear ratio
Auxiliary, contacts quantity and rating.
20.3.7.4 PADLOCKING DEVICE:
The isolator and earthing switch shall be provided with padlocking device to permit locking of the isolator
and earthing switch in both fully open and fully closed positions.
20.3.8 AUXILIARY POWER SUPLY
3.08.01 Auxiliary electrical equipment. shall be suitable for operation Oil the following supply systems.
a)
Power devices
415V, 3 Phase, 4xvirc 5OHz neutral grounded

AC system with variation of -30 to 100%
b)
AC control &
240 V single phase 2 wire 5OHz AC supply
protective devices
with one point grounded.
lighting fixture, space heaters

Fractional.horse power motors
c)
DC alarm control & 110V, 2 wire ungrounded DC supply with protective devices from variation of 20 to + 10% station batteries of
3.08.02 Above supply voltage may vary as follows:
a)
AC supply
Voltage variation : + 10% to -30%
Frequency variation: (+) or (-) 5%

Both variation may
occur
simultaneously Or independently,
b)
DC Supply
(-) 20% to (+) 10%
Each of the foregoing supplies shall be made available at one terminal point fo r each isolator for
operation of accessory and auxiliary equipment. Terminal point is the control cabinet of the isolator.
Bidders scope shall include distribution beyond the point of supply.
20.3.9 SIGNALING
20.3.9.1 Signaling of the close position shall not take place unless the movable contact has set in a
position in which the rated normal current, the peak- withstand current and the short time withstand
current can be carried safely.
20.3.9.2 Signaling of open position shall not take place unless the movable contact has reached the
position such that the clearance between the contacts is at least 80% of the isolating distance.
20.3.10 EARTHING:
20.3.10.1 Flexible copper connections shall be provided between rotating earth blades and the frame,
which shall have a cross section of at least 50 mm square and shall be tinned or suitably treated against
corrosion.
20.3.10.2 The frame of each disconnect and earthing switch shall be provided with two reliable earthing
terminals for connection to the purchaser's earthing conductor / flat so also clamping screw sui table for
carrying specified short time current. Flexible ground connectors shall be provided for connecting
operating handle. to the earthing flat. The diameter of clamping screw shall be at least 12 mm. The
connecting point shall be marked with earth symbol.
20.3.11 TERMINAL CONNECTORS
The disconnecting switches shall be provided with high conductivity bimetallic terminal connectors and
suitable for Aluminium pipes (BS 1600 schedule 40) and Drake ACSR conductors, the size of which will
be indicated. to successful bidder. The connector shall be rigid in respect of ACSR conductors. The
terminal connectors shall be expansion type in respect of Aluminium pipes. The terminal connector shall
conform to IS : 5561 1970.
Further the terminal connectors shall be suitable for both horizontal or vertical take off.
For bimetallic type of connectors, necessary steps shall be taken by the manufacturers to ensure that
there is no adverse effect on the connector and the connected equipment due to bimetallic action.
20.3.12 SUPPORTING STRUCTURE:
20.3.12.1 The bidder shall quote unit prices per Metric Tonne for support structure for the isolators
offered. These galvanized support structures shall be fabricated as per the drawings enclosed for the
respective class of isolators. The weight of the supporting structure indicated in the drawing is a
provisional weight. The bidder shall quote unit price per metric tonne.
20.3.12.2 The masonry or concrete in foundations shall be arranged and constructed by the Contractor.
20.3.13 ASSEMBLY
The disconnect shall be fully assembled at the works of the bidder. Typical operation shall be carried out
on each type of fully assembled disconnect to ascertain that all parts fit correctly and function
satisfactorily.
20.3.14 PAINTING, GALVANIZING AND CLIMATE PROOFING:
20.3.14.1 All interiors and exteriors of enclosures, cabinets mid other metal parts shall be thoroughly
cleaned to remove all rust scales, corrosions, grease and other adhering foreign matter and surfaces
treated by recognized phosphating (Eg. Seven tank phosphating sequence), After such preparation of
surfaces tow coats of zinc oxide primer shall be given by suitable stoving and air-drying, etc., before final
paint.
Colour of the final paint shall be of shade No. 631 of IS-5, i.e., epoxy light grey. The final painted cubicle
shall. present aesthetically pleasing appearance free from any dent of uneven surface
20.3.14.2 Paint inside the metallic housing shall be of anti - condensation type and the paint on outside
surfaces shall besuitable for outdoor installation.
20.3.14.3 All ferrous parts not suitable for painting such as structural steel, pipes, rods, levers, linkages,
nuts a-lid bolts used in other than current path etc., and also supporting structures shall be hot dip
galvanized. Galvanization shall be done after completion of fabrication which shall be capable to prevent
corrosion in view of the severe climatic conditions.
Thickness of zinc coating shall not be less than 610 gm of zinc per sq. meter of surface. Zinc coating
shall be smooth clean and of uniform thickness and free from defect. Preparation of gal vanizing and the
galvanizing itself shall not adversely effect the mechanical properties of the coated material, The quality
shall be established by tests per IS : 2633. Galvanizing of nuts and bolts shall be carried out by
centrifugal or suitable process so that the bolts will easily fit into the tapped holes / nuts.
20.3.14.4 All components shall be given adequate treatment of climate proofing as per IS : 3202 so as to
withstand corrosion and severe conditions.
20.3.14.5 Complete details of painting, galvanizing and climate proofing of the equipments shall be
furnished in the tender.
PART - III
21.1 TESTS :
21.1.1 Type tests :
21.1.1.1 The equipment offered, shall be fully type tested. The type test reports shall not be older than 5
years on the day of bid opening. The type tests are to conducted again if the reports are older than 5
years on the day of bid opening at no extra cost to owner. The bidder shall quote for all type tests
individually in schedules. The owner reserves the right to demand repetition of some of all the type tests
even though the test reports are less than 5 yeas old on the day of bid opening. In such cases the
payment will be made as per rates quoted in the schedule. Please refer to Clause 13 Inspection Testing
and Inspection Certificate., General technical Requirements, Volume - II.
21.1.1.2 During the type test the disconnect shall be mounted on its own support structure or equivalent
support structure and installed with its own operating mechanism to make the type test representative.
Drawing of equivalent support structure if any and mounting arrangement made for type tests shall be
furnished for purchaser's approval before conducting the type tests.
21.1.1.3 The type tests shall be conducted on the disconnect along with approved insulators and
terminal connectors.
21.1.1.4 Mechanical endurance test shall be conducted On the main switch as well as earth switch on
one disconnect of each type
21.1.1.5 LIST OF TYPE TESTS:
List of type tests to be carried out as per IS : 9921 Part - VI 1985, are as given below.
a)
ISOLATORS:
i)
Visual examination of components,
ii)
Dimensional verification of parts.
iii)
Assembly, interchangeability and verification of critical dimensions.
iv) Measurement of resistance of main circuit and earth circuit (before and after mechanical endurance
test)
v)
Temperature rise test (before and after mechanical endurance test)
vi)
Mechanical endurance test.
vii)
Short time withstand current and peak withstand current tests.
viii) One minute power frequency voltage wet withstand tests across the isolating distances and to
earth.
ix). Standard lightning impulse voltage withstand tests on auxiliary and control circuits and auxiliary
switches.
x). One minute power frequency withstand voltage test on auxiliary and control circuits and auxiliary
switch.
xi)
Verification of operation during application of rated mechanical terminal loads.
xii)
Galvanization tests.
xiii) Chemical composition of contact material, springs and fasteners and bushes.
xiv) Physical tests on springs and fasteners and copper strip / tubes.
b)
EARTHING SWITCHES:
i)
Visual examination of components.
ii).
Dimensional verification of components.
iii).
iv)
Measurement of resistance of earthing switch contact (before and after mechanical endurance test)
v)
Mechanical endurance test
vi)
Short time withstand current and peak withstand current tests
vii)
power frequency voltage tests on auxiliary switches at kV(rms) for one minute.
viii) Galvanization tests

ix)
Chemical composition of contact material, springs and fasteners and bushes.
x)
Physical tests on springs and fastners and copper strips.
21.1.1.6 Type test report for operating motor carried out as per relevant ISS or BSS shall be required to
be submitted for approval.
21.1.1.7 Temperature rise and breakage capacity tests reports for auxiliary equipments i.e., closing and
trip coils, auxiliary contacts, limit switch etc., shall also be required to be submitted for approval.
21.1.2 ACCEPTANCE AND ROUTING TESTS:
21.1.2.1 All acceptance and routine tests as stipulated in the relevant standards shall be carrie d out by
the supplier in presence of purchaser's representative.
21.1.2.2 Mechanical operation tests (routine test) shall. be conducted on the complete disconnect (man
switch and earth switch) at supplier's works and a certified test report be furnished to the purc haser.
Alternatively the bidder may offer to conduct this test at purchaser's sub -station in which case the
purchaser shall make necessary arrangement to erect the disconnect at his sub -station site under
supervision of bidders representatives for supervision shall not be borne by the purchaser.
21.1.2.3 The test report of power frequency voltage withstand test conducted on the insulator shall be
furnished for purchaser's acceptance in lieu of conducting the power frequency (dry) test on main circuit
(routine test).
21.1.2.4
LIST OF ROUTING TESTS:
List. of routine test to be carried out as per IS : 9921, Part - IV - 1985 are as given below:
a)
ISOLATORS
Visual examination of components.
One minute power frequency voltage dry withstand tests across the isolating distance and to earth.
Measurement of resistance of isolator contacts and between terminals of the main circuits.
Power frequency voltage withstand tests on auxiliary and control circuits and auxiliary switches at 2
KV (rms) for one minute.
Mechanical operation tests.
b)
EARTHING SWITCHES
Visual examination of components
Power frequency voltage withstand tests on auxiliary, and control circuits and auxiliary switches at
2KV (rms) for one minute.
Mechanical operation tests.
Immediately after finalization of the programme of type / acceptance / routine testing, the supplier shall
give three weeks advance intimation to the purchaser, to enable him to depute his representative for
witnessing the tests.
21.1.3 SPECIAL TESTS
Special tests listed below shall be carried out in presence of purchaser's representative.
1)
Test on insulators - Conforms to IS - 2544
2)
Test on insulators - Conforms to IEC - 168
3)
Test on terminal connecters IS : 5561
4)
Operation tests on operating mechanism and interlock
5)
Endurance test on Auxiliary switches.
- IS : 2623
1.05 Test certificates and documents of the following items shall be furnished at the time of routine tests.
Chemical analysis of copper along with a copy of central excise certificate / gate pass indicating
genuine source of procurement of electrolytic grade.
Bearings
Fasteners
Universal/ swivel joint coupling.
Insulators.
Gears
Auxiliary switch
Interlocking devices.
Terminal block
The purchaser may at his discretion request additional test certificates for other items as reasonably
required to substantiate the quality of the same.
21.2 INSPECTION
The inspection may be carried out by the purchaser at any stage of manufacture. The successful bidder
shall grant free access to the purchaser's representative at a reasonable time when the work is in
progress. Inspection and acceptance of any equipment under this specification by the purchaser, shal l
not relieve the supplier of his obligation of furnishing equipment in accordance with the specification and
shall not prevent subsequent rejection if the equipment is found to be defective. The supplier shall keep
the purchaser informed in advance, about the manufacturing programme so that arrangement can be
made for inspection. The purchaser reserves the light to insist for witnessing the acceptance / routine
testing of the bought out items.
21.3 DOCUMENTATION:
21.3.1 All drawings shall conform to International Standard Organization (ISO) ' A ' series of drawing
sheet / Indian standards specification IS : 656. All drawings shall be in ink and suitable for micro filming.
All dimensions and data shall be in system international units.
21.3.2 LIST OF DRAWINGS AND DOCUMENTS:
The bidder shall furnish four sets of following drawings along with his offer:
a)
General outline and assembly drawings of the disconnect, operating mechanism, structure insulator
and terminal connector.
b) Sectional views and descriptive details of items such as moving blades, contacts arms, contact
springs, contact support, turn and twist mechanism, bearing, housing of bearing, bushes, balancing of
heights, phase coupling pipes, base plate, operating shaft, guides, swivel -joint operating mechanism and
its components, etc.
c) Loading diagram.
d)Drawings with structure for the purpose of type test
e)Name plate
f) Schematic drawing
g)Type test reports in case the equipment has already been type tested
h)Test reports, literature, pamphlets of the bought out items and raw material.
21.3.3 The successful bidder shall, within four weeks of placement or order, submit three sets of final
versions of all the above said drawings. The owner shall communicate his comments on the drawings to
the supplier. The supplier shall, if necessary, modify the drawings and resubmit three copies of the
modified drawings within two weeks submit 10 prints and two good quality reproducible of the approved
drawings on plastic coated (film type) durable reproducible paper for owner's use.
21.3.4 Six sets of the type test reports, shall be submitted by the supplier for distribution, before
commencement of supply, adequate copies of acceptance alid routine test certificates, shall accompany
the dispatches consignment.
21.3.5 The manufacturing of the equipment shall be strictly in accordance with the approved drawings
and no deviation shall be permitted without the. .N7ritten approval of the purchaser. All manufacturing
and fabrication work in connection with the equipment prior to the approval of the drawing shall be at the
supplier's risk.
21.3.6 Approval of drawings/ work by purchaser shall not relieve the supplier of his responsibility and
liability for ensuring correctness and correct interpretation of the latest revision of applicable standards,
rules and codes of practices.
21.3.7 INSTRUCTION MANUALS
Twenty - five copies of the erection, operation and maintenance manuals in English shall be supplied for
each type of the disconnect one month prior to dispatch of the equipment. The manual shall be bound
volume and shall contain all drawings and information required for erection, Operation and maintenance
of the disconnect including but not limited to the following particulars.
Marked erection prints identify the component parts of the disconnect as shipped with -assembly
drawings.
Detailed dimensions and description of all auxiliaries.
Detailed views of the insulator stacks, metallics, operating mechanism, structure, interlocks, spare
parts etc.
21.4.1 The equipment shall be packed in crates suitable for vertical / horizontal transport, as the case
may be and suitable to withstand handling during transport and outdoor storage during transit. The
supplier shall be responsible for damage to the equipment during the transit, due to improper and
inadequate packing. The easily damageable materials shall be carefully packed and marked with the
appropriate caution symbols. Wherever necessary, proper arrangement for lifting, such as lifting hooks
etc., shall be provided. Any material found short inside the packing cases shall be supplied by the
supplier without any extra cost.
21.4.1.1 Each consignment shall be accompanied by a detailed packing list containing the following
information.
a)Name of the consignee.
b)Details of consignment.
c) Destination
d)Total weight of consignment
e)Sign showing upper / lower side of the crate.
f) Handling and unpacking instructions.
g)Bill of materials indicating contents of each package.
h)One set of approved drawings and manual.
21.4.1.2 The supplier shall ensure that the purchaser before dispatch approves the packing list and bill
of material.
SECTION II : TECHNICAL SPECIFICATION FOR 11 /6.6 KV CLASS, 400/800

AMPS, DOUBLE BREAK GROUP OPERATING SWITCHES
22.1 SCOPE:
This specification covers the manufacture, testing at manufacturers works and supply of 11KV isolators of
400/800 Amps capacity double break complete with accessories such as operating pipe, connecting
pipes, supporting insulators, link work, terminal, technical connector and locking arrangements as per
IS:4921/1981 and to our drawing N.KEB/SIC/BL/WS/012, dated 06.08.19 84. (The drawings can be
collected at the O/o the CEE(T and P), KPTCL, Kaveri Bhavan, Bangalore.)
22.2 The equipment offered shall confirms to IS:9921/1981 and latest amendments there off. The
switches shall be suitable for horizontal upright mounting.
22.3 CONSTRUCTION:
22.3.1 The base shall be made of robust rolled M.S channel section of size 75 x 40 mm. All ferrous
parts shall be hot dip galvanized and all copper parts shall be tinned. The rotating parts shall be fitted with
suitable bearing.
22.3.2 The blades and contacts shall be of best quality electrolytic copper and shall be capable of
carrying rates current continuously without exceeding the temperature limits specified in Indian
Standards.
22.3.3 The insulators shall be of pedestal post type brown glazed porcelain stacking type design E.22
as per IS:5350 (Part- 111) 1971 with tap screws and spring washers and to technical specifications
enclosed conforming to IS:2544/1973 with amendments thereof. Only the insulators baked in temperature
controlled kilns shall be used.
The insulators used shall be from the following firms only
1. BHEL
2. Jayashree Insulators
3. W.S.Industries
4. Modern Insulators Ltd.,
22.3.4 The operating pipe shall consist of tandem pipe of length 2450 mm and vertical pipe of length
5400mm. The pipes shall be of 25mm dia, class C. The tandem pipe length is furnished for a phase to
phase width of 920mm. If the length of pipe required is more, the same shall be offered. The G.I Pipe
used shall conform to IS:1239/Part/1979 and amendments thereof. A guide to the vertical pipe of the
operating pipe shall be providing to arrest its lateral movement. Necessary fixture for fixing the guide to
the pole shall also be supplied.
22.3.5 Bimetallic terminal connectors suitable for terminating 16mm/11mm diameter ACSR Conductor
shall be provided. The terminal connector shall confirm to IS:5561. The exact size of ACSR Conductor
will be confirmed during approval of drawings.
22.3.6 All the Iron parts shall be hot dipped galvanized and shall conform to the following ISs.
a)
IS 209/1969 Quality of Zinc for galvanization.
b)
IS 2629/1966 Hot dip galvanization.
c)
IS 2633/1972 Testing of Zinc coating on galvanised parts.
d)
IS 5358/1969 Hot dip galvanised coating on fasterners.
e)
IS 4759/1969 Hot dip galvanised coating on structural parts.
f)
IS 6745/1972 Determination of weight of zinc coating on galvanised iron and steel parts with latest
amendments if any.
22.3.7 ARCING HORNS :
The switches shall be supplied with hot dip galvanised arcing horns so that arcing takes place between
arcing horns while opening/closing the G.O.S and not between the contacts.
22.3.8 LOCKING ARRANGEMENTS:
Suitable locking arrangements shall be provided for the operating handle.
22.4 CHARACTERISTICS :
a)
System voltage 11KV / 13.2KV
b)
Rated voltage 15 KV
c)
Rated insulation level :

i)
To earth and between poles 75 KV (Peak)
ii)
Across isolating distance 85 KV
d)
Rated one minute power frequency with stand test voltage.
i)
To earth and between poles 28 KV
ii)
Across isolating distance 85 KV

d)
Rate normal current 400/800 Amps
e)
Rated duration of short circuit 3 sec
f)
Rated short time withstand current 13KV
g)
Type of break horizontal, double break.
22.5 TYPE TEST CERTIFICATES:

The bidder shall enclose type test certificates for similar isolators conducted older earlier. The type test
certificates shall not older five years prior to date of bid opening. The following type tests shall be
conducted free of cost to the KPTCL in a recognized laboratory on one GOS as specified in IS 9921 and
the test certificated along with the drawings attested by the concerned laboratory shall be s ubmitted for
approval and after approval supplied shall commence. The manufacturer also shall submit one sample
and get the same approved before commencing bulk supplies.
i)
Impulse voltage dry test
ii) Power frequency voltage dry test

iii) Power frequency voltage wet
iv) Temperature rise test

v) Measurement of resistance
vi) Test for rated peak short circuit currency
vii) Operating test
viii) Mechanism endurance test
22.6 ROUTINE TESTS :
The routine tests as per IS:9221 shall be conducted on each G.O.S and test certificates shall be
submitted duly signed by a responsible officer of the tenderers before dispatch of consignments.
22.7 DRAWINGS :
The bid shall contain the drawings for general arrangements, details of contacts, terminal connector,
insulator etc., successful bidder shall furnish.
22.8 PACKING :
The G.O.S. shall be securely packed to withstand rough handling during transit and storage.
22.9 NAME PLATE :
The group operating switch shall be provided with the name plate legibly and indelibly marked with
the following information.
a)
Name of material.
b)
Name of Manufacturer and trade mark
c)
Purchase order number and date.
d)
Serial No.
e)
Rated current
f)
Rated Voltage.
VOLUME IIA
SECTION 4(D)
CHAPTER : INSTRUMENT TRANSFORMERS
SECTION - 4(D)
CHAPTER : INSTRUMENT TRANSFORMERS
VOLUME-II(A)
TECHNICAL SPECIFICATIONS
SECTION 4(D):
CHAPTER - INSTRUMENT TRANSFORMERS
PARTICULARS
GENERAL
CONSTRUCTION FEATURES
Current transformers
Voltage transformers
Terminal connectors
Tests
Spare parts
Parameters
Testing and commissioning
Technical specifications for
Tables -IB
VOLUME II(A)
Section 4(D)
CHAPTER INSTRUMENT TRANSFORMERS
23.1 GENERAL
23.1.1 Qualifying Requirements Please refer to Volume I, Section IFB.
23.1.2 1.2
The instrument transformers and a shall conform to the latest version of the standards
specified below except to the extent explicitly modified in the specification and shall being accordance
with the requirements in Section - 1 & 2.
Sl.
No.
i)
ii)
IS-5/1978 (3 versions)
IEC-60044-1 or IS-2705
Colour of ready mixed paint and enamels

Current Transformers
iii)
IEC-60044-2 or IS -3156
Voltage Transformer
iv)
IS-335/1983, IEC-296, BS- Specification new Insulating oil

148
IS-1271/1958
Classification of insulating material for electrical
machinery and apparatus in relation to their
thermal stability in services.
FIS-1570 (Part-V)
Specification for Current Transformers
IS-2099/1985,
Bushing for alternating voltages above 1000 Volts
IS-5621/1980
FIS-1705/1981
Specification for Current Transformers
Part-1:General requirement
Part-2:Measuring Current Transformers
Part-3:Protective Current Transformers
IS-2932/1974
Enamel Synthetic interior
(a) under coating
(b) finishing
IS-3024/1965
Electric steel sheet oriented with amendment No.1
and 2
IS-4253/1980 Part-II
Cork and rubber
IS-5561/1970
Electric power connectors
IS-11322/1955
Method for partial discharge in instrument
transformer
IS-4201/1983
Application guide for Current Transformer
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
IS No.
Details
23.1.3 The instrument transformers shall be complete with its terminal box and a common marshalling
box for a set of 3 instrument transformers.
23.1.4 The instrument transformer tank along with top metallics shall be hot dip galvanized or pained as
per IS - 5 shade 697.
23.1.5 The impregnation details along with tests/checks to ensure successful completion of
impregnation cycle shall be furnished for approval.
23.1.6 Bellows if used for expansions of transformer oil shall be tested in accordance with relevant
standards. The details of the same to be furnished for approval.
23.1.7 Any deviation from this specification proposed by the tenderer calculated to improve upon the
performance, utility and efficiency of the equipment will be given due consideration thereof are furnished.
In such a case, the tenderer shall quote according to this specification and deviations, if any proposed by
him shall be quoted as an alternative/alternatives. In any case of any contradiction between the
provisions of the Indian Standards specification/recommendation of the IEC and this specification the
latter shall prevail.
23.2 CONSTRUCTION FEATURES :
The features and constructional details of instrument transformer shall be in accordance with
requirements stipulated hereunder :
23.2.1 Bushings/ Insulators :
a). Instrument transformers shall be of 220 KV , 110kV, 66kV Class, oil filled, self cooled with shielded
porcelain bushings/ Insulators suitable for outdoor service and upright mounting on steel structures.
b). Bushing/Insulators shall conform to requirements stipulated in Section 2. The Bushing/ insulator for
CT shall be one piece without any metallic flange joint.
c). Bushing shall be provided with oil filling and drain plugs oil sight glass for CT and electromagnetic
unit for CVT etc., The bushing/ insulator of instrument transformer shall have a cantilever strength of not
less than 350 Kg for 220 KV, 110KV and 66KV Instrument transformers or as per the value obtained vide
Section - 2 whichever is higher.
d) Instrument transformers shall
be hermetically sealed units. Pressure relief device shall also be
provided. Bidder/ Manufacturer shall furnish details of the arrangements made for the sealing of
instrument transformers along with the bid. Bidder/ Manufacturer shall furnish the details, tests to check
the effectiveness of hermetic sealing approval.
e). Polarity marks shall indelibly be marked on each instrument transformer and at the lead terminals;
at the associated terminal block.
23.2.2 Terminal box / Marshalling box:
Marshalling box / terminal box shall conform to the requirements of Section - 2 General Technical
Requirements Volume II(A)
23.2.3 Insulating Oil :
Insulating oil to be used for instrument transformers shall conform to IS : 335, (required for first filling)
23.2.4 Name Plate:
Name plate shall conform to the requirements of IEC incorporating the year of manufacture. The rated
current extended current rating in case of current transformers and rated voltage, voltage factor in case of
voltage transformers shall be clearly indicated on the nameplate. The rated thermal current incase of CT
shall also be marked on the nameplate.
The intermediate voltage in case of capacitor voltage transformer shall be indicated on the name plate.
23.3 CURRENT TRANSFORMERS:
a)
Current transformers shall be of dead tank type have single primary either ring type, or hair pin type
OR Live tank with Bar primary/ ring type and suitably designed for brining out the secondary terminals in
a weather proof (IP 55) terminal box at the bottom.
These secondary terminals shall be terminated to stud type of M6 size non disconnecting terminal blocks
inside the terminals box.
b)
Different ratios specified shall be achieved by secondary taps only without primary reconnection.
c)
Core lamination shall be of cold rolled grain oriented silicon steel or other equivalent alloys. The
cores used for protection shall produce undistorted secondary current under transient conditions at all
ratios, with specified CT parameters.
d)
oil.
The expansion chamber at the top of the porcelain insulators should be suitable for expansion of
e) Facilities shall be provided at terminal blocks in the marshalling box for star delta formation, short
circuiting and grounding of CT secondary terminals.
f)
Current transformer's guaranteed burdens and accuracy class are to be intended as simultaneous
for all cores.
g) For 123KV and 72.5KV class CTs the rated extended primary current shall be 120% on all cores of
the CTs specified in Section - 1.
h)
For 123KV and 72.5KV Current transformer, characteristics shall be such as to provide satisfactory
performance of burdens ranging from 25% to 100% of rated burden over a range of 10% to 100% of rated
current in case of metering CTs and up to the accuracy limit factor/ knee point voltage in case of
protection cores of CTs used for relay circuits.
i)
The current transformers shall be suitable for horizontal transportation. It shall be ensured that the
CT is able to withstand all the stresses imposed on it while transporting and there shall be no damage in
transit. The Contractor shall submit the details of packing design to the Owner for review.
j)
For 123KV and 72.5KV CTs the instrument security factor at all ratios shall be less than five (5) for
metering core. If any auxiliary CTs / reactors are used in the current t ransformers then all parameters
specified shall have to be met treating auxiliary CTs as an integral part of the current transformer. The
auxiliary CTs / reactors shall preferably be in built construction of the CTs.
k)
The wiring diagram plate for the interconnection of the three single phase CTs shall be provided
inside the marshalling box.
l)
The current transformers should be suitable for mounting on lattice support structure to be provided
by the Contractor in accordance with stipulations of Clause 25.0 of Section - 2 (GTR) and Clause 1.1 of
Section - 7.0 (Structure).
m) The CT shall, be designed as to achieve the minimum risks of explosion in service. Bidder/
Manufacturer shall, bring out in his offer, the measures taken to achieve this.
n) Normally no joints in the windings shall be allowed. Joints if unavoidable shall be brazed with
high silver alloy grade Ba Cu AG 6 of IS-2927/1975 or/but welded.
o) The current transformer shall have a single core with wound primary. Super enameled wire shall
preferably be used for secondary windings. COPPER CONDUCTOR shall be used for all windings.
23.4 LIMITS OF TEMPERATURE RISE:
23.4.1 Temperature rise of a Current Transformer winding when carrying a primary current equal to the
rated continuous thermal current at a rated frequency and with rated burden shall not exceed the
appropriate values given in the following table. The temperature rise of the windings is limited by the
lowest class of insulation either of the winding itself or of the surrounding medium in which it is
embedded.
TABLE OF TEMPERATURE RISE:
Class of Insulation
Max. Temperature rise in C
All classes immersed in oil
60
All classes immersed in bituminous compound
50
Classes not immersed in oil or bituminous
60
compound, Class-A
NOTE:
1.
The Temperature rise permissible shall be based on an ambient temperature of 45C.
2.
Class-A insulation: Materials or combination of materials such as cotton, silk and paper when
suitably impregnated or coated or when immersed in a dielectric liquid such as oil shall be used.
Materials or combination of materials may be included in this class if by experience or by accepted tests
they can be shown to be capable of operation at 105C.
23.5 MARSHALLING BOX:
23.5.1 Outdoor weather proof Marshalling box shall be supplied with each set o f C.Ts. (3 Nos.) in to
which secondary leads from each phase and each core shall be brought and terminated. Arrangements
for forming star/delta connection shall be made in this kiosk as also for ground connection. The kiosk
should be weather and vermin proof and shall be suitable to mount the same near the C.Ts. Core details
shall be clearly marked on the terminal blocks, which shall be capable of carrying the short time
secondary current and also shall be capable of withstanding 4 kV. The terminal shall be of 8 mm nut and
stud type made out of brass coated with nickel with two Nos. of flat brass washers nickel coated and
spring washer. Number of terminals to be provided shall be as follows:
220 KV, 66 kV & ]
27 Terminals (9 terminals in vertical column 3
rows each)
33kV class(3 cores)]
33 kV (2 core)
12 Terminals (6 terminals in vertical column)
Cable glands should be suitable for 4 Core PVC insulated, PVC sheathed 6/10 sq.mm. stranded copper
cable. 9 Nos. cable glands for other C.Ts. shall be supplied fitted to the marshalling box.
The outdoor kiosk shall be supplied for 220 KV, 66 kV and 33 kV class C.Ts.
Clearance between columns 150mm each from Base plate also terminals shall be at a height of 250mm.
23.6 TERMINAL CONNECTORS:
The terminal connectors shall meet the requirements as given in Section -1& 2.
23.7 TYPE TESTS :
23.7.1 In accordance with the requirements in Clause 13 Section - 2 current and voltage transformers
should have been type tested as per IEC/IS and shall be subjected to routine tests in accordance with
IEC 60044-1/IS : 2705 & IEC 60044-2 / IS : 3156 respectively. The type tested equipments only shall be
offered. The type test reports of not older than 5 years on the day of bid opening shall be furnished. The
contractor/ supplier shall arrange for conducting all type tests in case type test reports are older than 5
years on the day of bid opening at no extra cost to owner. However, the bidder shall quote the rates for all
type tests individually in the schedule. The owner at his discretion may require all or a few type tests, to
be conducted again even though type test reports are less than 5 years old on the day of bid opening. In
such cases the type test charges will be paid as per quoted rates in the schedule.
23.7.2 For 220 KV , 123K V / 72.5KV CTs and VTs following additional type tests are also proposed to
be conducted, in additional to the other type tests as per IS & IEC in the relevant schedule.
a)
Current Transformers :
1)
Radio interference test - As per IS: 8263
2)
Seismic withstand test (As per Annex - B of Section - 2)
3)
Thermal stability test i.e., application of rated voltage and rated current simultaneously by synthetic
test circuit.
4)
Thermal co-efficient test i.e. measurement of tan delta as a function of temperature (at ambient and
between 80 and 90C) and voltage (at 0.3, 0.7, 1.0 and 1. 1 Um/3)
b)
Voltage transformers :
1)
High frequency capacitance and equivalent series resistance measurement as per IEC60044 -2 .
2)
Seismic withstand test (as per Annex - B of Section -2)
3)
Stray capacitance and stray conductance measurement of the low voltage terminal - As per
IEC60044-2.
4)
Determination of temperature co-efficient test (as per IEC60044-2)
23.7.3 ROUNTINE TESTS

The current and voltage transformers shall be subjected to the following routine/ site tests in addition to
routine tests as per IEC/ IS.
a)
Current Transformers:
Routine Tests :
1) Measurement of Capacitance
2) High voltage power frequency withstand test on Secondary Winding
3) Over voltage inter turn test - As per BS : 3938

4) Oil leakage test
5) Measurement of tan delta at 0.3, 0.7, 1.0 and 1. 1 Um/3
6) Measurement of partial discharge, as per IEC 44 - 1
Site Test :
Dissolved gas analysis to be carried out at the time of commissioning. CTs must have adequate provision
for taking oil samples from the bottom of the CT without exposure to atmosphere. Bidder/ Manufacturer
shall recommend the frequency at which oil samples should be taken and norms for various gases in oil
after being in operation for different durations. Bidder/ Manufacturer should also indicate the total quantity
of oil which can be withdrawn from, CT for gas analysis before refilling or further treatment of CT
becomes necessary.
23.8 SPARE PARTS
The bidder shall include in his proposal spare parts in accordance with Section - 1 & 2.
23.9 PARAMETERS :
23.9.1 A) 123 / 72. 5kV Current Transformers
APPENDIX-3
Part 1 of 2
Technical Parameters of Current Transformers (Type & Rating)
No.
1
2
3
4
5
8.
9
10
11
12
Technical
Particulars
Normal
System
Voltage (KV)
Highest
System
Voltage (KV)
Frequency
Earthing
Basic
Insulation
Level (KV
Peak)
Power
Frequency
withstand
strength (KV
RMS)
Short Time
Current rating
(KA for 1 sec)
Secondary
winding
current rating
(Amp)
Number of
ratios
Ratio
Purpose for
which used
Method of
obtaining
Secondary
ratio
Type 2a
Type 2b
Type-3a
Type-3b
Type-3d
Type-4
Type-4a
110KV
110KV
66KV
66KV
66KV
33KV
33KV
123KV
123KV
72.5KV
72.5KV
72.5KV
36KV
36KV
50Hz
Effective
50Hz
Effective
50Hz
Effective
50Hz
Effective
50Hz
Effective
50Hz
Effective
50Hz
Effective
650
650
325
325
325
170
170
275
275
140
140
140
70
70
31.5
31.5
31.5
31.5
31.5
31.5
31.5
400200/1-11A
200100/1-11A
400-200/11-1A
200-100/11-1A
800-400/11-1A
400200/1-11A
200100/1-11A
66KV lines
Transform
usin Drake
er
& 630 Sq.
protection
mm cable
33KV line
protection
By
secondary
tapping
without
primary
reconnecti
on
By
secondar
y tapping
without
primary
reconnect
ion
66KV line
using
110KV
drake/
lines &
110KV
coyote &
110KV
Transform
31.5MVA
bus
ers
Tr. & 66KV
coupler
capacitor
bank
By
By
By
secondar secondary secondary
y tapping
tapping
tapping
without
without
without
primary
primary
primary
reconnec reconnecti reconnecti
tion
on
on
Up to
20MVA
66/11KV
Tr.
By
secondary
tapping
without
primary
reconnecti
on
By
secondar
y tapping
without
primary
reconnect
ion
No.
13
Technical
Particulars
Type 2a
Type 2b
Type-3a
Type-3b
Type-3d
Type-4
Type-4a
Suitability of
Bimetallic
terminal
connector
Drake
ACSR
(28.14m
m Dia or
50mm
Aluminiu
m Tube)
Drake
ACSR
(28.14mm
Dia or
50mm
Aluminium
Tube)
Drake
ACSR
(28.14mm
Dia or
50mm
Aluminium
Tube)
Drake
ACSR
(28.14mm
Dia or
50mm
Aluminium
Tube)
Drake
ACSR
(28.14mm
Dia or
50mm
Aluminium
Tube)
Drake
ACSR
(28.14mm
Dia or
50mm
Aluminiu
m Tube)
Drake
ACSR
(28.14mm
Dia)
APPENDIX-3
PART 2 OF 2
No
Type of
CTs
Distance/
110KV
Differential
CT Type
Scheme
2a
Core 1
Core 2
Core 3
Purpose
Metering
Backup
protection
110KV
Distance/
CT Type
Differential
2b
Scheme
Core 1
Core 2
Core 3
Rated
burden
Accura
cy
Class
Accurac
y limit
factor
Instrume
nt
security
factor
--
PS
--
--
10VA
0.2
--
30VA
5P
20
5 at all
ratios
--
--
PS
--
--
400V at
200/1A
10VA
0.2
--
--
20
5 at all
ratios
--
Backup
protection
PS
--
30VA
--
5P
Core 3
800V at
400/1A
---
4 Ohm at
400/1A
--
2 Ohm at
200/1A
30mA at
Vk/4
---
30mA at
Vk/4
Metering
66KV
CT
Differential
Type-3a Scheme
Core 1
Core 2
Seconda
ry
Knee
winding Magneti
point
resistanc
zing
volts (
e max. at current
min) VK
750C
RCT
Metering
10VA
0.2
--
5 at all
ratios
Back
30VA
5P
20
--
-1600V
at
400/1A
800V at
200/1A
--
--
4 Ohm at
400/1A
2 Ohm at
200/1A
--
--30mA at
Vk/4
30mA at
Vk/4
--
66KV
CT
Differential
Type-3b
Scheme
Core 1
Core 2
Core 3
33KV
CT
Type-4
Core 1
Core 2
Core 3
33KV
CT
Type-4a
Core 1
Core 2
PS
--
800V at
200/1A
Metering
10VA
0.2
--
5 at all
ratios
--
Back
30VA
5P
20
--
--
--
Core 3
66KV
Distance/
CT
Differential
Type-3d
Scheme
Core 1
Core 2
--
--
PS
Metering
10VA
0.2
--
5 at all
ratios
Back
30VA
5P
20
--
PS
--
10VA
0.2
--
5 at all
ratios
30VA
5P
20
--
Metering
10VA
0.2
Protection
30 VA
5P
-Differential
Scheme
Metering
Back
-20
5 at all
ratios
--
1400V
at
800/1A
2 Ohm at
200/1A
30mA at
Vk/4
--
---
5 Ohm at
800/1A
--
30mA at
Vk/4
--
--240V at
400/1A
---
---
-5 Ohm at
400/1A
---
30mA at
Vk/4
---
--
--
--
--
23.10 TESTING & COMMISSIONING:

23.10.1 An indicative list of tests is given below. Contractor shall perform any additional test based on
specialties of the items as per the field Q.P/ Instructions of the equipment Supplier or Owner without ay
extra cost to the Owner. The Contractor shall arrange all instruments required for cond ucting these tests
along with calibration certificates and shall furnish the list of instruments to the Owner for approval.
23.10.2
Current Transformer
a)
Insulation Resistance Test for primary and secondary
b)
Polarity test
c)
Ratio identification test - checking of all ratios on all cores by primary injection of current.
d)
Dielectric test of oil (wherever applicable)
e)
Magnetizing characteristics test.
f)
Tan delta and capacitance measurement
g)
Secondary winding resistance measurement
TECHNICAL SPSCIFICATION FOR VOLTAGE TRANSFORMERS :

24.1 SCOPE :
24.1.1 This specification provides for design, manufacturer, inspection and testing before dispatch,
packing and delivery FOR (Destination) testing and commissioning of electro magnetic type outdoor
voltage transformers along with all accessories specified herein for protection and metering services. The
voltage class of VTs required are 220 KV ,110KV, 66KV and 33KV.
24.1.2 Following is the list of documents constituting this specification:
i)
Technical specification
ii)
Technical Data sheets
24.1.3 The voltage transformers, shall conform in all respects to high standards of engineering, design,
workmanship and latest revisions of relevant standards at the time of offer and owner shall have the
power to reject any work on material, which in his judgment is not in full accordance there with.
24.2 STANDARDS:
24.2.1 Unless otherwise specified elsewhere in this specification, the voltage transformers shall conform
to the latest revisions and amendments there-of of the following standards
Sl No
1
2
3
4
5
6
7
8
9
Standard No
IER : 1956
IS : 5
IEC : 44(4)
IEC : 60
IS : 104
UEC : 171
IEC : 270
IS : 335
IS : 649
10
11
12
IS : 2071(Part I to III)
IS : 2099
IS : 2147
13
14
15
16
17
IS : 2165
IS : 2927
IS : 3156
IS : 3024
IS : 3134
18
19
20
IS : 3347
IS : 5561
IS : 5621
Title
Colours for paint and enamels
Voltage transformers-measurement of PDs
High voltage testing techniques
Ready mixed paints and brushing
Insulation coordination
Partial discharge measurement
Insulating oil for transformers
Methods of testing of steel sheets for magnetic circuits and
power electrical apparatus
Method of high voltage testing
High voltage porcelain bushings
Degree of protection provided by enclosures for low voltages,
switchgear and control
Insulation coordination for equipment of 220 KV and above
Brazing alloys
Electrical steel sheets (oriented)
Guide for selection of insulators in respect of polluted
conditions
Dimensions for porcelain for transformer bushings
Electrical power connectors
Hallow insulators for use in electrical equipments
Sl No
21
22
Standard No
IS : 6792
IEC : 8263
Title
Determination of electrical strength of insulating coils
Method of RIV test on high voltage insulators
24.2.2 Equipment meeting with the requirements of other authoritative International Standards, which
ensure equal or better performance that the standards mentioned above, shall also be considered. When
the equipment offered by the supplier conforms to other standards, salient points of difference between
standards adopted and the standards specified in this specification shall be clearly brought out in the
relevant schedule. Two copies of such standards with authentic translation in English shall be furnished
along with the offer.
The Voltage Transformers covered in this specification shall meet the technical requirements listed
hereunder:
Sl. No
1
Item
Type / Installation
2
3
4
5
Type of mounting
Highest system frequency
Suitable for system frequency
Voltage Ratio:
i) Rated primary voltage
6
7
8
9
10
11
12
123 KV
72.5 KV
36 KV
Single phase oil filled hermetically
sealed outdoor type
------ Pedestal Type --------123
72.5
36
-------- 50 Hz -----------
110kV / 66kV /3
33kV / 3
3
ii) Secondary voltage (volts)
---------- 110V / 3 --------Method of earthing the system ----- Effectively earthed ----where the VT will be installed
(Solidly grounded)
1.2 / 50 micro second lightning 550
325
170
impulse withstand voltage (KVP)
1 minute dry power frequency 230
140
70
withstand voltage primary (KV
rms)
Minimum creepage distance of 3075
1813
900
porcelain housing (mm)
---- 1.5 for 30 seconds --- 1.2
continuous
1 minute power frequency
withstand voltage
i) Low voltage terminal (HF) and 4 if the low voltage is exposed to
earth terminal (KV rms)
weather
ii) Withstand voltage for ----- 2 -------secondary winding (KV rms)
Max temperature rise over ---- As per IEC 86 ----ambient of 50 deg C
Sl. No
13
14
15
16
Item
Rated total thermal burden
123 KV
72.5 KV
36 KV
--- 300 VA ---for core I
---- 200 VA ---for core II
---- 50 VA --- for core III
No. of terminals in control All contacts and control circuits to be
cabinet
wired up to control cabinet plus 20 %
extra terminals exclusively for owners
use.
Siesmic
accelaration ------- 0.3 g ------(Horizontal)
Standard reference voltage for
which accuracies are valid
97% to 103% for protection
99% to 101% for metering
COREWISE DETAILS OF VOLTAGE TRANSFORMERS

No.
1
2
3
4
PARTICULARS
Rated
primary
voltage
Type
No. of Secondaries
5
6
Phase angle error

Rated voltage (volts)
Application
Accuracy
Output Burden
123 Kv
REQUIREMENTS
72.5kV
36kV
110kV / 3
66kV / 3
------single phase VT -------------- 1.2 continuous --------------- 1.5 for 30 seconds --------------- + / - 20 minutes ------CORE I 110V CORE I 110V /
/ 3
3
CORE II 110V CORE II 110V /
/ 3
3
CORE III CORE III 110V /
110V / 3
3
Metering
Metering
protection
protection
Open
Delta Open
Delta
protection
protection
0.2
0.2
3P
3P
3P
3P
300VA
300VA
200VA
200VA
50VA
50VA
33kV /3
CORE I 110V / 3
CORE II 110V /
3
CORE III 110V /
3
Metering protection
Open
Delta
protection
0.2
3P
3P
300VA
200VA
50VA
24.4 DEFINITIONS AND TERMINOLOGY:

In accordance with Clause 3.0 and sub-clauses there of as per IS : 3156 (part I to III ) 1998.
24.5 SERVICE CONDITIONS:
This shall be in accordance with Clause 4.0 and sub -classes thereof as per IS : 3156 ( Part I ) 1998
except for the Clauses 4.4 , 4.5 (a), 4.5 (b) 4.5(c) (ii). However , the voltage transformers shall be suitable
for tropical conditions and for atmospheres conductive to the growth of fungi and condensation of
moisture. The VTs shall be suitable for installation in a solidly grounded system.
24.6 INSTALLATION REQUIREMENTS, TYPE AND CONSTRUCTION :
24.6.1 GENERAL :
The VTs shall be suitable for outdoor installation and for upright mounting on steel structures. The
necessary flanges, bolts, etc., for the base of VT shall be supplied and these shall be galvanized.
24.6.2 They shall be of the oil immersed, self cooled type and provided alternatively with an inert gas
cushion or with metallic bellows above the-insulating oil level. A pressure relief device valve type may
also be provided if permitted to design. The base shall be provided with suitable. welded M.S. Channels
for bolting the VT in an upright position to the VT mounting structure.
24.6.3 DESIGN :
The VTs may be built up of high-grade non ageing cold rolled grain oriented silicon steel lamination,
conforming to IS : 3024, of low hysterisis losses and high permeability to ensure high accuracy at both
normal rated and above rated voltages. The laminations shall be coated on both sides with sui table
insulation capable of withstanding stress relieve annealing. The cores shall meet with the requirements of
the accuracy class, corresponding to the voltage factors in respect of the composite limits of accuracy as
applicable for each type of core namely metering and protection.
24.6.4 INSULATING OIL
The oil shall be mineral insulating oil conforming to IS : 335-1983.
24.6.5 LIMITS OF TEMPERATURE RISE:
This shall be with reference to an ambient temperature of 45 C at specified rated frequency and at rated
burden or at the highest rated burden connected to the secondary windings. The limits of temperatures
rise shall not exceed the values specified in Table 3 of IS : 3156 (Part -1) 1998. However, if the voltage
transformers has an inert gas cushion above the oil at the top of the tank or housing shall not exceed 50
C.
24.6.6 WINDING:
24.6.6.1 Primary Winding:
Primaries of Potential Transformers will be connected in phase of Neutral with the neutral point solidly
earthed. The neutral of the system is also solidly earthed. The primary winding shall be of copper.
24.6.6.2 Secondary Winding:
Potential Transformers shall be provided with three secondary windings each rated for 63.5 Volts. Core -I
will be used for metering, Core-II for protection and Core-III for Open Delta. The secondary winding shall
be of copper.
24.6.6.3 Normally no joints in the winding shall be allowed. Joints unavoidable shall be braized with high
silver alloy grade of IS: 2927 or but welded.
24.6.7 BUSHING:
This shall be as per Clause 4.1 of IS : 3156 ( Part-l )-1992. A prismatic oil sight gauge glass shall be
provided on the top of the bushing metal assembly. The minimum creepage length of the bushing
insulator/ hollow insulator shall be as follows:
123kV
3075 mrn
72.5 kV
1813 mm
36 kV
900 mm
24.6.8 EARTHING:
Refer Earth mat specification, Volume - 11.
24.6.9 TERMINAL ARRANGEMENT:

24.6.9.1 Primary:
The primary bushing terminals shall be of the rigid type suitable for connection to an ACSR conductor
through terminal connectors. The terminal shall be of tin plated copper, the connector shall be a bimetallic
connector conforming to IS : 5561-1970 and shall be as per Clause 7.00 infra specified herein.
The HV neutral end terminal shall not be earthed directly to the metal body of the VT but shall be brought
out through a porcelain 2 KV class bushing. Similarly an earth bushing, shall also be provided for
connecting to the owner's GI flat earth riser. A tinned copper link of the bolted type shall be provided to
connect the HV neutral end terminal and the earth bushing. Both the HV neutral end bushing and the
earth bushing shall be housed in a. dust tight, vermin proof box with a front access bolted type gasketted
cover. This housing shall be on the opposite face of the secondary terminal box. The HV neutral terminal
box shall be provided with caution plate indicating it is dangerous to open this link when the PT is
charged. (Red colour)
24.6.9.2 Secondary :
The secondary terminals of the VT shall be housed in a dust tight, vermin proof box and with a front
access gasketted cover. The terminal box shall be of mild steel of thickness 3 mm. The terminals shall be
made of brass and of the front projection stud type. The stud shall be provided with a locking checknut
and other checknuts for securing the crimped terminals of external VT secondary cables. The bottom of
the box shall be provided with nickel-plated cable glands to receive and support 2 x 6 sq mm PT
secondary cables. The number of glands shall be equivalent to the number of secondary cores.
24.6.9.3 V.T. Marshalling Box:
A weather proof, vermin proof, outdoor type separately mounted marshalling box shall also be supplied
and installed for each of the three phases, at the rate of one number for each set of 3 nos. of phase
connected VTs. The marshalling box shall be of such size so as to accommodate three sets of vertically
mounted terminal blocks. The secondary leads from each phase and core are to be connected to these
terminal blocks for forming star or delta connection. The terminal blocks shall be of the cast resin
moulded type capable of withstanding 2 KV for 1 (one) minute. The terminals shall be of the front
projection brass stud and nut type provided with locking checkouts and with hexagonal nuts, flat spring
washers for securing the crimped conductor lugs of external cables. Insulated cast resin barriers shall
also be provided in between the different terminals in the terminal block. Each terminal block shall contain
9 (nine) numbers of terminals. 9 Nos. of terminals in each column x 3 columns for each core 1, core 2,
core 3 with minimum of 150mm space between each column to facilitate wiring.
Bottom of the each column should be atleast 250mm above the base plate / Glanding plate to facilitate to
pull the cable for connection. Terminal Bolt / stud type Brass coated with nickel, along with flat washers /
spring washers of Brass coated with nickel size not less than 8mm. The box shall be provided with a front
access gasketted cover and an earthing stud. The cover shall be of the bolted type. The earthing stud
shall be provided with brass locking checknuts both on tile inside and outside and with brass nuts, flat
and spring washers. The bottom plate of the box shall be provided with 3 (three) Nos. of cable glands
suitable to receive 2 x 3 sq mm VT secondary control cables. The terminals shall preferably be shrouded
with transparent plastic covers.
The top of the box shall be provided with 3 (three) Nos. of 25 mm circular dummy plates for fixing PVC/G
l pipes for leading in the secondary lead wires or cables from the VT secondary terminals of each
individual VT. The kiosk shall be painted both on the inside and outside with two coats of grey enameled
paint as per Clause 8.00 infra
24.7 PRIMARY TERMINAL CONECTOR:
24.7.1 The connection shall be a rigid bimetallic connector suitable for receiving ACSR conductor as
follows
123 KV DRAKE ACSR of overall diameter 28.14mm
72.5 KV DRAKE ACSR of all diameter 28.14 mm / LYNX ACSR of overall
diameter 19.53mm
36 KV DRAKE ACSR of all diameter 28.14 mm / LYNX ACSR of overall
diameter 19.53mm / COYOTE ACSR of overall diameter 15.86mrn
24.7.2 The connector shall conform in all respects to Clauses (4),(5),(6),(7),(8) and sub -clauses thereof
as per IS : 5561-1970. The connector shall also be etched with the name of the ACSR conductor, which it
shall receive.
24.7.3 The rating of the connector shall be as follows
Rated current
400Amps
Rated frequency
50 Hz
Rated short time current
31.5 KA for 123 KV,

72.5KV & 36 KV
24.8 PAINTING:
All metal surfaces in contact with insulating oil shall be painted with heat resistant paint insoluble to oil
and insulating varnish. The pre-painting procedure shall consist of sand blasting, de-rusting, phosphating
and priming of both the exterior and interiors in accordance with IS : 6005 - 1970.
24.9 MARKING
Every VT shall have the markings conforming to Clause 7.0 and sub clauses thereof as per IS : 3156
(Part - I) and (Part -II) - 19992 and clause 9.0 and sub - clauses thereof as per IS : 3156 (Part III) 1992.
24.10
24.10.1
TESTS:
Classification:
This shall be as per clause 9.0 and sub-clauses thereof as per IS: 3156 (Part-I) - 1992.
24.10.2
Type Tests :
This shall be in accordance with clauses 8. 1. 1 as per IS : 3156 (Part-I) 1992; 8.1 of IS : 3156 (Pa-it - 11)
- 1992, Clause 9.0 of IS: 3156 (Part - II) - 1992. The type tested equipments only to be offered. The type
test reports not older than 5 years on day of bid opening shall be produced, otherwise type tests shall be
conducted at no extra cost to owner.
24.10.3
Routine Tests :
The shall be as per Clause 9.12 IS : 3156 (Part - I) - 1992, 9.0 of IS : 3156 (Part - II) - 1978, Clause 9.2
of IS : 3156 (Part - III) - 1992.
24.10.4
Special Tests
This shall be as per Clause 9.1.3 (a) only as per IS: 3156 (Part - I) 1992.
24.10.5
Routine Tests and Test Reports
All routine and acceptance tests shall be conducted in the presence of owner's representative. All test
reports shall be got approved from the owner. No dispatches shall be effected without approval to the test
certificates.
24.10.6
Inspection
A representative of the owner shall have free access at all times to inspect the manufacturer's work and
to witness the tests.
SECTION - 8
MECHNICAL WORKS
B. MECHANICAL WORKS
SPECIFICATIONS FOR PUMPING MACHINERY
GENERAL SECTION:
G.0 GENERAL AND MISCELLANEOUS SPECIFICATIONS:
G.1 PUMP HOUSE AND EQUIPMENT:
The equipment mentioned is required to be provided and installed at Mulwad Pump House
situated near intake under KBJNLs Lift Irrigation Scheme for lifting of requisite quantity of T.M.C.
water for irrigation purpose.
The ambient temperature to be adopted for the design of the equipment shall be 45 0.
G.2 SCOPE OF MISC. AND CIVIL WORKS:
All the works like foundation laying, grouting, R.C.C. work for chairs of valves, manifolds, thrust
blocks and painting etc. As described in detail in the following paras (nos. G3 to G11) will have to
be inclusive of all such items. The required material, labour and machinery for such works are to be
arranged by the contractor at his end.
G.3 FOUNDATION WORKS:
The surfaces of foundations shall be dressed to bring the top surface to the required level, prior to
the placement of equipment/equipment bases on the foundations.
All the equipment bases and structural steel base plates shall be grouted and finished as per these
specifications unless otherwise recommended by the equipment manufacturer.
The concrete foundation surfaces shall be properly prepared by chipping, grinding as required to
bring the top of such foundation to the required level to. Provide the necessary roughness for
bondage and to ensure enough bearing strength. All laitance and surface film shall be removed
and cleaned.
G.4 GROUTING MIX:
The grouting mixture shall be composed of Portland cement, sand and water. The Portland
cement to be used shall conform to is 269 or equivalent, sand shall conform to relevant applicable
is or equivalent. The grout proportions for flat bases where the grouting space does not exceed 25
mm shall be 50 kg. of cement 75 kg. of sand. Only the required quantity of water shall be added so
as to make the mix must workable and the mix shall not show excess water on stop when it is
being puddle in
place. For thicker grout beds upto 65 mm, the amount of sand shall be increased to 105 kg. per
bag of cement. Bases which are hollow and are to be filled full of grouting shall be filled to a level
of 26 mm, above the outside rim with a mortar mix in the volumetric propo rtions of one part of
cement. 1.5 part sand and 1.5 part 6 mm, hard gravel by volume. An acceptable plasticizer may
be added to the grout mixes in a proportion recommended by the manufacturer of plasticisers. All
such grouts shall be thoroughly mixed and shall be used immediately after mixing.
G.5 PLACING OF GROUT:

Before actually placing the grout a low dam shall be set around the base at a distance that permit
pouring and manipulation of the grout. The height of such dam shall be at least 25mm above the
bottom of the base. Suitable size and number of chairs shall be introduced under the base before
placing the grout so that such chairs can be moved back and forth to push the grout into every part
of the space under the base.
G.6 FINISHING OF THE EDGES OF THE GROUT:
The poured grout should be allowed to stand undisturbed unit it is well set immediately thereafter,
the dam shall be removed and grout which extends beyond the edges of the structural or
equipment base plates shall be cut off, flushed and removed. The edges of the grout shall then be
pointed and finished with 1:2 cement-sand mortar pressed firmly to bond with the body of the grout
and smoothened with a tool to present a smooth vertical surface. The work shall be done in a
clean and scientific manner and the adjacent floor spaces, exposed edges of the foundations and
structural steel and equipment base plates shall be thoroughly cleaned of any spillage of the grout.
G.7 CHECKING OF EQUIPMENT AFTER GROUTING:
After the grout is set and cured, the contractor shall check and verify the alignment of equipment,
alignment of shafts and rotating machinery, the stops of the bearing pedestals, centering of rotors
with respect of their sealing bores couplings, etc, as applicable and the like items to ensure that no
displacement has taken place during grouting. The values recorded prior to grouting shall be used
during such post grouting check-up and verifications.
Such pre and post grout records of
alignment details shall be maintained by the contractor in manner acceptable to the Engineer.
G.8 SHAFT ALIGNMENT:
All the shafts of rotating equipment shall be properly aligned to those of the matching equipment to
as perfect an-accuracy as practicable.
The equipment shall be free from excessive vibration so as to avoid overheating of bearings or
other conditions which may tend to shorten the
life of the equipment. All bearings, shafts and other rotating parts shall be thoroughly cleaned and
suitably lubricated before starting.
G.9 DOWELING:
All the drive motors and other equipment shall be suitably doweled after alignment of shafts with
tapered machined doweling as per the direction of the Engineer.
G.10 PAINTING:
All exposed metal part of the equipment including pumping, structures, railings, etc., wherever
applicable, after installation unless otherwise surface protected, shall be first painted with at least
one coat of suitable primer which matches with the shop primer paint used after thoroughly
cleaning all such parts of all dust, rust, scales, greases, oils and other foreign materials by wire
brushing, scraping or sand blasting, and the same being inspected and approved by the engineer
for painting. Afterwards the above parts shall be finished with two coats of alloyed resin machinery
enamel paints. The quality of the finish paint shall be as per the standards of relevant i.e. or
equivalent and to be of the colour as approved by the engineer.
G.11 COLOUR CODE FOR PIPE SERVICES:
All pipe services wherever applicable are to be painted in accordance with the manufactures
standard colour scheme by the Contractor.
DETAILED ITEM WISE SPECIFICATIONS

VERTICAL TURBINE PUMPS
1.1
GENERAL:
For mounting.
These components shall be from pump manufacturers only. The complete
assembly consisting of steel base frames, sole plate and bottom pieces shall be stress relieved
after fabrication and before machining. Test certificate from manufacturer regarding stress relieving
with observation sheets from column pipe, discharge head, base frame, motor stool etc., shall be
furnished. All necessary details regarding pump and motor mounting shall be furnished well in
advance by the contractor for prior approval and to ensure necessary pockets in civil works.
Work of erection pumps, motors including laying under this section, specifications of vertical turbine
pumps are outlined. The Vertical turbine pumps shall generally conform to IS 1710 of 1972.
The specifications given in this section are for the following type of V.T. pumps.
V.T. Pumps-self water lubricated-surface discharge type.
V.T. Pumps-self water lubricated-sub surface discharge type.
V.T. Pumps-forced water lubricated-surface discharge type.
V.T. Pumps-forced water lubricated-sub surface discharge type.
1.2
PUMP DUTIES:
1.2.1 DUTY POINT DISCHARGE:

The pump shall have to give a discharge at normal water level conditions at duty head and shall
give corresponding higher discharge for the lesser heads.
1.2.2 DUTY POINT PUMP HEAD:
Duty point pump heads for pumps, as corresponding to normal W.L. shall be designed by the
bidders.
No loss of head what-so-ever in entry, strainer, bell mouth, bowl assembly, column pipes and
discharge tee is accounted for in the calculations of pump head. The bidder/manufacturer shall
have to account for these losses while designing the pumps. However, head loss delivery pipe,
valves fittings, rising mains and velocity head beyond discharge flange on discharge head/pumps
casing are to be included. Thrust bearing loss may be declare separately by the manufacturer.
1.2.3 DUTY POINT EFFICIENCIES:
The Tenderer should evaluate the above efficiencies and specify the same in their offer alone with
calculations. The curves for both types of efficiencies viz., pump efficiency and overall efficiency
for entire starting from shut off the static head should be invariably submitted along with the offer.
1.2.4 HEAD RANGE AND PARALLEL OPERATIONS:
The pumps will satisfy the head requirement as per the system resistance curves, while operating
in solo and in any combination as per design requirement. The pumps should be suitable for
operation in head range. The system resistance curves of the pumps shall be submitted by the
bidders.
1.2.5 POWER MARGIN:
The pumps shall be capable of operating in the range without being overloaded at any point and
keeping a margin of at least 5% of power in the moto r pump over entire operating range.
Requirement of power at shut off should not exceed power requirement at duty point. The pump
should be capable of starting against fully closed Butterfly valve without being overloaded at any
point upto valve fully open.
1.2.6 PUMP CHARACTERISTICS:
The pump characteristics shall be of stable nature and such that the efficiency is fairly steady for
the water level variations as mentioned in the foregoing clauses. The maximum efficiency point will
be nearer to the duly point and fairly constant for larger range on either side. The pumps should
run smoothly from lowest head to shut off point, without cavitations and vibration (within H.L.S.
limitations for vibrations). The variation in the efficiencies for any point of operati on in the entire
operating range should be minimum.
1.2.7 NPSH CONDITIONS (NET POSITIVE SUCTION HEAD CONDITIONS):
NPSH required by pumps offered by the Tenderer should be lesser by at least 0.5 meters than
N.P.S.H.A. at duty point and shall not exceed the N.P.S.H. available at any point of operation in the
range, with solo and parallel operations.
The Tenderer shall take following values of the
corresponding parameters for the purpose of calculation of N.P.S.H.A. at the site.

i)
Atmospheric
9.6 Meter column of water
ii)
Vapour pressure of water :
0.6674 Meters
(at 37.80 C Normal temperature) column f water.

1.2.8 SPEED:
Pump speed should be decided by the tenderers based on optimum and cost economic
consideration.
1.2.9 SOLID HANDLING CAPACITY:
The pumps shall be suitable for pumping of raw river water containing silt coarse sand and gravel /
suspended solids upto 20 mm size. Tenderer to get water analysis done and suitable preventive
special alloy coating needs to be provided to the impellers and casings to avoid any d amage due to
abrasive material in raw water.
1.2.10 CLASS OF OPERATION:
The pumps shall be suitable for non stop continuous 24 hours operation without interruption.
1.3
SUMP MODEL TESTING:
It is obligatory on the part of the Contractor to carry out Sump Model tests at C.W.P.R.S. Pune or
Indian Institute of Science Bangalore or any such reputed laboratory with prior approval of the
Engineer, at his own cost and at the earliest after issue of Work Order. The Contractor must fully
satisfy himself about the suitability of the proposed design and layout of the
sump, to ensure vortex free and cavitations free operations of the pumps. Two representative of
the KBJNL will be deputed of this test, if so desired by KBJNL. The Contractor will have to bear
the expenses to wards their traveling, boarding and lodging etc., for attending the above test. Test
results in triplicate of the Contractors Sump Model testing should immediately be sent to the
Engineer-In-Charge, along with proposals of the Contractor if any, for his consideration.
1.4
DEFINITIONS OF EFFICIENCES:
For all purpose of this contract, the various efficiencies will have the same meaning and effect as
defined in the IS 1710-1972 (page 5) which are reproduced below.
I)
BOWL EFFICIENCY:
The ratio of bowl assembly output to bowl assembly input expressed as percentage.
II)
PUMP EFFICIENCY:
The ration of pump output to pump input expressed as percentage.

III)
OVERALL EFFICIENCY:
The ratio of pump output to driver input expressed as percentage.

1.5
CONSTRUCTION FEATURES FOR V.T. PUMPS:
The pump shall vertical, spindle suspended and non-pullout type. Number of stages should be
decided by the tenderers. The pumps shall comprise of Bowl Assembly, line shaft enclosing tubes,
line shaft bearings, line shaft bearing holders, discharge head thrust bearings, sole plates, base
frames, flexible coupling etc.
1.5 A) The pump shall be self water lubricated type or
1.5 B) The pump shall be forced water lubricated type as the case may be
1.5.1 The pump bowl/bowls shall be flanged with machined mating faces. The bowl shall be
flange joined to the discharge nozzle or suction nozzle. Bowl wearing rings be of replaceable type.
The casing shall be provided with water lubricated bearings.
1.5.2 A Ni-Cl bell mouth shall be fitted to suction nozzle to reduce inlet velocity to 1.5 mtrs/sec.
Maximum. The suction strainer shall be of galvanized MS and sufficiently strong to stand the
suction pressure. Area of opening shall not be less than 2.5 times bell mouth area.
1.5.3 Impellers shall be enclosed type, cast in one piece and balanced both statistically and
dynamically. The impellers shall be provided with wearing
ring on it. The interior surfaces and passages shall be smoothly finished to obtain the highest
efficiency and shall be designed to ensure smooth operation free from any cavitation or vibrations.
As raw water is being pumped, balancing holes/ devices will not be accepted for balancing the
hydraulic thrust.
1.5.4 The pump height (i.e., impellers) should be adjustable from the top of pump head. There
should be a sufficient vertical clearance between the bowl and impeller to accommodate for the line
shaft elongation due to hydraulic thrust, while in operation.
1.5.5 The impeller shaft will not overhung at the bottom and will be rotating in bearing support at its
bottom.
1.5.6 The line shaft shall be solid type and will be designed to take all types of loads such as
torsion, tensile and dynamic etc. Impeller shaft will have muffled coupling arrangements.
The line shafts bearing shall be water lubricated type with cutlass rubber, grooved to facilitate
lubrication. Line shaft bearing shall be provided at suitable intervals to ensure that first critical
speed is at least 25% more than rotative speed. Suitable steel sleeves be provided to line shafts.
(e.d) The line shaft protection tubes shall be provided for forced water lubrication to line shaft
bearings. The line shaft protection tubes should be of heavy duty seamless steel tubes and shall
withstand all mechanical and hydraulic forces exerted on it with an allowance for corrosion and
wearing.
1.5.7 The column pipe shall be of extra heavy weight, electrical fusion welded (EFW) single
longitudinal joint, or electrical resistance welded (ERW) pipes with both ends flanged, machined on
surfaces, edges and spigotted to facilitate the alignment. The flanges shall have grooves to
accommodate the rubber rings.
1.5.8 The discharge head/motor stool shall be of full diameter, flanged at ends, flanged surfaces
and Tee ends machined, fabricated out of MS in smooth 90 0 bend so as to have minimum loss of
head in and stress relieved before machining. The pump discharge head shall be fabricated and
suitably reinforced to withstand all types of static, dynamic loads, hydraulic thrust, torshional loads
imposed by the pump, motor and to limit vibrations. The pump discharge head/motor stool shall
house thrust bearings with cooling arrangement and contain cast iron stuffing box in which the
pump top shaft shall be sealed. A sufficient opening should be provided so as to have an easy
access and workability on stuffing box. Non reverse rotation ratchet arrangement is to be provided
either in pump or in motor so as to prevent the pump from rotating in reverse direction.
1.5.9 The column assembly shall be in standard lengths as far as possible.
1.5.10 The clearance between bell mouth, strainer and sump floor and also nearing walls should
be such that the vortex free operation is obtained. Any changes in this clearance if required other
than those specified shall be clearly mentioned in the offer, with reasoning thereof.
1.5.11 The pump shall be subsurface discharge type with discharge-head with integrated or
separate motor stools suitable for mounting in the R.C.C. floor of pump house. The construction
should be such that the pump discharge head with thrust bearings, motor stool along with the
motor shall be resting on the pump floor only.
1.5.12 Steel sole plates of adequate thickness shall be provided under the pump discharge
head/pump head/motor stool, together with all necessary anchor bolts, nuts and washers to
provide precise horizontal and vertical alignment. The sole plate shall be fixed on steel based
frames to be anchored in R.C.C. floors. The surfaces of base frame, sole plate and base plate
shall be smoothly and snugly fitted so that no vibration shall occur. The fastening of base frame to
sole plate and sole plate to base of pump/motor shall be through nut bolts or headed studs.
The opening in the sole plates and the base frame shall be of sufficient diameter to pass the
complete bowl assembly including suction bell and strainer.
The erection and dismantling of both the pumps and motors shall be possible from the motor floor,
with EOT / HOT crane available in the motor hall. The motor or the pump discharge head shall not
be rested either on the pump floor or motor floor while erecting or dismantling on places other
than respective base frames/sole plates. The above components should always be carried from or
to the service bays directly, while assembling, or dismantling. The contractor will be responsible to
get design from the pump manufacturer and approved from KBJNL. The steel base frames
fabricated from plates together with machined bottom pieces, sole plates, all anchoring
arrangement, support etc., for pump and mong of foundation, grouting, shaft alignment, doweling
and painting etc., shall be done by the contractor at his own cost as per general and miscellaneous
specifications mentioned earlier.
1.5.13 The thrust bearing shall be anti friction heavy duty type. The bearing shall be designed to
accommodate all possible loads under normal operations or shut of condition and shall be suitable
for reverse rotation upto at least 1.5 times the normal forward speed. The bearing shall be oil
lubricated type and shall be provided with oil level gauge and temperature measuring and sensing
system and cooling system as given below.
One no. temperature probe suitable for dial type thermometer with dial temperature.
One no. 3 wire platinum element having DC resistance f 100 ohms at 0 0 C suitable for use with a
digital temperature, scanner as specified in electrical section.
The cooling water supply for the pump thrust bearing if required, shall be taken from a adequate
tapping from the pump discharge head or line shaft bearing lubrication (forced water). Necessary
valves, strainers and non-flow sensors and annunciation system on panel board shall be provided
for this cooling system. The life of thrust bearings shall not be less than 40000 hours of operation.
1.5.14 (c, d) FORCED WATER LUBRICATION AND COOLING SYSTEM:
The forced water lubrication system for transmission bearing and supply of cooling water to pump
thrust bearing and for motor cooling shall be generally as mentioned below.
Set of manual type Pressure filters along with differential pressure switches, pressure gauge built
in valves etc., are to be provided to clean stream of water from main header containing fine, un-
dissolved solids like sand, dust, abrasives etc. The raw water should be made to enter into the
inlet of Pressure filter at sufficient pressure. The contaminant should be separated and should
pass downwards and ultimately discharging out of the drain of the Pressure filter.
The clean and solids free water free from the outlet of filter should be used for the thrust bearing
cooling and lubrication of line shaft/transmission rubber bearings of the V.T. Pumps and for cooling
of vertical motors.
The system shall comprise of following:
One set of manual Pressure filter of adequate size for each pump shall be provided having
sufficient design capacity of V.T. Pump lubrication and cooling to thrust bearing and motor cooling.
Booster pump sets complete with motor, base plate, switches and starter etc. (One working + One
stand bye) suitable for group of 8 or less V.T. pumps sets shall be provided having adequate
capacity in discharge and head with sufficient margin.
Suction pipe for Booster pumps with valves etc., for raw water to be taken off from the R.C.C.
storage tank being provided for the purpose by the Contractor.
All Pumping valves, gauges press switches, Solenoid valves etc., shall be p rovided as per
schematic drawing.
Electrical interlocks with suitable sensors must invariable be provided for forced water lubrication
system and cooling system. The arrangement
should trip the main pump motor in the even of failure of water supply from booster line to either of
line shaft lubrication system thrust bearing cooling or motor cooling. The arrangement for tripping
the main pump motor should be such as to allow contains time lay for the stand by booster to take
over.
Automation with all relays, sensors, switch gears and solenoid valves etc., shall be provided so that
if any Booster pumps trips or fails to deliver water the stand -bye set should start automatically and
feed V.T. Pumps sets the lubrication and cooling system and stop the defective Booster pumps.
1.5.15 (c.d) The water storage tank provided to initial start could be made the only source of
water for feeding the booster pumps. These tanks could be continuously fed with water from the
delivery system so as to keep the water level more or less constant. So, that the tank could feed
the booster pump on a continuous basis. To avoid head load on pressure filtration system water to
be drawn from the storage tanks at a level not lower than the middle level of the tank.
1.5.16 A. A suitable arrangement to take out the entrapped air in the pump column discharge tee
shall be provided with pipe fitted in the tapping at suitable place in the pump, with valve, etc.,
complete the make the system work satisfactorily.
1.5.17 Suitable topping appropriate place shall be provided for mounting a delivery pressure
gauge. The pressure gauge shall be Bourdon type and shall be provided with piping U type and
tabulating socket etc. This pressure gauge shall be provided and located at operating level i.e.,
motor floor level. Gauge range shall be twice the head to be measured. Drain cocks should be
placed immediately below the gauged so that frequent tests could be made to determine whether
pipe connections of the gauge are filled with water. The bourdon type gauge shall be fixed in such
a way that no strain is placed on its case so that readings are not affected. Gauge shall be
calibrated prior to after the tests and shall be fixed in upright position.
1.5.18 (c.d) In case of emergency i.e. failure of Booster pumps of filtration system, necessary
system shall be installed by the contractor for supply of raw water for lubrication of Pumps and
motor by necessary tapping from pump delivery line, by passing the regular cooling/lubrication
system.
1.6
MATERIALS OF CONSTRUCTION FOR V.T. PUMPS/BOOSTER PUMPS:

Bell mouth, pump bowls, suction
Ni-CI conforming to IS 210 grade 20
casing
And discharge nozzle
Impellers shaft for V.T. Pumps and
Stainless steel AISI SI 410
Booster Pumps
Column pipes
Mild steel IS 2062 EFW/ERW pipes
Line shaft protection tubes
Seamless MS
Flexible coupling
Forged steel conforming to IS 3495
Wearing rings for V.T. Pumps and
Gun metal/stainless steel as Appropriate
Booster pumps
Column flanges
Mild steel IS 2062
Nut bolts and washers upto bottom
Stainless steel AIST ST 304/316
of
Discharges lead
Line shaft
Stainless steel AISI-410
Line Shaft coupling

Line shaft bearing
Stainless steel AISI 410
Pump shaft bearing
Cutlass rubber
Discharge head
Cutlass rubber
BOWL drawing
Ni-CI Conforming IS 210 or Mild

Steel fabricated IS 2062
Strainer
Gun Metal
Casing of Booster Pumps
Ni-CI or galvanised steel
1.7
Pressure filters
Ni-CI conforming to IS 210 grade 20
Body and flanges
MS fabricated
Sealing material
CAF
PRESSURE FILTER:
Design Duty
50 Micron
Degree of filtration
End connections
2 NB 150
Fluid
Water
Viscosity
1 cp
Flow rate
Adequate with sufficient margin
Design pressure
Adequate
Pressure drop
0.2 kg/cm 2 (Clean condition)
Hydrants Pressure
1.5 Times of design pressure
Applicable standard
IS 2825
1.8
PUMPS STARTING/CLOSING LOGICS AND INTERLOCKS:
(A)
LOGIC OF PUMPS STARTING:
After single push button command, following operations shall take place in sequence.
i)
Taped water lubrication system/pre-lubrication starts.
ii)
After a time delay, the main pump motor will start and capacitor cubicle circuit will be ON.
iii)
The delivery valve start opening.
(B)
LOGIC OF PUMP CLOSING:
The delivery valves will be closed.

After closing of valves completely, the main pump motor will STOP and capacitors cubicle circuit
will be OFF.
Forced water lubrication and cooling system will be closed.
(C)
INTERLOCKS:
i)
V.T. Pumps will not start if lubrication system and cooling has not started functioning.
ii)
V.T. Pumps will not start unless valve opening command in passed on.
1.9
TESTING AND INSPECTION FOR V.T. PUMPS:
All the nos. of vertical turbine pumps proposed shall be inspected and tested at the manufacturing
works and site as below in the presence of Engineers representatives.
1.9.1 HYDROSTIATIC TEST / DYNAMIC BALANCING / DYE PENETRATION TEST FOR V.T.
PUMPS:
a)
All pumps bowl assemblies shall be subjected to Hydrostatic test at manufacturers works.
The test pressure shall be either One and One Half times the shut off head developed by pump
level assembly or twice the rated head, whichever is greater and applied for standard time.
b)
All pumps discharge heads and columns upto 10% shall be subjected to hydrostatic test
pressure as specified at (a) above.

c)
Dynamic balancing test of impellers and impeller shafts together shall be arranged at
manufacturers works, which will be witnessed by engineers (as per IS 1940-1973 II)
d)
Dye penetration test for impellers shall be arranged at manufacturers works, which will be
witnessed by the engineer.

1.9.2 PERFORMANCE TEST AT FACTORY FOR V.T. PUMPS:
All pumps shall subjected to performance test as IS 1710 of 1972 at manufacturers works at full
load and full speed by shifting one of electric
motors for respective pumps to be supplied under this contract as primer mover. Performance
testing shall include determination of head, discharge, power demand and efficiency over a range
of cutoff to shut off head.
Site conditions for minimum no positive suction head shall be simulated as near as possible for
testing purpose. The tenderer shall furnish the facility available agency and place for conducting
above test. The following values of parameters applicable for the site may be considered for
calculation for VPSH by the contractor.
Atmospheric pressure
9.60 meters column of water
Vapor pressure of water

(at 37.80 C normal temp.)
0.6674 meters column of water
1.9.3 OTHER INSPECTIONS AT FACTORY FOR V.T. PUMPS:

Contractor shall arrange for following inspections at manufactures works.
i.
Inspection for critical dimensions to components viz. dia, of line shaft, dia and wall thickness
of column pipe, flange thickness of column pipe, thickness of sole plate etc.
ii.
Inspection for verification of metallurgy of various components by reviewing metallurgical
tests carried out by the manufacturer.

iii.
Inspection for machining or finish quality and undue wear of fast moving parts after trial runs
by stripping down the machine.

iv.
Inspection for verification of test observations and reports for stress relieving of components,
specified earlier in detailed specifications.

v.
X Ray test for impeller shafts shall be arranged at Manufacturers works, which will be
witnessed by Engineer.
1.9.4 TEST REPORT AND OTHER DOCUMENTS FOR V.T. PUMPS:
Contractor shall furnish to the Engineer the following documents before dispatch of material.
1)
Test reports for chemical analysis of materials of construction for major components like
impellers, pump shaft, line shafts bowl assembly etc.

2)
Pump performance test reports with sample calculations and actual pump performance
curves and pump performance test acceptance report.

3)
Other test and inspection reports as above.
4)
Final construction drawings of the pump.
5)
Operation, maintenance and spare parts manual for pumps.
2.0
NON-RETURN VALVES/DUAL PLATE CHECK VALVE:
2.1
GENERAL:
Each pump will be provided with one Non Return Valve in its delivery pipe. The non-return valves
shall be all flanges type single door type Multi door (well proven type, free acting quick opening
giving non-sigma closure etc., and with low head loss characteristics conforming to IS 5312. The
valves shall be equivalent to IS 1538 1976/BS 4504.
2.2
MATERIALS OF CONSTRUCTION:
Body, cover, door, hinges
Cast Steel, IS : 210, FG-220
Hinge, pins, door pins,
Stainless Steel, SS:304
Suspension pins
Disc facing
Leaded in Bronze IS 318
GR LTB 2G
Seating in body
GR LTB
Bearing bushes, Body rings,
Door faces
GR LTB 2
Bolts and nuts
Carbon Steel
2.3
TESTING
The valves shall be subjected to seat and body test in accordance with IS 5312 at the
manufacturers work vide table below. These tests shall be carried out at manufacturers work in
presence of Engineer or his representative, before delivery test certificate shall be furnished in
triplicate. The valve rating, seat test pressure and body test pressure shall be decided by the
tenderers and shall be furnished along with bid.
Valve Rating
Seat Test Pressure
Body Test Pressure
PN-1.6
20.0 Kg/cm2
30.0 Kg/cm2
The closing period of NRV should be mentioned by the manufacturer. Also the velocity range in
which NRV open and closes should also be mentioned by manufacture. The NRV should be
tested for closing and opening characteristics at contractors cost. And any modification in NRV if
required after testing to suit the anti-surge device should be carried out at contractors cost.
3.0
BUTTERFLY VALVES:
3.1
GENERAL:
Each pump shall be provided with a butterfly valve in the delivery pipe. The butterfly valve shall be
flanged water works pattern, eccentrically pivoted and shall be electrically actuated. The actuators
shall suitable for opening and closing against the maximum head released under operating
conditions and any necessary spur or other gearing and likes etc., shall be incorporated. The
actuator motors shall be complete with limit switches, interlock switches for remote control and also
contacts for close, open, in operation and percentage opening position indications. The actuators
shall be suitable for operation with DOL starting on 415 V. 3 phase, 50 H Z AC power supply.
Necessary arrangement with hand wheels shall be provided for emergency manual operation with
suitable interlocking mechanism to prevent the actuator operations when the valve is being
operated manually and vice versa. The actuator shall be located at motor floor and so also the
manual operation of valve shall be from motor floor. The valves shall generally conform to BS
5155.
The closing time for electrical actuator shall be from 2 to 3 minutes. The actuator shall incorporate
Banklash hammer blow feature.
Body / Disc
CI / Cast steel
Shaft :
Stainless Steel (BS 970 431 S29)
Clamping Ring Segment
Stainless Steel (ASTMA 479 Type 304/
Bearings
Stainless Steel Banked PTFE
Rubber seal
Precision moulded nitrite rubber ring
Ring :
(shore hardness 55 to 65)
Hardware
A 35 ICF 8)
Stainless Steel
Used inside
Inside portion of the valve shall be painted by black paint conforming to IS 158
3.2
LOCAL OPERATIONS SWITCH:
Local operation switches near the valves should invariably be provided for operation of the valves.
3.3
TESTING:
The valves shall be subjected to seat and body test in accordance with BS 5155 at the
manufacturers works vide table below. This test shall be carried out in presence of engineer or his
representative before delivery test certificates shall be furnished in triplicate.
4.0
Valve Rating
Seat Test Pressure
Body Test Pressure
PN-1.6
20.0 Kg/cm2
30.0 Kg/cm2
SLUICE VALVES:
The specifications under this section cover the design, performance, manufacture and construction
features, delivery, erection and testing etc., of Sluice Valves with hand wheel to be supplied under
this tender.
One sluice valve shall be provided in the suction pipe of each pump.
The valve shall be double flanged, water works pattern, inside screw with non-rising spindle. The
valve shall be suitable for working pressure 10 Kg/cm 2, 16 Kg/cm2. The valve shall have suitable
size hand wheel with arrow marked for open and close.
The material of construction shall be of cast iron with Stainless steel spindle of grade specified in
IS 2906 and 780.
1.
Body / Bonnet / Wedge / Gland / Hand Wheel, Cast Iron, IS:210, FG:220
2.
Body / Seat Ring / Wedge Seat Ring
SS: AISI: 304
3.
Wedge Nute
LTB-2, IS:318
4.
Spindle
SS: AISI:410
5.
Bolt Nuts
Carbon Steel IS: 1363-1967
6.
Packing
Asbestos IS: 4687
7.
Gasket
Rubber:IS:638-1979, Type-B
4.1
TESTING:
The valves shall be subjected to seat and body test in accordance with BS 5155 at the
manufacturers work vide table below. This test shall be carried out in presence of Engineer or his
representative before delivery test certificates shall be furnished in triplicate. The valve rating seat
test pressure and body test pressure shall be decided by the bidders and shall be furnished along
with bid.
5.0
DOUBLE KINETIC AIR VALVES:
5.1
GENERAL:
Kinetic Air Valve for vertical turbine pump set shall be provided and installed on the del ivery pipe
coming out from each vertical turbine pump. The valves shall be provided at locations shown in
the drawing Kinetic Air Valve shall be of two orifice type, the small orifice releasing air from pipe
carrying water under pressure under normal working condition while the large orifice shall admit or
release air when the pipe is being emptied or filled. The air valve shall be designed to operate
satisfactorily at normal working pressure of the system. Each air valve shall be provided with an
isolating sluice valve and having cast iron hand wheels for manual operations. Sluice valve shall
be in conformation with IS 780 with gun metal single (Non rising type.)
5.2
MATERIALS OF CONSTRUCTION:
Float chamber bowl
Grey cast iron conforming to IS 2101978
And cover
Grade FG 200/220
Small Orifice Float
Stainless steel
Orifice
SS, AISI 304
Valve Seat, Nut
Loaded in Bronze
6.0
DELIVERY PIPES/MANIFOLD:
The scope of work includes:

i)
Design of delivery pipes, manifold with respect to following aspects.
a)
Selection of diameter with wall thickness and number of rows of pipes to carry required
quantity of water up to delivery with head loss calculations and total head requirement.
b)
Velocity of flow.
c)
Operating pressure, maximum gauge pressure and designed test pressure of system.
d)
Stability of pipe system.
e)
Protection against corrosion.
ii) Supply, installation, jointing of delivery pipe from each pump to manifold including necessary
butterfly valve, non-return valve and air valve including rubber expansion joints.
iii) Fabrication and installation of MS manifold out of MS pipe of sufficient diameter with required
number of inlets and outlets with flanges drafted end inspection manhole of suitable diameter with
blank flanges with gaskets. Wall thickness of MS manifold shall be as per D/t ratio of 120.
iv)
Construction and installation of MS rising mains of suitable type diameter with required number
of rows from manifold upto delivery chamber with anchor blocks saddles as required. Entire
process right from design to commissioning shall be carried out as per relevant IS Standard.
The contractor shall provide at his cost all the material required such as tapers, distance pieces,
bends, nut bolts gaskets. The work of joining delivery pipelines to the respective manifolds for
turbulence free smooth flow is included in this tender. Flanged joints shall be adopted for valves
and but welding joints of flanged joints in jointing of delivery pipe.
Concrete saddles for valves and pipe work inside pump house shall be provided by the contractor
as per design and drawings furnished by him and approved by Engineer.
The scope should include necessary excavation foundation with anchor supports concrete thrust
blocks, outside the pump house for all delivery pipes/manifold rising mains.
7.2
MATERIAL OF CONSTRUCTION:
7.2.1 All the pipes and specials shall be fabricated out of steel plates confirming IS 2062.
The fabrication of pipe should generally confirm IS 1582-1966. The fasteners required for delivery
pipe connections shall be of carbon steel.
The flange thickness shall be as per BS-1504.
7.3
The interior of the pipe work and specials shall be provided with cement mortar (1:1.5) inner
lining and 15mm thick external CM 1:3 concrete guniting of minimum 25mm thickness as per IS
1916:1989.
7.4
SURGE ANALYSIS AND PROTECTION:
This shall be calculated as per standard procedure necessary have to be provided a appropriate by
them or the rising main for dampening and elimination of the surge effect. This is included in the
scope of the work.
i)
Water hammer in pump discharge line caused by power balance.
ii)
Due to sudden failure of single pump where multiple pumps are in parallel open them
iii)
Due to variation in discharge concerned by month wise more than a pulling of.
The design criteria for the surge protection for a pumping down are started margin alignment down
surge or up surge for the critical design condition of power failure. The strength of the delivery
piping and valves in the house shall be so designed as to withstand level with pres sure due to
single pump piping since the surge protection for using mams can not take care of such pump
ripping condition. Design of using mams and valves etc. i.e., Type of wall thickness and diameter
shall be based on above surge analysis.
7.5
TESTING:
1.Contractor to submit manufactures test certificates in respect of MS /pipe materials.

2.Contractor to conduct radiography test on welded joint if any at manufacturing stage and also at
site during jointing. Test reports shall be submitted to employer.
3.Contractor to arrange hydraulic pressure testing in sections of delivery pipe, manifold, rising
mains and again tested after installation and jointing/welding at site to the designer test pressure
for a minimum of 24 hours. Any loss of pressure due to leakage noticed shall be rectified by the
contractor Re-test shall be conducted to the satisfaction of Engineer-in-charge. All the above test
certificates shall be part of handing over document.
8.0
DISMANTLING JOINTS:
A dismantling joint, Butterfly valve size shall be provided in delivery pipe lint of each pump. The
dismantling joint shall be placed between pump and non return valves and shall be fabricated from
M.S. plates designed to withstand the 1.5 times of working pressure. However plate thickness for
barrels shall not be less than 10 mm. The design of the joint shall ensure that no forces are
transmitted to the pump foundation and the flanges of dismantling joints are held rigid during
normal working. For dismantling it should be possible to side flanges at one end by at least 20 mm
to enable dismantling and refitting. General arrangement drawing shall be got approved from the
engineer-in-charge before actual fabrication of the joint.
MOTORS AND ALLIED ELECTRICAL INSTALLATIONS

9.0
H.T. MOTORS FOR V.T.PUMPS:
9.1
GENERAL:
The vertical solid shaft squired cage CACW type induction motors shall be suitable for operation on
6.6 KV, 3 phase, 50 Hz, AC supply and suitable for direct coupling with pumps stated under the
detailed specification here before. The motors shall generally be as per the latest revision of IS
325 and 4722 and other relevant ISS. The motor shall have minimum power facing of 0.866 at
duty point or without capacitor as far possible.
9.1.2 The motors shall be capable to meet the power requirement of the pump in the complete
range of its operation without being overloaded at any point and keeping a margin of at least 5%
over entire operating range. The Tenderers shall design the KW requirement and provide motors
of suitable capacity. However all the motors shall have the same capacity and shall be similar in all
respects. The motor should be capable to meet the requirement of pump under various conditions
of operation as described in item no.1 for pumps.
ELECTRICAL TECHNICAL SPECIFICATION:
Motor shall be capable of delivering rated out put with:
(A)
Terminal voltage differing from its rated value by not more than 10% or
(B)
The frequency differing from its rated value by not more than 5% or
(C)
Any combination of (a) and (b) for continuous, duty operation.
Method of Starting:
Soft starters of FCMA Type or equivalent shall be provided, limiting the starting current to less than
three times of FLC.shall be provided.
The motor shall also be suitable for frequent start/stop operations as per the system requirements.
9.1.3 Motors, when started with the drive imposing its full starting torque, under the specified
supply voltage variation, shall be capable of withstanding at least two successive starts from cold
condition and one start from hot condition, without damage to the winding.
The motor shall have good starting torque and withstand to high starting current and it shall also
have high pull-our torque with good overload capacity (210%).
The motor shall be capable of taking overload as per IS 325.
9.1.4 The HT motor winding shall be provided with the insulation conforming to I class. Maximum
temperature of winding shall be kept well below the maximum temperature limit specified for class
B insulation.
9.1.5 The motor construction shall be suitable for easy dismantling and re -assemble at site with
the help of simple overhead crane. The motors shall be of core pack construction attached to the
stator frame to facilitate easy removal and replacement of the winding for maintenance purpose.
The overhang for the winding at both the ends of the core shall be accessing for visual inspection,
without resorting to major dismantling. The insulation shall be given tropical and fungicidal
treatment for successful operation of the motor in hot, humid tropical climate.
9.1.6 Motor frames shall be rigid fabricated steel, they shall be suitably annealed to eliminate any
residual stresses introduced during the process of fabrication and machining.
The dimensions shall be in accordance with IS 325 CACW type and the enclosure shall be CACW
type. The degree of protection for CACW enclosure shall be IP55. Inspection window shall be kept
for inspection and cleaning, winding, overhead, bearing grow force. However, they shall be
blended by their light blanking plates fitted with bolts force and holes shall be provided at equal
distance along peripheries top for inspection of air gap.
Stator lamination shall be made from suitable grade sheet steel varnished on either side and they
shall be adequately designed to avoid overheating during starting and running conditions,
stipulated above. Rotor short circuiting end rings shall be such that it is free to move with
expansion of the bards without distortion. The connections of the bars to end rings shall be made
by brazing.
9.1.7 Locked rotor withstand time under hot condition at 110% voltage shall be more than starting
time at minimum permissible voltage by at least two seconds
9.1.8 Suitable insulation shall be provided on the shaft/bearing housing to prevent short current.
The insulation provided shall be such that it shall retain its dielectric properties even after, its
handling for number of times during dismantling and reassemble. Bearing assembly shall be such
that it prevents dust and water from getting into the bearing. Further, the bearing lubricant shall not
find access to the motor windings.
Each bearing shall be provided with 1 number, 3 wire, platinum elements, having a DC resistance
of 100 ohms at 00 C for bearing temperature detection.
The bearing shall operate continuously at any speed corresponding to the pump operati on range
without injury. It shall operate safely at over speed at which the motor is designed for the duration
which is not less than twice the over speed duration of the motor.
9.1.9 Separate terminal boxes shall be provided for main terminals for the motor and for
Resistance Temperature Detectors (R.T.D) and for space heaters.
The terminal box for the main and neutral terminals of the motor shall be segregated type suitable
for 3 core, designed XLPEAL cable.
9.1.10 6 nos. 3 wire platinum element, embedded resistance type Temperature Detectors (RTD)
for stator winding, each having a DS resistance of 100 ohms at 0 0 C shall be embedded in stator
winding at locations where highest temperature may be expected.
9.1.11 Motors shall have space heaters suitable for 240 volts single p hase 50 Hz AC supply.
Space heaters shall have adequate capacity to maintain motor internal temperature above due
point to prevent moisture condensation on insulation during shut down periods.
9.1.12 Motors shall be preferably of low Height to Width Ratio to have greatest stability and low
vibration limits. Motors stools of suitable size shall be supplied free of cost with motor. Motors
overall size should be such that it could be easily accommodated in the Pump House, being
constructed as per tender drawings, with sufficient space for ease of operation. The tenderer shall
furnish along with their offer, the details of efficiency, total losses and power at different loads etc.,
required in form of guaranteed performance and technical particulars.
9.1.13 The arrangement for supply clear cooling water to motor radiators and thrust bearing from
Pressure Filter through necessary valves, piping, flanges, non flow indications, relays etc., shall be
done by contractor at no extra cost.
9.1.14 The tenderers shall offer energy saving motors having high optimum efficiency. The
tenderer shall furnish the calculations to prove how efficiency optimization has been achieved on
cost of motor and corresponding saving in energy loss. Karnataka State Electricity Board tariff rate
as applicable on the last date of sale of tender specification shall be considere d by Tenderer for
this purpose. He shall indicate how his motors compare with provision of following NEMA
standards and their latest issue.
No MG-10-1977 Energy management guide for and use of polyphase motors.
No MG-1-1978 values of nominal efficiency and corresponding minimum efficiency for induction
motor.
No MG-1-12-53 Efficiency labeling standards. The Tenderer shall furnish, along with their offer the
details of efficiency, total losses and power at different load etc., required in the form of Guarantee
performance and Technical particulars of Schedule.
9.2
ERECTION:
The work of erection of motors and its alignment with the pump including laying of foundations,
grouting, doweling and painting etc., shall be done by the contractor at his own cost as per general
and miscellaneous specifications mentioned.
9.3
Emergency stop switches near the motors should be provided for switching off motors in
case of emergency.
9.4
TESTING:
One motor shall be type tested and all motors shall be routine tested at the suppliers works in the
presence of engineer or his representative. In addition to the above shop tests and site tests
should also be conducted on motors. The scheduler for part I, part II, part II I and part IV for each
of the above tests i.e., type tests, routine tests, shop tests and site tests should be followed as
below.
TYPE TEST ON MOTORS PART I:
1)
No load running of motor and reading of voltage, current, power input and speed.
2)
Reduced voltage, running of tests at no load to check the ability of motor to run upto full
speed on no load in each direction of rotations with 1/1, 732 of rated line voltage applied to the
stator terminal.
3)
Locked rotor readings of voltage, current, power input and values of torque of motors (Note:
This test may please be made at a reduced voltage)

4)
Full load reading of voltage, current, power input and speed.
5)
Temperature rise test.
6)
Momentary overload test.
7)
Insulation resistant test (both before and after the high voltage test)
8)
Vibration test.
9)
High voltage test.
10)
Test to determine losses and efficiencies.
II.
ROUTINE TEST ON MOTORS-PART II:
1.
Insulation resistance test
i)
High voltage test
ii)
No load running of motor and reading of current in three phases and voltage.
iii)
Locked rotor reading of voltage, current and power input at suitable reduced voltage.
iv)
Reduced voltage running up test at no load to check the ability of motor to run upto full speed
on NO load in each direction of rotation with 1/1, 7321 of the rated line voltage applied to the stator
terminal.
III.
SHOP TESTS ON MOTORS-PART III:
1.
Line out of motor and pump shafts including and fixing of coupling bolts and checking of
bearing faces.
2.
Over run test.
3.
Vibration test.
4.
Motor frame dimensional check and general appearance check.
5.
General appearance of main shaft and dimension of the same.
6.
Insulation resistance dielectric and coil resistance test of poles.
7.
Match mark check test will be made only where applicable.
8.
Dimensional check and general appearance check after assembly of complete motor and
assembly of pump with motor.

9.
Efficiency test.
10.
Measurement of air gap length.
11.
High voltage test.
12.
Tests to determine losses and efficiency.
13.
Heat run test to determine the temperature rise of various parts including windings, bearings
etc., of the motor when the machine is in operation continuously at the rated and overload output.
14.
Dielectric test of motor windings.
IV.
SITE TEST ON MOTORS PART-IV:
1.
Measurement of resistance of windings.
2.
Insulation resistance test.
3.
High voltage test.
4.
Measurement of air gap.
5.
No load test.
6.
Over run test.
The motor and pump is to run continuously for 72 hours at full load and temperature of various
parts including windings bearings etc., are to be observed. This test is to be carried out on each
pump separately and measurements of discharges at rated head is to be measured.
7.
Losses and efficiency of pump set are to be carried out on any two motors selected by the
Engineer.
8.
Measurement of insulation resistance of windings.
9.
Alignment of pump and motor and pump shaft.
10.
Vibration test.
9.5
415 Volts, INDUCTION MOTOR:
For Horizontal split case centrifugal pump Horizontal shaft, squirrel cage, S.P.D.P. Induction Motor
suitable for operation on 415 Volts 3 phase 50 Hz. A.C. supply and suitable for direct coupling with
centrifugal pumps stated under detail specifications here before. Motor shall be generally as per
IS-325 and IS-44722 and latest, amendments. Motor shall be suitable for supply characteristic
such as voltage, frequency and fault levels of system.
Motor should have rating to meet 5% over load during entire range of operational conditions.
Tenderer should design and provide Motor of suitable H.P. capacity to fulfill requirement of site
condition.
Motor shall be provided class B insulation. Motor should be continuously rated as per IS 325.
Motor should be dynamically balance reducing the vibration to minimise to ensure smooth running,
quiet operation and maximum bearing life.
Motor construction shall be such that it can be easily dismantled and reassembled by chain pulley
clock.
All motors shall be routine tested and one motor shall be typo tested at suppliers work in presence
of customers representative as per IS 325.
In addition to above pare no. 9.1.2. to 9.4 of this section are applicable for induction motor for
horizontal split case pump.
10.0 CAPACITOR CUBICLES:
10.1 Each motor shall be provided with the bank of capacitors to improve the power factor of
motors to 0.95. However, care shall be taken that KVAR of capacitor shall not exceed magnetizing
KVAR of the motor, in that case the corrected power factor may be less than 0.95, the capacitors
shall be provided in separate expanded metal housing with top completely covered with MS
sheets. The capacitors shall be mounted on rigid framed structure. The bushings required for
supporting interconnection of capacitors and HRC fuses shall be as per IS 2834 but shall also meet
the requirement as per BSS 1950 of 1965 wherever these are applicable.
The tenderer should ensure that power factor of the system does not fall below 0.90 lag during o ff
load and/or monsoon period.
The Tenderer should make necessary arrangements for connecting the required capacity KVAR
capacitors bank in the circuit with load break switches, fuse units etc., during off load and/or
monsoon period.
10.2 The capacitors shall be provided with earth terminals. The earth fault relay is included under
HT Panel. The one no of CBCT to detect the earth fault required for each fault relay shall be
provided.
10.3 Each capacitors cubicle will comprise of following.
I.
Bank of capacitors of suitable KVAR rating for each motor to improve the P.F. of motor to
0.95.
II.
HRC fuses suitable for operating voltage
III.
Earthling terminals
IV.
Switching device to isolate individual bank of capacitors.
10.4 EMERGENCY STOP SWITCHES:
Emergency stop switches near the capacitors should be provided for switching off the unit in case
of emergency.
10.5 Number of capacitor cubicles may have separate A.C.B / Vacuum contact breaker, which
connect them in line circuit.
Note: These capacitors can be put OV especially when there will be low power factor of the
system, in rainy season or when the motor will be idle.
1.
Capacitors shall be protected against over current by means of suitable Breakers with
adjustable over current relays, which are adjusted to interrupt the circuit. When the current
exceeds the permissible limits specified in 5.3 of IS 2834-1964.
2.
Suitable discharge device may be provided across the second axis of the current
transformers used for over current protection to afford necessary protection against transient over
voltage during switching. Suitable discharge device shall be provided to discharge the capacitors.
3.
The protection against internal fault of a capacitor bank should be provided by suitable
means to isolate automatically a faulty unit.

10.6 L.T. CAPACITOR CUBICLE:
1.
These capacitors will be suitable for operation on 440 V three phase AC and to improve
power factor of Butterfly Valve actuator motor, Booster pump motors to 0.95 and other L.T.
Auxiliary loads e.g. lighting, Air-conditioning, Ventilation, Sump Pump, Vacuum Pumps etc.
2.
These capacitors should be provided with HRC switch fuse unit for each bank.
3.
These will be mounted near L.T. Panel.
4.
Every capacitor should have discharging resistance to reduce the voltage to 50 V within 60
seconds when capacitor is taken out of circuit.

5.
Capacitor winding shall be free from oxidation and protected from humidity.
6.
Capacitors should have minimum dielectric loss, self heating property and should not short
between the phases throughout its life. It should have negligible temperature rise for better
performance with longer life.
10.7 TESTING:
The Capacitor will be tested in manufacturers works as per IS 2834-1964 in presence of the
Engineer or his representative.
11.0
T SWITCH GEAR PANNEL (MAIN PANNEL):
Main panel shall be of sheet steel dust and vermin proof indoor floor mounting type HT panel with
Bus Bars suitable for 6.6 KV system voltage completely assembled, wired, tested and painted with
rustproof paint confirming to relevant IS. The panel shall comprise of following incoming breakers.
The degree of protection should be IP-42 as per IS.
11.1 INCOMING BREAKER SHALL CONSIST OF FOLLOWING:
i)
Vacuum circuit breaker, draw out type suitable for 6.6 KV voltage three phase, 50 Hz. AC
with motor charged spring closing mechanism and facility for remoter operation.
Surge
suppression arrangement iv VCB is essential.

ii)
Three nos. double core current transformers of ratio rated cap/1.1A. one core for metering
class 1 accuracy 30 VA burden and the other core for protection Class 5 P-10 15 VA burden.
iii)
Three numbers single core current transformers of rated CAP/1 amps / Class -p 5 accuracy
with suitable knee point voltage to be used for differential protection of transformers.
The
requirement of knee point voltage shall be subject to prior approval.

iv)
Three numbers single phase potential transformers to be star/Star connected with ratio rated
voltage/ 1.7321 (110 V/1. 7321) Class-I accuracy and rated burden 150 V.A.
v)
Trip neutral, close, circuit breaker control switch.
vi)
Indication lamps, red/ green / amber for circuit beaker ON / OFF / auto trip indication rated
for 110 volts DC.

vii)
White indication lamp for trip circuit healthy indication suitable for 110 volts DC.
viii) 96 sq. mm ammeter of suitable scale with 3 way and ON/OFF selector switch.
ix)
96 sq. mm voltmeter of suitable scale with 3 way and ON/OFF selector switch.
x)
High speed tripping relay.
xi)
Static type pole inverse definite minimum time lag (IDMTL) relay with two element one for
over current protection having setting range 50 to 200% on IDMTL unit and other element for earth
fault protection with setting range 20 to 80% on IDMTL unit with common instantaneous setting
range of 500 to 2000%.
xii)
Cable termination arrangement with cable end box suitable for terminating XIDE cable
coming from transformer.

xiii)
DC fail relay.
xiv) Auxiliary relays, AC and DC fuses etc., as required.

xv)
Remote / Local selector switch with locking arrangement.
xvi) (MWH) Mega Watt Hour meter suitable for 3 phase, 3 wire unbalanced load.
xvii)(RRVAH) Reactive Kilo Volt Ampere Hours suitable for 3 phase, 3 wire Maddened load.
xviii) Power factor meter showing the power factor of system (0.50 Lag to 0.50 Lead).
xix) Time delay relay.
xx)
Single pore instantaneous under voltage relay.
xxi) Frequency indicator having range of 45 Hz to 60 Hz.

xxii) Counter showing no. of trappings made by breaker.
xxiii) Phase sequence indicators.
11.2 OUTGOING FEEDERS FOR MOTORS:
Each feeder to have the following:
i)
Minimum chitchat breaker draw out type suitable for installation with minimum rupturing
capacity.
ii)
3 nos. double core current transformers of suitable rating on primary side and 121 amp. On
secondary side, one core for metering Class-1 accuracy 20 V.A burden, one core for protection
Class-5 P 10 accuracy with 15 VA burden.
iii)
3 Nos. single phase PT with ratio (system voltage/1, 7321) / ((110 V/1, 7321) Class -I
accuracy and 150 VA burden.

iv)
Under voltage relay with time lag arrangement.
v)
Trip, neutral, close, circuit breaker control switch.
vi)
Indicating lamps Red / green / Amber for circuit breaker On / Off / Auto Trip indication rated
110 volts DC.

vii)
Indicating lamp for trip circuit healthy indication suitable for 110 Volts D.C.
viii)
Indication for valve actuator motor operation for following position.
1.
Valve fully open
2.
Valve partially open
3.
Valve fully closed.
ix)
Indication and annunciation for following.
1.
Low water level in sump
2.
High water level in sump
3.
Capacitor earth fault.
x)
96 sq.mm Ammeter shall be with suitable scale with 3 way ON/OFF selector switch.
xi)
High speed tripping relay.
xii)
Protection relays with flange for following.
CIMN make English, Electric or equivalent comprehensive motor protection relay (relay subject to
approval by Dept.) having following protection.
a.
Thermal overload
b.
Instantaneous earth fault
c.
Instantaneous unbalance
d.
Stalling protection
In addition to above following relays for fault shall be provided :

a.
Earth fault relays for capacitor earth fault.
b.
High/Low water level in sum with sensing element.
xiii) Disconnecting links for disconnection of cable of capacitors.

xiv) Cable termination arrangement with cable end box suitable for terminating cables as per
cable Schedule (for motor and for capacitor)
xv)
Remote/ local, selector switch with locking arrangement.
xvi) Remote switch gear panel/local selector switch with locking arrangement for valve motors.
xvii) Auxiliary relays, terminals, AC and DC fuses etc., as required.
xviii) Time delay relay.
xix) Forced water lubrication pump start/stop switches with indication lamps.
xx)
Hour motor one for each motor panel and square panel operating on 230/110 V.A. C/D.C.
supply.
xxi) Butter fly valve operation switches OPEN/CLOSE with indication lamps indicting valve
positions of fully open/ Fully close / Partly open / Operating.
11.3 Outgoing feeder for connection Aux. Transformer comprising of following.
i)
Air circuit breaker / Vacuum circuit breaker draw out type suitable for installation with a
minimum rupturing capacity.

ii)
Three sets of single core C.Ts of suitable rating on primary side and I AMP on secondary
side for metering Class-I accuracy and 20 V.A burden.

iii)
Three sets of single core C.Ts. of suitable rating on primary side and I AMP on secondary
side for protection Class-5, P-10 accuracy and 15 V.A burden.

iv)
v)
Trip, neutral, close, circuit breaker control switch.

Indication lamps Red / Green / Amber for circuit breaker On / Off / Auto trip indication rate
for 110 volts DC.

vi)
One indication lamp for trip circuit healthy indication suitable for 110 volts DC.
vii)
Indication for following:
1.
Buchholtz relay operated
2.
Over current earth relay operated.
viii) 96 sq. mm Ammeter having suitable scale with 3 way and ON/OFF selector switch.
ix)
High speed tripping relay for IDMT and buchholtz.
x)
Static type triple pole IDMT relay with two elements one for over current protection having
setting range 50 to 200% in IDMTL unit and one element for earth fault protection with setting
range 20 to 80% on IDMTL unit with common instantaneous setting ranges of 500 to 2000%.
xi)
Cable termination arrangement with cable end box suitable for terminating cable as
mentioned in cable scheduled.

xii)
Auxiliary relays, terminals, AC and DC fuses etc., as required.
xiii) Remote/ Local control switch.

11.4 ANNUNCIATION:
1)
1 No. buzzer suitable for operation on 110 volts DC.
2)
1 No. Bel suitable for operation on 230 volts AC
Note: The bell and Buzzer will operate in parallel with corresponding Annunciation of Remote
Control panel.
11.5 DETAILED TECHNICAL SPECIFICATIONS:

11.5.1 AIR CIRCUIT BREAKERS / VACCUM CIRCUIT BREAKERS:
I. Each Breaker shall have following accessories:
i.
Operation counter to register number of Breakers operations.
ii.
Mechanical operating device for manual closing and tripping of breaker.
iii. Device for manual charging of closing spring.

iv. Mechanically operated Red 'Trip' shrouded push button.
II. There should be looking facility in SERVICE, TEST and ISOLA TED position.
III. In TEST position, the Breaker / ACB will be tested without energizing the power circuit.
IV. It should not be possible to plug in a closed Breaker or to draw out a Breaker / ACB in closed
position.
V.It should not be possible to operate Breaker / ACB unless it is fully plugged IN, TEST or fully
isolated position.
VI. Through the Breakers are to be suitable for electrical operation, provision of manual charging,
closing and tripping shall be made.
VII. All Breaker / ACB of identical current ratings shall be interchangeable.
VIII. Charging motor and closing coil shall operate between 85 to 110 percent of 110 volts DC
supply and trip coil between 70 to 110 percent of 110 volts DC supply. Suitable thermal protection
shall be provided for charging motor.
11.5.2 BUS BARS AND SUPPORTS:
Bus Bars shall be of Electrolytic Aluminum and of ample size. It shall be adequately s upported on
non-hygroscopes, non-combustible, fibber glass reinforced, plastic insulator. The Bus Bars up to
incoming of Breakers and also up to the outgoing terminals, including all joints, shall be fully
insulated with heart shrinkable PVC sleeves. They shall be uniform and continues throughout the
length of Switch Board. The Bus Bars shall be extendable on both sides.
11.5.3 BUS COUPLER PANEL:
6.6 KV, VCB 2000 Amps rating, 25 KA SC rating for 1Second with O/C, E/F relay with extension
Bus bars, Earth bus extension to Ammeter , Voltmeter with S/switch with CT etc.. complete
housed in the sheet metal cubicle.
11.5.4 CONTROL WIRING:
All control wiring shall be of adequate capacity and all outgoing circuits shall be wired upto terminal
blocks for external connections. Wires shall be properly colour coded and ferruled to distinguish
different circuits. They shall be neatly routed through PVC channels of adequate size. All control
wiring shall be carried out with 1.1 KV, grade, 2.5 sq. mm. PVC insulated wires.
11.5.5 PANELS:
The panel shall be indoor, free standing type, fully compartmentalized and properly ventilated. It
shall be totally enclosed, dust and vermin proof. It shall be possible to extend the assembly on
either side. It shall be made out of at least 10 SWG sheet steel suitably reinforced to provide flat
level surface, resistant to vibration and rigid during transportation and installation. Door and
removable covers may be of 14 SWG sheet, Breaker compartment shall have front hinged door
with lock and key
12.0 L.T. DISTRIBUTION PANEL:
12.1 One sheet steel totally enclosed dust and vermin proof L.T. panel board suitable for indoor
floor mounting with requisite capacity aluminum bus bar and neutral of half the racing for operation
on 433 V. 3 phase, 50 Hz. A.C. System completely assembled, wired, tested and painted with rust
proof paint for controlling L.T. supply to different auxiliaries of pump house. Each panel shall
consist of following items well installed and connected to suitable size of bus bars provided in the
panel.
13.0 PROVIDING TOOL SETS AND SPARES:
14.1 The contractor shall provide a set of recommended spares for 5 years operation &
maintenance period of the plant. These spares shall be suitable for the equipment provided under
this contract and form the original Manufacturers only.
14.2 The contractor shall provide one set of tools required for operation, maintenance, repairs
and over hauls of the complete plant during its five (5) years O&M period.
14.0 TESTING TRIALS, COMMISSIONING AND OPERATION 1 JOB:
15.1 TRIAL OPERATION:
The plant in the pump house shall be on trial operation during which period all necessary,
adjustments shall be made while operating over the full load range enabling the plants to be made
ready for performance and guarantee test.
15.2 The duration of trail operation of the complete equipment shall be fourteen (14) days out of
when at least seventy two (72) houses shall be continuous operation of full load or any other
duration on higher side as may be agreed to between this Engineer and contractor. The trial
operation shall be considered successful provided that each item of the equipment can operate
continuously at the specified operating characteristics for the period of trial operation.
15.3 Minor Interruptions not exceeding four (4) hours at a time caused during the continuous
operation shall not affect the total duration of trial operation. However, if in the opinion of the
Engineer, the interruptions are long, the trial operation shall be prolonged for the period equal to
that of interruption.
15.4 A trial operation report comprising observations and recordings of various parameters to be
measured in respect of above trial operations shall be prepared by the contractor. This report
besides recording the details. Of the various observations d uring trial run shall also include the
dates of start and finish of the trial operations and shall be signed by the representatives of both
the parties. The report shall have sheets recording all the details of interruptions occurred
adjustments made and any major repairs done during the trial operation. Based on the
observations necessary modification / repair to the plant shall be carried out by the contractor to
the full satisfaction of the Engineer to enable the latter to accord permission to carry out
performance and guarantee tests on the plant. However minor defects which do not endanger the
safe operation of the equipment, shall be considered as reasons for withholding the aforesaid
permission.
16.0 COMMISSIONING AND OPERATION:

The commissioning and operation period generally will be 90 days and will follow the trial operation
of individual set of pumping equipment unless otherwise specially agreed.
During the
commissioning and operation period, the contractor shall depute his personnel; full time to operate,
maintain and repair the equipment. Only water and electricity shall be provided by the corporation.
During this period the corporations personnel who shall continuously work with the contractors
personnel shall be adequately trained by the contractors personnel to take full responsibility of
operating, maintaining, repairing etc., of the equipment and plant.
17.0 PERFORMANCE AND GUARANTEE TEST:
1.
The final test as to the performance and guarantee shall be conducted at site by the
contractor as per IS 1937. The contractors commissioning and start up engineers shall make
equipment ready for such test and assist the corporation in conducting the test free of cost such
test will be commenced after the successful completion of operation of 75 days or 1000 hours,
whichever is more.
2.
These tests shall be binding on both the parties of the contract to determines compliance of
the equipment with the performance guarantee. The acceptance of tee tests will be subject to
provision made.
3.
Un-measurable parameters shall be taken into account in a reasonable manner by the
engineer for the requirement of these tests. The test will be conducted on the completed
installations without any special modifications for test purpose.
No separate allowances or
deviations from specified conditions in test procedures shall be allowed while evaluating the
performance.
4.
Any special equipment tools and tackle required for the successful completion of the
performance and guarantee tests shall be provided by the contractor free of cost.
5.
The guarantee performance figures of the equipment shall be provided by the contractor
during these performance and guarantee tests. Should the results of these tests show any
decrease from the guarantee valves. The contractor shall modify the equipment as required to
enable it to meet the guarantees in such case performance and guarantee test shall be repeated
within one month from the date.
Equipment is ready for the test and all cost of modifications including labor, materials and the cost
of additional testing to prove that the equipment to meet the guaranty, shall be borne by the
contractor.
SECTION - 9
CIVIL WORKS
CIVIL WORKS
1.0
GENERAL:
The intent of specification covers the following :

Design, engineering, and construction of all civil works relating to entire job including jack
well/pump house, delivery chamber, including substation etc. All civil works shall also satisfy the
general technical requirements specified in other sections of this specification and as detailed
below. They shall be designed to the required service conditions/loads as specified else where in
this Specification or implied as per National/International Standards.
All civil works shall carried out as per applicable Indian Laws, Standards and codes All material
shall be of best quality confirming to relevant Indian Standard and Codes, The Contractor shall
furnish all design, (Unless otherwise specified) drawings labour, tools, equipment, materials,
temporary works, constructional plant and machinery fuel supply transpiration and all other
incidental items not shown or specified but as may be required for complete performance of the
works in accordance with approved drawings, specifications and direction of department.
The work shall be carried out according to the desig n/drawings to be developed by the contractor
and approved by the Department or supplied to the contractor by the department. For all buildings,
structures. Foundations etc, necessary layout details shall be developed by the contractor keeping
in view of the functional requirement of the equipments and facilities and providing enough space
and access for operation use and maintenance based on the input provided by the department
Certain minimum requirements are indicated in this specification for guidance purpose only.
However the Bidder shall quote according to the complete requirement.
1.2
VOID:
1.3
SITE PREPARATION:
The layout and levels of all structure etc. Shall be made by the contractor at his own cost from the
general grid of the plot and benchmarks given by the Engineer-in-Charge. The Contractor shall
give all help in instruments, materials and personnel to the engineer-in-charge for checking the
detailed layout and shall be solely responsible for the correctness of the layout and levels.
1.31 SCOPE:
This clause covers the design and execution of the work for site preparation, such as clearing of
the site, supply and compaction of fill material, excavation and compaction of back fill for
foundation, road construction. Drainage, trenches and final topping by grav el (broken hard stone).
1.3.1 GENERAL:
1)
The contractor shall develop the site area to meet the requirement of the intended purpose,
The site preparation shall conform to the requirements of relevant sections of this specification or
as per stipulations of standard specification.
2)
If fill material is required the fill material shall be suitable for the above requirement, The fill
shall be of such a material and the site so designed as to prevent the erosion by wind and water of
material from its final compacted position of the in-situ position undisturbed soil.
3)
Material unsuitable for founding of foundation shall be removed and replaced by suitable fill
material and to be approved by KBJNL.

4)
Backfill material around foundations or other works shall be suitable for the purpose for
which it is used and compacted to the density described under Compaction.

1.3.3 EXCAVATION AND BACKFILL:
1.
The scope includes soil investigation to be conducted by the bidder
2.
Excavation and back fill for foundation shall be in accordance with the relevant code.
Whenever water table in met during the excavation, it shall be denatured
and water table
shall be maintained below the bottom of the excavation level during excavation concerting and
back filling.
4.
When embankments are to be constructed on slopes of 15 or greater benches or steps with
horizontal and vertical faces shall be cut in the original slope prior to placement of embankment
material. Vertical faces shall measure not more than I am in height.
5.
Embankments adjacent to abutments culverts retaining walls and similar structures shall be
constructed by compacting the material in successive uniform horizontal layers not exceeding 15
cm in thickness (of loose material before compaction) Each layer shall be compacted as requi red
by means of mechanical tempest approved by the Owner. Builders Rocks later than 10 cm Shall
not be placed in embankment adjacent to structures.
1.
Earth embankments of roadways and site areas adjacent to buildings shall be place in
successive uniform horizontal layers not exceeding 20 cm in thickness in loose stage

measurement and compacted to the full width specified. The upper surface of the embankment
shall be shaped so as to provide complete drainage of surface water at all times.
1.3.4 COMPACTION:
1.
The method and equipment used to compact the fill material shall be suitable to achieve the
density that will give the allowable soil bearing pressure required for the foundations, roads etc, in
each layer of fill material. Each layer of earth embankment when compacted shall be as close to
optimum moisture content as practicable. Embankment material which does not contain sufficient
moisture to obtain proper compaction shall be wetted. If the material contains an excess of
moisture. Then it shall be allowed to dry before rolling. The rolling shall begin at the edges
overlapping half the width of the roller each time and progress to the center of the road or towards
the building as applicable. Rolling will also be required on rock fills No compaction shall be carried
out in rainy weather.
2.
At all times unfinished construction shall have adequate drainage. Upon completion of the
roads surface course. Adjacent shoulders shall be given a final shaping true alignment and grade.
3.
The density to which fill materials shall be compacted shall be as per relevant IS and as per
direction of Engineer-in-Charge, All compacted send filling shall be confined as far as practicable.
Back filled earth shall be compacted to minimum 95 of the Standard proctors density at filling shal l
be compacted to minimum 95 of the Standard proctors density at OMC.
1. 3. 5 REQUIREMENT FOR FILL MATERIAL UNDER FOUNDATION:
The thickness of fill material under the foundations shall be such that the maximum pressure from
the footing. Transferred through the fill material and distributed onto the original undisturbed soil
will not exceed the allowable soil bearing pressure of the original undisturbed. For expansive soils
the fill materials and other protections etc. to be used under the foundation is to be got approved by
the KBJNL.
3.4
ANTIWEED TREATMENT & SITE SURFACING:

3.4.1 SCOPE OF WORK:
The contractor shall furnish all labor, equipment and materials required for complete performance
of the work in accordance with the drawing specification and direction of the Engineer in Charge.
3.4.2 GENERAL REQUIREMENT:
The material required for site surfacing/gravel filling shall be free from all types of organic materials
and shall be of standard approved quality and as directed by the Engineer-in-Charge.
3.4.2.1 The contractor shall furnish and install the site surfacing to the lines and grades as shown
in the drawing and in accordance with the requirements and direction of the Engineer-in-Charge.
The soil of the entire switchyard area shall be subjected to sterilizatio n/ anti-weed treatment before
placing the site sum acing/gravel fill material strictly as per instruction/requirement of the
manufacture of the chemical required for soil sterilization/anti-weed treatment. After all the
structures and equipment have been corrected and accepted, and soil sterilization as specified is
complete the site shall be maintained to the suitable water sprinkling to form a smooth and
compact surface condition which shall be matching with finished ground level of the switchyard
area.
3.4.2.2 After the soil sterilization material is applied and surface prepared compacted to the
required slope/grade a base layer of uncrushed/crushed broken stone/pebbles (grouch of 20mm
nominal size shall be spread and rolled/compacted by using ton toiler (30m width and 24 dia)
with 4 to 6 passes and water sprinkling to form a minimum 50mm layer on the designed finished
formation level of the entire switchyard area.
3.4.2.3 A final surface course minimum 50mm. Uniform layer of encrusted crushed broken
stone/pebble (gravel) of 20mm. nominal size as specified shall be spread over the base
layer/course. This final surface course shall be applied in all areas exclusive of roadways and shall
extend beyond the fenced area as medicated in the drawing This surface course shall ten be
compacted by light roller using ton steel roller (width 30 x dia 24) and 4 to 5 passes or any other
means with water sprinkling as directed by the Owner Engineer-in-Charge. Water shall be
sprinkled in such a manner that bulking does not take place The 20mm nominal size (for both
layers) shall pass 100 present through I.S. Sieve designation 10mm and nothing through 16.0mm
I.S. Sieve.
3.4.2.4 In areas that are considered by the Engineer-in-Charge to be too congested with
foundation and structures for proper tolling of the base course material by normal rolling
equipments the material shall be compacted by hand if necessary. Due care shall be exercised so
as not to damage any foundation structure or equipment during rolling compaction.
3.4.2.5 CHEMICAL TO BE USED FOR SOIL STERILIZATION ANH-WEED TREATMENT:
The details of quantities and method of application of chemicals used for soil sterilization/anti -weed
treatment shall be as per manufacturers recommendations Bidders are required to submit the
details of chemicals proposed to be used and recommendation of manufacturer with required
guarantee along with their bids for necessary approval of KBJNL. Approval of KBJNL by no means
shall relieve the Contractor from their contra actual obligations as stipulated in General and Special
conditions of contract
1.5
SITE DRAINAGE:
Adequate site drainage system shall be provided by the Contractor. The Contractor shall
obtain rainfall data and design the storm water drainage system, (culverts. Ditches, drains etc..) to
accommodate the most intense rainfall that is likely to occur over the catchments area in one hour
period on an average of one per ten years. The surface of the site shall be sloped to prevent the
pounding of water.
2
The maximum velocity for pipe drains and open d rains shall be limited to 2.4 m/sec and
1.8m/sec respectively. However, minimum non-silting velocity of 0.6m/sec shall be ensured.

Longitudinal bed slope not milder than 1 in 1000 shall be provided.
3
For design of RCC pipes for drains and culverts. IS:456 and IS: 783 shall be followed.
The Contractor shall ensure that water drains are away from the site area and shall prevent
damage to adjacent property by this water. Adequate protection shall be given to site surface,
roads, ditches, culverts, etc, to prevent corrosion of material by water.
5
The drainage system shall be adequate with out the use of cable/pipe trenches.
For pipe drains, concrete pipe of class NP2 shall be used. However, for road crossings etc,
higher strength pipe of class NP3 shall be provided. For rail Crossings, pipes conforming to railway
loading standards or at least NP4 class shall be provided Manholes shall be provided at every 30m
interval at connection pints and at every change of alignment.
Open surface drains shall be provided with bricks of class designation 75 in cement mortar
1:4 including 100mm thick bed concrete of grade 1:4:8 and 12mm thick cement plaster 1:4 with a
floating coat of neat cement inside the drains. Its top and exposed sides as per design and drawing
to be got approved by the KBJNL, For expansive soils, the guide lines of IS: 9451 shall be
followed.
8
In general. Effluent drainage shall be through buried concrete pipes and all storm water
drainage shall be designed to drain the road surface as well as the entire free and covered areas
etc.
9
Pipe drains shall be connected through manholes at an interval of max 30m effluents shall
be suitably treated by the Contractor to meet all the prevalent statutory requirements and local
pollution control norms and beaded effluents shall be conveyed to the storm water drainage system
at a suitable location for its final disposal.
10.
Invert of the drainage system shall be decided in such a way that the water can easily be
discharged above the High Flood Level (1111) out side substation boundary at suitable location
and approved by KBJNL pumps for drainage of water (if required shall provided by Contractor.
11.
All internal site drainage system, including the final connection/disposal to KBJNL
acceptance points shall be part of Suppliers scope including all required civil work, mechanical &
electrical systems. The Contractor shall connect his drain(s) at one more points,
12
The precast unanholes shall be preferred against cast-in-situ type. The drainage scheme
may either employ open drain system or underground pipe system or a combination of both. A
manhole shall be provided at every turn Corner in case of underground type in addition to the
normal requirements.
13
Suitable pumping arrangement shall be provided by the contractor to pump out the water
from sump to the open channel automatic float valve type pump shall be provided and installed by
Contractor.
14
The Contractor shall locate the out fall pint outside the substation vicinity and the substation
storm drainage must be connected to this point.

15
The drainage scheme and associated drawings shall be got approved.
1.6
ROADS AND CULVERTS:
1.
Roads provided for access to equipment and building are in the scope of bidder. Layout of
the roads shall be based on General detail & Arrangeme nt Drawing. Parking areas, shall be
provided for site personnel and visitors at convenient locations. Adequate turning space for
vehicles shall be provided and bend radii shall be set accordingly. Road to the.
Transformer/Reactors shall be as short and straight as possible.
2.
All roads be constructed so as to permit transportation of all heavy equipment. The single
lane road shall have minimum. 5.5 m black topping with 1.5m wide shoulder on either side of the
road.
3.
Finished top ( crest) of roads shall be 600mm (min) above the surrounding grade level
(Formation level)
4.
Road construction shall be as per IRC standards.
Adequate provision shall be made for road drainage.
6.
All the culverts and its allied structure (requited for road/rail. Drain trench crossings etc.)
shall be designed for class AA loading and checked for Class A loading as per IRC standard.
7.
(a) All roads shall be designed for class E of traffic as per IRC-37-1984 Guide-lines for the
design of flexible pavements.

1.7
CABLE & PIPE TRENCHES:
1.
The cable trenches shall be constructed by stone masonry as per drawing furnished by the
owner and present removable RCC. Cover( with lifting arrangement) shall be constructed using
RCC of M20 grade.
2.
The cable trenches shall be constructed as per the drawing furnished by the owner for the
following loads.
3.
Cable trench covers shall be designed for self-weight of top slab + concentrated load of 200
kg at span on each panel.

4.
Cable trench crossing the road/rails shall be designed for class AA class A and class 70R
loading or IRC/relevant IS Code and should be checked for transformer / reactor loading.
5.
Trenches shall be drained. Necessary sumps be constructed and sump pumps shall be
supplied. Cable trenches shall not be used as storm water drains.

6
The top of trenches shall be kept at least 1502mm above the finished ground level. The top
of cable trench shall be such that the surface rainwater do not enter the trench.
7.
All metal parts inside the trench shall be connected to the earthling system.
Cables from trench to equipments shall run in hard conduit pipes.
Trench wall shall not foul with the foundation. Suitable clear gap shall be provided.
10.
A Clear (vertical) space of at least 200mm shall be available for each tier in cable trench.
From trench bed to lowest tier, a minimum clearance of 150mm shall be available.
11.
The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular to the run.
12.
All the construction joints of cable trenches i.e. between base slab to base slab and the
junction of vertical wall the base slabs well as from vertical wall to wall and all the expansion joints
shall be provided with approved quality PVC water stops of approx. 230 * 5 mm size for those
section where the ground water table is expected to rise above the junction of base slab and
vertical wall of cable trenches.
13.
Cable trenches shall be blocked at the ends if required with brick masonry in cement sand
mortar lid and plaster with 12mm thick 1:6 cement sand mortar
1.10 FOUNDATION / RCC CONSTRUCTION:
1.10.1 GENERAL:
1.
Work covered under this Clause of the specification comprises the design supply and
installation of foundations and other RCC constructions for

switchyard structures. Equipment supports. Trenches drains. Jacking pad pulling block fencing &
systems buildings tanks or for any other equipment or service and any other foundation required to
complete the work. This clause is as will applicable to the other RCC constructions. The circuit
breakers/reactor/transformer shall rest on block foundations only.
2.
Concrete shall conform to the requirements mentioned in IS:456 and all the tests shall be
conducted as per relevant Indian standard Code.

3.
If the site is sloppy the foundation height will be adjusted to maintain the exact level of the
top of structures to compensate such slopes.

4.
The switchyard foundations plinths and building plinths shall be minimum 300mm and
500mm above finished ground level respectively.

5.
Minimum 75mm thick lean concrete (1:4:8) shall be provided below all underground
structures. Foundations, trenches, etc to provide a base for construction.

6.
Concrete made with Portland slag cement shall be carefully cured and special importance
shall be given during the placing of concrete and removal shuttering.

7.
The design and detailing of foundations shall be done based on the approved soil data and
sub-soil conditions as well as for all possible critical loads and the combinations there of. The
spread footings foundation or pile foundation as may be required based on soil/sub-soil conditions
and superimposed load shall be provided.
8.
If pile foundations are adopted the same shall be cast-in-situ driven/bored or precuts of
under reamed type as per relevant IS code. Only RCC piles shall be provided. Suitability of the
adopted pile foundations shall be justified by way of full design calculations. Detailed design
calculations shall be submitted by the bidder showing complete details of piles/pile groups
proposed to be used. Necessary initial load test shall also be carried out by the bidder at his cost to
establish the piles design capacity. Only after the design capacities of piles have been established,
the contractor shall take up the job of piling. All the work (design & testing) shall be planned i n such
a way that these shall not cause any delay in project completion.
1.10.2 DESIGN:
1.
All foundations shall be in reinforced cement concrete. The design and construction of RCC
structures shall be carried out as per IS-456 and minimum grade of concrete shall be M-20 Higher
grade of concrete than specified above may be used at the discretion of Bidder, which has to be
stated at the time of bidding.
2.
Limit state method of design shall be adopted unless specified otherwise in the specification.
3.
For design and construction of steel concrete composite beam IS:1 1384 shall be followed.
4.
For detailing of reinforcement IS:2502 and SP:34 shall be followed. Cold twisted deformed
bars (Fe=415 N/mm2) conforming to IS:1786 shall be used as reinforcement. However in specific
areas. Mild steel Grade D conforming to IS:432 can also be used Two layers of reinforcement
(inner and outer face) shall be provided for wall & slab sections basing thickness of 150 mm and
above. Clear cover to reinforcement towards each face shall be 40mm in case of side walls of
cable ducts and for sewer foundations & equipment foundation clear cover shall be 50mm.
5.
RCC water retaining structures like storage tanks. Cooling water basin etc, shall be designed
as uncracked section in accordance with IS: 3370 (part 1 to 4) by working stress method. However,
water channels shall be designed as cracked section with limited steel stresses as per IS: 3370
(part 1 to 4) by working stress method.
6.
The procedure used for the design of the foundations shall be the most critical loading
combination of the steel structure and or equipment and /or super structure and other conditions
which produce the maximum stresses in the foundation or the foundation component and as per
the relevant IS Codes of foundation design. Detailed design calculations shall be submitted by the
bidder showing complete details of piles/pile groups proposed to be used.
7.
All foundations shall rest below virgin ground level and the minimum depth of foundation
below the virgin ground level shall be at least 500mm for equipment foundations and 1000mm for
towers, transformers and reactors
8.
Design shall consider any sub-soil water pressure that may be encountered following
relevant standard strictly.

9.
Necessary protection to the foundation work if required shall be provided to take care of any
special requirements for aggressive alkaline soil, black cotton soil or any other type of soil. which is
detrimental/harmful to the concrete foundations.
10.
RCC columns shall be provided with rigid connection at the base.
11
All sub-structures shall be checked for sliding and overturning stability during both
construction and operating conditions for various combinations of load. Factors of safety for these
cases shall be taken as mentioned in relevant IS codes or as stipulated elsewhere in the
Specifications. For checking against overturning, weight of soil vertically above footing shall be
taken and inverted frustum of pyramid of earth on the foundation should not be considered.
12.
Earth pressure for all under ground structures shall be calculated using coefficient of earth
pressure at rest coefficient of active or passive earth pressure (whichever is applicable). However,
for the design of substructures of any underground enclosure s. earth pressure at rest shall be
considered.
13.
In addition to earth pressure and ground water pressure etc. a surcharge load of 2T/Sq.m
shall also be considered for the design of all underground structures including channels sumps
Tanks, trenches substructure of any underground hollow enclosure etc. for the vehicular traffic in
the vicinity of the structure.
14.
Following conditions shall be considered for the design of water tank in pumps house.
Channels sumps trenches and other underground structured.

a)
Full water pressure from inside and no earth pressure & ground water pressure & surcharge
pressure from outside (application only to structures, which are liable to be filled up with water or
any other liquid).
b)
Full earth pressure, surcharge pressure and ground water pressure from outside and no
water pressure from inside.

c)
Design shall also be checked against buoyancy due to the ground water during construction
and maintenance stages. Minimum factor of safety of 1.5 against buoyancy shall be ensured
ignoring the superimposed loading.
15.
Base slab of the any underground enclosure shall also bed designed for empty condition
during construction and maintenance stages with maximum ground water table (GWT). Minimum
factor of safety of 105 against buoyancy shall be ensured ignoring the superimposed loadings.
16.
Basic slab of any underground enclosure like water storage tank shall also be designed for
the condition of different combination of pump sumps being empty during maintenance stages with
maximum GWT. Intermediate dividing piers of such enclosures shall be designed considering
water in one pump sump only and the other pump sump being empty for maintenance.
17.
The foundations shall be proportioned so that the estimated total and differential movem ents
of the foundations are not greater than the movements that the structure or equipment is designed
to accommodate.
18.
MECHINE FOUNDATIONS:
a)
All machine foundations shall be designed in accordance with the provisions of the relevant
parts of latest revisions of Indian Standards

IS: 2974, IS: 456 and IS: 2911. The provisions of DIN 4024 (latest) shall also be followed.
b)
All block foundations resting on soil or piles shall be designed using the classic half space
theory.The mass of the RCC block shall not be less than three times the mass of the machine.
Dynamic analysis shall be carried out to calculate natural frequencies in all the modes including
couple modes and to calculate vibration amplitudes. Frequencies and amplitude criteria as laid
down by the relevant IS codes and/or machine manufacturers shall be satisfied. Minimum
reinforcement shall be governed by IS: 2974 and IS: 456.
c)
For the foundations supporting minor equipments weighing less than one tone or if the mass
of the rotating parts is less than one hundredth of the mass of the foundation. No dynamic analysis
is necessary. However, if such minor equipment is to be supported on building structures. Floors
etc. suitable vibration isolations shall be provided by means of springs neoprene pads etc. and
such vibration isolation system shall be designed suitably.
19.
OTHER FOUNDATIONS:
All foundations shall be designed in accordance with the provisions of the relevant part latest
revisions of Indian Standards IS: 2911 and IS 456.

20.
Type of foundation system i.e. isolated footing or raft or pilling shall be decided based the
load intensity and soil strata. Of foundation system i.e., isolated footing or raft or pill shall be
decided based on the load intensity and soil strata.
21.
Minimum three piles shall be provided in any pile group if required.
22.
The tower and equipment foundations shall be designed for a factor of safety of 2.2
normal/broken wire condition and 1.65 for short circuit condition.

1.10.3 ADMIXTURES & ADDITIVES:
1.
Only approved admixtures shall be used the concrete for the Works. When more than one
admixture is to be used, each admixture shall be batched in its own bat and added to the mixing
water separately before discharging into the mixture. Admixtures shall be delivered in suitably
labeled containers to enable Identification.
2.
Admixtures in concrete shall conform to IS: 9103. The water proofing cement additives shall
conform to IS: 2645. Concrete Admixtures/Additives shall approved by KBJNL.

3.
The Contractor shall use an approved neutralized vinyl resin air-entraining agent all
concrete. The Air entraining agent shall be supplied add batched

as a solution with a solids content not exceeding 15 percent by weight with suitable stable an
consistent PH. Air-entraining requirements shall be in accordance with CP 100 part I.
4.
The Contractor may propose and the Owner may approve the use of a water-reduction set-
reducing admixture in some of the concrete. The use of such an admixture will not be approved to
overcome problems associated with inadequate concrete plan capacity of improperly planned
placing operating and shall only be approved as a aid overcoming unusual circumstances and
placing conditions.
5
The water reducing set-retarding admixture shall be an approved brand of Iron sulphate
type admixture..
6.
The water-proofing cement additives shall be used as required/advised by KBJNL.
1.10.4 HOT WEATHER REQUIREMENTS:

1.
As per relevant Code during hot weather. Precautions shall be taken to avoid premature
stiffening of the fresh mix and to reduce water absorption and evaporator losses and when the
temperature of the surrounding air is higher than 30 degree C the following shall apply unless
otherwise approved by the Owner.
a.
The framework shall be continuously sprayed with cold water in advance of concertina and
excess water shall be remove from inside the forms immediately prior to placement of concrete.
b
The reinforcement and the framework (if metal forms are used) shall be protected form the
effect of hot winds and direct sunlight..

c.
Suitable barriers shall be provided to protect the freshly placed concrete from wind until the
concrete is sufficiently hard.

d.
The concrete when place. Shall be maintained at a temperature of less than 30 degree C by
the use of chilled water or by spraying the aggregate with cold water.
e.
The concrete shall be mixed. Transported, placed and consolidated, as rapidly as possible
and shall then be covered with an impervious membrane or wet Hussein until moist curing begins.
1.
Curing compounds shall not be used as an alternative to the requirements of clause 8.10.3.
2.
During hot weather (atmospheric temperature above 40 degree C) or cold weather
(atmospheric temperature at or below 5 degree c) the

concreting shall be done as per the procedure set out in IS: 7861 (part I &II)
1.10.5 WATER SUPPLY
The contractor shall be overall responsible for supply of water within switchyard for fire fighting
drinking purpose and other miscellancous purposes water shall be made available at single poi nt
by the contractor by providing at least 1 bore points To scope is also inclusive of supply and
erection of all tanks pipes. Fittings etc required for water supply to be taken from the terminal point
to the respective buildings A scheme still be prepared by the contractor indicating the layout and
details of water supply when shall be got approved by the owner before actual start of work. Any
extra boreholes if required shall be within the scope of contractor.
1.10.6 STATUTORY RULES:

1
Contractor shall comply with all the applicable statutory rules pertaining to enquire act (as
applicable for the sate). Fire safety rules of Tariff Advisory committees water act for pollution
control etc.
2
Preventions for fireproof doors of staircases fire separately we plastering on structural
members (in fire prone at case) etc., shall be made according to the recommendations of Tariff
Advisory Committee.
3
Statutory clearance and norms of state pollution control board shall be showed as per Water
Act for effluent quality from plant.
Requirement of sulfate resistant cement (SRC) for sub -structural works should decided in
accordance with the Indian Standards based on the findings of the detailed investigation to be
carried out by the Bidder
5
Foundation system adopted by Bidder shall ensure that relating settlement shall be as per
provision in IS: 1904 and other Indian Standards

6
All water retaining structures designed as un-cracked section shall also be tested for water
tightness at full water level in accordance with clause no 10 of 3370 (part-I).

7
Construction joints at the following locations shall be provided.
a)
At the meeting points of the columns and the raft.
b)
At the point of contra flexure in the columns.

Additional reinforcements and shear keys shall be provided at the construction joints.
8.
All underground concrete structures like basements pumps. retaining structures etc. shall
have plasticizer cum water proofing cement addition conforming to IS: 9103. In addition. Limit an
permeability as given is IS: 2615 shall also be met with. The concrete surface of these structures in
contact with earth shall also be provided with two coat of bituminous painting for water/damp
proofing.
In case of water leakage in the above structures. Injection method shall be applied for repai ring the
leakage.
SECTION I
EXCAVATION FOR LEAD OFF CANAL, INTAKE, MULWAD JACK WELL, RAISING MAINS,
DELIVERY CHAMBER, AND STRUCTURES ETC.
1.1
SCOPE OF WORK:
(a)
The work to be done under these specifications consists of the excavation in various strata,
and the conveyance and disposal of the excavated stuff for canals (including distri1butaries,
laterals etc.,) for cut-off trenches of embankment, for diversion channels, drains and ditches, for the
trenches of pipe laying, for training of nalas, for catch water drains, for service road and inspection
path and for structures. The contractor shall furnish all tools, plant, labour and materials and
execute the work satisfactorily.
(b)
When existing public facilities like road drainage, drinking water supply pipe lines, telephone
lines and power lines etc. are to be disturbed for constructions activities, the contractor shall, after
due approval of the Engineer, provide and maintain in satisfactory condition at his cost, temporary
structure like diversion roads for ensuring uninterrupted and satisfactory functioning of the facilities.
Precautionary measures like signal, night lamps, fencing and barricading etc. will also be provided
by him at his cost. The cost of permanent measures for the rehabilitation of the facilities, however,
will be borne by the KBJNL.
1.2
INDIAN STANDARDS FOR REFERENCE
1.
IS : 1498-1970
Classification identification of soils for

General Engineering purpose.
2.
IS : 2720-1983
Method for test for soils (part-I to X and part XIV)
3.
IS : 3764-1966
Safety code for excavation work.
4.
Is : 4081-1967
Safety code for blasting and related drilling Operations.
5.
IS : 4668-1967
Ammonium nitrate for explosive (Reaffirmed 1978)
6.
IS : 4701-1968
Code of practice for earthwork on canals.
7.
IS : 5441-1969
Pneumatic portable drilling machine.
8.
IS : 6609
Method of test for commercial blasting (part-I to V) explosives and

accessories.
9.
IS : 7209-1974
General requirements for blast hole drilling rigs
10.
IS : 7293-1974
Safety code for working with construction machinery.
11.
IS : 7632-1975
Detonators
12.
IS : 3696-1966
Safety code for scaffolds and ladders Part-I (part I) Scaffolds.
13.
IS : 3696-1966
Safety code for scaffolds and ladders - Part II (part II) Ladders.
1.3
SETTING OUT WORKS
(a)
In the vicinity of the Canal Distributaries, temporary Bench Marks are established by the
Department, which the contractor shall use as control points for the entire length of the canal. The
contractor shall establish sufficient number of reference Bench Marks for facilitating setting out of
works and taking levels for purpose of measurements.
In setting out levels for the canals and structures, the contractor is responsible to check all levels
against the Bench Mark at the head of the respective canal, with the precision specified for second
order surveys.
(b) Before starting any work, the contractor shall erect permanent Bench Marks, reference lines
and check profiles at convenient locations approved by the Engineer-in-charge. The Bench Mark
shall be 20 cms. X 20 cms. X 60 cms. With 40 cms, embedded under firm ground and 20 cms.
Projecting above ground. The word B.M. showing value of R.L. shall be conspicuously pointed on
the Bench Marks. The reference line shall comprise the base line properly dogbelled on the
ground with the numbered concrete masonary pillars, suitably spaced.
(c)
The check profiles shall be located 30 meters apart or closer as directed by the Engineer-in-
charge so as to ensure execution of all slopes, steps and elevation, to the profile or profiles
indicated in the approved drawings. All important levels and all control points with respect to
Bench Marks and reference lines shall be fixed and got correlated by the Engineer-in-charge.
(d) All materials and labour for setting out works including construction of Bench Marks,
reference line, check profiles and surveys, as may be required at the various stages of
constructions, shall be supplied by the contractor at his cost. The cost of such work shall be
deemed to have been included in the price quoted by the bidde r.
1.4
PREPARATION OF SITE
1.4.1 CLEARING THE SITE

(a)
The contractor shall clear the entire area, required for setting out, of all tree stumps, roots,
brush wood, rubbish of all kinds, loose stones and all other objectionable materials. The ownership
of the useful materials so removed from clearing site and / or excavation shall rest with the KBJNL.
Cutting of trees, covered under this item shall not be resorted to without the permission of the
Engineer-in-charge. The contractor shall remove all the stumps and roots of trees for which no
additional payment will be made. The roots of trees shall be grubbed to a depth of 100 cms. The
contractors shall dispose off all such materials as directed by the Engineer-in-charge.
(b) No separate payment will be made to the contractor for complying the requirements of this
paragraph and all cost shall be deemed to have been included in the price quoted by the bidder.
1.4.2 STRIPPING
Before commencing the excavation for canal, the stripping shall be carried out as specified in para
2.3 of section - II.
1.5
RECORDING OF CROSS SECTIONS
(a)
After clearing the site prior to the beginning of excavation, initial cross sections of existing
ground shall be taken at every 5 mtrs. interval or closer, depending on the nature of ground, normal
to axis of canal upto sufficient distance outside the limits of the work. Levels on these cross
sections shall be taken at 5 mtrs. or closer intervals for canal works, while for structure works, they
shall be taken at 3 mtrs. or closer intervals as directed by Engineer-in-charge and entered in the
field books by the Engineer-in-charge in the presence of the contractor or his authorised agent if he
so desires and these shall be binding on the contractor. The contractor or his authorised agent
shall sign the field book in token of acceptance. These cross sections shall form the basis of all
future measurements and payments. The original cross sections duly signed by the contrac tor and
the Engineer-in-charge shall be preserved.
(b) No separate payment will be made to the contractor for the labour and materials required for
taking the cross sections.
1.6
PLANNING
Prior to the commencement of the work, all relevant data shall be collected by the contractor for
planning (i) the excavation, (ii) the disposal of the useful materials of the excavation and (iii) the
disposal of the remaining excavated stuff. He shall prepare drawings showing therein the location
and quantities of excavation and bankwork in different kinds of material and the location of canal
structures along with their requirement of rubble, broken stone, filing around foundations etc. based
on the data, a scheme for disposal of the excavated materials shall be evolved and shown in the
same drawing. If within the reach, there is a surplus of useful excavated material the disposal of
the same in separate heaps/stacks for being used in other reaches in the neighborhood may also
be though of and provided for in the scheme. The drawing shall be submitted to the Engineer
within 15 days before starting the work and got approved.
1.7
DRILLING AND BLASTING
I.
GENERAL
The Blasting operation if required be started only after written approval of the executive Engineer.
Blasting where required will be permitted only when proper precautions have been taken for the
protection of persons and property in accordance with IS : 4081-1967 (Indian Standard
specification for the safety code for blasting and related drilling operations). While carrying out
excavation, adequate precautions in accordance with IS: 3764-1966 (Indian Standard
specifications for safety code for excavation work) shall be taken.
II.
EXPLOSIVES
It shall be the responsibility of the contractor to procure the explosive s required for the work.
III.
EXPLOSIVES AND BLASTING
The contractor shall acquaint himself with the applicable laws and regulations concerning
acquiring, storing, handling and the use of explosives. All such laws, regulations and rules, as
prevalent from time to time shall be binding upon the contractor.
The provisions detailed in the specifications are supplementary to the above laws and regulations
and are also applicable except where they conflict with the aforementioned laws, from time to time.
Further, the Engineer-in-charge may issue modifications, alterations and new instructions from time
to time. The contractor shall comply with the same without these being made a cause for any
claims.
IV.
MATERIALS
All the materials such as explosives, detonators, fuse coils, tamping materials etc., that are
proposed to be used in the blasting operations shall have the prior approval of the Engineer-incharge. Only explosives of required make and strength are to be used.
Black powder and safe explosive (as commonly current in India) shall be used wherever possible.
Explosives with nitro-glycerine shall be used where the above explosives are not effective.
The use of fuse with only one protective coat is prohibited. The fuse shall be sufficiently water
resistant as to be unaffected when immersed in water for thirty minutes. Rate of burning of the
fuse shall be uniform and not less than 4 seconds per 25 millimeters of length with 10% tolerance
on either side. The fuse known as instantaneous fuse shall not be used.
Before use, the fuse shall be inspected and moist, damaged or broken once discarded. The rate of
burning of all new types of fuses or when they have been in stock for long shall be tested before
use. The detonators used shall be capable of giving an effective blasting of the explosives.
V.
PERSONNEL
Excavation by blasting will be permitted only under the personal supervision of competent and
licenced persons and trained workmen employed by the contractor at his cost. All supervisors and
workmen in-charge of make up, handling, storage and blasting work shall be adequately insured by
the contractor.
The storage shall be in-charge of a very reliable person approved by the Engineer-in-charge, who
may, if necessary cause police enquiry being made as to his reliability, antecedent etc. The
contractor shall have to produce security for the person-in-charge of the explosives, if and required
by the Engineer-in-charge or the civil authorities of the District.
The contractor shall make sure that his supervisor workmen are fully ; conversant with all the rules
to be observed in storing, handling and use of the explosives. It shall be assured that the
supervisor-in-charge is thoroughly acquainted with all the details of the handling and the blasting
operations.
VI.
STORAGE OF EXPLOSIVES
The location and design of stores for explosives, method of their transport and general precautions
to be taken by the contractor to prevent accident shall be in accordance with the provisions of
Indian Explosive Act and the regulations and rules framed there under.
The contractor shall provide portable magazine for storing the explosive at work spot. The site of
the portable magazine shall be subject to approval by the Engineer-in-charge and the Inspector of
Explosives.
A careful and day to day account of the use of explosives shall be kept by the contractor in register
in a manner approved by the Engineer-in-charge. The Engineer-in-charge may also pay surprise
visits to the storage magazine. In case of any unaccountable storage of the explosives, or if the
account is not found to have been maintained in a manner approved by the Engineer-in-charge,
the contractor shall be liable to be panalised in which case, he shall not be entitled to any
compensation for the losses etc. The action taken under this clause shall be in addition to that
which might be taken by the competent civil authorities in the court of Law.
VII. USE OF EXPLOSIVES

For the transport of the explosives and detonators between the store and the site, closed and
strong containers made of soft materials such as timber, zinc, copper, leather shall be used.
Explosives and detonators shall be carried in separate boxes. For the conveyance of primer,
special container shall be used.
The boxes and containers used, shall be kept closed. Explosive shall be stored and used
chronologically to ensure the ones revived earlier being used first. A makeup house shall be
provided at each working place in which cartridges will be made up by competent and licensed
men as required for the work. The make up house shall be separated from other buildings. Only
electric storage lamps will be used in this house.
No smoking shall be allowed in the make up house or generally while dealing with explosives.
VIII. DISPOSAL OF DETERIORATED EXPLOSIVES
All deteriorated explosives shall be disposed off in an approved manner, the quantity of
deteriorated explosives to be disposed off shall be intimated to the Engineer-in-charge prior to its
disposal.
IX.
PREPARATION OF PRIMERS
The primers shall not be prepared near open flames or fire. The work of preparation of primers
shall always be entrusted to the same personnel. Primers shall be used as early as possible after
they are ready.
X.
CHARGING OF HOLES
The work of charging of holes shall not commence before all the drilling work at the site is
completed and the contractor's supervisor satisfies himself to
that effect by actual inspection. While charging open lamps shall be kept away. For charging with
powered explosives, naked flame shall not be allowed. Only wooden tamping rods without any
kind of metal on the rod shall be allowed to be used. The tamping rods shall have cylindrical ends.
Bore hole must be of such size that the cartridges can easily pass down them, they shall not
however be too big.
Only one cartridge shall be inserted at a time and gently pressed into the hole with the tamping
rods. The sand clay or other tamping materials used for filling the holes completely shall not be
tamped too hard.
XI.
BLASTING
Blasting shall be carried out during fixed hours of the day, which shall have the approval of the
Engineer-in-charge. The hours once fixed shall not be altered without prior written approval of the
Engineer-in-charge. The site of blasting operations shall be prominently demarcate d by red danger
flags. The order to fire shall be given only by the contractor's supervisor-in-charge of the work and
this order shall be given only after giving the warning signal three times, so as to enable all the
labour, watchman etc. to reach safe shelters.
A whistle/bugle with distinctive note shall be used to give warning signals. The bugle shall not be
used for any other purposes. All the labour shall be made acquainted with the sound of the bugles
and shall be strictly warned to leave their work immediately at the first warning signal and to move
for safe shelters. They are not to leave the shelters until the all clear signal has been given.
All the roads and footpaths leading to the blasting area shall be watched.
In special cases, suitable extra precautions shall be taken. The Engineer-in-charge may however
permit blasting for underground excavation, without restriction of fixed time, provided that he is
satisfied that proper precautions are taken to give sufficient warning to all concerned and that the
work of other agencies on the site is not hampered For lighting the fuse, a lamp with a strong name
such as carbide lamp shall be used.
The contractor's supervisor shall watch the required time for the firing of the fuses and shall see
that all the workmen are under safe shelters in good time.
XII. ELECTRICAL FIRING
Only the contractor's supervise of in-charge shall possess key of the exploder an short firing
accessories and he shall keep it always with himself. Special apparatus shall be used as a source
of current for the blasting operations power lines shall not be tapped for the purpose.
The detonators shall be checked before use for blast in series, only detonators of the same
manufacture of the same group of electrical resistance shall be used.
Such of the electrical lines as could constitute danger for work of charging shall be removed from
the site.
The firing cables shall have a proper insulating cover so as to avoid short circuiting due to contact
with water and metallic parts of rock.
The use of the earth as a return line shall not be permitted.
The firing cables shall be connected to source of current only when nobody is in the area of
blasting. Before firing, the circuit shall be checked by a suitable apparatus. After firing whether
with or without an actual blast the contact between the firing cable and the source of current shall
be cut off before any one is allowed to the leave the shelters.
During storms, charging with electrical detonators shall be suspended. The charges already
placed in the holes shall be blasted as quickly as possible but taking all the safety precautions, and
giving necessary warning signals. If this is not possible the site shall be abandoned till the storm
has passed.
XIII. PRECAUTIONS AFTER BLASTING

After the blast, the contractor's supervisor must carefully inspect the work and satisfy himself that
all the charges have exploded. After the blast has taken place in underground works, workmen
shall not be allowed to go to the place till all the toxic gasses are evacuated from the place.
XIV. MISFIRES
If it is suspected that part of the blast has failed to fire or is delayed, sufficient time shall be allowed
to elapse before entering the danger zone. When fuse and blasting caps are used a safe time
should be allowed and then the contractor's supervisor alone shall leave the shelter to see the
misfire.
None of the drillers are to work near this hole until one of the two following operations have been
carried out by the supervisor.
Either (i) the supervisor should very carefully (when the tamping is on damp clay) extract the
tamping with a wooden scraper or jet of water or compressed air (using pipe of soft materials) and
withdraw the fuse with the primer and detonator attached after which a fresh primer and detonator
with fuse should be placed in this hole and fired out or (ii) the hole may be cleared of 300 mm. of
capping and the direction then be ascertained by placing stick in the hole. Another hole may be
drilled at least 225mm. away and parallel to it. This hole should then be charged and fired. The
balance of the cartridge and detonators found in the muck shall be removed.
Before leaving his work, the contractor's supervisor inform the supervisor of the relieving shift of
any case of misfires and should point out the position with red cross denoting the same, also
stating what action if any, he has taken in the
matter. A register of misfires and their location and how they were dealt with shall be maintained by
the contractor.
The contractor's supervisor should also at once report at the contractor's office all cases of
misfires, the cause of the same and what steps were taken in connection therewith.
The names of the day and night shift supervisors of the contractor must be noted daily in the
contractor's office. If misfire has been found to be due to a defective detonator, or dynamite, the
contractor's office for inspection and shall be disposed off.
Drilling in holes not completely exploded by blasting shall not be permitted for underground
excavation The contractor should produce the firer's license and furnish the particulars in the
following statement:
Sl. No.
Name No. of firer's Licence & Date
Validity period
XV. SAFETY OF PUBLIC AND PROPERTY

Blasting operation, when considered necessary shall be resorted to only with the written
permission of the Engineer-in-charge. Prior inspection shall be carried out for the safety and
stability of the public and property. Blasting operations in the proximity of over head power lines,
communication lines, utility lines or other structures shall not be carried on until the operator or the
owner or both of such lines have been notified and precautionary measures deemed necessary
have been taken.
The drilling pattern, the method of blasting, the charge per hole, the finishing order etc., shall also
be suitably designed to the satisfaction of the Engineer.
XVI. CONTROLLED BLASTING
(1)
THE OBJECTIVES OF CONTROLLED BLASTING TECHNIQUES INCLUDE
a)
Minimization of over breaks and or fracturing of rock beyond the designed boundary of
excavation so as to achieve smooth post blast surface for the canal and a sound foundation for the
canal structure.
b)
Control of fly rock and or ground vibration within permissible limits and
c)
To serve both the above purposes.
(2)
TECHNIQUES FOR MINIMISING ROCK DAMAGE
The main purpose of controlled blasting is to minimize fracturing and loosening of the rock mass
beyond the predetermined excavation line / profile.
The objective is normally achieved by
minimizing and judicious use of explosives in the blast holes. Several controlled blasting
techniques such as line drilling, pre spliting, smooth blasting, cushion blasting and buffer blasting
are used to achieve the objective.
LINE DRILLING
The line drilling; may be one of the techniques used for over break control. In line drilling, a single
row of closely spaced, unloaded, small diameter holes is drilled along the neat excavation line.
This provides a plane of weakness to which the primary blast can break and to some extent
reflects the shock waves created by the blast, reducing the shattering and s tressing in the finished
wall. Line drilling is best suited to homogenous formations where bedding planes, joints and seams
are at a minimum.
Line drilling has very limited application. The only place where it is applicable is in areas where
even in the light explosive loads associated with other controlled blasting techniques may cause
damage beyond the excavation limit, or where line drilling is used between loaded holes to
promoted shearing and guide the pre split line.
PRESPLITTING
Pre splitting involves a single row of holes drilled along the excavation line. Pre spilt in the rock
forms a discontinuous zone, which minimizes or eliminates over break from the subsequent
primary blast and produces a smooth, finished rock wall. Pre splitting is also used to reduce
ground vibration in some critical cases.
SMOOTH BLASTING
Smooth blasting is sometimes referred to as contour blasting, perimeter blasting, or sculpture
blasting. This method is widely accepted method for controlling over break in canal, underground
headings and slopes. In smooth blasting the holes are drilled along the excavation limits, lightly
loaded with well distributed charges and fired after the main excavation is removed. By firing
instantaneously or with minimum delay between the holes, a shearing action is obtained which
gives smooth walls with minimum over break.
Smooth blasting, pre splitting etc., techniques differ mainly from the line drilling principle in that
some or all of the holes are loaded with relatively light, well distributed charges of explosives. The
fact that the firing of these charges
tends to crack or split the rock between the holes permits wider hole spacings than when line
drilling. Consequently drilling costs are reduced and in many cases better control of over breack is
obtained. However in the case of pre spliting, it is difficult to determine results until excavation of
the primary blast is complete to the finished wall.
CUSHION BLASTING
Cushion blasting is sometimes referred to as trimming, slabbing or slashing, line smooth wall
blasting, a single row of holes is drilled along the excavation line, loaded with light, well distributed
charges, and fired after the main excavation is removed. In cushion blasting, the charged holes are
further decoupled by reducing the diameter or using stemming materials of crushed stone or sand
to provided cushioning effect. This cushions shock from the finished wall as the holes are
detonated and minimizes, the stresses and fractures in the finished wall. This technique is rarely
used today because the reduction in decoupling could be achieved by the use of small diameter
explosive cartridges, which serves the same purpose. The holes are blasted using the last delay
number in the same blasting round preferably with jumping delay of 50 Ms.0
The suitable parameters for controlled blasting for minimizing rock damage shall be established
through trial blasts. Usually it needs to establish the optimum hole spacings and the charge per
hole. Slopes of the canals are designed and prescribed by the Engineer in accordance with the
geology of the rock. The controlled blasting methods shall be such as would enable maintain the
prescribed slope.
(3)
GROUND VIBRATION CONTROL TECHNIQUE
When an explosive charge is detonated inside a blast hole it is instantly converted into hot gases
and the expanding gases exert intense pressure on the blast hole walls. A high intensity shock
wave travels through the rock mass which attenuates sharply with distance. Simultaneously the
rock around the blast hole up to twice the radius of the original hole gets completely crushed.
Expanding gases continue to work on the rock, extending the cracks and moving the rock outward
and upward. These activities consume a major part of the explosive energy. However a small left
over portion passes beyond the zone of intended work in the form of elastic ground vibrations. As
seismic waves travel through the rock mass, they generate particle motions which are termed as
ground vibrations. The velocity of oscillation of rock particles is called "particle velocity" and its
maximum value is called "peak particle velocity (PPV) "Internationally, peack particle velocity is
used to express the intensity of ground vibrations from blasting. Damage caused by ground
vibration is dependent on the ground velocity and on the frequency of the ground motion. Even
though, the use of explosives has unwanted side effect in the form o f vibratio n, explosive
provide an inexpensive source of energy for rock excavation in mining and civil engineering
projects.
The principal factors that effect vibration level at a given point of interest are the maximum charge
per delay, the distance from the blast, the delay period used and the blas t geometry.
SAFE LIMITS OF VIBRATION
The permissible peak velocity (mm/s) at the foundation level of structures is as follows:
Type of structures
Dominant excitation frequency, Hz
<8 Hz 8-25 Hz
(a)
>25 Hz
Building/structures not belonging to the

owner
(i)
Domestic houses / structures
10
15
(Kutcha, Brick and Cement)

(ii)
Industrial Buildings
10
20
25
10
(R.C.C. & framed structures)

(iii)
Objects of historical importance &

sensitive structures
(b)
Buildings belonging to the owner with

limited span of life
(i)
Domestic houses / structures
10
15
25
(Kutcha, Brick and cement)

(ii)
Industrial Buildings
15
25
50
(R.C.C. & Framed Structures)
VIBRATION CONTROL PROCEDURES

1. The most common method of controlling ground vibration is by minimizing the charge
weight per delay. Delay blasting permits to devide total charge into smaller charges which are
detonated in a predetermined sequence at specified intervals. Blasting without delay or sufficient
delay numbers increases ground vibrations due to increases in maximum charge per delay.
2.
Vibration can be significantly reduced by optimizing blast design parameters. The contractor
shall establish optimum burden, hole spacing, powder factor and hook up to control vibration in the
vicinity of the existing structures.
(4)
FLY ROCK CONTROL TECHNIQUES
The rock fragments ejected from the blast called "fly rock" is a serious hazard of blasting
operations, particularly when the blast is conducted in the vicinity of village and structures. The
factors which influence the fly rock distance include:
1)Height of stemming column in the blast holes and type / quality of stemming materials.
2)Irregular shape of free face
3)Excessive large burden or blasting without free face
4)Muffling of the blast area and the muffling material type Scattering and overlapping of
delay timings of the delay detonators/relays.
5)Presence of water in blast holes.
The first four parameters can be controlled by properly designing the blasting pattern whereas the
last two parameters are not easily controllable.
Fly rock shall be controlled by proper blast design and by muffling / covering. From the experience
it is found that unless blast design is proper, muffling will not be effective. Proper blast design and
accurate implementation of the blast are the two areas of fundamental concern for controlling the
fly rock. The third important parameter is understanding the local geology and adjusting the
explosive charge with regard to the geological features.
The reliable and effective method of controlling fly rock fragments from the mouth of the blast holes
(vertical fly rock on the rear side) is he height of stemming column. It has been observed that the
fly rock, particularly towards and rear side, was effectively controlled by maintaining the height of
stemming column in all holes greater than the burden. The height of stemming column should be
1.2 to 1.5 times the true burden in all holes.
A good stemming material should retain bore hole pressure till the burden rock starts to move. Dry
angular materials under the effect of the impulsive gas pressure tends to form a compaction arch
which locks into the wall of a blast hole, thus increases its resistance to ejection. In general drill
cutting is better stemming material as compared to sand and should be preferred except in case of
watery holes. In case of watery holes only sand free of clayey materials should be used as
stemming material.
If fly rock is originating from the face and flying far distance, it could be an indication that too little
burden is used or that mud seams or other geological discontinuity are prevalent. Most fly rock
however, is not produced from the face., It is produced from the top.
When the fly rock towards the face side is also to be contained, the blasting should be done using
the technique of buffer blasting along with muffling. Buffer blasting is a technique in which a buffer
of blasted rock of 4 to 6m thick should be left against the next round of blast.
Muffling or covering of holes including entire area to be blasted is one of the most common method
to contain the distance of travel of flying fragments particularly when blasting is done within the
danger zone.
In mining blasts, the most common practice is cover the blast using wire mesh of 50 mm x 50 mm
to 75 mm x 75 mm. Gunny bags and cartridge empty boxes 4 to 5 numbers are filled with sand or
drill cutting and place over the wire mesh. Sometimes the entire area to be blasted is covered by
old belt conveyors over the wire net, which was found to be more effective as compared to wire
nets alone. Gunny bags filled with sand, free of pebbles, weigh in at least 30 to 40 kg are placed
over the belt conveyor, which is placed over the wire nets at an interval of 2 in between and within
the rows. This method will contain the vertical fly to a great extent.
Flying fragments is excessive when blasting is done in shallow holes and where bench height or
hole depth is less than two times the burden. Therefore for controlling fly rock, the bench height
must be greater than two times the true burden and preferable three times the burden. The fly rock
is also excessive in watery holes.
The contractor shall establish by trial blasting suitable technique for the control of fly rocks
wherever necessary. The technique adopted shall be got approved from the Engineer. For
excavation within the danger zone, the prior approval of the blasting methods shall be o btained
from the chief Engineer.
1.8
CLASSIFICATION OF EXCAVATED MATERIALS.
1.8.1 CLASSIFICATION
All materials of excavation shall be classified by the Engineer-in-charge in he following groups.
(a)
SOIL
This shall include the following:

I.
Ordinary soils, viz. Vegetable or organic soil, turf, sand, silt, loam clay, mud, peat,
black cotton soil, soft shale, loose murrum, a mixture of all these and similar materials which yield
to the ordinary application of pick and shovel rake or other ordinary digging implement. Removal of
gravel or any other nodular material having diameter in any one direction not exceeding 75 mm.
occurring in such strata shall be deemed to be covered under this category.
II.
Hard soils viz. stiff/heavy clay, soft shale, or compact murrum requiring g rafting tool or
pick or both shovel, closely applied.

III.
Gravel, cobble stone, soft laterite, kanker and boulders having maximum diameter in
any one-direction upto 520 mm.

IV.
Soft conglomerate, where in stones may be detached form the matrix with pick s;
V.
Soling of roads, water bound macudum layers, asphalted roads.
VI.
Lime concrete and stone masonary in lime mortar or in lean cement mortar.
VII.
Marshy soil excavated below the original ground level of marshers and swamps and
soils excavated from other areas requiring continuous pumping or bailing of water.
VIII.
Generally any material which requires the close application of picks, or scarifies to
loosen and not affording resistance to digging greater than any item mentioned in (I) to (VII) above.
(b) SOFT ROCK WITH OR WITHOUT BLASTING
This shall include
i) Highly disintegrated granite, trap or limestone where the rock material is completely
disintegrated except for a few unweathered rock fragments.
ii) Sand stone, hard laterite, laminated limestone, heavily jointed trap, breccia, red bole, hard
shale, hard conglomerate and moderately to highly weathered granite.
iii) Closely jointed fissured and fractured hard rocks.
iv)
Unreinforced cement concrete beds of lean proportions upto and including C.C. 1:
3: 6 and stone masonry in C. M. 1: 3 or of richer mix laying below ground level.

v) Generally any material or combination of materials which requires excavating efforts
similar to excavation of items (i) to (iv) above.
vi)
Soft rocks are of such hardness that they can not be excavated by picks and hand
shovels. They may be either (a) quarried or split with crow bars, or (b) excavated by drilling and
blasting, depending upon jointing pattern, the degree of weathering and moisture content.
(c)
HARDROCK WITH BLASTING / CONTROLLED BLASTING

This shall include
i) Massive and sheet rock formations of lime stone, granite, quartzite, trap, dolerite and
pegmatite
ii) Slightly weathered to fresh hard rock formation of solid rock of trap, lime stone, granite and
quartzite &dolerite pegmatite ,gneiss and any other hard rock formation
iii)
The hard rock boulders of size more than 520mm (0.14 cum) requiring blasting for
removal surrounded by sand or by soft material.

iv)
C. C. of 1 : 2 : 4 proportion or of richer proportion and R. C. C.
v) Any material requiring excavating efforts similar to items i) to iv) above

1.8.2 Under the hard rock, there may be one more classification for the purpose of measurements
and payments, when the schedule - B provides for an item of payment for controlled blasting to
control fly rock and vibrations vide para 1.7 (xvi) above.
1.8.3 AUTHORITY FOR CLASSIFICATIONS
The classification of excavation shall be decided by he Engineer-in-charge and his decision shall
be final and binding on the contractor. Merely the use of explosives in excavation will not be
considered as a reason for higher classification unless blasting is clearly necessary in the opinion
of the Engineer-in-charge.
The excavated materials from hard rock shall be stacked on the site as directed by the Engineer-incharge for facilitating measurements. The stacks shall be measured and 40% deducted for voids.
The quantity arrived at by section measurement shall be verified with the quantities of stacks.
1.9
EXCAVATION FOR CANAL/PIPELINE TRENCHES.
1.9.1 GENERAL
(a)
Excavation for canals in rock shall be to the underside of the lining shown on the drawings.
Excavation for canals in materials other than rock shall be left 200mm. above the underside of the
concrete lining until immediately before placing the concrete lining. Before placing the concrete
lining the sub-grade shall be wetted if necessary and compacted at optimum moisture content and
carefully excavated to the underside of the grade M15 concrete lining. The employer reserves the
right, during the progress of the work, to vary slopes of excavation and the dimensions dependent
thereon.
(b)
Blasting shall be done in such a manner so as not to cause over breakage which in the
opinion of the Engineer-in-charge is excessive. Special care shall be taken to prevent overbreakage or loosening of material on bottom and side slopes against which concrete lining is to be
placed. To achieve this techniques for minimising rock damage as specified in para 1.7 (xvi) shall
be followed for the sides and bed of canal. The smooth blasting shall e such that on the finished
surface at least 50% of the drill hole surfaces could be seen. If satisfactory rock surface is not
obtained through controlled blasting the final cutting may be by chiseling or with the help of
pavement breakers. All these operations shall be carried out at contractor's cost without any claim
for separate payment.
If excavation is required to be done within 50 meters from existing transmission / power lines o r
300 meters from village limits and if it is not considered expedient by the department to shift the
power lines or the village to safer distances or otherwise extend protection, the excavation shall be
carried out with extra care to control vibrations and fly rocks as specified in paras 1.7. xvi(3) and
1.7 xvi(4) and the payment are regulated as in para 1.7xvi(6).
(c)
Except the areas of rock, all areas to be excavated for canal sections shall be pre wetted so
that at the time of excavation moisture content shall be about optimum. However, in case the
excavated materials from canal are not to be used for embankment, such pre wetting need not be
done.
(d)
The contractor shall not be entitled to any additional rate above the rates quoted in schedule -
B on account of the requirement for allowing additional time for drying, stockpiling and rehandling
the excavated material which have been deposited temporarily and stock -piled for re-use.
1.9.2 CONVEYANCE AND DISPOSAL OF EXCAVATED MATERIALS
The usable excavated material available from the canal excavation shall be used in the appropriate
z o ne o f the
c anal e mb ank me nt b y co nve ying
the s ame
with all leads and lifts. Lead charges for 50 mtrs., are included in the excavation items and the
additional lead charges, if any, shall be included in the respective items of embankment. If usable
excavation material is in excess of the requirements of banking the same shall be used for the
construction of approaches to the road bridges and for selected bedding materials and bac kfill
around structures for which payment will be made at the rates entered in schedule -B, remaining
material from the excavation shall be used to strengthen the embankment on either side of canal,
or deposited in low areas on either side of canal to backfill borrow pits or spread in other approved
location as directed by the Engineer-in-charge. Usable rubble available from hard rock excavation
shall be sorted out and arranged in separate regular stacks without any extra charges as and
where directed by the Engineer-in-charge. The balance excavated stuff will be deposited in spoil
banks. The spoil banks shall not be constructed continuous. A gap of 10 mtrs., shall be provided
at 150 mtrs., interval. Spoil banks shall not be allowed within 30 mtrs., on ei ther side of the
structure on both the banks of canal unless otherwise directed by the Engineer-in-charge.
1.9.3 DEWATERING CANAL TRENCHES AND EXCAVATION UNDER WET CONDITIONS

Water encountered in canal excavation shall be diverted to nearby drain and nalas by cutting an
open channel within the canal section to be excavated. When the drain / nala bed is higher than
the encountered water level this water shall be evacuated into the nala by pumping and no
separate payment will be made for dewatering by pumping. No distinction shall be made in
payment whether the material being excavated is dry, moist or wet. Removal of accumulated silt,
slush and dewatering shall be done by the contractor, without any extra cost till the work is finally
handed over to the Department or till the expiry of the contract period, whichever is earlier.
1.9.4 OVER EXCAVATION
Over excavation caused by the contractor beyond the limits shown in the drawings for any purpose
or reason, except as directed by the Engineer-in-charge shall not be measured and paid for. The
over excavation shall be rectified at the expense of the contractor by filling and compacting with
suitable soil in the case of excavation in soils. The over excavation in rock of canal bed and side
slopes shall be back filled with cement concrete 1: 5: 10, if the over excavation is within 15 cms
and with U.C.R. masonry in C.M. 1: 5 proportion, if the over excavation is more than 15 cms. The
over excavations in case of canal embankment should be filled with respective mate rials excavated
and should be compacted. The cost of back filling the over excavation will be considered as
included in the rate quoted for excavation items and no separate payment will be made for this.
1.9.5 TOLERANCE IN ALIGNMENT AND GRADE

Departure from established alignment: + 20 mm on straight section.
50mm on tangents.
I00 mm on curves.
Departure from established grade + 20 mm
1.9.6 PAY LINE
(a)
Pay line is the limit of excavation as required by design without any allowances for over
breaks. The canal shall be excavated as indicated on drawing or as directed by the Engineer-incharge excavation.
(b)
In case of changes in canal section and side slopes, the contractor shall carry out work at the
rates quoted for the item without claiming any extra rate because of these changes. Modifications
in the slopes prescribed will however, be intimated to the contractor in writing by the Engineer-incharge.
1.10 EXCAVATION FOR STRUCTURES
1.10.1 GENERAL
(a)
The foundation levels shown on the plans accompanying the tenders or in the detailed
drawings furnished at the commencement of work are tentative and the actual levels will be
decided by the Engineer-in-charge on the basis of actual site conditions revealed after opening of
the foundation.
(b)
Blasting shall be done in such a manner as not to cause over breakage which in the opinion
for the Engineer-in-charge is excessive. Special care shall be taken to prevent over breakage or
loosening of material on bottom and side slopes against which concrete is to be placed. To achieve
this technique for minimising rock damages as specified in Para 1.7.xvi(2) shall be followed on the
sides and if found necessary the final cutting in foundation bed shall be carried out by chiseling or
with the help of pneumatic pavement breakers for which no extra rate will be payable.
c).
for excavation of hard rock under control blasting (HRCB) to control vibration and fly rock
while blasting in the vicinity of high tension power line and village /town limits the procedure
detailed under Para 1.7(6) holds good for this case also
(d)
The quantities to be paid will be to the dimensions shown on the drawings or instructed in
writing by the Engineer-in-charge.

(e)
The recommended side slopes for pay lines are considered safe without shoring and
strutting. However, if necessary arises the contractor shall provide shoring and strutting without
extra costs.
(f)
Whenever water is met with during excavation for structures, dewatering shall be resorted to
by the contractor. The rate for the excavation for structures includes the cost of dewatering and
desilting. No extra claim for dewatering and desilting will be entertained.
(g)
Usable material removed from the excavation for structures shall be used for backfill and
embankment, otherwise it shall be disposed of as directed by the Engineer-in-charge.

1.10.2 OVER EXCAVATION
(a)
Over excavation performed by the contractor beyond the limits shown on the drawings for
any purpose or reason, except as directed by the Engineer-in-charge shall not be measured. The
over excavation in the bed shall be rectified at the expense of the contractor by filling back with
same grade of concrete as that specified for leveling course. In the case of over excavation of the
sides, the same shall be filled back with suitable soil at the expense of contractor to the same
specification as that for the item of back filling in foundation trenches.
1.10.3 PAY LINE

(a)
Regardless of whether the excavation for construction of any structure preceeds or follows
the excavation of the canal at the site of structure, measurement for excavation for structures shall
include only the required excavation outside the pay lines for the canal excavations and below the
original ground surface, measured to the dimensions and slope s specified below:
Sl. No.
Strata of Excavation
Slope for pay line
1.
Soil, murrum
1.5 to 1
2.
Soft rock
0.5 to 1
3.
Hard rock
0.25 to 1
The pay line for excavations of foundations of structures, shall be determined from the bottom edge
of the foundations based on the slopes given in sub para (a) above. Alternatively, steeper slopes
can be retained by providing shoring and strutting for which no separate payment will be made. In
all cases payment will be regulated for the slopes as mentioned in the sub-para (a) above.
1.11 Civil works to be executed shall be as proposed by the bidder for the following major
components (but not limited to) at the bid stage and subsequently at the detailed design stage as
approved by the Employer:
1.12 Approach canal to the tunnel, Tunnel, Exit canal from the Tunnel, Inspection path, Plantation
at the entrance and exit of tunnel, Monitoring of programme and progress (computer aided)
SECTION II
EMBANKMENT
2.1
SCOPE OF WORK
The work to be done under these specification consists of all canal embankments, rock fill
embankments, CNS layers backfilling of cut-off trench, earth work for approaches to the road
bridges, dyke embankment for nala /drains, back filling around the canal structures rock toe and
filters of different type and sizes. The contractor shall furnish all materials, tools and plants, labour
and execute the work satisfactorily.
2.2
1.
IS : 1888-1971
Method of load test on soils
2.
IS : 2131-1963
Method for standard penetration test for soils.
3.
IS : 2809-1972
Glossary of terms and symbols relating to soil Engineering.
4.
IS : 4332-1967
Method of sampling and preparation of (Part-I) (reaffirmed

stabilized soils for testing1978)
5.
IS : 4558-1983
Code of practice for under-drainage of lined canals
6.
IS : 5529-1969
Method of test for in-situ permeability test, code of practice for

Part-I is over burden.
7.
IS : 7894-1975
Code of practice for stability analysis of earthen dams
8.
IS : 8237-1976
Code of practice for protection of slope for reservoir

embankments
9.
IS : 8414-1977
Guidelines for design of under seepage control measures for

earth and rock fill dams.
Contractor
207
Executive Engineer
10.
IS : 8419-1977
Filtration media - sand and gravel. (part I)
11.
IS : 8826-1978
Guidelines for design of large earth and rock fill dams.
In addition to the above, Indian Standards mentioned under para 1.2 of section-I may also be
referred to, where relevant.
2.3
STRIPPING
2.3.1 GENERAL
Before the embankment works commence, the base shall be stripped of unsuitable surface soil,
including all vegetation, grass, organic matter, bushes, roots and other unsuitable matter and shall
dispose off the same as directed with a lead. and all lifts. Similar operations shall be done in the
borrow areas and in such cutting reaches of canal which yield useful embankment materials.
Stripping shall be done as per IS code 4701-1982 or its latest version. (as per Is the depth for
stripping for soil congaing light grass cover is 5 to 7.5 Cm and for agricultural land 15 to 22.5 Cm.
2.3.2 RECORDING OF CROSS SECTION
(a)
After clearing the site for embankment and prior to stripping the natural ground surface cross
sections shall be surveyed (as described in para 1.5)

(b)
After stripping is completed, the initial cross section shall be taken as described in Para 1.5.
The natural ground surface cross sections and initial cross sections shall form the basis for arriving
at the quantities of excavation for stripping.
2.4
PREPARATION OF FOUNDATION UNDER EMBANKMENT
(a)
No materials shall be placed for the earth fill of the embankment until the foundation of the
embankment has been dewatered, suitably prepared and approved by the Engineer-in-charge. All
portions of excavation made for test pits or other sub -surface investigations and any existing
cavities below the foundations of the embankment shall be filled with soil of same quality as
specified for the earth fill and suitably compacted.
(b)
Pools of water shall not be permitted in the foundation of the embankment and any water
shall be drained off and cleared prior to placing the first layer of embankment materials.
(c)
SOIL FOUNDATION
Soil foundations of the embankment shall be scarified and loosened by means of a plough, ripper
or any other means to depth of about 15 cms to 20 cms to the satisfaction of the Engineer-incharge.
Roots or other debris turned up during scarifying shall be removed from the foundation area which
thereafter shall be moistened to slightly above the optimum moisture content of the foundation soil
and shall be compacted by the compaction equipment to the same degree of compaction as that of
the embankment. The purpose of using higher moisture than optimum is to ensure forcing of the
soil into any soft zones existing below the surface. The first four layers of the fill for the
embankment shall be 10 cms. to 15 cms thick and shall be carefully placed and uniformly
compacted to form satisfactory bond between the foundation and the fill. These layers in the
hearting zone should be composed of most impervious materials.
Sheep foot roller shall preferably be used for the compaction of impervious soil and vibratory type
rollers for compaction of pervious and semi pervious soils and rock.
(d)
ROCK FOUNDATION
i.
The treatment of the rock surface under the embankment shall be so done as to ensure
a tight bond between embankment and the foundation. This shall be attained by the following
procedure.
ii. The area of the rock surface which is to be in contact with the embankment shall be fully
exposed by removing all the loose and disintegrated rock leaving a rugged rock surface. Hard rock
projections and overhang shall be knocked off and removed. If blasting is to be restored to care
shall be taken to avoid objectionable shocks to foundation rock. As far as possible the whole
contact area shall exposed at one time to enable examination of the surface characteristics of the
rock and for planning the method of treatment.
iii. If the foundation rock is fairly impervious but has a highly rugged surface, it shall be
treated by laying embankment material in 10 cms thick layers at a moisture content slightly above
the O.M.C. and compacted with mechanical equipment / pne umatic tampers to ensure that all
irregular depressions in the rock surface are filled with soil to create an effective and complete
bond.
(e)
SAND FOUNDATION
Sand encountered in foundation shall be tested for its natural relative density.
It shall be
compacted by any approved methods to obtain a minimum relative density of 70% before the filling
commences.
2.4.1 BACK FILLING OF CUT-OFF TRENCHES
(a)
The cut-off trench shall be backfilled with same kind of materials and in same manner, as the
earthfill of the impervious core of the canal embankment. Each layer of the fill shall be continuous
and approximately horizontal layer of specified thickness and compacted under optimum moisture
content to the specified degree of compaction.
(b)
During placing and compaction of impervious materials in the cut-off trench where
dewatering is involved, the sub-soil water level at every point in the cut-off trench shall be
maintained below the bottom of he earthfill until the compacted fill in the cut-off trench at that point
has reached a height of 3 mtrs., after which the water level shall be maintained at least 1.5 mtrs.,
below the top of compacted fill.
2.5
BORROW AREAS
2.5.1 GENERAL
(a)
All materials required for the construction of impervious or pervious zones of embankment
and back fill for cut-off trech and structures which are not available from canal excavation,
excavation for structure or from excavation of other ancillary works, shall be obtained from the
designated borrow areas or as designated by the Engineer-in-charge in consultation with field
laboratory. The depth of cut in all borrow areas shall be designated by the Engineer-in-charge and
the cut shall be made to such designated depth only. Each designated borrow area shall be fully
exploited before switching over to the next designated borrow area. Haphazard exploitation shall
not be permitted. The type of equipment used and the operations in the excavation of materials in
borrow areas shall be such as to produce the required uniformity of the mixture of materials for the
embankment/CNS layer.
2.5.2 STRIPPING OF BORROW AREAS
(a)
Borrow areas shall be stripped of topsoil and any other objectionable materials to the
required depth. Stripping operations shall be limited only to designated borrow areas. Materials
from stripping shall be disposed of in the exhausted borrow areas or in the approved adjacent
areas.
(b)
Stripping of borrow area shall not be measured and paid for separately. The cost of stripping
is to be included in the unit rate for the respective embankment/CNS layer item in schedule B.
2.5.3 BORROW AREA WATERING
(a)
Borrow areas watering shall be done by the contractor wherever necessary and in the
manner specified by the Engineer-in-charge.

(b)
The initial moisture content of the material in the borrow areas shall be estimated with the
help of laboratory test. The optimum moisture content for the material in the particular borrow
areas shall be determined by field tests. The additional moisture requirements if any shall be
introduced into the borrow areas by watering well in advance of the excavation to ensure uniformity
of moisture content.
All care shall be taken to reduce excessive moisture in any of the locations of a borrow area before
or during excavation to secure the materials with mo isture contents close to the optimum to avoid
formation of pools in the borrow areas during excavation operation. Drainage ditches from borrow
areas to suitable outlets shall be excavated, wherever necessary. On exhausting all useful
materials or abandoning borrow areas the pits shall be fully drained to ensure no ponding of water.
2.6
EMBANKMENT
2.6.1 GENERAL
The embankment may comprise of different zones viz.
(i) Impervious zone of earth fill of controlled compaction at controlled moisture content.
(ii) Semi-pervious/pervious earth fill of controlled compaction at controlled moisture content,
and
(iii) All in fill of controlled compaction at random moisture content.
2.6.2 EARTH FILL
1)
Bushes, roots, sods or other organic or unsuitable materials shall not be place in the
embankment. The suitability of each part of the foundation for placing embankment materials
thereon and of all materials for use in embankment construction will be determined by the
Engineer-in-charge on the basis of field laboratory tests. As for as possible levels of embankment
along with the cross-section shall be the same. any difference in levels between zones if un
avoidable shall not exceed the thickness of one layer .. Placing of the layers for the embankment
portion programmed for construction in the season shall be continuous and approximately
horizontal.
2)
Placement of fill within the zones as shown on the drawings shall be performed in an orderly
sequence and in an efficient and workmanlike manner.

3)
Chemical and physical tests of the soil in the embankment shall be carried out by the quality
control organization of the department to ensure that the soil does not contain soluble lime, soluble
salts or cohesion less fines and unsound materials in quantities harmful to the embankments.
Useful materials from canal excavation and excavation of structures and from borrow areas shall
be classified, transported and placed in the specified zones of embankment as directed by the
Engineer-in-charge.
4)
Normally, the contractor shall utilize not less than 80% of suitable excavated material from
the canal and structures to construct embankment, whenever such utilization is economical in the
opinion of the Engineer by conveying from the spoil heaps with all leads and lifts as mentioned in
schedule B and he will not be authorized to obtain material from borrow areas until he does so.
The balance of soils shall be obtained from borrow areas approved by the Engineer-in-charge. If
the contractor fails to utilize atleast 80% of the usable excavated materials from the canal and
structures and obtains instead material from the borrow area, payment for this material shall be
made as if obtained from canal excavation within the leads mentioned in schedule -B. The decision
of Engineer about the usability of soils available from the canal excavation is final and binding upon
the contractor.
5)
Embankment materials shall be spread in successive horizontal layers extending to full width
of the embankment plus 45 cms on either side to facilitate satisfactory compac tion in the full
designed width. No payment shall be made for placing the additional 45 cms. widths or for their
subsequent removal. No addition shall be allowed to the slopes of the bank after the bank is raised.
Trimming of inside slopes to final dimensions, lines and grades shall precede the lining work. This
shall be done not more than two days prior to lining.
6)
Thickness of embankment layers may be adjusted by the Engineer-in-charge if the
contractor by carrying out trial compaction and requisite tests satisfies the department that the type
of compactors used by him provide required density. The thickness of loose layers in embankment
shall be normally as under:
Sl. No. Type of compaction Machine
1. 1.5 mts. Dia.drum sheep foot rollers
Weight
Thickness of loose layer
6000 kgs./running mrts.
25 cms
2.
1 mtrs. Dia drum sheep foot rollers
3000 kgs/running mrts.
20cms to22cms.
3.
Pneumatic Tamper
................................
7.5cms to 10 cms.
4.
D. R. R.
10,000 kgs.
20cms to 25 cms.
5.
Vibratory roller
................................
30cms to 45 cms.
7)
No embankment layer shall be laid until the previous layer is properly watered, compacted
and tested as per requirement. The work of spreading and compaction shall be so adjusted as not
to interfere with each other and in such a way that neither of the operations is held up because of
non-completion of the rolling and watering. If the work is held up due to failure of machinery, no
claim whatsoever will be entertained even in case of machinery is supplied by the department. The
surface of embankments shall at all time of construction be maintained true to required cross
section.
8)
The distribution of materials in each layer shall be such that the compacted materials will be
homogeneous and free from lenses, pockets or other imperfections The excavating and placing
operations shall be such that the materials when compacted will be blended sufficiently to secure
the best practicable degree of compaction, impermeability and stability.
9)
The material of the earth fill zones of controlled compaction and moisture content shall be
compacted to a density as specified on the drawings but not less than 96% of the standard proctor
density.
10)
In the above zones, no lumps or stone or pebbles having larger dimension than 7.5 cms in
impervious core and 13 cms. in pervious/semipervious zones shall be permitted. The total
percentage of lumps or stones or pebbles of permissible size shall not exceed 5% in the case of
impervious core and 15% elsewhere. The percentage is in respect of every 3 cubic metre of batch
material conveyed to the site of placement.
11)
The homogeneous section for canal embankment shall be provided in the reaches where
design requirements are met with without hearting. The soil for the embankment shall generally be
in accordance with recommendations contained in IS : 8826-1978 (para 8). The available coarser
and more pervious material shall be placed near the outer slopes in order to have increasing
permeability from inner to outer side.
12)
The impervious hearting zone wherever shown in the drawings shall be constructed of
material having required percentage of clay so that it can be compacted at optimum moisture
content by suitable compacting equipment to achieve not less than 96% of the standard Proctor
density.
Water tightness of material shall be checked by carrying out permeability tests both at the site and
laboratory. Permeability of impervious materials shall not be greater than 30 cms/year.
13) The casing zone shall consist of material which provides support to impervious core under
various conditions of saturation and draw down. The distribution of material shall be such that the
compacted material shall be homogeneous, free from cracks, pockets or other imperfections. The
excavating and placing operations shall be such that the material when compacted shall be
blended sufficiently to secure the best practicable degree of compac tion, impermeability and
stability. The casing material should normally have a standard Proctor density not less then 1.75
gms/cc.
14) All suitable material with dry density greater than 1.35 gms/cc. Shall be used in all -in-fill
zone. Suitable sub-zones shall be formed within the all-in-fill if so directed by the Engineer-incharge, by depositing materials of different type, texture and particle size in different sub -zones. In
general, fragments of smaller size shall be deposited towards the inner slope and larger fragments
towards the outer slope of all-in fill. Formation of service roads and inspection paths in reaches of
full cutting will be treated as all-in-fill and will be paid for accordingly.
15) The top surface of the bank shall be leveled with a gradie nt of 1 to 80 away from the inner
edge to facilitate proper drainage. The canal embankment shall be constructed to the top width
and height equal to designed height shown on the drawing, plus 2.5% of the designed height to
allow for settlement. The embankment width, at various levels should be regulated accordingly.
However, the bottom width of embankment shall as shown on the drawing or as directed by the
Engineer-in-charge.
16) For proper bond between embankment placed in a previous season with the current
embankment, work shall be carried out and finished as under :
i.
Where an existing embankment is to be extended hoizontally it shall be cut to a slope
not steeper than 1 in 3 and the surface so prepared shall be scarified loosened atleast to a depth of
15 cms and wetted. Following, the embankment material shall be laid in layer and compacted to
the required degree of compaction.
ii.
If the old bank is to be raised vertically, vegetation shall be cleared followed by
scarifying, and watering and placing of the new earth layer as specified above. Raising shall be
done after the bottom layer is tested. No extra payment will be made in this regard for the
operations of clearing, scarifying and watering etc.
iii.
The surfaces which are damaged due to rain shall be repaired by filling with proper
material duly compacted by tampers.
17) The finished fill shall be free from lenses, pockets, streak of layers of materials differing
substantially in texture or gradation from the surrounding materials. Successive loads of the
materials shall be dumped on the earth fill so as to produce best practicable distribution of the
materials subject to the approval of the Engineer-in-charge.
2.6.3 MOISTURE CONTROL
i.
Prior to and during compacting operations the material in each layer of earth fill zones of
controlled compaction and moisture content shall have optimum moisture content. The permissible
variation in the OMC is +/-3.
ii.
As far as possible, the material excavated from the borrow area shall have adequate
moisture content. If additional moisture is required, it shall be added preferably at the borrow area
and only to a limited extent, if required, on the embankment by sprinkling water before placement.
If moisture content is more than required, the material shall be allowed to dry before compaction.
The moisture content shall be uniform throughout the layer of material for which plough, disc
harrowing or other methods of mixing shall be applied. If the moisture content is more than the
required moisture content specified above or if it is not uniformly distributed throughout the layer,
rolling shall be stopped and shall be started again only when the above conditions are satisfied.
2.6.4 COMPACTION
i.
Material shall be placed in layers of specified thickness as shown in the table under Para
2.6.2(6). the proper moisture content where prescribed shall be uniformly distributed through out
the material, before it is compacted. Compaction shall be done in strips overlapping not less then
0.30 mtr. The compacting equipment shall travel in a direction parallel to the axis of the canal.
Turns shall be made carefully to ensure uniform compaction. Each layer of soil placed in the bank
as specified above shall be compacted with 8 to 10 tonnes power rollers or suitable crawler tractor
drawn, heavy sheep foot rollers. The compaction shall have to be uniform over the full width of the
bank. The roller shall be made to travel overt the entire designed width of each layer so that the
soil is uniformly compacted to the required degree and it leaves no visible marks on the surface.
Where flat roller are used, the surface of each layer of compacted materials shall be roughened
with a harrow or thoroughly furrowed/pick-marked as directed before depositing the succeeding
layer of materials and care shall be exercised to avoid the occurrence of horizontal seams.
ii.
In those parts of the structure which are inaccessible to the specified rolling equipments, or
around and in contact with structures and in proximity to structures, where the rolling equipment is
not permitted to operate, compaction shall be accomplished by mechanical or pneumatic rammers
of approved type as directed. Rollers shall not be permitted to operate within 0.60 metre of
concrete or masonry structures and the earth fill within this distance shall be tamped by mechanical
or pneumatic rammers. All materials to be so tamped shall be spread in layers. 7.5cms to 10 cms.
thick when loose and the moisture content of the material and the amount of tamping shall be such
as to produce a degree of compaction equal to the specified degree of compaction for rolled fill
portion Special care shall be exercised to obtain good contact and bond with surface of concrete or
masonry structures.
iii.
Where canal embankment covers barrels of cross drainage structure first 45 cms. of the
embankment shall be compacted with pneumatic hand tempers in loose layers 7.5 cms. to 10 cms.
thick. Further fill shall be compacted by using suitable light rollers to avoid damage to the
structures, by adjusting the thickness of layers until sufficient height is achieved to permit
compaction by heavy rollers. Density test shall be conducted from time to time on site to ascertain
whether the compaction is attained as specified above. Separate tests shall be conducted for each
layer of hearting and casing zone of embankment at least one field density test shall be taken in
each zone for every 30 mtrs. or less of compacted earth work. A minimum of three density tests
one is hearting one in inner casing and one on outer casing shall be taken per day. IN case the
specified densities are not attained, suitable measures shall be taken by the contractor either by
moisture correction or by removal and relaying of layer or by additional rolling so as to obtain the
specified density which shall be checked again at the same locations. In addition, tests shall also
be carried out at the limits of the embankment and adjacent to filters at the discretion of the
Engineer-in-charge.
Necessary unskilled labour required for collection of samples shall be
provided by the contractor at his cost. However, testing charges shall be borne by the department.
iv.
Atleast three standard proctor tests shall be carried out at regular intervals for hte material to
be used to account for variation in the borrow area material as well as excavated material.
Wherever material from different sources are used for embankment i.e. material from borrow areas
or from excavation, atleast three tests shall be carried out to determine standard proctor density of
each material.
v.
The department might review the design if necessary on examination of density and other
test results and the contractor shall have no claim arising out of such a review and consequent
change if any in the design.
vi.
Where compaction of cohesionless free draining materials such as gravel is required, the
materials shall be deposited in horizontal layers and compacted to the specified relative density.
The excavating and placing, operations shall be such that the material, when compacted, shal l be
blended sufficiently to secure the highest practicable unit weight and best stability. Water shall be
added to the materials as may be required to obtain the specified density by method of compaction
being used.
2.6.5 COMPACTION OF ALL-IN FILL
The all-in-fill zone of the bank wherever shown in the drawings or instructed to provide, shall be
formed in layers of uniform thickness and for the full width of zone. The thickness of loose layer
shall not be more than that given in the table in para 7 in clause 2.6.2. When construction of
controlled earth fill zone proceeds the formation of the all-in-fill zone, the slope of the earth fill zone
at the junction shall be stepped if so directed to ensure proper bonding between the two zones.
All clods and lumps of soil shall be broken to a size not exceeding 7.5 cms. The finer of the
materials available shall be deposited on the inner side and the coarser materials towards the
outside of the embankment. Each layer shall be well compacted by the flat rollers, sheep foot roller
vibratory rollers, crawler tractor or by combination of any of the above as is best suited to the type
of the fill material, as directed. The minimum relative density of the compacted material shall not
be less than 70% of the dry density as determined in laboratory tests in the case of cohesionless
materials. In the case of cohesive materials, the degree of compaction should not be less than
96% of the proctor's density. A minimum number of passes of the compacting equipment would be
prescribed and followed to obtain optimum compaction.
2.6.6 LAYING AND COMPACTING COHESIVE NON-SWELLING MATERIAL
i.
Where the canal is excavated through soils, a layer of cohesive non-swelling (CNS)
material shall be placed between the expansive soil and the concrete lining in accordance with
paragraph 5.2 of IS : 9451-1985. The CNS material shall have the following properties:
- Gradation
Clay (less than 2 micron)
15 to 20%
Silt (0.06 mm.- 0.002 mm.)
30 to 40%
Sand (2mm.-0.06.)
30 to 40%
Gravel (Greater than 2 mm.)
0 to 10%
- Index properties
Liquid limit
less than 55% but greater than 30%
Plasticity Index
ii.
less than 30% but greater than 15%
If the CNS material does not conform to above properties, it should be suitably b lended with
suitable soils to achieve the properties as directed by the Engineer-in-charge.

iii.
Immediately prior to placing the first layer or CNS material, the surface of the excavation and
embankment to receive the material shall be adequately wetted, as approved by the Engineer-incharge.
iv.
After the canal prism has been shaped to a reasonably true and even surface, CNS material
shall be placed compacted to not less than 96% of standard proctor density unless otherwise
specified, on adequately wet surface in specified layers depending upon the type of compacting
equipment deployed. Each layer of CNS material shall be moistened before compaction.
v.
In case of distributaries with smaller bed width in cutting reaches it may not be possible to
compact the CNS layer by power rollers. In such cases the CNS material filled up in the excavated
section shall be hand tamped in suitable layers till adequate width is available for compaction, by
power rollers. Further layers shall be compacted by power rollers. In case of wider section of the
distributaries, the placing and compaction of the CNS layers shall be done on both the side slopes
independently. After compaction is done, the canal section shall be cut to the required neat lines
and excavated CNS materials shall be re-used in further reaches. Laying and compaction of CNS
layers shall be done as per drawings to achieve specified field densities.
2.6.7 WEATHER CONDITIONS
(a)
Embankment material shall be placed only when weather conditions are satisfactory to
permit accurate control of the moisture content in the embankment material. Before closing the
work on embankment, in any continuous reach prior to monsoon, the top surface shall be graded
away from the canal and rolled with a smooth wheeled roller to facilitate runoff. Prior to resuming
work, the top surface shall be scarified and moistened or allowed to dry as the case may require.
(b)
The contractor shall provide suitable protection works to protect the slopes from erosion due
to rain. No payment whatsoever shall be made for providing such protection work and repairing any
monsoon damages.
2.6.8 INSPECTION AND TESTS
2.6.8.1 GENERAL
(a)
The Engineer-in-charge would exercise thorough check on the quality of fill material
delivered to the embankment and on the degree of compaction. He would further arrange to obtain
and record the data of in-situ properties of the high banks after compaction, for comparison with
design assumptions. To achieve these objectives, a programme of field testing and inspection shall
be planned.
(b)
The scope of testing and inspection is as under:

i)
The quality of materials used for bank work will be checked periodically.
ii)
Checks on the effectiveness of placement and compaction procedures shall be made
by field density tests at prescribed intervals.

iii)
Record tests of compacted fill shall be made at regular intervals
2.6.8.2 BEFORE COMPACTION

(a)
Material delivered to the fill shall be visually examined and their properties estimated
by way of inspection.
Borrow Area
i)
Excavation of borrow areas shall be limited in extent and depth as indicated on plans.
ii)
Estimation of moisture content of materials shall be made by visual examination and

feel.
iii) Sample shall be taken for laboratory analysis in case of soil is of different characteristics.
(b)
These inspection /checks shall be supplemented by sampling the materials at prescribed
intervals and by testing the samples in the laboratory for gradation and moisture content etc.
Embankment
i.
Moisture content tests shall be carried out in the laboratory while placing the fill materials.
ii.
Moisture content shall be controlled by adding water or allowing the soil to dry up to the
extent required.
iii.
It shall be ensured that the methods of dumping, spreading and moisture conditions are such
as will result in reducing segregation and variation of moisture content to a minimum.

2.6.8.3 DURING COMPACTION
Inspection during compaction shall ensure:
i.
That the layer thickness of the material is as specified.
ii.
That the fill is compacted at least upto 90% of Standard Proctor density or as otherwise
specified or 70% relative density as the case may be.

iii.
That no excessive rutting, waving or scaling of the fill occurs during compaction.
2.6.8.4 AFTER COMPACTION

The condition of the fill after compaction shall be observed and recorded particularly with
respect to rutting or waving. However, the properties of materials after compaction shall be
determined primarily by field density tests. Routine tests on samples taken from construc ted
embankment shall include, density tests, and moisture content tests. The record tests shall include
grain size distribution Atterburg limits, permeability & consolidation characteristics.
2.6.9 FREQUENCY OF TESTING
(a) Before and after compaction, the sampling and testing of materials shall be done at sufficient
frequencies so that effective checks on the full operations are maintained. Testing frequencies
shall be as per standards prescribed by the department. However, the actual frequencies shall be
adjusted to suit to the nature and variability of materials placed and the rate of fill placement as per
the directions of the Engineer-in-charge.
(b) Testing shall be performed at higher frequencies than those specified above during initial
stages of construction in order to establish control and testing techniques. Testing shall be
conducted additionally, as and when required in case of special problems such as variation in the
construction materials, in equipment performance and weather.
(c) In addition, these tests shall be made
i.
In areas where the degree of compaction is doubtful and
ii. In areas where embankment operations are concentrated.

(b)
Locations of likely insufficient compaction shall cover the following or any other areas
so determined by the Engineer-in-charge.

i.
The junction between areas of mechanical tamping and rolled embankment along structures.
ii.
Areas where rollers turn.
iii.
Areas where improper water content has been encountered.
iv.
Areas where dirt clogged rollers have been encountered.
v.
Areas containing materials differing substantially from the average.
2.6.10 RECORD AND REPORT

The Contractor shall maintain chronological and location wise record of the source of
materials and the embankment placing operations in order to have a continuous check o n the
works. Thus, it should be possible to have a complete description of materials that has gone into in
any portion of the embankment.
2.6.11 PROTECTION
The Contractor shall take all precautions necessary for the protection of all works by
diversion of adjacent streams, surface drainage, rain water etc. Any damage to earth work due to
any reason whatsoever shall be repaired by the contractor at his cost till the work is certified as
completed and taken over by the Department.
2.7
BACK-FILL IN FOUNDATION TRENCHES AND AROUND STRUCTURES
2.7.1 GENERAL
(a)
The type of material used for backfill and manner of depositing the material, shall be subject
to approval. As far as practicable, backfill material shall be obtained from the excavation for
structures or from adjacent canal excavation or from excavation of other ancillary works.
(b)
Back-fill material shall contain no stones larger than 7.5 cms. size, or as prescribed by
Engineer-in-charge.
(c)
The backfill material shall be placed to the lines and grades as shown on the drawings or as
prescribed in this paragraph or as directed by the Engineer-in-charge.

(d)
The backfill material shall be placed carefully and spread in uniform layers of specified
thickness and each layer will be moistened and comp acted to required degree of compaction at
specified moisture contents. The backfill shall be brought up as uniformly as practicable on the
both sides of walls and all sides
of structures to prevent unequal loading. The backfill material shall be placed at about the same
elevation on both side of the pipe portions of the structures and culverts and difference in elevation
shall not exceed 15 cms. at any time. The contractor shall be responsible for providing adequate
earth cover wherever necessary such as over the pipes or pipe culverts, to prevent damage due to
loads of construction equipments.
(e)
If a haul road is built over a pipe, all backfill around and over the pipe shall be placed to a
uniform surface and no humps or depressions shall be permitted at the pipe crossings.
2.7.2 COMPACTION OF BACKFILL
When compacting soil against abutment of masonry or concrete structures, width to an
extent of 0.6 mtr. shall be compacted with pneumatic tampers. Roller shall not be used close to
structures to avoid damage. The size and weight of compacting equipment shall depend on nature
of material, the height and load assumed in design of a structure. The backfill close to the structure
upto the rolled layer shall be compacted in suitable uniform layers, using pneumatic tampers to a
dry density of at least 96% of standard proctor. The moisture content of the earth fill placed against
the rock or the structures shall be about 2% higher than O.M.C. to allow for penetration into
cavities. Compaction at joints of earthwork and backfill around structures shall be carried out with
special care without claiming any extra cost.
The back filling above the structure shall be done initially by spreading layers not exceeding
10
cm in thickness compaction has to be done by pneumatic tamper. This method of back filling is to
be continued till the filling reaches a height of not less than 0.6 mts above the highest level on the
structure. it is only after this back filling in regular layers and compaction by power rollers in the
case of embankment will be permitted.
.2.8 ROCKFILL
2.8.1 GENERAL
Rock fragments available from the canal excavation shall be used in all-in-fill embankment if found
suitable, as per the directions of the Engineer-in-charge. The thickness of loose layer of rockfill
shall not be more than 60 cms using well-graded rock fragments varying form 0.014 cum (1/2 cft)
to 0.75 cum. (1 cubic yard). The rockfill shall be placed or dumped in approximately horizontal
layers with finer materials in the interior of the embankment and larger materials towards the outer
edge. Voids in the rockfill shall be filled and packed with smaller stones of not less than 7.5 cms in
size, in such a manner as to obtain a dense fill with minimum of voids to the satisfaction of the
Engineer -in-charge. Compaction shall be done by movement of crawler tractor or loaded tippers.
The relative density of the hand packed and compacted rockfill shall not be less than 70%.
2.9
ROCK TOE
(a) Materials for rock toe shall consist of suitable free draining rock fragments, cobbles and
boulders. The stones / rubble available from the excavation shall be used. If the materials is not
sufficient, stones/rubbles shall be brought from the approved quarries.
The material shall be got approved by the Engineer -in - charge prior to being brought to site.
The material shall be clean and well graded consisting principally of rock fragments. Fragments
less than 0.01 cum. shall not be used. Sufficient fine material such as rock spalls, cobbles and
coarse gravel to fill the voids among the larger stone shall be used. Use of stones above 0.028
cum is not obligatory. The material shall be selected and placed in such way that the larger stones
shall be placed near the outer slope and the smaller ones adjacent to the inner slope. The stones
shall near the outer slope and the smaller ones adjacent to the inner slope. The stones shall be
properly hand packed, so as to produce a dense and well graded fill with no large voids and
cavities. The surface of the outer slope shall be fairly even and uniform.
(b) Suitable outfall for draining the seepage water collected in the rock toe shall be provided
depending upon the site conditions.
(c) The dimensions of the rock toe zone shown in the drawings are tentative and if required,
modifications may be ordered by the Engineer during execution of the work. The contractor shall
work according to such modifications without any increase in unit rates.
2.10 LAYING OF FILTERS
Filters media shall be provided to the dimensions shown in the drawing or as directed by the
Engineer - in-charge. The number of layers, the thickness of each layer and gradation of filter
material shall be as specified in drawing or as directed by the Engineer - in-charge. The placing of
the filter materials shall be such that the segregation within the layer is prevented. The Filter
materials shall be watered and compacted so as to achieve a relative density of not less than 70%.
Care shall be taken not to mix up the filter materials of a layer with soil or with filter ma terials of
adjoining layer.
Suitable transition filter is intended to be provided between earth fill and all-in -fill zone
consists of less than 50% of minus 80 mm. material. The contractor shall provide the transition filter
as shown in the drawing or as directed by the Engineer-in-charge for which payment will be made
at quoted rates. Horizontal filter blanket shall be provided, wherever prescribed, connecting the
inclined filters as shown in the drawings or as directed by the Engineer-in-charge. Before placing
the horizontal filter layers, the foundation thereof shall be cleared and brought to level by filling in
depressions (if any) with selected impervious materials compacted at OMC. Each layer of filter
media shall be adequately watered and compacted by moving the hauling and spreading
equipment over it or by other means approved by the Engineer-in-charge. The rock toe, if
prescribed, shall then be laid in such a way as not to damage the filter blanket in any way.
Inclined filters abutting the outer slope of the impervious core shall be provided as per
approved drawings or as directed by the Engineer - in - charge. Filter materials shall be so placed
that it conforms to the position indicated in the drawing and the continuity of each layer is ensured.
The thickness and location of each individual filter layer shall be maintained by placing the material
between temporarily placed mild steel sheets or wooden boards which shall be withdrawn before
compaction. The inclined filter and the embankment material adjacent to it shall be raised together.
2.10.1 FILTERS DRAINS
Filters drains shall be provided at suitable locations and to the dimensions shown in the
drawing to collect seepage from the embankment and to discharge the same away from the
embankment by suitable means according to the site conditions as directed by the Engineer-incharge.
2.10.2 FILTER MATERIALS
(a) The filter materials shall consist of well-graded sand, gravel or crusher broken aggregate. The
material shall be free from debris, brushwood, vegetable matter, decomposed rock, and other
deleterious matter. Sand in filter media shall confirm to the specifications in IS: 383-1970 or its
latest version. Silt and clay content in sand shall be less than 5% (IS: 1498-1970)
(b)
Filter materials shall not be placed until the sub-grade has been inspected and finally
approved by the Engineer-in-charge. The filter material shall be laid in layers not exceeding 15
cms. in thickness or as prescribed by the Engineer-in-charge. The number of layers, the thickness
of each layer and the size of the ingredients shall be as per the final design which will be furnished
to the contractor based on the laboratory test satisfying primarily the following filter criteria:
i)
D15(F) < 4
D 85(B)
ii)
D15(F) = between 4 and 40

D 15 (B)
Where D 15 and D 85 are particle diameter corresponding to 15% and 85% passing
'F' denotes filter material 'B' denotes base material. The percentage being determined by weight
after mechanical analysis.
(c)
The gradation curves of the filter material shall be nearly parallel to the gradation curves of
the base material

(d)
The requirement for grading of the filter shall be established by the field laboratory on the
basis of mechanical analysis of adjacent materials

(e)
The size and grading of filter material shall generally be as indicated in the drawing. The
Engineer-in-charge may at his discretion modify the gradation in the filter layer to satisfy the filter
criteria. The contractor shall do the necessary processing of the filter materials at his own cost.
(f)
The material brought by the contractor to the site shall be tested by the quality control
organization of the department in the laboratory at the project site. The result thereof shall be fi nal
and binding. All material not conforming to the requirement so determined shall not be permitted for
us on the said work.
2.11 TURFING
Turfing the down stream slope shall be done with locally available approved good quality grass
according to the directions of the Engineer-In-charge. Turfing shall be laid on 25cms thick soil of
approved quality over the finished embankment face. The rate shall include the cost and
conveyance and laying of 25cms thick soil and approved gross and watering. The rate shall also
include maintaining the turfing till the end of the maintenance period, including watering and
replacement of gross wherever necessary.
SECTION - III
3.CONCRETE LINING
3.0
MANUAL CONCRETE LINING
3.1
SCOPE OF WORK
(a)
Concrete lining shall be done by laying un-reinforced cement concrete of required grade with
maximum size of aggregate of 20 mm for the canal reach having side slopes of 0.25:1 and 0.5:1.
The concrete used shall be of controlled grade the mix proportion being decided by the preliminary
tests. The thickness of lining shall be as shown in the drawing. The thickness of lining generally
varies from 7.5 cms to 10 cms depending upon the section of the canal. The canal sections shall
be as shown on the drawings. If during construction it is found necessary to alter the canal sections
and side slopes or the thickness of lining, the contractor shall be informed in writing of such
changes, and he shall execute the work accordingly at the rates quoted in schedule -B without any
extra claim on account of changes in the section of the canal and thickness of lining.
(b)
In certain situations such as the reaches where bed filing is more than 3 mtrs, and other
special reaches nominal reinforcement is likely to be specified in the bed and side lining.
(c)
The scope of work also includes the following:

i)
Preparing the base for lining and laying the concrete lining including
dewatering and desilting.

ii)
Providing grooves for joints to required depth and width at specified intervals as
per drawings and as directed by the Engineer-in-charge.

iii)
Providing filter materials of approved quality, where specified as per drawings.
iv)
Trimming the canal section for preparing sub-grade for concrete lining, in all
sorts of soil, murrum and rock and back filling the over excavated sections with suitable
materials including watering and compacting the bed and slopes using suitable compacting
equipment and dewatering and desilting where
3.2
required.
APPLICABLE PUBLICATIONS
All concrete, its constituents, methods and procedure of manufacture shall conform to the
latest versions of the Indian standard specifications and other publications listed below unless
otherwise specified.
3.2.1 INDIAN STANDARDS FOR REFERENCE

1. IS : 8112-1989
43 grade ordinary portland cement-specification (First revision)
2. IS : 383-1970
Coarse and fine aggregates from natural sources for concrete
3. IS : 456-1978
Code of practice for plain and reinforced concrete
4. IS : 460-1978
Test sieves
5. IS : 516-1959
Method of tests for strength of concrete.
6. IS : 650-1966
Standard sand for testing of cement (Reaffirmed 1980)
7. IS : 1119-1959
Methods of sampling and analysis of concrete
8. IS : 1489-1976
Portland Puzzolona cement
9. IS : 1791-1968
Batch type concrete mixers
10. IS : 2386 : 1963
Methods of tests for aggregate for concrete. (Part I to VIII)
11. IS : 2430 - 1969
Methods for sampling of aggregates for concrete .
12. IS : 2505 - 1980
Concrete Vibrators, immersion type.
13. IS : 2506 - 1964
Screed board concrete vibrators
14. IS : 2580 - 1965
Jute bags for packing cement.
15. IS : 2722 - 1964
Portable swing weigh - batchers for concrete (Single and double

bucket type)
16. IS : 3085 - 1965
Methods of test for permeability of cement, mortar and concrete.
17. IS : 3873 - 1979
Code of practice forlaying in - situ cement concrete lining on the

canals
18. IS : 4031 - 1968
Methods of physical tests for hydraulic cement.
19. IS : 4032 - 1968
Methods of chemical analysis of hydraulic cement (Reaffirmed

1980)
20. IS : 4558 - 1983
Code of practice for under drainage of lined canal.
21.IS : 4634 - 1968
Method of testing performance of batch type concrete mixers.
22. IS : 4656 - 1968
From vibrators for concrete
23. IS : 4845 - 1968
Definitions and terminology relating to hydraulic cement.
24. IS : 4925 - 1968
Concrete batching and mixing plant.
25. IS : 4926 - 1976
Ready mixed concrete.
26. IS : 5256 1968
Code of practice for sealing joints in concrete lining on canals.
27. IS : 5512 - 1983
Flow table for use in tests of hydraulic cement and pozzolonic
materials
28. IS : 5513 - 1976
Vicat apparatus
29. IS : 5515 - 1983
Compaction factor apparatus.
30. IS : 5529
Code of practice for in - situ permeability tests.
31. IS : 5640 - 1970
Method of test for determining aggregates impact value of

coarse aggregates.
32. IS : 5816 - 1970
Method of test for splitting tensile strength of concrete cylinders .
33. IS : 5889 - 1970
Vibratory plate compactor.
34. IS : 5892 - 1970
Concrete transit mixers and agitators.
35. IS : 6461 - 1972
Glossary of terms relating to cement concrete aggregates,

materials etc.
36. IS : 6923 - 1973
Method of test for performance of screed board concrete vibrator.
37. IS : 6925 - 1973
Method for test for determination of water soluble chlorides in

concrete admixtures.
38. IS : 7245 - 1974
Concrete Pavers
39. IS : 7320 -1974
Concrete slump test apparatus.
40. IS : 7861
Code of practice for extreme weather concreting
41. IS : 7861-1971
Recommended practice for hot weather concreting(PartI) (Part II

1981) Recommended practice for cold weather concreting
42. IS : 8041 - 1978
Rapid hardening Portland cement.
43. IS : 8043 - 1970
Hydrophobic Portland cement.
44. IS : 8112 - 1976
High strength ordinary Portland cement
45. IS : 8142 - 1976
Method of test for determining setting time of concrete by

penetration resistance.
46. IS : 9013 - 1978
Method of making curing and determining compressive strength

of accelerated cured concrete test specimen.
47. IS : 9103 - 1979
Admixtures for concrete.
48. IS : 9284 - 1979
Method of test for abrasion resistance of concrete .
49. IS : 3860 - 1966
Pre-cast concrete slabs for canal linings.
50. IS : 4969 - 1968
Method of test for determining flexural strength of pre-cast

concrete slabs for canal lining.
3.2.2 OTHER PUBLICATIONS
3.3
1.
Concrete Manual (latest edition)
2.
American Society for Testing of Materials
3.
Manual of Canal lining
U.S.B.R.
C-491-80 water reducing agent
C.B.I. & P.
CLEARING SITE
The area proposed for lining the canal as a whole shall be cleared of all objectionable
material. Any waste material obtained from such site clearance shall be disposed off in a manner
directed by the Engineer - in-charge. The cost of this operation shall be deemed to have been
covered under the rates quoted for canal lining.
3.4
PREPARATION OF SUB-GRADE FOR CONCRETE LINING
3.4.1 GENERAL
A sound and firm bed for lining shall be obtained by suitably preparing the sub -grade as
follows: (a)
As specified in Para 1.9.1 the last 200 mm of excavation in soils and soft rock will be carried
out immediately before placing the concrete lining. Prior to this excavation, the sub - grade soil will
be scarified and wetted if necessary and compacted at optimum moisture content. The compacted
sub-grade thereafter shall be trimmed and dressed to required profile.
(b)
If there are over excavations, the back filling will be carried out as specified in Para 1.9.4.
which gives suitable procedure of back filling the over excavation of soils and of rock. If at any point
the sub-grade consisting of earth is disturbed or loosened, it shall be moistened, as required, and
thoroughly compacted by tamping, rolling or other approved methods to form firm foundations for
placing the concrete lining. In case of excavation in soft or hard rock, all loosened and disturbed
sub-grade will be knocked out and removed and the excavation, if any so caused shall be treated
as specified in para 1.9.4.
(c)
All loose materials shall be removed at the end panels of existing lining against which lining
is to be placed under the specifications, and all voids beneath the existing lining shall be refilled
and thoroughly compacted.
(d)
Suitable material trimmed from the canal shall be used for canal embankments, for road
embankment, for back fill around structures or for bedding material. Where material suitable for
bedding as determined by the Engineer-in-charge is encountered during trimming operations and
cannot be placed in one continuous operation, such material shall be stockpiled along the right of
way where designated by the Engineer - in - charge.
3.4.2 TOLERANCE IN PREPARATION OF SUB-GRADE
Excavated profile provides the final base for lining and departure from the lines show on the
drawings shall not exceed:
Alignment
:20 mm on straight section

:50 mm on tangents
:100 mm on curves
Departure from levels shown on the drawings :20 mm

The above tolerance shall be negotiated gradually through smooth transition in a length of
30 mtrs.
3.5
MATERIALS
3.5.1 CEMENT
a)
Cement shall be 43 grade ordinary Portland cement'
b)
Sampling and testing will be done by and at the expense of the KBJNL. No cement
shall be used until notice has been given that the test result are satisfactory. Cement older than 90
days shall not be used unless test results satisfy the minimum strength requirements. The 43 grade
ordinary Portland cement shall, for its physical and chemical requirements conform to IS : 81121989 ordinary Portland cement ( First Revision)
3.5.2 FINE AGGREGATE
i. GENERAL
All aggregates shall conform to IS: 383 - 1970 and its latest edition and shall be proposed as
directed by the Engineer-in-charge. Sand shall be natural sand from river bed, and the maximum
size, shall be limited to 4.75 mm (3/16''). Fine aggregates will be tested by the Engineer-in-charge
for their gradation, specific gravity, water absorption, fineness modules, soundness, petrographys
analysis, deleterious constituents and alkali - aggregate reactivity.
ii. QUALITY
(a)
Sand shall consist of hard, dense, durable and uncoated silicious gritty materials. It
shall be free from injurious amount of dust, lumps, soft and flaky particles, shale, alkali, organic
matter loam and other deleterious substances. The maximum percentage of each of the
deleterious substances in sand as delivered to the mixer shall not exceed the following values:
Material passing : IS No. 8.
(BSS No. 200) : 3.0 percent by weight
Clay lumps
: 1.0 percent by weight
Cinders and clinkers
Mica
Total of all deleterious substances including alkali,

coated grains, Soft and flaky particles, loams etc.
(b)
mica
:5.0 percent by weight
Sand shall be free from injurious amount of organic impurities and sand producing a colour
darker than the standard in the calorimetric test for organic impurities shall be rejected.
iii. GRADING
Sand shall be well graded so as to impart good workability and good finishing. Sieve
analysis of natural sand shall conform to the following limits of gradation.
IS Sieve Designation
Percentage passing for

Grading
Grading
Zone II
Zone III
10 mm
100
100
100
100
4.75mm
90-100
90-100
90-100
95-100
2.36 mm
60-95
75-100
85-100
95-100
1.18 mm
30-70
55-90
75-100
90-100
Zone I
Grading Grading
Zone IV
600 micron
5-34
35-59
60-79
80-100
300 micron
5-20
8-30
12-40
15-50
150 micron
0-10
0-10
0-10
0-15
The grading of fine aggregates, when determined as described in IS - 2386 (Part-I) 1963 shall be
within the limits given in the table 4 of IS: 383 and shall be described as fine aggregates, Grading
zones, I, II, III, IV. Where the grading falls outside the limits of any particular grading zone of sieves
other than 600 micron IS sieve by a total amount not exceeding 5% it shall be regarded as falling
within that grading zone. This tolerance shall not be applied to percentage passing the 600 micron
IS. Sieve or to percentage passing any other sieve size on the co arse limit of Grading Zone I or the
finer limit of Grading Zone IV.
iv. STORAGE
All sand shall be stored on the site of work in such a manner as to prevent intrusion of
foreign matter.
3.5.3 COARSE AGGREGATE

i. GENERAL
(a)
Coarse aggregate for concrete shall consist of clean, hard dense, free from vegetation and
durable, crushed metal or gravel. Predominantly flaky aggregates shall not be used. All coarse
aggregates shall be washed and / or screened by the contractor, if required. The percentage of
deleterious substance in coarse aggregate shall not exceed the following values:
Sl.
Deleterious
Method of
Fine aggregate %
Coarse Aggregate% No.
SubstanceTest by weight max
by weight max
Uncrushed Crushed
1.
i.
2
coal & Lignite
Uncrushed Crushed
IS : 2386
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
3.00
15.00
3.00
3.00
(Part II ) 1963
ii.
Clay lumps
IS : 2386
(Part II ) 1963
iii.
iv.
Material find than
IS : 2386
75-/I-IS sieve
(Part I ) 1963
Soft fragments
IS : 2386
3.00
1.00
5.00
2.00
5.00
5.00
(Part II ) 1963
v.
Shale
IS : 2386
(Part II ) 1963
vi.
Total percentage of ---all deleterious

materials (except
mica)including
Sl. No. I to V for
Col. 4, 6 & 7 and
Sl. No. i and ii for
Col. 5 only
Coarse aggregate will be tested by the Engineer-in-charge for their gradation, specific gravity,
water absorption, impact and abrasion values, soundness, petrographic analysis, deleterious
constituents, flakiness, and elongation indices, and alkali aggregate reactivity.
(b)
The sum of the percentage of all the deleterious substance shall, however, not exceed 5%
by weight. The coarse aggregate shall satisfy abrasion, soundness, crushing and alkali aggregate
reactivity test and water absorption results as laid down in IS : 383 - 1970 and other relevant Indian
standard specifications.
ii. GRADING
(a) Coarse
aggregate shall
be
well graded
and shall
have a maximum size
of 20 mm.
(b) The gradation shall give a dense concrete of the specified strength and consistency that will
work readily into position without segregation and without the use of excessive water content.
(c) The grading of coarse aggregate shall be in the nominal size as mentioned in table - II of IS :
383-1979 reproduced below :
I.S. Sieve Designation
% Passing for graded
80.00 mm
63.00 mm
40.00 mm
100
20.00 mm
95-100
16.00 mm
12.50 mm
10.00 mm
25-55
4.75 mm
0-10
2.36 mm
However, the exact gradation required to produce a dense concrete of specified

strength and desired workability shall be decided by he Engineer-in-charge.
(d) The aggregate should be collected in separate stockpiles for the gradation 20 to
10 mm and down wise. Testing for gradation and batching will be carried out only when the
collection is done in above manner.
iii. STORAGE
(a)
Aggregate shall be stacked in such a way as to prevent the admixture of foreign materials
such as soil, vegetable matter etc. Heaps of fine and coarse aggregate shall be kept separate.
When different sizes of fine or coarse aggregates are procured separately, they shall be s tored in
separate stock piles, sufficiently away from each other to prevent the materials at the edge of the
piles from getting intermixed.
(b)
The aggregate shall be stock-piled adjacent to the mixer site as to require minimum
rehandling and labour when conveyed to the mixer.
(c)
The aggregate shall be placed on a dry hard patch of ground if available otherwise a platform
of planks or plain galvanized iron sheets or alternatively on a floor of dry bricks or thin layer of lean
concrete.
(d) The aggregate shall be kept free from getting dirty by people through rubbish like papers,
vegetable matter and bidi etc.
(e)
To minimize moisture variations, the stock piles shall be as large in area as possible but low
and fairly uniform in height preferably 1.25 to 1.50 metre and the lowest layer of about 30 cms shall
be allowed to act as drainage layer and not used till the end. Generally not less than 10 days
requirement shall be stock piled.
3.5.4 WATER
(a)
Water used for mixing of concrete and mortar should be free from injurious amounts of
deleterious materials. Potable water is generally considered satisfactory for mixing and curing.
(b)
Where water is found to contain any sugar or acid, alkali or salt, the Engineer-in-charge will
refuse to permit its use. As a guide the following table represents the maximum permissible
values:
Organic
0.02%
Inorganic
0.30%
Sulphate
0.05%
Alkali Chlorides
0.10%
Suspended matter
0.20%
PH value
6 to 8
3.5.5 AIR ENTRAINING ADMIXTURES

i. GENERAL
Air entraining admixture when approved for being used as an admixture, shall be added to the
concrete batch in solution when directed by the Engineer-in-charge. It shall be batched by means
of mechanical batcher capable of correct measurement and in such manner as will e nsure uniform
distribution of the agent throughout the batch during the specified mixing period. The amount of air
entraining agent used shall be such as to effect air entertainment of 6 percent by volume in that
portion of the concrete containing aggregate smaller than the 20 mm. square mesh sieve after its
placement and vibration in the forms. The actual percentage of air shall be as fixed by the
Engineer-in-charge and will be changed whenever such change is deemed necessary to meet the
varying conditions encountered during constructions. The admixture shall be supplied by the
contractor himself, at his cost for use in the concrete mix. Charges for labour, transport, storage
and mixing shall be borne by the contractor. No claim on any account for use of this admixture or
any other admixture in the concrete shall be entertained by the department.
ii. TESTS FOR DETERMINING MIX PROPORTIONS
Sample required for evolving design mix of concrete have to be furnished by the contractor 3
months in advance of the concrete placement programme. Samples shall be collected from
approved quarries relevant to the portion of work. Contractor shall provide satisfactory facilities for
easy and quick collection of adequate test samples. All tests for deciding the mix proportions for
the evaluation and approval of admixutres, if any, shall be made by and at the expense of the
department.
The cement content of the mix design would be decided not only from the
considerations of strength requirements but also from durability.

3.6 CAST-IN-SITU CONCRETE LINING
3.6.1 GENERAL
This work shall generally conform to I.S. 3873-1978. All concrete for lining work shall be governed
by I.S: 456-1978. Concrete for lining works shall be of controlled grade with suitable admixtures of
approved air entrining agents, using well graded aggregate with maximum size of aggregate of 20
mm.
3.6.2 BATCHING
(a) The contractor shall provide such means and equipment as are required to accurately
determine and control the relative amounts of the various materials including water, cement,
admixtures, sand and each specified size of coarse aggregate for the concrete. Such means and
the equipment and its operation shall be subjected at all times, to the approval of the Engineer-incharge. The amount of cement, fly ash if required, sand and each size of coarse aggregate
entering each batch of concrete shall be determined by weighing and the amount of water shall be
determined by weighing and the amount of water shall be determined by weighing or volumetric
measurement.
(b) The measuring and weighting equipment shall operate within the limits of accuracy specified.
Standard sets of weights required for checking the satisfactory performance shall be provided by
the department.
(c) The equipment shall be capable of controlling the delivery of material so that the combined
inaccuracies in feeding and measuring during normal operations do not exceed 1% for water and
3% for all aggregates. Periodical tests shall be made at least once in every month in case of
equipment measuring sand and coarse aggregate. However, this shall not obstruct any surprise
checking and testing at any time as desired by the Engineer-in-charge. Repairs, replacement or
adjustments shall be made as necessary to secure satisfactory performance.
(d) The weighing equipment shall conform to the requirement of IS : 2772-1964 and the batching
and mixing plant to the requirement of IS : 4925-1968. The contractor may provide central
batching plant for supplying concrete.
(e) In case of uniformity in the materials used for concrete has been establish over a period of time,
proportioning may be done by volume batching, provided periodical checks are made on
Mass/Volume relationship of the material. When weight batching is not practicable, quantities of
fine and coarse aggregate (not cement) may be determined by volume. If fine aggregate is moist
and volume batching is adopted, allowance should be made for bulking in accordance with IS
2386-part III - 1963.
3.6.3 MIXING
(a) Concrete shall be mixed in a mechanical ready mix mixer and shall be as dense as possible,
plastic enough to consolidate well and stiff enough to stay in place on the slopes.
(b) Mixing shall be continued until there is a uniform distribution of materials and the concrete is
uniform in colour and consistency. The time of mixing shall be as shown in table -I of IS : 457-1957
reproduced below :
Capacity
Minimum time of mixing
of Mixer
Natural Aggregates
Manufactured Aggregates
m3 or larger
2 minutes
2 minutes
m3
1 minutes
2 minutes
1 minutes
1 m3 or smaller
3.6.4 CONSISTENCY
The amount of water used in the concrete shall be fixed a required from time to time during
the course of concreting work to secure concrete of the proper consistency and to adjust for any
variation in the moisture content or grading of the aggregates as it enters the mixture. Addition of
water to compensate the stiffening of the concrete resulting from over mixing or objectionable
drying before placing shall not be permitted. Uniformity in concrete consistency from batch shall be
required. Where concrete is laid from bottom to the top of the slope. A slump 50-70 mm shall be
allowed for lining. Where canal lining machines are used the slump shall be 50 mm. To have a
close control of the consistency and workability of concrete, the slumps of concrete shall not vary
by more than 20 mm which would otherwise, interfere with the progress and quality of the work.
3.6.5 CONVEYANCE
(a)
Concrete shall be handled from the place of mixing to the place of final depositing as rapidly
as practicable by use of equipment such as transit mixers which will prevent initial setting,
segregation or loss of any of the ingredients. It shall be transported and compacted in its final
position within 30 minutes of its discharge from the mixer.
(b)
If segregation occurs during transport, the concrete shall be remixed before being placed,
after observing the time requirements as above.

3.6.6 PLACING AND COMPACTION
(a)
Concrete shall be placed only in the presence of a duly authorized representative of the
department. Concrete shall be placed and compacted before initial setting time and should not be
subsequently disturbed.
(b)
Placing of concrete shall not be started until all form work is completed and all parts to be
embedded are placed and preparation of surface upon which concrete is to be laid, has been
completely inspected and then so directed by the Engineer-in-charge. All absorptive surfaces
against which concrete is to be laid shall be moistened adequately so that moisture will not be
withdrawn from freshly placed concrete. The surfaces however, shall be free from standing water
and mud.
(c)
Concrete shall be deposited and spread on the bed and sides of the canal as indicated on
the drawings, in alternate panels. It shall be well compacted by using tampers vibrators and
screeds and finished smooth by wooden floats and travel to get smooth, hard and even surface.
For lining of side slope, concrete shall be screeded up the slope, and vibrated ahead of the screed.
Concrete required for keys as shown on drawings shall be laid integrally with side -slope lining. Slip
forms shall be used for the side slopes of the canal.
(e)
As an alternative to hand placing, or the slip forms, the contractor may choose to use
longitudinally operating self aligning, slip from machine with built in vibrators attached the side
forms as effectively compact and finish concrete.
3.6.7 SLIP FORM FOR SIDE SLOPES OF THE CANAL
The slip form used for placing concrete to the side slopes of the canal shall comprise of
weighted steel faced slip form screed, about 70 cms wide, pulled up the slopes by hoisting
equipment placed on the canal berms or on the top of the service road/inspection path. The screed
travels up over the screed guides which are firmly laid over the sub grade of the side slopes, at the
two ends of the panel being concreted and are correctly positioned to serve, in addition, as form
work for those two sides. When the adjacent panels are already concreted, the screed guides are
dispensed with and the slip form screed travels supported over the adjacent panels at its two ends.
The screed guides may comprise rolled steel channels the heights of which correspond to the
thickness of the lining. The screed guides shall be correctly aligned, transverse to the canal
alignment and shall be correctly positioned conforming to the designed side slopes of the canal.
The slip form screeds shall be of rigid construction and shall not deflect during the concreting
operation. The weights placed over the slip form screed shall be adequate and uniformly placed so
as to exert enough pressure on the concrete and to ensure smooth operation without being lifted or
otherwise disturbed during the concreting operations.
The screed shall be steel faced and
univibrated. The concrete shall be vibrated ahead of the slip form screed using immersion type
vibrators. The construction of the slip form including the pulling ropes, the hoists and the hoisting
arrangements shall be such as to ensure that the slip form screed would move up the slope evenly
and slowly. Laborers vibrating the concrete would be positioned over the top of the traveling slip
form screed and would ensure that the concrete is well vibrated and dense as it is slipped under
the screed. Together enough concrete for being vibrated and fed under the slip form screed, a
steel plate lip is provided at the rising end of the slip form and the arrangement works like a moving
hopper. The workability of the concrete and the concreting operation including the vibrating
arrangements shall be such as to ensure that the surface made by the slip form will require no
further screeding and very little finishing.
The slip forms of above description shall be employed without fail in all main canals, branch canals
and major distributaries. The concreting method in smaller channels like laterals may comprise of
manually moving up the screeds over the screed guides laid on the sub grade. The size of the
screed, in such cases would be smaller. Consolidation of concrete lining is accomplished mainly in
the screeding operation. Three-meter screed panels should be quite practicable for two -man
operation of the screed.
3.6.8 FINISHING
(a)
All exposed concrete surfaces shall be cleaned of impurities, lumps of mortar or grout and
unsightly stains. Finished surface shall be even, smooth and free from pockets and equivalent to
that obtainable by effective use of a long handle steel trowel. Surface irregularities shall not
exceed 6 mm for bottom slab and 12 mm for side slopes, when tested with a straight edge of 1.5
meter length.
(b)
The surface of concrete finished against form shall be smooth and shall be free from
projections, honeycombing and other objectionable defects. Immediately on the removal of forms,
all unsightly ridges or lips shall be removed and under desirable local bulging on exposed surfaces
shall be remedied by tooling and rubbing.
(c)
Repairs to concrete surface and additions where required shall be made by cutting regular
opening into concrete and placing fresh concrete to the required lines. Chipped opening shall be
sharp and shall not be less 75 mm in depth,. Plastering of concrete surface will not be allowed.
(d)
The unformed surface of lining shall conform to U4 finish as described in Para 4.14. 2 iv).
The form surface of lining shall conform to (F4) finish as described in Para 4.14.1 e) iv).
3.6.9 CURING
(a) Water Curing
Subsequent to laying of concrete lining and after a period of 24 to 36 hours, the lining should be
cured for atleast 21 days. On bed, this may be done by constructing 15cms deep earthen bunds
across the bed so that a small depth of water will stand on the bed. The curing of side slopes may
be done by constructing masonry drains with weep holes or perforated pipes on the coping at the
top of the lining or by sprinklers such that the surface is always kept wet. If the surface is covered
with gunny bags or straw, intermittent sprinkling may also be allowed provided that the underneath
of the gunny bags and straw are always wet.
(b) Membrane Curing
i. As an alternative to water curing, membrane curing may also be done using curing
compounds of approved manufacture conforming to specifications ASTM designation cx 309-38.
Curing compounds should not be used on surfaces that are to receive additional concrete, paint or
tile that require a positive bond, unless it has been demonstrated that the membrane can be
satisfactorily removed before a subsequent application or that the membrane can serve
satisfactorily as a base for the application.
ii. The compound shall be applied at a uniform rate sufficient to comply with the requirement
of the test for water retention (ASTM-C156-65). The usual values for water retention coverage
range from 3.5 to 5.0 sqm per litre.
iii. Curing compound can be applied by hand spray or mechanical distributors at about 75 to
100 psi (5 to 7 kgs per sqm.) On small areas such as patches curing compounds may be brushed
with a wire or bristled brush.
iv. On formed concrete surfaces the curing compound shall be applied immediately upon
removal of the form. If there is any drying or appreciable loss of moisture the surface should be
sprayed with water and allowed to reach a uniformly damp appearance with no free water on the
surface when the compound is applied.
v. The contractor shall demonstrate the effectiveness of the curing compound he intends to
utilize. Such compounds shall be used on the work only after successful demonstration to the
satisfaction of the Engineer-in-charge. The contractor shall also produce a test certificate to show
that the material conforms to stated specifications.
vi. Application of the curing compound shall be strictly as per the manufacturer's
specifications. After application of the curing compound the membrance shall be protec ted by
covering of sand or earth of not less than 25 mm. in thickness or by other means, if concrete is
subjected to foot traffic or other construction activity. Protective covering shall not be placed until
the sealing membrane is thoroughly dry and shall be removed by the contractor after the final
acceptance of the work. The curing compound shall be used only if it has been tested and
approved by the Engineer-in-charge. the cost of furnishing transporting, handling and supplying all
materials including labour etc. used for curing of concrete shall be included in the unit rate
tendered for the concrete. The contractor shall maintain adequate and appropriate curing material
and means of applications at site of work failing which his work may have to be halted and for
which the contractor shall not be entitled for any claim whatsoever.
3.7
TESTS OF CONCRETE AND ACCEPTANCE CRITERIA
3.7.1 GENERAL
Testing of concrete shall be carried out at the cost of the KBJNL by the quality control Division in
representative samples taken at the site of laying the concrete in accordance with relevant Indian
Standard specifications.
3.7.2 SAMPLING PROCEDURE AND FREQUENCY
(a)
Sampling procedure
A random sampling procedure shall be adopted to ensure that each concrete batch has a
reasonable chance of being tested, i.e. the sampling should be spread over the entire period of
concreting and should cover all mixing units.
(b)
Frequency
The minimum frequency of sampling of concrete of each grade shall be in accordance with the
following:
Quantity of concrete per Shift Cum.
1 to 5
Number of Samples
1
6 to 15
16 to 30
31 to 50
51 and above
4 plus one additional

sample for each additional
50 Cum. or part thereof.
Note: At least one sample shall be taken during each shift, at each placement location.
3.7.3 SAMPLING AND STRENGTH TEST OF CONCRETE
Sample from fresh concrete shall be taken as per IS : 1199 -1959 and cubes shall be made, cured
and tested at 28 days in accordance with IS : 516-1959.
3.7.4 TEST SPECIMEN
(a)
Three test specimen shall be made from each sample for testing at 28 days. Additional
cubes may be required for various purposes, such as to determine the strength of concre te at 7
days or at the time of striking form work, or to determine the duration of curing or to check the
testing cubes cured by accelerated methods as described in IS : 9013-1978. The specimen shall
be tested as described in IS : 516-1959.
(b)
Test strength Samples

i) The test strength of the sample shall be average of three specimen. Individual variation
should not be more than 15% of the average.

ii) Contractor shall provide necessary unskilled labour and facilities for transport for collection
of samples, cores, etc., and shall be present at the time when the samples, cores etc, are taken.
Testing shall be carried out at the testing laboratories set up at the site or a any other laboratory
that the Engineer-in-charge may decide upon and the results given thereby shall be considered as
correct and authentic and acceptable to the contractor.
The contractor shall be given access to all operations and tests that may be carried out as
aforesaid. All testing charges are to be borne by the department.
3.7.5 STANDARD DEVIATION
Standard Deviation based on test results:
(a)
Number of test results - The total number of test results required to constitute an acceptable
record for calculation of standard deviation shall be not less than 30. Attempts should be made to
obtain the 30 tests, results, as early as possible, when a mix is used for the first time.
(b)
Standard Deviation to be brought up to date - The calculation of the standard deviation shall
be brought up to date after every change of mix design and at least once a month.
Determination of Standard Deviation:
(a)
Concrete of each grade shall be analyzed separately to determine its standard deviation.
(b)
The standard deviation of concrete of a given grade shall be calculated using the following
formula from the result of individual tests of concrete of that grade obtained as specified in 14.4 ; or
IS : 456-1978.
Estimated Standard Deviation, S =
n 1
Where
=Deviation of the individual test strength
from the average strength of 'n' samples, and
n=
(c)
number of sample test results.
When significant changes are made in the production of concrete batches (for example
changes in the materials used, mix design, equipment or technical control) the standard deviation
value shall be separately calculated for such batches of concrete.
Assumed Standard Deviation
Where sufficient test results for a particular grade of concrete are not available the value of
standard deviation given in Table 6 of IS : 456-1978 clause 14.5.3 may be assumed.
TABLE 6
ASSUMED STANDARD DEVIATION
(CLAUSE 14.5.3 OF IS : 456-1978)
Grade of Concrete
Assumed Standard Deviation {N/mm 2}
M 10
2.3
M 15
3.5
M 20
4.6
M 25
5.3
M 30
6.0
M 35
6.3
M 40
6.6
However, when adequate past records for a similar grade exist and justify to the designer a value
of standard deviation different from that shown in Table 6, of IS: 456-1978 it shall be permissible to
use that value.
3.7.6 ACCEPTANCE CRITERIA
The concrete shall be deemed to comply with the strength requirements if:
(a)
Every sample has a test strength not less than the characteristic value
or
(b) The strength of one or more samples though less than the characteristic value, is in each
case not less than the greater of :
(1)
The characteristic strength minus 1.35 times the standard deviation and
(2) 0.80 times the characteristic strength ; and the average strength of all the samples not
less than the characteristic strength
plus (1.65 - .
1.65
.) times the Standard Deviation
(Number of samples)
The concrete shall be deemed not to comply with the strength requirements if:
(a)
(b)
The strength of any sample is less than the greater of:

(1)
The characteristic strength minus 1.35 times of the standard deviation and
(2)
0.80 times the characteristic strength
The average strength of all the samples is less than the characteristic strength
plus (1.65 - .
. times the Standard Deviation
(Number of samples)
Concrete which does not meet the strength requirements as specified in 15.1 of IS 456-1978 but
has a strength greater than that required by @ 5.2 of IS : 456-1978 may at the discretion of the
designer, be accepted as being structurally adequate without further testing.
If the concrete is deemed not to comply pursuant to 15.2 of IS : 456-1978 the structural adequacy
of the parts affected shall be investigated (sec 16 of IS : 456-1978) and any consequential action
as needed shall be taken.
Concrete of each grade shall be assessed separately.
Concrete shall be assessed daily for compliance.
Concrete is liable to be rejected if it is porous or honey combed, its placing has been i nterrupted
without providing a proper construction joint, the reinforcement has been displaced beyond the
tolerances specified or construction tolerance have not been met.
However, the hardened
concrete may be accepted after carrying out suitable remedial measures to the satisfaction of the
Engineer-in-charge.
3.7.7 CORE TEST
Core / samples may also be taken by drilling the hardened concrete of the lining for testing the
compressive strength. Cores shall be of diameter 7.5 cms and tested as per IS : 516-1959. Three
test cores taken at any cross section will constitute one sample. Test samples shall be taken for
branch canals, distributaries etc. at intervals as indicated below or at closer intervals, if considered
necessary.
Discharge Capacity
Approx. Average intervals
1.
Above 14 Cumecs.
250 mtrs.
2.
Greater than 3 to 14 Cumecs.
500 mtrs.
3.
Above 0.30 Cumecs, upto 3 Cumecs.
750
mtrs.
4.
0.3 Cumecs. & below
1000 mtrs.
The points from which cores are to be taken and the number o f cores required shall be at the
discretion of the Engineer-in-charge and shall be representative of the whole of concrete
concerned. In no case, however, shall fewer than three cores be tested.
Cores shall be prepared and tested as described in IS : 1199-1959 and IS : 516-1959.
Concrete in the member represented by a core test shall be considered acceptable if the average
equivalent cube strength of the cores is equal to atleast 85% of the cube strength of the grade of
concrete specified for the corresponding age and no individual core has a strength less than 75%.
Cored holes shall be refilled with the same grade of concrete without any extra cost. In the event of
difference between the test results of cubes specimen taken while laying concrete and core
specimen taken later, result of core sample testing will prevail.
3.8
JOINTS
Joints shall be spaced and located as shown in the drawing or as directed by the Engineer-incharge. The joints shall be formed in the manner as specified below when the concrete is hand
placed.
In situ sleepers, in case bed and precast in case of sides shall be provided under the joints. The
sleeper shall be of sizes shown on the drawing. Concrete used for sleeper shall be of the same
grade as for lining. Before laying cement concrete, the top of the sleeper both in bed and side
slopes shall be treated with two layers of sealing compound as prescribed in clause 9 of IS: 52561968 and as shown in the drawing. Slabs shall be laid in alternate compartment with an interval of
at least one day for setting and contraction. The faces of the previously placed concrete shall be
painted with sealing compound as prescribed in IS: 5256-1968 to ensure that no bonding takes
place The grooves at the joints shall be of size and shape as shown on the drawing and filled with
hot applied sealing compound. Filling of the joint with hot applied sealing compound should be
taken up after completion of all other canal work. In the mean time the grooves shall be filled with
clean coarse sand.
Expansion Joints
Expansion joint shall not be provided except where structure intersects the canal.
At intersecting structures an expansion joint of 25 mm width filled with sealing compound
conforming to IS: 5256-1968 or with P.V.C. water stops shall be provided.
Construction Joints
A construction joint is placed at any location where it is suited as an exigency to construction
(interruption of work.). It later performs the function of a transverse, longitudinal or expansion joint.
Contraction joints Contraction joint shall be provided at places shown on the drawings or directed
by the Engineer-in-charge in accordance with provisions laid down in 6.2.1 and 6.2.2. of IS : 38731978. Where lining operations are continuous, transverse grooves or longitudinal and transverse
grooves both in cases of concrete lined canal with lined perimeter more than 10 mtrs. Shall be
formed as shown in Fig. (1) in accordance with "Table 2 of IS: 3873-1978.
Deviations from established lines, grades and dimensions shall be tolerated to the extent set forth
herein provided that the department reserves the right to diminish the tolerance set forth herein if
tolerances impair the structural action or operational function of the lining.
i.
Departure form established alignment
20 mm on straight reaches
50 mm on tangents.
ii.
Departure from established grade
100 mm on curves, 20mm

on straight reaches
iii.
Variation in concrete lining thickness
10% of lining thickness

provided average thickness
is not less than specified
thickness
Any departure from alignment or grade shall be uniform and no correction in alignment be
made in less than 50 mtrs.
3.9
DEWATERING
Canal reaches where water in encountered above canal bed level shall be dewatered continuously
during preparation of sub-grades and placing of concrete for lining till the concrete has attained
necessary strength. No separate payment shall be made for dewatering operations, as the same
shall be deemed to have been included in rate of related finished item of work in the schedule - B.
3.10 DESILTING
Whenever desilting is encountered in canal reaches during preparation of sub -grades and placing
of concrete for lining, it shall be done by the contractor. No separate payment shall be made for
this operation as the same be deemed to have been included in the rate of the concerned finished
item of work in the schedule - B.
ii. CONCRETE LINING WITH NOMINAL REINFORCEMENT
The quantity of cement concrete lining with nominal reinforcement will be measured on volume tric
basis on the same lines as of plain concrete lining. Payment shall be made at the unit rate quoted
in schedule - B. The rate is inclusive of costs of all materials transport with all lead and lifts, all
tools, plant and labour for mixing, conveying, placing, compacting, finishing, curing etc. and also for
dewatering and desilting during the placing of the reinforcement and the concrete.
3.12 GUARD STONES/BOUNDARY STONES/CHAINAGE STONES
All stones shall be quarried from the approved quarry only. The stones shall be clean, hard,
durable, dense, tough and shall be free from decay, whethered portions, skin, veins, flaws, cracks,
cavities, vescicules and other defects. Stone shall be as far as possible uniform in colour and
texture. Stones shall be of fine medium grained and shall give ringing sound when struck with a
hammer. They shall be of the required size and shall be dressed neatly on the exposed faces. The
guard stones shall be hammer dressed.
The stones shall be fixed on both the sides of canal at intervals as directed by the Engineerin-charge. The size of stones shall be 75 cm x 20 cm x 20 cm and the portion above the ground
level shall be dressed to the required size and as directed by the Engineer-in-charge. Arrow marks
shall be engraved for boundary stones as directed. The stones shall be fixed by excavating a pit
and back filled with excavated material. The stones shall be white washed as directed. The rate
quoted by Contractor for this item shall includes cost and conveyance of all material, with all leads
and lifts, dressing to the required size and shape including engraving arrow mark (for boundary
stones) and white washing as directed by the Engineer-in-charge fixing in position by excavating a
pit of required size and refilling with excavated materials including consolidation, watering etc.,
complete.
3.13 CANAL BED STONE
Providing and fixing canal bed stones
The canal bed stones shall be fixed at intervals 20 metres as directed by the Engineer-incharge. The size of stones shall be 75cm x 20cm x 20cm and the portion above the ground level
shall be dressed to the required size and shape as directed by the Engineer-in-charge, the stone
be fixed by excavating pit of required size and refilling with excavated material. The rate quoted by
the contractor for this item include cost and conveyances of all materials with all leads and lift
dressing to the required size and shape as directed by the Engineer-in-charge, fixing in position by
excavating pit of required size and refilling with excavated material complete.
3.14 KM STONE/1/10(HECTOMETER) STONE OF SIZE 0.65 X 0.15 X 0.10M AND KM
STONE SIZE 1.11M X 0.35M X 0.25M
The stone shall be fixed as directed by the Engineer-in-charge. Size of the stone shall be as per
IRC including painting surface with two coats of approved colour and shade and lettering with black
paint of approved quality as directed. The stone shall be fixed by excavating a pit to the depth of
0.3m filled with CC m-10 Prop block of size 0.7 x 0.45 x 0.40 and hectometres size of 0.5 x 0.45 x
0.40. The rate quoted by the contractor for this item shall include cost and conveyance of all
materials dressing this tones painting and lettering as directed etc., complete with all lead and lift.
SECTION - IV
PLAIN AND REINFORCED CONCRETE
4.1
SCOPE OF WORK
The specification covers the requirements of plain and reinforced concrete for use in various
components of structures. The work covered under this section consists of furnishing all materials
including formwork, equipment, labour for the manufacture, transport, placing, vibrating, finishing
and curing of the concrete for the structures and performing all the operations necessary and
ancillary thereto including dewatering and desilting etc., as required. For the reinforced concrete
structures, granite, quartzite, dolerite or trap shall only be used as coarse aggregate.
4.2
APPLICABLE PUBLICATIONS
All concrete, its constituents, methods and procedures of manufacture, placement etc. shall
conform to Indian Standard Specifications and other publications listed below unless otherwise
specified.
4.2.1 INDIAN STANDARDS FOR REFERENCE
1.
IS : 303-1975
Plywood general purpose
2.
IS : 432-1966 (part-I)
Mild steel and medium tensile steel bars
3.
IS : 516-1976
Portland slag cement
4.
IS : 516-1959
Methods of test for strength of concrete
5.
IS : 2505-1980
Concrete vibrators immersion type.
6.
IS : 2506-1964
Screed board concrete vibrators.
7.
IS : 3370-1965-1967
Code of practice for concrete structures
(All parts)
for the storage of liquids.
IS : 3558-1983
Code practice for the use of immersion
8.
vibrators for consolidating concrete.

9.
IS : 4656-1968
Form vibrators concrete
10.
IS : 4990-1981
Plywood for concrete shuttering works.
11.
IS : 5242-1979
Method of test for determining shear

strength of mild steel.
12.
IS : 8989 -1978
Safety code for erection of concrete

framed structure.
13.
IS : 9077-1979
Code of practice for corrosion protection of steel

reinforcement in R.B. and R.C.C. construction.
In addition to the above, relevant Indian Standards referred in Section-III shall also apply.
4.2.2
OTHER PUBLICATIONS
1.
2.
Indian road congress standard
Section I
Specifications and code of
Section II &
Practice for road bridges.
Section III
Concrete Manual
U.S.B.R.
(Latest Edition)
3.
American Society for testing of materials
C. 494.80
4.
Design aids to IS : 456-1978 for
SP 16(S & T)
reinforced concrete.
1980
4.3
COMPOSITION
(a)
Concrete shall be composed of cement, fine aggregate (natural sand of manufactured sand
or both), coarse aggregates (manufactured or natural gravel) admixtures and water, well mixed in
proportion and brought to the proper consistency. The design mix proportions shall be adjusted to
produce a durable and workable concrete, suitable for specified conditions of placements and
design strength.
(b)
For all items of concrete in any portion of the structure or its associated works, controlled
concrete shall be used where specified.

4.4
MATERIALS
4.4.1 CEMENT
(a)
Only 43 grade ordinary Portland cement shall be used for R.C.C. constructions while
puzzolona Portland cement (P.P.C.) shall be allowed to be used for plain concrete.
(b)
Immediately, upon receipt at the site of the work, cement shall be sto red separately in dry,
water tight and properly ventilated structures. All storage facilities shall be subject to approval and
shall be such as to permit easy access for inspection and identification. Sufficient cement shall be
kept in stock for completion of concreting undertaken. Cement shall be used in order of receipt
and cement older than 90 days shall not be used unless the test results satisfy the minimum
strength requirements. The provision made in Para 3.5.1 shall also apply.
4.4.2 FINE AGGREGATES
The provisions made under Para 3.5.2 shall apply.
4.4.3 COARSE AGGREGATES.
(a)
Coarse aggregates shall consist of hard, strong, durable particles of crushed stone or gravel
and shall be free from thin elongated soft pieces, organic

or other deleterious matter. It shall have no adherent coating. It shall be from a source, approved
by the Engineer-in-charge. Coarse aggregates shall conform to IS : 383-1970 and IS : 515-1959.
(b)
Coarse aggregates shall be washed if necessary to remove all vegetations and other
perishable substances and objectionable amounts of other foreign matter. The cost of washing
and screening shall be borne by the contractor.
(c)
Following table gives an indication of the maximum size of coarse aggregate for the different
items of work. However maximum size of coarse aggregate shall be adopted as indicated on the
drawings:
Sl. No. Item of work
Maximum Nominal size

of coarse Aggregate (MSA)
(i)
Foundation floor and gravity
40 mm / 80 mm
retaining walls (mass concrete)

(ii)
R.C.C. Rafts, piers, Abutments
40 mm
Barrels, cutoff walls, Breast walls

Staunching rings etc.
(iii)
R.C.C. work in main and cross girders,
20 mm
Deck slab, wearing coat, kerb, parapet

walls, approach slab, pier caps,
diaphragm wall and other thin
walled members and in zones of congestion
(d)
For heavily reinforced concrete members, as in the case of ribs of main beams, maximum
size of aggregate shall usually be restricted to 5 mm. less than the minimum lateral celar distance
between the main bars or 5 mm less than the minimum cover to the reinforcement, whichever is
smaller. However, if required under special circumstance, the Engineer may permit an aggregate of
maximum size 25% more than this/critical spacing / cover, provided that proper vibration is
ensured. The other provision of section 3.5.3 shall apply.
4.4.4 REINFORCEMENT STEEL
The provisions of SECTION - V shall apply.
4.4.5 WATER
The provision of Para 3.5.4 shall apply.

4.4.6 ADMIXTURES
Admixtures like water reducing agents, air entraining agents, water proofing agents etc. shall be
used only if permitted by the Engineer. The kind of admixutre its make and quality, the proportion
and the manner of mixing shall be subject to Engineer's approval.
4.4.7 EPOXY
Use of epoxy for bonding fresh concrete for repairs shall be permitted on written approval of the
Engineer. Epoxy shall be applied in accordance with the instructions of the manufacturers. The
cost of such repair shall be borne by the contractor.
4.5
CONCRETE FOR STRUCTURES
Controlled concrete shall be used for the structures in three grades designated as M-10, M-15 and
M-20. The mix shall be designed using representative samples of available coarse and fine
aggregate as well as cement and water to achieve the required workability strength and durability
standards. Mix design studies and test will be made by the KBJNL.
4.6
STRENGTH REQUIREMENT OF CONCRETE
The compressive strength requirement for the various grades of controlled concrete shall be as per
TABLE NO.1 given below:
TABLE NO.1
Grade of
concrete
Compressive test strength in N/Sq mm of 150 mm cube conducted in

accordance with IS : 516-1959
Min. at 7 days
Min. at 28 days
M-10
10
M-15
10
15
M-20
13.5
20
M-25
17.0
25
M-30
20.0
30
Note : in all cases, the 28 days compressive strength specified in table shall alone be the criteria
for acceptance or rejection of the concrete on the basis of its strength. Where the strength of a
concrete mix as indicated by tests lies in between the strength for the two grades specified in table,
such concrete shall be classified for all purpose as concrete belonging to the lower of the two
grades between which its strength lies.
4.7
PROPORTIONING CONCRETE
(a)
Concrete mix shall be designed on the basis of preliminary test.
The proportion of
ingredients shall be such that concrete has adequate workability for conditions prevailing on the
work in question and can be properly compacted with
the means available. Samples of construction material required for evolving design mix shall be
supplied 3 months in advance.
(b)
Unless it can be shown to the satisfaction of the Engineer-in-charge that supply of properly
graded aggregates of uniform quality can be maintained till the completion of the work, grading of
aggregate shall be controlled by obtaining the coarse aggregate in different sizes and blending
them in the right proportions as required. Different sizes shall be stacked in separate stockpiles.
Required quantity of materials shall be stock piled atleast 3 days in advance before use. Grading of
coarse and fine aggregates shall be checked as frequently as possible, frequency for a given job
being determined by the Engineer-in-charge to ensure that the supplies are maintaining the
uniform grading as approved for samples used in the preliminary tests. In proportioning concrete
the quantity of both cement and aggregate shall be determined by weight. Water shall either be
measured by volume in calibrated tank or weighed. All measuring equipment shall be maintained
in a clean serviceable condition. Their accuracy shall be periodically checked.
(c)
It is most important to maintain the specified water cement ratio. To this end, moisture
content in both fine and coarse aggregates shall be periodically determined and the amount of
mixing water shall be adjusted to compensate for any variations in the moisture content. For the
determination of moisture content in the aggregates IS : 2386-1963 (Part III) shall be referred to.
Suitable adjustment shall also be made in the batched weight of the aggregate depending upon the
variations in their moisture content.
(d)
The following amount of cement for various grades of concrete may be considered for
quoting rates in Schedule - B:
TABLE
Sl.
Description
Grade of
Approx quantity of
No.
concrete
cement per cum of

concrete
1.
M-15 CC,(20mm CA) for lining
M -15
270
2.
M-15 CC,(20mm CA) for lining with paver
M -15
275
3.
M-10 CC,(40mm CA) for foundation
M -10
220
4.
M-15 CC,(20mm CA)
M -15
270
M -20
330
5.
M-20 CC,(20mm CA) for sub structure and

super-structure
6.
M-15 CC,(40mm CA) for foundation filling
M -15
240
7.
M-20 CC,(20mm CA) for RCC Trough
M -20
330
8.
M-20 CC,(20mm CA) for Deck slab
M -20
330
9.
M-20 CC,(20mm CA) for columns and beams
M -20
330
10.
M-20 CC,(20mm CA) for wearing coat
M -20
330
Note: Table to be separately enclosed, with respect to different items of concrete referred
in
Schedule-B of the tender as per SR adopted.

(e)
Actual cement level required for the aggregates to be used shall be determined by
Laboratory tests. The mix proportions shall be selected to ensure that the workability of the fresh
concrete is suitable for the conditions of handling and placing, so that after compaction it surrounds
all reinforcements and completely fills the formwork. When concrete is hardened, it shall have the
required strength, durability and surface finish. A mix shall be designed to produce the grade of
concrete having the required workability and characteristic strength not less than that stipulated in
table under para 4.6 above. Due to the change in design mix, if it becomes necessary to use less
or more cement per cubic metre of concrete than shown in the above table, no extra payment will
be made to the contractor for variation in cement content during execution.
(f)
The quantity of water shall be just sufficient to produce a dense concrete of required
workability and strength for the job. An accurate and strict control shall be kept on the quantity of
water.
(g)
Incase of reinforced concrete work, workability shall be such that the concrete surrounds and
properly grips all reinforcement. The degree of consistency, which shall depend upon the nature of
work and methods of vibration of concrete, shall be controlled by regular slump tests. Following
slumps shall be adopted for different types of works:
Type of work
i.
Mass concrete for RCC foundations,
Slump Allowed
40 mm to 50 mm
footing and retaining walls

ii.
Beams, slabs and columns
40 mm. to 50 mm.
iii.
Thin RCC section with
50 mm. to 60 mm.
congested steel
4.8
PRODUCTION OF CONCRETE
4.8.1 PRODUCTION OF AGGREGATES

Production of aggregates may include quarrying of the raw material and processing viz.
transporting, crushing, screening and washing. Water used for washing aggregates shall be clean
and free from alkali, salts and other impurities. After washing, fine aggregates must be stored in
stock piles with a free draining base for atleast 3 days to ensure that sand, delivered to the
batching plant will have a reasonably uniform moisture content. The storage and handling shall be
in such a manner as to prevent inter mingling of various sizes of aggregates required separately for
grading purposes. No foreign matter shall be allowed to mix with aggregate.
4.8.2 BATCHING
(a)
The prescribed amount of the various materials of concrete, including water, cement,
admixtures the groupings of fine aggregates and each individual size of coarse aggregates shall be
measured and controlled within the specified limits of accuracy. The amount of water, cement and
aggregates shall be determined by weighing. In the case of fine aggregates, the surface moisture
shall be determined in accordance with the method prescribed in Appendix D of IS : 456-1978 and
its subsequent amendment or publications. In the case of coarse aggregates, percentage of free
water shall be determined by weighting representative sample, then surface drying each particle
individually with a clean piece of cloth and reweighing.
(b)
The batching equipment shall be constructed and operated so that the combined
inaccuracies in feeding and measuring the materials shall not exceed 1% for water and cement
and 2% for each size of aggregate.
(c)
The operating performance of each scale or other measuring device shall be checked by test
weight and the test shall cover the ranges of measurements involved in the batching operations.
Tests of equipments in operation shall be made atleast once every fortnight and adjustment,
repairs or replacement, be made as necessary to meet the specified requirements for accuracy of
measurement.
(d)
Aggregate shall not be batched for concrete or mortar when free water is dripping from the
aggregate.
(e)
Incase uniformity in the materials used for concrete has been established over a period of
time, proportioning may be done by volume batching, provided periodical checks are made on
mass / volume relationship of the material. When weigh bathing is not practicable, quantities of
fine and coarse aggregate (not cement) may be determined by volume. If fine aggregate is moist
and volume batching is adopted, allowance would be made for bulking in accordance with IS :
2386-Part III - 1963.
4.8.3 MIXING
(a)
The concrete ingredients shall be mixed thoroughly in ready mix batch mixers of satisfactory
type and size, which are so designed as to ensure uniform distribution of all the constituent
materials throughout the mass at the end of mixing period. The plant shall be so designed and
operated that all materials entering the mixer can be accurately proportioned and readily controlled.
The entire batch within the mixer shall be discharged before re -charging. The volume of mixed
materials per batch shall not exceed the rated capacity. A mixer will be considered unsatisfactory,
if from three tests of any one batch, a range in slump exceeding 25 mm or a range in air content
exceeding one percent is noticed between representative samples taken at different portions of the
mixer discharge.
(b)
For any one batch, uniformity of fresh concrete weight of air free mortar of two samples one
taken at the front and one at the end of the mixer discharges, when determined in accordance with
the provisions of the mixer performance test, designation 26 in the appendix of the seventh edition
of the United States Bureau of Reclamation concrete manual, shall not exceed 1.6 percent of the
mean value. The adequacy of mixing shall also be determined in accordance with "Method of
sampling and analysis of concrete" as per IS : 1199 -1959 and its subsequent amendments.
Excessive variation on the unit weight of air free mortar indicates that mixing time should be
increased. Mixer efficiency test shall be made at the start of a job and at such intervals as may be
necessary to ensure compliance with the requirements for effective mixing. The minimum mixing
time specified herein may be reduced if mixer efficiency test conform that the reduced time permits
satisfactory mixing.
(c)
The first concrete batch at the start of continuous mixing operation or after a lapse of 30
minutes in continuous mixing operation shall be made richer by the addition of extra cement as
directed
(d)
For any one batch, the difference between the unit weight of coarse aggregate from concrete
samples from the front and end of the mixer or mixer discharge, when determined in accordance
with the above mentioned mixer performance test shall not exceed 10% of the mean value.
(e) The mixing of each batch shall continue, for not less than the period stated in table I of IS:
457-1957 reproduced at Para 3.6.3 unless tests of mixer performance show that variation in the
prescribed time is necessary or acceptable. Each mixer shall have a timing device for indicating
the completions of the required mixing period.
(f)
The actual time of mixing shall be checked atleast twice during each shift and in the case of
central batching plant where the timing device is provided, the same shall be adjusted if there is
error. The timing device shall be so interlocked with the discharge gate of the batch hopper that
timing does not start until the discharge gate is fully closed and all ingredients are in the drum. A
suitable record shall be kept of the average time consumed in charging, mixing and discharging a
batch during each run.
(g)
The full contents of the drum shall be discharged quickly to avoid segregation.
(h)
The minimum periods specified are conditional on the materials being fed into the mixer in a
manner which will facilitate efficient mixing and an operation of the mixer at its designed speed.
The following sequence of charging the mixer may be adopted.
i.
Five to ten percent of the total quantity of water required for mixing adequate to wet the drum
thoroughly shall be introduced before the other ingredients in order to prevent any caulking of the
cement on the blades or sides of the mixer.
ii.
All dry ingredients (cement and the fine and coarse aggregate) shall be simultaneously fed
into the mixer in such a manner that the period of flow for each ingredient is about the same.
Eighty to ninety percent of the total quantity of water required for mixing shall be added uniformly
along with the dry ingredients.
iii.
The remaining quantity of water shall be added after all the other ingredients are in the
mixer.
iv.
Portion of the coarse aggregate, however, may be added last. This will facilitate clearance of
the chutes and removes any fine aggregates or cement adhering to the sides
(i)
Excessive mixing, requiring additions of water to preserve the required concrete consistency
will not be permitted.

(j)
When the mixer is stopped, before placing again any ingredie nts in the mixer, all hardened
concrete or mortar shall be removed from the inner surface of the mixer.
(k)
The retampering of partially hardened concrete or mortar requiring renewed mixing with
or without the addition of cement aggregate or water shall not be permitted.
4.9
TEMPERATURE OF CONCRETE AND WEATHER CONDITIONS
The temperature of concrete at the time of placement shall not exceed 35 degree C. concreting
operations shall be temporarily suspended during excessively hot weather when their temperature
inside the form exceeds 45 degree C. or when conditions are such that the concrete cannot be
placed at the required temperature. Wherever necessary, exposed surfaces of fresh or green
concrete shall be adequately shaded from the direct rays of the sun and protected against
premature setting or drying by curing under continuous fine spray of water.
4.10 TRANSPORTING OF CONCRETE
(a)
Concrete shall be handled from the place of mixing to the place of final depositing as rapidly
as practicable by use of equipment such as transit mixers which will prevent initial setting,
segregation or loss of any of the ingredients. It shall be transported and compacted in its final
position within 30 minutes of its discharge from the mixer.
(b) Where the tie of haul exceeds 20 minutes, mixed concrete shall be transported in suitable
agitators or transit mixers as stated herein above.
(c)
If buckets are used for conveying low-slump concrete, they shall be capable of promoting
discharge in controlled quantities without splashing or segregation and shall be of such capacity
that there is no splitting of batches in loading buckets. Buckets shall be of the bottom dump type
permitting an even, controlled flow into the forms or hopper without undue splashing or
segregation.Conveying vehicles shall be designed to facilitate uniform delivery rather than quick
dumping.
(d)
Chutes used for conveying concrete shall be of such size and shape as to ensure a steady
uniform flow of concrete in a compact mass without separation or loss of ingredients and shall be
protected from wind and sun where necessary to prevent loss of slump by evaporation and shall be
furnished with a discharge hopper. Free fall or drop of concrete shall be limited to 150 cms. Chute
sections shall be made of or lined with metal and all runs shall have approximately the same
slopes not flatter then 1 vertical to 2.5 horizontal. The required consistency of concrete shall not be
changed in order to facilitate chuting. Where it becomes necessary to change the consistency, the
concrete mix shall be completely redesigned. Wherever there is free fall within the conveying
system, suitable baffle plates, splash board, or down spouts shall be provided to prevent
segregation, splashing or loss of ingredients. Whenever it is necessary to hold the discharge end
of a chute more than 3 meters above the level of the fresh concrete, a flexible down spout shall be
used to break the fall and confine the flow. The lower end of the spout shall be held close to the
place of deposit. Whenever depositing is intermittent, a discharge hopper shall be provided. All
chutes shall be thoroughly cleaned before and after each run. All washed water and debris shall
be disposed off outside the forms.
(e) Equipment used for transporting concrete from the mixer to the forms shall be maintained
free from deposits of stiff concrete and leakage of mortars. Batch containers, transit mixers,
agitators, chutes, concrete pumps. Pipe lines and discharge hoppers shall be thoroughly cleaned
after each run. All wash water and debris shall be disposed of outside the forms.
4.11 PREPARATION FOR PLACING CONCRETE
4.11.1 GENERAL
(a)
Concrete shall not be placed until all form work required is completed, embedded parts if any
installed and checked and surface prepared for placing. No concrete shall be deposited until the
foundation has been inspected and approved.
(b) All surfaces of forms and embedded materials that have become encrusted with dried mortar
or grout from concrete previously placed shall be cleaned of all such mortar or grout before fresh
concrete is placed and shall be oiled with a commercial form oil or alternatively covered with LDPE
film as specified in para 4.13.4
4.11.2 FOUNDATION SURFACES
(a)
Immediately before placing concrete, all surfaces of foundations upon or against which the
concrete is to be placed shall be free from standing water, mud and debris. All surfaces of rocks
upon or against which concrete is to be placed shall in addition to the foregoing requirements be
cleaned and free from all lubricants, objectionable coating and loose semi-detached or unsound
fragments. The surface of absorptive foundations upon or against which concrete is to be placed
shall be moistened thoroughly and kept sufficiently wet for atleast 24 hours pri or to placing
concrete so that the moisture will not be drawn from the freshly placed concrete. The cleaning and
roughening of the surfaces of rock shall be performed by the use of high velocity air water jets, wet
sand blasting, stiff brooms, picks or by other effective means. The washing and scrubbing process
shall be continued until the wash water collected in puddles is clear and free from dirt. In the final
cleaning process the wash water may have to be removed by sponges. If any drilled holes are l eft
in the foundation surface, which are not longer needed, the same shall be cleared with air water
jetting and filled up completely with cement slurry.
(b) In the case of earth or shale foundations, all soft or loose mud and surface debris shall be
scraped and removed. The surface shall be moistened to a depth about 15 cms (6 inches) to
prevent the sub grade from absorbing water from he fresh concrete. Just before placing the
concrete, the surface of the earth shall be tamped or otherwise consolidated sufficiently to prevent
contamination of concrete during placing. If subsoil water is met within the foundation, it shall be
dewatered as directed till the placing and setting of concrete. All concrete shall be placed upon
clean damp surface free from standing water and never upon soft mud, dried porous earth or upon
fills that have not been subjected to approved rolling and desired compaction.
(c)
Foundation of porous or free draining material shall be thoroughly compacted by flushing and
by subsequent tamping or rolling, if necessary. The finished foundation surface shall then be
blanketed with a layer of tar paper or closely woven burlap carefully lapped and fastened down
along the seems so as to prevent the loss of mortar from the concrete.
4.11.3
(a)
SURFACE OF CONSTRUCTION AND CONTRACTION JOINTS
The surface of construction / contraction joints shall be clean, rough and damp but free from
standing pools of water when receiving the next lift. Clean up shall comprise removal of all
laitance, loose or defective concrete coating, sand, curing compounds if used and other foreign
materials, if necessary by scrapping, chipping or other suitable means.
(b)
The surface of construction / contraction joints shall be cleaned by use of high-pressure
water jet or by wet sand blasting and swashed thoroughly. Water jetting and blasting and washing
shall be performed just prior to the placing of concrete.
(c)
The method used in disposing of water employed in cutting, washing and rinsing of concrete
surface shall be such that the waste water does not stain, discolour or effect exposed surfaces of
the structures. Methods of disposal of waste water shall be subject to approval.
4.12 PLACING AND COMPACTING CONCRETE
(a)
After the surfaces have been cleaned and dampened as specified, surfaces or rock and
construction joints shall be covered, wherever practicable, with a layer of mortar approximately 10
mm to 15 mm thick. The mortar shall have the same proportions of water, air entraining agent if
any, cement and fine aggregate as the concrete mixture which is to be placed upon it. The water
cement ratio of the mortar, which is placed, shall not exceed that of the concrete to be placed upon
it and the consistency of the mortar shall be suitable for being spread uniformly and worked
thoroughly into all irregularities of the surfaces.
(b)
In so far as it is practicable, concrete shall be placed directly in its final position and shall not
be caused to flow in a manner to permit or cause segregation. Methods and equipments emp loyed
in placing concrete will ensure that aggregate is not separated from the concrete mass.
(c)
In placing mass concrete in a lift successive batching of concrete shall be placed in a
systematic arrangement in order to avoid exposure of parts of the live surface of a concrete layer.
(d)
In mass concrete placement, delay may occur resulting in cold joints within a lift. When
placement is resumed while concrete is so green (and therefore capable of ready bonding) that it
can be dug out with a hand pick, the usual contraction joint treatment will not be required if the
surfaces are kept moist and the concrete placed against the surface is thoroughly and
systematically vibrated over the entire area adjacent to the older concrete. If the delay is short
enough to permit penetration of the vibrator into the lower layer during routine vibration of
successive layers, the vibration will assure necessary bonding.
(e)
If for any cause, the working surface is left exposed until it has hardened to a considerable
extent, it shall be left to set and cured for not less than 56 hours or longer. If for any reason a
strength greater than 15.2 kg/sqm (500 PSI) has been attained before completing the lift, the
surface thus interrupted shall be given a thorough clean up as for normal lift joint surface and the
work shall be commenced with a mortar layer as specified.
(f)
In placing mass concrete, the exposed area of fresh concrete shall be maintained at the
practical minimum by first building up the concrete in successive approximately horizontal layers to
the full width of the block and full height of the lift over a restricted area at the downsteam end of
the block and then continuing upstream in similar progressive stages to the full area. The slope
formed by the unconfined upsteam edge of the successive layers of concrete shall be kept steep
as practicable in order to keep its area minimum. Concrete along these edges shall not be vibrated
untill adjacent concrete in the layer is placed, except that it shall be vibrated immedi ately when
weather conditions are such that the concrete will be harden to an extent the later vibration may
not fully consolidate and integrate in with more recently placed adjacent concrete.
(g)
Retampering of concrete shall not be permitted. Any concre te, which has become so stiff
that proper placing without retampering cannot be ensured shall be wasted.

(h)
In formed work, structural concrete placement shall generally be started with an over sanded
mix containing 20 mm maximum size aggregate and an extra sack of cement for one cubic metre
and having a 125 mm slump placed several centimeters deep on the joins at the bottom of the
form. Concrete placement shall commence immediately thereafter.
(i)
Concrete shall be compacted to the maximum practicable de nsity, in such a manner that it is
free from pockets of coarse aggregate and is in intimate contact with surface of forms and
embedded materials. Unless otherwise permitted, all concrete shall be compacted by mechanical
vibrator.
(j)
Compaction of concrete shall whenever practicable be carried out by use of immersion type
vibrators having vibrating heads of 100 mm or more in diameter shall be operated at speed of
atleast 6,000 revolutions per minute when immersed in the concrete.
(k)
Vibrators having vibrating heads less than 100 mm. in diameter shall be operated at speed of
atleast 7,000 revolutions per minute in the concrete. Normally formwork shall be designed to
provide for the insertion and operation of mechanical vibrators in the placed concrete. Form
vibrator shall be used wherever internal vibration is not possible or would be inadequate.
(l)
In compacting each layer of concrete, the vibrator shall be operated in almost vertical
position and the vibrating head shall be allowed to penetrate and revib rate the concrete in the
upper portion of the underlying layer. In the area where freshly placed concrete in each layer joins
previously placed concrete, more vibration than usual shall be performed the vibrators penetrating
deeply at close intervals along these contacts, Layers of concrete shall not be placed until layers
previously placed have been vibrated thoroughly as specified. Contacts of the vibrating head with
surface of the forms shall be avoided.
(m) During placing and until curing is completed, the concrete shall be protected against the
harmful effect of exposure to sunlight, wind and rain as directed.
4.13 FORM WORK
4.13.1 GENERAL
(a)
Form work shall be used wherever necessary to confine the concrete and shape it to the
required lines, or to ensure against contamination of the concrete by material caving or sloughing
from adjacent surface left by excavation or other features of the work All exposed concrete
surfaces having slope steeper than of one horizontal to one vertical shall be formed.
(b)
Form work may be of timber, steel or precast concrete panels or such other suitable -
materials or combination of such materials as may be directed by the Engineer. Form work shall
be substantially and rigidly constructed to the shapes, lines and dimensions required, efficiently
propped and braced to prevent deformation due to placing, vibrating and compacting concrete,
other incidental loads or the effect of weather.
(c)
The surfaces of form work shall be made such as to produce surface finishes as specified
and formwork joint space be tight enough to prevent loss of liquid from concrete. Joints between
the form work and existing concrete structures shall also be "grout tight". The form work shall be
arranged to facilitate easing and removing of the various parts in correct sequence, without jarring
or damaging the concrete. Fixing blocks, bolts or similar devices may be embedded in the
concrete, provided they do not reduce the strength or effective cover of any part of the structure
below the required standard but he use of through bolts shall be avoided as far as possible.
Temporary opening shall be provided at all points necessary in the forms to facilitate cleaning and
inspection immediately before placing of the concrete.
(d)
Forms shall overlap the hardened concrete in the life previously placed by not less than 75
mm and shall be tightened strongly against the hardened concrete so that when concrete
placement is resumed, the forms will not spread and allow off-set or loss of mortar at construction
joints. Additional bolts or form ties shall be used as necessary to hold forms tight against hardened
concrete. Particular attention shall be paid in setting and tightening the forms for construction
joints so as to get a smooth joint free from sharp deviations or projections.
(e)
Moulding strips shall be placed in the corners of forms so as to produce chamfered edges as
reaured on permanently exposed concrete surface.

4.13.2 MATERIALS TO BE USED
(a)
Materials used for form sheathing and lining shall conform to the following requirements :
Required
Timber Sheathing or lining
Steel sheathing or lining
Any type and grade meeting
Steel sheathing permitted
the dimensional requirement
steel lining permitted
of surface finish except
except on surfaces of
that metal form shall be
internal transverse and
used on surfaces of internal
longitudinal joint in the
transverse and longitudinal
structure component where
finish
F1
joints in mass concrete
F2
steel sheathing is
gravity walls.
Required.
Common grade timber or
Steel sheathing permitted
plywood sheathing or lining.
steel lining permitted if

strongly supported.
F3
F4
For plain surface common grade
Steel sheathing permitted,
timber or plywood.
steel lining not permitted.
For warped surfaces timber which
steel sheathing permitted,
is free from knots and other

Imperfections and which can be
cut and bent accurately to the
required curvatures without
splintering or splitting.
steel lining not permitted.
Steel sheathing denotes steel sheets not supported by a backing of timber boards, steel lining
denotes steel sheet, supported by a back of timber boards.
(b)
Timber sheathing or lining shall be of such kind and quality or shall be so treated or coated
that there will be no chemical deterioration or discoloration of the formed concrete surfaces. The
type and condition of form sheathing and lining and the ability of forms to withstand distortion
caused by placement and vibration of the concrete and the workmanship used in the form
construction shall
be such that the formed surfaces will conform to applicable requirements of this specification
pertaining to finish or formed surfaces.
(c)
Forms for concrete surfaces required to receive F2 and F3 finish shall be constructed so as
to produce uniform and consistent texture and pattern on the concrete faces Metal patches on
forms for these faces will not be permitted. The form sheathing or lining shall be so placed that all
horizontal form marks are continuous across the entire surface. Where finish F2 is specified the
sheathing or lining shall be placed so that the joint marks on the concrete surfaces will be in
general alignment both horizontally vertically and the form sheathing material us ed for such
surfaces shall be restricted to one type in any one major features of the work.
(d)
Forms for surfaces required to receive F4 finish shall be constructed so as to conform
accurately to the required curvature of the section. Where necessary to meet requirements for
curvature the form sheathing shall be built up of laminated splices cut to make right, smooth form
surface. The forms shall be constructed that the joint marks on the concrete surface shall in
general, follow the line of water flow.
(e)
After the forms have been constructed all surface imperfections shall be corrected. All the
nails shall be hidden and any roughness and all angles on the surface of the forms caused by
matching the forms materials shall be dressed to curvature.
(f)
Embedded ties for holding forms shall remain embedded and except where F1 finish is
permitted, they shall terminate not less than two diameters or twice the minimum dimension of the
tie or ten millimeters, whichever is greater from the formed faces of the concrete. The use of metal
rods or other similar devices embedded in he concrete for holding forms shall be permitted if the
ends of the rods are omitted or subsequently removed to a depth as specified above from the
surface of the concrete without injury to the concrete, provided that for walls subjected to water
pressure on one side and required to be watertight the rods shall not be taken through the wall.
Complete removal of embedded rod shall not be permissible. Removal of embedded fasteners on
the ends of the rods shall be done so as to leave holes of regular shape for reaming. All holes left
by the removal of fasteners from the ends of the rods shall be immediately reamed with suitable
toothed reamers so as to leave the surfaces of the holes clean and rough and completely filled with
dry patching mortar and the surfaces shall be finished to match the adjacent concrete. Wire ties
shall be permitted only where specifically approved and shall be cut off flush with the surface of the
concrete after the forms are removed. Wire ties shall not be used when permanently exposed
finished surfaces are required. Where F1 finish is permitted, ties may be cut off flush with formed
surface.
(g)
The ties shall be constructed so that removal of the end or end of fasteners can be
accomplished without causing appreciable spalling at the faces of the concrete. Recesses resulting
from removal of the ends of he form ties shall be filled in accordance with the provision for repair of
concrete as per Para 4.15.
4.13.3
(a)
FORM, CENTERING AND TEMPORARY WORKS
All centering, form work and temporary works shall be constructed according to the approved
drawings and specifications. The IS: 883: 1970 code of practice for design of structure timber in
building shall be applicable for this work.
(b)
As soon as practicable, after the acceptance of his tender, the contractor shall submit a
scheme showing the order or procedure and method by which he proposes to carryout the work,
together with such details as are necessary to demonstrate the adequacy, stability and safety of
the methods.
(c)
Necessary data for the general scheme of centering shall be obtained well in time.
(d)
After approval of the general scheme, the contractor shall prepare detailed design and
drawings for execution of the form work, centering and temporary works. These shall be forwarded
to the Engineer-in-charge for approval. No work shall be carried out without prior approval of the
Engineer-in-charge.
(e)
Not withstanding the approval given to the design criteria and loading and the general
scheme for the centering, the entire responsibility for the satisfactory execution of the centering
and all temporary works shall rest with the contractor and he shall be liable to pay all claims and
compensation arising from any loss or damage to life and property due to any deficiency, failure or
malfunctioning of the centering or the temporary works.
(f)
All centering and supports shall be properly braced and cross braced in 2 directions. The
supports shall be strong enough to withstand the weight or pressure when considerable quantity of
wet concrete is poured. When the centering posts rest on soft ground, their load shall be
distributed by means of scantlings / planks of not less than 5 cms thickness / short piles. Wherever
the stage of centering is more than 3 mtrs. Invariably steel centering shall be resorted to.
(g)
Reuse of forms etc.

Forms required to be used more than once shall be maintained in serviceable condition and
shall be thoroughly cleaned and repaired before reuse. Where metal sheets are used for lining
forms, the sheets shall be placed and maintained in the forms without humps and other
imperfections. All forms shall be checked for shape and strength before reuse.
4.13.4
CLEANING AND TREATMENT OF FORMS
At the time the concrete is placed in the forms, the surfaces of the forms shall be free from
encrustations of mortar, grout or other foreign material. Before concrete is placed, the surfaces of
the forms designated to produce F-1, F-2, F-3 and F-4 finishes shall be oiled with a commercial
form oil, that will effectively prevent sticking and will not stain the concrete surface. For timber
forms, form oil
shall consist of pure, refined, pale paraffin mineral oil or other approved form oil. For steel forms
form shall consist of refined mineral oil suitably compounded with one or more ingredients, which
are appropriate for the purpose. Care shall be taken to keep form oil out of contact with
reinforcement. In the alternative the surfaces of the forms des ignated to produce formed surfaces
shall be overlaid with LDPE film of 200 microns.
4.13.5 REMOVAL OF FORMS
(a) Except as otherwise provided in this Sub-Clause forms shall be removed as soon as the
concrete has hardened sufficiently, thus facilitating satisfactory curing and earliest practicable
repair of surface imperfections.
(b) Forms on upper sloping surfaces of concrete, such as forms on the water sides of wrapped
transition, shall be removed as soon as the concrete has attained sufficient stiffness to prevent
sagging. Any needed repair or treatment required on such sloping surface shall be performed at
once and be followed immediately by the specified curing.
(c) In order to avoid excessive stresses in the concrete that might result from swelling of the forms,
timber forms shall be loosened as soon as this can be accomplished without damage to the
concrete.
(d) Subject to approval, forms on concrete surface close to excavated rock surface may be left in
place provided that the distance between the co ncrete surface and the rock is less than 400 mm
and that the forms are not exposed to view after completion of the works.
(e) Forms shall be removed with care so as to avoid damage to the concrete. Concrete damaged if
any in form removal shall be repaired in accordance with the provisions for repair of concrete as
per Para 4.15.
(f) The following minimum intervals of time will generally be allowed when using ordinary Portland
cement between placing concrete and striking form work, but the period shall be modified in case
of wet weather and also as per direction of Engineer-in charge.
i)
Walls, columns and vertical faces
24 to 48 hours or as may be
decided by
the
Engineer-in
charge
ii)
Slabs
14 days
iii)
Beam Soffits
14 days
iv)
Slab spanning upto 6.0 mtrs.
14 days
v)
Slab spanning over 6 mtrs.
21 days
NOTE : In normal circumstances, and where ordinary Portland cement is used forms may
generally be removed after expiry of the above period. For other cements, the stripping time
recommended for ordinary Portland
cement may be suitably modified.
Where the shape of the element is such that the form work has re - entrant angles, the
formwork shall be removed as soon as possible after the concrete has set, to avoid shrinkage
cracking, occurring due to the restraint imposed.
4.14
FINISHES AND FINISHING OF CONCRETE SURFACES
4.14.1 FORMED SURFACES

(a) Allowable deviation from plumb or level and from the alignment profile, grades and dimensions
shown on the drawings is defined as 'tolerance' and is to be distinguished from the irregularities in
finishes as described herein. The tolerance in concrete construction is specified in para 4.21.
(b) The classes of finish and requirements for finishing of concrete surface shall be as shown on
the drawing or as hereinafter specified. In the event of finishing not being definitely specified herein
or on the drawings the finishes to be used shall be as directed by the Engineer-in-charge. Finishing
of concrete surface shall be performed only by skilled workmen.
(c) Completed concrete surfaces will be tested where necessary to determine whether surface
irregularities are within the limits hereinafter specified.
(d) Surface irregularities are classified as 'Abrupt' or 'gradual' offsets caused by displaced or
misplaced form sheathing, or lining or form sections or by loose knots or otherwise defective timber
form will be considered as abrupt irregularities and shall be tested by direct measurements. All
other irregularities shall be considered as gradual irregularities and will be tested by use of
template, consisting of a straightedge or the equivalent thereof for curved surfaces. The length of
the template shall be 150 cms for testing of formed surfaces and 300 cms for testing unformed
surfaces.
(e)
The clauses of finish for formed concrete surface are designated by one of the symbols F1,
F2, F3 and F4. The jute bags rubbing or sand blasting will not be required on formed surfaces and
grinding will not be required on formed surfaces other than that necessary for the repair of surface
imperfections. Unless otherwise specified or indicated on the drawings, the classes of finish, which
will apply, are as follows:
i)
Finish F1
This finish applies to surfaces where roughness is not objectionable, such as those upon or
against which fill material, masonry or concrete will be placed, the upstream face of the structure
that will permanently be under water or surface that will otherwise be permanently concealed. The
surface treatment shall be the repair of defective concrete, correction of surface depression deeper
than 25 mm and filling of the tie rod holes. Form sheathing will not leak mortar when the concrete is
vibrated. Forms may be built with a minimum of refinement.
ii)
Finish F2
This finish is required on all permanently exposed surface for which other finishes are not
specified, such as in Head Regulators, Cross Regulators, Drainage syphons, Bridges and
Retaining Walls not prominently exposed to public view except wherein F1 finishes are permitted.
Forms shall be built in a workmanlike manner to the required dimensions and alignment, without
conspicuous offsets or bulge. Surface irregularities shall not exceed 5 mm for abrupt irregularities
and 10 mm for gradual irregularities measured with 1.5 mtrs. template.
iii)
Finish F3
This finish is designated for surface of structures prominently exposed to public view where
appearance is also of special importance. This shall include inside of drainage barrels, piers of
bridges and beams and slabs of cross regulators, syphons, aqueducts, drops, parapets, railings
and decorative features on the structures and on the bridges. To meet with the requirements for
the F3 finish forms shall be built in a skillful, workmanlike manner, accurately to dimensions. There
should be no visible offsets, bulges, or misalignment of the concrete. At construction joints the
forms shall be tightly set and securely anchored close to the joint. Abrupt irregularities shall not
exceed 5 mm for irregularities parallel to the directions of flow and 2.5 mm for irregularities in other
directions. Gradual irregularities shall not exceed 5 mm. Irregularities exceeding this limit shall be
reduced by grinding on a bevel of 1 to 20 ratio of height to length.
iv)
Finish F4
This finish is required for formed concrete surface at the cut and ease waters of the piers
portions of outlets, draft tubs, high velocity flow surfaces of outlet work downstream from gates and
spillway tunnels of dams and where evenness of surface is esse ntial. The forms must be strong
and held - rigidly and accurately to the prescribed alignment. For wrapped surface the forms shall
be built up in section cut to make tight smooth form surfaces after which the form surfaces are
dressed and sanded to the required curvature. Gradual irregularities shall not exceed 5 mm. Abrupt
irregularities shall not be permitted. Formations of air holes on the surface of the concrete
designated to receive finish shall be minimized and where such air holes are found, they shall be
repaired in accordance with the provisions of relevant paragraph.
4.14.2 UNFORMED SURFACES
(a) The classes of finish for unformed concrete surfaces are designated by the symbols, U1, U2,
U3 and U4. Unless otherwise specified or indicated on the drawings, these classes of finish shall
apply as follows:
i)
Finish U1
This finish applies to unformed surfaces that will be covered by fill material, masonry or
concrete, or where a screeded surface meets the functional requirements. Finish U1 is also used
as the first stage of finishes for U2 and U3. Finishing operations shall consists of sufficient leveling
and screeding to produce an even uniform surface. Surface irregularities measured as described in
this section, shall not exceed 10 mm.
ii)
Finish U2
a. This is a floated finish, and used on all out door unformed surfaces not specified to receive
finishes U1 and U3. It may be used for such surfaces as apron and floors of cross regulators and
head regulators, drainage barrels, aqueducts and escapes and inside of slopping aqueduct
troughs.
b. Finish U2 is also used as the second stage of finish for U3. Floating may be performed by hand
or power driven equipment. Floating shall be started as soon as the screeded surface has stiffened
sufficiently to prevent the formation of laitence and shall be the minimum necessary to produce a
surface that is free from screed marks and is uniform in texture. If finish U3 is to be applied, floating
shall be continued until a small amount of mortar without excess water is brought to the surface,
so as to permit effective trowelling. Surface irregularities measured as described in this section
shall be removed as directed.
iii)
Finish U3
This is a trowelled finish and may be specified for tops of parapets prominently e xposed to
view and conduit invert immediately downstream of regulating gates and valves. When the floated
surface has hardened sufficiently to prevent excess of fine material from being drawn to the
surface, steel trowelling shall be started. Steel trowelling shall be performed with firm pressure that
will flatten the sandy texture of the floated surface and produce a dense uniform surface free from
blemishes and trowel marks. Surface irregularities, measured as described in relevant parts of this
section, shall not exceed 5 mm where hard steel trowelled finish is specified, the regular U3 finish
shall be trowelled again after the surface has nearly hardened using firm pressure and trowelling
until the surface is hard and has a slightly glossy appearance.
iv)
Finish U4
a.
This is a steel trowelled finish similar to finish U3 except that light surface pitting and light
trowel marks such as obtained form the use of machine trowelling or lining machine will be
acceptable, provided the surface irregularities do not exceed the limits specified for finish U3.
b.
Unformed surfaces which are nominally level shall be sloped for drainage as shown on the
drawings or as directed, unless the use of other slopes or level surface is indicated on the drawing,
narrow surface such as tops of parapets, tops of walls and kerbs shall be sloped approximately half
centimeter per 30 cms of width.
For canal lining the finish U4 shall be adopted.
4.15 REPAIR OF CONCRETE
4.15.1 GENERAL
(a)
Repair of concrete shall be performed by skilled workers and in the presence of an
experienced Engineer. The Contractor shall correct imperfections on the concrete surfaces as
necessary to produce surface that conform with requirements of the paragraph "finishes and
finishing of concrete surfaces". Repairs on formed concrete shall be completed as soon as
practicable after removal of forms and within 24 hrs after removal of forms. Concrete that is
damaged from any cause and concrete that is honeycombed, fractured or otherwise defective and
concrete which because of excessive surface depressions has to be excavated and built up to
bring the surface to the prescribed lines shall be removed and replaced by dry pack mortar or
concrete as hereinafter specified. Where bulges and abrupt irregularities protrude outside the limits
specified in the paragraph 'finishes and finishing of concrete surfaces', the protrusions shall be
reduced by bush hammering and grinding so that the surfaces are within the specified limits.
(b) Before repair is to commence, the methods proposed for the repair shall be approved by the
Engineer -in charge. Routine curing should be interrupted only in the area of repair operations.
4.15.2 METHODS OF REPAIRS
For new works four methods are used as under:
i) DRY PACK METHOD
This method should be used for holes having a depth nearly equal to, or greater than the
least surface dimensions, for cone bolt, she bolt and grout insert holes, and narrow bolts cut for the
repair of cracks. Dry pack should not be used for relatively shallow depressions where
lateral restraint cannot be obtained, for filling in back of considerable lengths of exposed
reinforcement; nor for filling holes which extend entirely through the wall, beam, etc.
ii) CONCRETE REPLACEMENT METHOD

Concrete replacement should be used when holes extend entirely though the concrete
section, when holes in un reinforced concrete are more than 1,000 sqcms in area and 100 cms or
more in depths and when holes in reinforced concrete are more than 500 sqcms in area and
deeper than the reinforcement steel.
iii) MORTAR REPLACEMENT METHOD
This should be used for holes too wide to dry pack and too shallow for concrete replacement
and for all comparatively shallow depressions, large or small, which extend no deeper than for side
of the reinforcement bars nearest to surface.
iv)
EPOXY METHOD
A thermosetting plastic known as epoxy can be used as a bonding medium whenever long
time curing of conventional concrete cannot be assured. Also epoxy mortars of fine sand as well as
plain epoxy are suitable for concrete repair work and should be used whenever very thin patches
are to be placed or immediate reuse of the area is required or where moist curing cannot be
effectively accomplished. Preparation for epoxy-bonded repairs should in general be identical to
that for other concrete repairs except that every efforts should be made to provide surfaces
thoroughly dry. Drying of the immediate surface for atleast 24 hrs. and warming to temperature
between 18 degree C to 27 degree C. are essential for proper application of epoxy bonded repairs.
Preparation for the use of epoxy mortars should include thorough cleaning and drying of the areas
to be repaired. A wash of dilute 1:4 muriatic acid rinsing with clean water and subsequent drying is
desirable, where feasible. If acid wash is not feasible, preparation may be accomplished as for
other concrete repairs with final cleanup being by means of sandblast method, followed by air
water jet washing and thorough drying, epoxy repairs shall be carried out only by a trained
personnel. The type of epoxy to be used shall be got approved by the Engineer-in charge.
4.15.3
PREPARATION OF CONCRETE FOR REPAIRS
All concrete of questionable quality should be removed. It is better to remove too much
concrete than too little because affected concrete generally continues to disintegrate and while the
work is being done it costs but little more to excavate to ample depth. Moistening, cleaning, surface
drying and complete curing are of utmost importance when making repairs, which must be
thoroughly bonded, watertight and permanent. Surfaces within trimmed holes should be kept
continuously wet for several hours, preferably overnight prior to placing new
concrete. Immediately before placement of the filling, the holes should b e cleaned so as to leave a
surface completely free from chipping dust, dried grout and all other foreign materials. Preliminary
washing as soon as the chipping and trimming are completed is desirable to remove loose
material. Final cleaning of the surfaces to which the new concrete is to be bonded should be done
by wet sandblasting followed by washing with air water jet for through cleaning and drying with an
air jet. Care should be taken to remove any loose materials embedded in the surface by chisels
during the trimming and to eliminate all shiny spots indicating free surface moisture. Cleaning of
the steel if necessary should be accomplished by sand blasting. The prepared surface shall be
approved by the Engineer-in charge.
I.
DRY PACKING OF CONCRETE

For this method of repair, the holes should be sharp and square at the surface edges, but the
corners within the holes should be rounded, especially when water tightness is required. The
interior surfaces of holes left by cone bolts, she bolts etc. should be roughned to develop an
effective
bond.
Other
holes
should
be
under-cut slightly in several places. Holes for dry pack should have minimum depth of 25 mm.
ii)
CONCRETE REPLACEMENT
Preparation for this method should be as follows:

a. Holes should have minimum depth of 100 mm. in new concrete and the minimum area of repair
should be 500 sqcms for reinforced and 1,000 sqcms for unreinforced concretes.
b. Reinforcement bars should not be left partially embedded. There should be a clearance of
atleast 25 mm around each exposed bar.
c. The top edge of the holes at the face of the structure should be cut to a fairly horizontal line. If
the shape of the defect makes it advisable, the top of the cut may be stepped down and continued
on a horizontal line. The top of the hole should be cut to 1 to 3 upward slope from the back towards
the face of the wall or beam. It may be necessary to fill the hole from both sides, in which case the
slope of the top of the cut should be modified accordingly.
d. The bottom and sides of the holes should be cut sharp and approximately square with the face
of the wall when the hole goes entirely through concrete section, spalling or featheredges shall be
avoided by having chippers worked from both faces. All interior corners should be rounded to a
minimum radius of 25 mm.
iii.
MORTAR REPLACEMENT
When mortar gun is used with this method, comparatively shallow holes should be flattered
outwardly at about 1 to 1 slope to avoid inclusion of rebound. Corner within the holes should be
rounded.
Shallow imperfections in concrete may be repaired by mortar replacement if the work is done
promptly after removal of the forms and while the concrete is still green, for instance when it is
considered necessary to repair the peeled areas resulting from surface material sticking to steel
forms the surfaces may be filled using mortar gum without further trimming or cutting. Whenever
hand placed mortar replacement is used, edges of chipped out areas should be squared with the
surface leaving no feather - edges.
iv.
USE OF DRY PACK MORTAR

The surface after preparing should be thoroughly brushed with a stiff mortar or grout barely
wet enough to thoroughly wet the surface after which the dry pack material should be immediately
packed into place before the bonding grout has dried. The mix of bonding grout shall be 1 to 1
cement and fine sand mixed to a consistency like thick cream. Under no circumstance should
bonding coat be wet enough or applied heavily enough to make the dry material more than very
slightly rubbery. Dry pack is usually a mix (by dry volume or weight) of one part of cement to 1.50
parts of sand that will pass No. 16 ASTM Screen.
4.15.4 PROCEDURE OF REPLACEMENT OF CONCRETE, CURING OR REPAIRS ETC.
All procedures for replacement of concrete, mortar replacement, use of expoxies and curing
of repairs shall according to the provisions laid down in chapter VII "Repairs and Maintenance of
Concrete" Concrete Manual of the United States Bureau of Reclamation, Seventh Edition 1963.
4.16
CURING OF CONCRETE
4.16.1 GENERAL
(a) All equipment, material etc, needed for curing and protection of concrete shall be at hand and
ready for installing before actual, concreting begins. Detailed plans, methods and procedures
whereby the various phases of curing and protection shall firmly established,. shall be settled and
got approved in writing from the Engineer - in charge sufficiently in advance of the actual
concerting The equipment and method proposed to be utilised shall provide for adequate control
and avoid interruption or damage to the work of other agencies.
(b)
All Concrete shall be cured by water in a accordance with the requirement of sub-clause (3)
of this Clause or membrane curing in accordance with the requirement of sub-clause (4) of this
Clause. Concrete surfaces to be painted shall not be cured by membrane curing.
4.16.2 WATER CURING
(a) Uniform top surfaces of walls and piers shall be moistened by covering with water saturated
material or by other effective means as soon as the concrete has hard ened sufficiently to prevent
damage by water i.e. normally after 24 to 36 hrs of placement of concrete. Exposed finished
surfaces of concrete shall be protected against heating and drying from the Sun for at least 72 hrs
after placement in location. When finishing or repairs are involved, concrete shall not be disturbed
by workmen walking on it or by storing materials on the surface or otherwise for atleast 10 hours
after placing. These surfaces and steeply sloping and vertical formed surfaces shall be kept
completely and continuously moist, prior to and during form removal, by water applied on the
unformed top surfaces and allowed to pass down between the forms and formed forms and
formed concrete faces. This procedure shall be followed by the specifie d water curing and
membrane curing.
(b) Concrete cured with water shall be kept wet for at least 21 days immediately following
placement of the concrete or until covered with fresh concrete by covering with water saturated
material or by a system of perforated pipes, or mechanical sprinklers or porous hoses or by any
other suitable method, which will keep all surfaces continuously (not periodically) wet.
For
uncovered portions curing should continue for specified period.

(c) The contractor shall make arrangements at work site for storing the water required for atleast 3
days curing. The concrete work shall not be started until the water required for 3 days curing is
stored in advance.
4.16.3 MEMBRANCE CURING
(a) Membrane curing shall be by application of a suitable type of white / pigmented curing
compound which forms a water retaining membrane on the surface of concrete, provided that on
concrete surfaces which will be permanently exposed to view clear curing compound may be
required excepting canal lining as per Para 3.5.9(b) Curing compound shall be applied to the
concrete surfaces after demonstrating its effectiveness as per Para 3.5.10 by spraying one coat to
provide a continuous uniform membrane over all area, with a maximum coverage per gallon as
prescribed by he manufacturer's instructions according to the roughness of the surface to be
covered. If necessary to cover the surface adequately, a second coat of curing compound shall be
applied by spraying at right angle to the direction at which the firs t coat was applied. Mortar
encrustations and fines on surfaces for which finish F4 is specified shall be removed prior to
application of curing compound. Curing compound shall be applied to all areas of concrete surface
except that those areas with surface imperfections, which shall be omitted until repaired.
(b) When curing compound is to be used for unformed concrete surfaces, application of the
compound shall commence immediately after the finishing operations are completed.
(c) When curing compound is to be used on formed concrete surfaces, the surface shall be
moistened with light spray of water immediately after the forms are removed and shall be kept wet
until the surfaces do not absorb more moisture. As soon as the surface film of moisture disappe ars
but while the surface still has a damp appearance, the curing compound shall be applied. There
must be ample coverage with compound at edge, corners and rough spots of formed surface.
After application of curing compound has been completed and the co ating is dry to the touch, any
required repairs of concrete surfaces shall be performed. Each repair, after being finished, shall be
moistened and coated with curing compound in accordance with the foregoing requirements.
(d) Traffic and other construction operation shall be such as to avoid damage to coating of curing
compound for a period of not less than 28 days after application of the curing compound. Where it
is impossible because of construction operations to avoid traffic over surfaces coated with curing
compound, the membrane shall be protected by a covering of sand or earth not less than 25 mm in
thickness or by other effective means. The protective covering shall not be placed until the sealing
membrane is completely dry. Any sealing membrane, that is damaged or that peels from concrete
surface within 28 days after application, shall be repaired without delay.
(e)
4.17
Curing compound shall be of approved quality.

REQUIREMENT OF CONCRETE CONSTRUCTION
4.17.1 GENERAL
All concrete construction shall conform to the permissible tolerance and technical provisions
as described in this section and to the detailed requirement of the following paragraphs. All
structures shall be build in a workmanlike manner or to the lines, grades and dimensions shown in
the drawing or as prescribed by the Engineer-in-charge. The location of all the construction joint
shall be subject to the approval of the Engineer-in-charge. The dimensions of each structure
shown on the drawings are tentative and shall be subjects to such change as may be found
necessary by the Engineer-in-charge due to design considerations.
17.2 CONCRETE IN VARIOUS COMPONENTS OF BRIDGES, DRAINAGE SYP HON

AQUEDUCTS, ETC.,
(a)
The items of the schedule B for concrete in aforesaid structures include all concrete in the
various components of the structure and blockouts.

(a)
Expansion joints shall be constructed as shown on the drawing or as directed. Premoulded
bituminous fibre type expansion joint material shall be placed in the expansion joints. Lighting
recesses shall be constructed in the parapets as directed by the Engineer-in-charge. Open joints
or false joints shall be constructed as shown on the drawings or as directed
(b)
by the Engineer-in-charge. Performed expansion joint filler shall be placed in the roadway
and side walls where shown on the drawing or as directed by the Engineer-in-charge.
4.17.3 CONCRETE IN BLOCKOUTS
(a)
All concrete required to be placed in blockouts to permit the installation and adjustment of
mechanical and other equipments shall be included in the respective concrete as described above.
The concrete surface of the blackouts shall be chipped and roughened as described hereinafter
before the concrete is placed in blockouts.
(b)
Exceptional care shall be taken in placing the concrete in blockouts in order to ensure
satisfactory bond with the concrete previously placed and to secure complete contact with all metal
work in the blockouts.
(c)
The roughening of the concrete surface of the blockouts shall be performed by chipping or
sand blasting as approved by the Engineer-in-charge and in such a manner as not to loosen, crack
or shatter any part of the concrete beyond the roughened surface. After being roughened the
surface of the concrete shall be cleaned thoroughly of loose fragment, dirt and other objectionable
substances and shall be sound and hard to ensure good mechanical bond between the existing
and new concrete. All concrete, which is not hard, dense and durable, shall be removed to the
depth required to the satisfaction of the Engineer-in-charge.
4.17.4 EMBEDMENT IN CONCRETE
In some of the locations of structures as shown on the relevant drawings a few conduits or
openings shall have to be provided through R.C.C. / P.C.C. / masonry work. Construction of the
surface for either placement of concrete or for laying of masonry shall have to be suitably carried
out as to meet with the placement of such conduits or openings. No extra claim for such
construction shall be entertained.
4.18 CONSTRUCTION JOINTS IN UNREINFORCED CONCRETE WALLS

(a)
Concreting shall be carried out continuously upto the construction joins, the position and
details of which shall be as shown on approved Drawing or as directed by the Engineer-in-charge.

(b)
For vertical construction joints stopping boards shall be fixed previously at a predetermined
position and shall be properly stayed for sufficient lateral rigidity to prevent its displacement or
bulging when concreting is completed against it. Concreting shall be continued right upto the
board. The board shall not be removed before expiry of the specified period for removal of vertical
forms.
(c)
Before resuming work at any construction joints when concrete has not yet fully hardened, all
laitance shall be removed thoroughly, care being taken to avoid dislodgement of coarse
aggregates. The surface shall be thoroughly wetted and all free water removed from the surface
shall then be coated with cement slurry. On this surface, layer of concrete not exceeding 150 mm
in thickness shall first be placed and shall be well rammed against old work particular attention
being paid to corners and closed spots, work thereafter shall proceed in a normal way.
(d)
When work has to be resumed on a surface, which has hardened, it shall be thoroughly
raked, swept clean, wetted and covered with a layer of neat cement grout. The neat cement grout
shall be followed by a 15 mm thick layer of mortar mixed on the same proportion as in concrete
and concreting resumed immediately thereafter. The batch of concrete shall be rammed against
the old work to avoid formation of any stone pockets, particular attention being paid to corners and
close spots.
In all cases, the position and detailed arrangements of all construction joints shall be
predetermined and got approved by the Engineer-in-charge.
4.19 TEST AND ACCEPTANCE CRITERIA
GENERAL
Samples from fresh concrete shall be taken as per IS : 1199-1959 and Cubes shall be made, cured
and tested at 28 days in accordance with IS : 516-1959
NOTE : For relatively small and isolated works in which quantity of concrete is less than 15 cum
the strength tests may be waived by the Engineer-in-charge at his discretion.
In order to get a relatively quicker ideas of the quality of concrete, optional tests on beams for
modulus of rupture at 72 + hrs. or at 7 days, or compressive strength tests at 7 days may be
carried out in addition to 28 days compressive strength tests. For this purpose the values given in
Table 5 may be taken for general guidance in the case of concrete made with ordinary Portland
cement. In all cases, the 28 days compressive strength specified in Table 1 shall alone be the
criteria for acceptance or rejection of the concrete. If however, from tests carried out in a particular
job over a reasonably long period, it has been established to the satisfaction of the Engineer-incharge that a suitable ratio between 28 days compressive strength at 7 days may be accepted, the
Engineer-in-charge may suitably relax the frequency of 28 days compressive strength specified in
14.2 of IS : 456-1978 provided the expected strength values at the specified early age are
consistently met.
TABLE - 5
Optional requirement of concrete
(clause 14.1.1 of IS : 456-1978)
Grade of
Compressive strength
Concrete
On 15 cms Cubes Min.

At 7 days N/sqmm
Modules of Rupture by Beam Test

Min. at 72+ hrs.
N/sqmm.
Min at 7 days
N/sqmm
M 10
7.0
1.2
1.7
M 15
10.0
1.5
2.1
M 20
13.5
1.7
2.4
M 25
17.0
1.9
2.7
M 30
20.0
2.1
3.0
M 35
23.5
2.3
3.2
M 40
27.0
2.5
3.4
FREQUENCY OF SAMPLING
Sampling Procedure:
A random sampling procedure shall be adopted to ensure that each concrete batch shall
have a reasonable chance of being tested; that is, the sampling should spread ove r the entire
period of concreting and cover all mixing units.
Frequency:
The minimum frequency of sampling of concrete of each grade shall be in accordance with
the following:
Quantity of Concrete
Number of
in the work, Cum.
Samples
1 to 5
6 to 15
16 to 30
31 to 50
51 and above
4 plus one additional sample

for each additional 50 cum or part thereof.
NOTE: At least one sample shall be taken from each shift.
TEST SPECIMEN
Three test specimens shall be made from each sample for testing at 28 days. Additional cubes
may be required for various purposes, such as to determine the strength of concrete at 7 days or at
the time of striking the formwork, or to determine the duration of curing or to check the testing error.
Additional cubes may also be required for testing cubes cured by accelerated methods as
described in IS: 9013- 1978*. The specimen shall be tested as described in IS: 516-1959.
TEST STRENGTH OF SAMPLE:
The test strength of the sample shall be the average of the strength of three specimen. The
individual variation should not be more than plus or minus 15 percent of the average.
STANDARD DEVIATION:
Provision made under para 3.7.5 shall apply.
ACCEPTANCE CRITERIA:
The provision made under para 3.7.6 shall apply.
CORE TEST
The locations at which cores are to be taken and the number of cores required shall be at the
discretion of the Engineer-in-charge and shall be representative of the whole of concre te
concerned. In no case, however, fewer than three cores shall be tested.
Cores shall be prepared and tested as described in IS: 516-1959*.
Concrete in the member represented by a core test shall be considered acceptable if the average
equivalent cube strength of the cores is equal to atleast 85 percent of the cube strength of the
grade of concrete specified for the corresponding age and no individual core has a strength less
than 75 percent.
In case the core test results do not satisfy the requirements o f IS: 456-1978 or where such tests
have not been done, load test (as per IS: 456-1978) may be resorted to.
HYDRAULIC TEST
After curing period of the water retaining structure is over, a hydraulic test shall be carried out.
Water should be filled in the structure to the designed depth and maintained for a period of 7 days.
Starting from the end of 7 days, observations of water level will be made for a period of 7 days. The
drop in the water level observed should correspond to evaporation loss applicable to
circumstances. There should also be no visible dampness or sweating on the exposed surfaces. In
case of leakage, rectification work shall be carried out to achieve the desired water tightness. After
rectification is done hydraulic tests shall be repeated.
4.20 STEEL REINFORCEMENT
The provision made under SECTION - V shall apply.
4.21 TOLERANCE IN CONCRETE CONSTRUCTION
4.21.1 GENERAL
(a)
Permissible surface irregularities for the various classes of concrete surface finishes
specified in he relevant portion of the paragraph of "Finishes and Finishing of Concrete Surfaces",
are defined as "finishes" and are to be distinguished from "Tolerance" as described in this section.
Deviation from the established lines, grades and dimensions shall be permitted to the extent set
forth in this clause, provided that lesser tolerance than that set forth in this clause may be
prescribed at site if such tolerances are considered to impair the structural action or operational
action or operational function of the structure.
(b)
Where tolerances are not stated in the specifications or drawings for any individual structure
of feature thereof, permissible deviations shall be interpreted in conformity with the provisions of
this Clause.
(c)
Concrete work that exceeds the tolerance limits specified in this section shall be either
remedied satisfactorily or removed.

4.21.2 TOLERANCE FOR CANAL STRUCTURE
Variation in alignment, grade and dimensions of the structures from the established alignment,
grade and dimensions shown on the drawings shall be within the tolerances specified in Table
below. Variation shall not be cumulative. Where the provisions of paragraph 4.14, "finishes and
finishing of concrete surfaces", as specified herein before, would permit greater variations than
those allowed in the table, provisions of the table given on the following page shall apply.
TABLE
a.
Pipe Culverts, float wells and similar structures

i.
Departure from established alignment
25mm
ii.
Departure from established grade
25 mm
iii.
Variation from plumb or specified batter for

lines and surfaces of columns, piers and walls and for arises.
When overall length of line or surface is:
3 mtrs or less
More than 3 mtrs.
iv.
Exposed
10mm
Buried
20 mm
Exposed
12 mm
Buried
25mm
For any two successive intermediate points on the line or

surface separated by
3 mtrs or less
More than 3 mtrs.
b.
Exposed
10mm
Buried
20mm
Exposed
12mm
Buried
25mm
Variation from level or specified grades for slabs.

i.
When overall length of line or surface is:

3 mtrs. or less
More than 3 mtrs.
ii.
Exposed
10mm
Buried
20mm
Exposed
12mm
Buried
25mm

surface separated by :
3 mtrs or less
More than 3 mtrs
c.
Exposed
10mm
Buried
20mm
Exposed
12mm
Buried
25mm
Variation in cross-sectional dimensions of columns, beams, slabs, walls and similar

members of
...................................................minus 6mm
...................................................plus
d.
Variation in sizes and locations from those specified for slab

and wall openings..........................
e.
12mm
Variation fom plumb or pipe erected vertically in any length of

.................................................3mtrs.
f.
12mm
12mm
Tolerances for bridges:

Departure from established alignment................................. 6mm
g.
Footings
i.
Variation of dimensions
ii.
in plain ........................................................minus
12mm
..........................................................plus
50mm
Misplacement of eccentricity 2 percent of the footing width in the

direction of misplacement but not more than
iii.
h.
50mm
Reduction in thickness............ 5 percent of specified thickness.
Variation from plumb or specified batter for lines and surfaces of piers and walls.
i.
Exposed construction:
When overall height of line or surface is:
3 mtrs or less..........................................
10mm
more than 3 mtrs.....................................
12mm
for any two successive intermediate points on the line

ii.
3 mtrs or less..........................................................
10mm
more than 3 mtrs....................................................
12mm
Buried construction...........................................
Twice the amounts

listed in h(1) above.
i.
Variation from level of specified grades for beams Horizontal grooves, railing off sets and
diaphragms:
i.
Exposed Constructions:
When overall length of line or surface is :
3 mtrs or less..........................................................
more than 3 mtrs.....................................................
10mm
12mm

ii.
J.
3 mtrs or less..........................................................
10mm
more than 3 mtrs....................................................
12mm
For buried construction: Twice the amounts listed in i (i) above
Departure of bridge deck and rails from

specified grades........................................................
k.
6mm
Variation in cross-sectional dimensions from those specified for piers, walls, beams and
similar parts of bridge structures.
l.
...............................................
minus
6mm
................................................
plus
12mm
minus
3mm
Variation from that specified in the

thickness of bridge slabs .............
.. plus
6mm
4.21.3 (a) GENERAL

Bulges, Depressions and offsets are defined as concrete Surface irregularities. Concrete surface
irregularities are classified as "abrupt" or "gradual" & are measured relative to the actual concrete
surface.
(b)
ABRUPT SURFACE IRREGULARITIES
Abrupt surface irregularities are defined herein as offsets such as those caused by misplaced or
loose forms, loose knots in form member, or other similar forming faults. Abrupt surface
irregularities are measured using a short straight edge, atleast 15 cms. long held firmly against the
concrete surface over the irregularity and the magnitude of the offset is determined by direct
measurement.
(c)
GRADUAL SURFACE IRREGULARITIES
Gradual surface irregularities are defined herein as bulges and depressions resulting in gradual
changes on the concrete surface. Gradual surface irregularities are measured using a template
conforming to the design profile of the concrete surface being examined. Templates for measuring
gradual surface irregularities shall be provided by the contractor, templates shall be atleast 2.5
mtrs. in length. The magnitude of gradual surface irregularities is defined herein as a measure of
the rate of change in slope of the concrete surface.
(d) The magnitude of gradual surface irregularities on concrete surfaces shall be checked by the
contractor to ensure that the surface are within specified tolerances. The department will also
make such checks of hardened concrete surfaces as determined ne cessary to ensure compliance
with these specifications. Templates for these surface shall be furnished by the concrete free of
change and shall be available for use by the department at all times.
4.22 UNACCEPTABLE WORK
All defective concreting work, including those due to honeycombing, under sizing, under-strength
etc. shall be demolished and rebuilt by the contractor at his cost. In exceptional cases where such
work is accepted by the Engineer-in-charge after the contractor has made specified repairs, all cost
of repairs shall be borne by the contractor. Acceptance of such works will be in accordance with
the provisions of IS: 456-1978. In the event of the work being accepted, allowing under sizing
commensurate with higher materials strength and accepting materials not fully meeting the
specifications etc. the contractor shall be paid for the work actually carried out by him at a reduced
rate derived from the tendered rate as approved by the Engineer-in-charge.
SECTION - V
REINFORCEMENT
5.1
SCOPE OF WORK
The work includes supplying, cutting, bending, binding, welding and erecting in position high yield
strength deformed (H.Y.S.D.) steel bars and mild steel (M.S.) bars as reinforcement for concrete of
various components of drainage syphons, syphon aqueducts, road bridges, cross regulators, head
regulators, escapes, lining and other structures.
5.2
1.
IS : 226-1975
Structural steel (Standard Quality).
2.
IS : 280-1978
Mild steel wire for general Engineering purposes.
3.
IS : 432-1966
Mild steel and medium tensile bars and drawn stead

wire for concrete reinforcement
4.
IS : 432-1966(part-I)
Mild Steel and medium tensile steel bars.
5.
IS : 432-1996 (part-V) Hard drawn steel wire.
6.
IS : 814-1974
Covered electrodes for metal or welding of structural

steel.
7.
IS : 814-1974(part-I)
For welding products other than sheets.
8.
IS : 814-1974(part-II)
For welding sheets
9.
IS : 1139-1966
Hot rolled mild steel medium tensile steel and

high yield
strength steel deformed bars for concrete
10.
IS : 1278-1972
Filler rods and wires for gas welding.
11.
IS : 1481-1970
Metric steel scales for Engineers.
12.
IS : 1521-1972
Method for tensile testing of steel wires.
13.
IS : 1566-1967
Hard drawn steel wire fabrics for concrete

reinforcement.
14.
IS : 1608-1972
Method for tensile testing of steel products.
15.
US : 1786-1979
Cold twisted steel bars for concrete

reinforcement.
16.
IS : 2502-1963
Code of practice for bending and fixing of bars for

concrete reinforcement
17.
IS : 2751-1979
Code of practice for welding of mild steel bars

used for reinforced concrete construction.
18.
IS : 5525-1969
Recommendations for detailing of reinforcement

In reinforced concrete works.
19.
IS : 9417-1979
Recommendations for welding cold worked steel

Bars for reinforced concrete construction
In addition to the above the relevant Indian Standard codes referred to in

SECTION - IV shall also apply.
5.3
STEEL REINFORCING BARS
5.3.1 GENERAL
(a)
Steel reinforcing bars shall be placed in concrete where shown on the drawings or as
directed by the Engineer-in-charge. The drawings issued with these specifications show only in
part the requirement of reinforcement and further drawings shall be iss ued by the Engineer-incharge during the course of the contract.
(b)
As far as possible, high yield strength deformed bars conforming to IS: 1786-1979 shall be
used as reinforcement.
However, in case of Non-availability of such bars other steel bars
conforming to IS: 432-1966 and / or IS: 1139-1966 shall be used as per the directions of the
Engineer-in-charge.
5.3.2 CUTTING, BENDING AND BINDING
(a)
The contractor shall be responsible for the accuracy of the cutting, bending and placing of the
reinforcement. Reinforcement shall be inspected for compliance with the requirement of grade,
size, shape, length splicing and locations after it has been placed. No concreting shall be started
unless the reinforcement as placed in the work is finally checked, record ed and certified by the
Engineer-in-charge.
(b)
Before the reinforcement is placed, the surface of the bars and the surfaces of any metal bar
supports shall be cleaned of the rust, loose mill scale, dirt, grease and other objectionable foreign
substances. After being placed, the reinforcing bars shall be maintained in a clean condition until
they are completely embedded in the concrete.
(c)
Reinforcing bars shall be accurately placed and secured in positions as shown in the drawing
so that the bars and fabric shall not be displaced during the placing of concrete. The contractor
shall also ensure that there is no disturbance of reinforcing bars already placed.
(d)
Wire for binding reinforcement shall be of soft and annealed mild steel and shall conform to
IS: 280-1978. The binding wire shall have tensile strength of not less than 56kg/sqmm. The wire
shall have minimum diameter of 1 mm.
Chairs, hangers, spacers and other supports for
reinforcement, may be of concrete, metal or other approved material. Where portions of such
supports will be exposed on concrete surfaces designated to receive F2 or F3 finish, the exposed
portion of support shall be galvanized or coated with other corrosion resistant material without
which the concreting will not be permitte Such supports shall not be exposed on surfaces of F4
finish unless otherwise shown on the drawings. The minimum allowable clearance between
parallel round bars shall not be less than 1.50 times the diameter of the larger bars and for square
bars shall not be less than twice the side dimensions of the larger bars. In no case the minimum
clearance between the bars shall be less than 1.50 times the maximum size of aggregate
irrespective of the shape of the reinforcing bar. Bars crossing each other where requi red shall be
secured by binding wire in such a manner that they do not slip over each other at the time of fixing
and concreting.
5.3.3 SPLICING
(a)
Where it is necessary to splice reinforcement the splices shall be made by lapping, by
welding or by mechanical means.

(b)
Joints or splices in reinforcing bar shall generally be made at the locations where neither
shear nor bending moment is maximum, but the contractor would be permitted to take joints or
splices at other position provided that such positions are approved by the Engineer-in-charge and
joints and splices in adjacent bars are staggered as directed by the Engineer-in-charge. Approval
of such additional splices will generally be restricted to splices not closer than 9 mtrs. in horizontal
bars and 4 mtrs. in vertical bars measured between midpoint of laps.
(c)
If the contractor proposes to use welded splices in reinforcing bars the equipment, the
material and all welding testing procedures shall be subject to the approval of the Engineer-incharge. The contractor shall also carry out test welds as required by the Engineer-in-charge.
(d)
For welded splices for reinforcing bars conforming to IS : 1786-1979, welding shall be done in
accordance with IS : 9419-1979. For reinforcing bars conforming to IS: 432 (part-I) 1966 and IS :
1139-1966 welding shall be done in accordance with IS : 2751-1966. Electrodes for manual metal
arc welding shall confirm to IS : 814 (part-I) 1974 and IS : 814 (part-II) 1974, mild steel filler rods for
oxyacetylene welding shall conform to IS : 1278-1972 provided they are capable of giving a
minimum butt weld tensile strength of 41 kg-/ sq mm.
(e)
Reinforcing bars 28mm'in diameter and larger may be connected by butt welding, provided
that lapped splices will be permitted if found to be more practicable than butt welding and if lapping
does not encroach on cover limitation or hinder concrete or reinforcement placing.
(f)
Reinforcing bars 25mm diameter and less may be either lapped or butt welded, whichever is
most practicable.
(g)
Butt welding of reinforcing bars shall be performed under cover from weather and may be
performed either by the gas pressure or flash pressure welding process, or by the electric arc
methods. The following requirements shall apply to all welding of reinforcing bars including butt
welding and the preparation of welded reinforcement mats.
(h)
Welded pieces of reinforcement shall be tested at the rate of 5% of total number of joints
welded. Specimen shall be taken from the actual site of work. Streng th of the weld provided shall
be at least 25% higher than the strength of bar.
(i)
If the contractor proposes to use mechanical couplings for reinforcing bars he shall submit
samples of the proposed coupling to the Engineer-in-charge for approval not less than 60 days
prior to their proposed use.
5.3.4 CARE OF PLACED REINFORCEMENT AND CONCRETE
Where reinforcement bars are bent aside at construction joints and afterwards bent back into their
original position, care shall be taken to ensure that at no time the radius of the bend is less than 6
times the diameters for deformed bars and 4 times diameters for plain mild steel bars. Care shall
also be taken, when bending such bars, to ensure that the concrete around the bars is not
damaged.
The position and dimension of lapped splices will normally be shown on the reinforcement
drawings. Where splices are required for the work the following minimum over lap of spliced bars
shall be used for the various sizes and grades shown. Hooks will not normally be prescribed for
splices in structural grade deformed bars.
Diameter of Bar
Grade of Bar
Minimum
length
of
Straight splice
6mm
10mm
12mm
16mm
20mm
22mm
25mm
30mm
35mm
Structural Plain
Structural Plain
Structural deformed
Structural deformed
Structural deformed
Structural deformed
Structural deformed
Structural deformed
Structural deformed
SECTION - VI
30cm
46cm
38cm
48cm
58cm
66cm
86cm
97cm
107cm
overlap
in
6.0
GATES
6.1
RADIAL GATES FOR REGULATORS AND ESCAPES
6.1.1 APPROVAL OF DESIGNS AND DRAWINGS

The item is for supplying and erection of radial gates for the vents of the cross regulators on main
canal or Branch Canal or escapes and head works of branch canal. The dimensions and the
outline arrangements of gates shown in the tender drawings are tentative. The KBJNL shall
however supply, working drawings of the structures showing therein the precise dimensions of the
gates, the hoisting arrangements etc. On receipt of these drawings, the contractor shall submit
within 60 days design and drawings of the gates including those of embedded parts, anchorages,
hoisting arrangements etc. for the approval of the department. The designs and drawings shall be
transmitted to the contractor with the approval or the suggestions for modification within a period of
60 days. If the drawings are returned with suggestions for modification the contractor shall effect
necessary modifications and submit the final drawings within a period of 45 days and the final
approval shall be communicated in not more than 30 days, provided all suggestions made are
complied with in full.
6.1.2 DESIGN PROCEDURE FOR GATE AND HOISTS
The design of the radial gates shall be in conformity with IS: 4623-1967. "Recommendations for
structural design of radial gates". The design of hoists shall be in conformity with IS: 6836-1978
design of rope drum and chain hoists for hydraulic gates.
6.1.3
MATERIAL
The materials for the various parts of the radial gates shall be as specified below :
Sl.
Ref. To IS
Recommended
Component part
No.
Specification
Material
1.
IS : 226-1962
Structural steel
Skinplate
Structural steel
Stiffners,
IS : 2063-1962
2.
IS : 2062-1962
Horizontal girders
3.
IS : 2062-1962
Structural steel
IS : 808-1964
Arms bracings, tie

members, anchorage
girder, yoke girder,
embedded girder,
rest girder, load
carrying anchors.
4.
IS : 1030-1962
Cast steel
Guide rollers
5.
IS : 1030-1962
Cast steel
Trunnion hub & bracket
6.
IS : 1030-1962
Corrosion resisting steel Pin
7.
IS : 818-1962
Bronze
Bushing
8.
6mm thick stainless
Seal seat, sill beam
steel plates
9.
IS : 226-1962
Structural steel
Seal base
10.
IS : 4623-1967 and
Structural steel
Rubber seal
Appendix-A
and rubber
6.1.4 ANCHORAGES AND HOISTING ARRANGEMENT

The gate shall be preferably designed with independent anchorages and rear suspension with
galvanised wire rope, cast steel rope drum and electrically operated hoist. The contractor shall
supply suitable electrical motor with switch and switch panel also, including necessary wiring as
directed. Provisions shall also be made for manual operation in case of power failure. The gear
arrangements shall be such as to facilitate easy operation by two operators.
6.1.5 PROCUREMENT OF MATERIALS
The contractor shall make his own arrangements for procurement of the necessary material. The
department will however supply structural steel if available at divisional issue rates. All materials
shall be of approved quality and for all materials procured from sources, other than the
departmental stores, the contractor shall produce necessary I.S.I test certificates.
1. Fabrication
Fabrication may be done either at work spot or in contractors work shop elsewhere under
intimation to the department. The contractor shall afford all facilities for the inspection of the
fabrication by the departmental officer. All fabrication shall be done in a workmanlike manner, in
accordance with relevant I.S. specifications and as directed.
2. Transportation
The fabricated parts shall be transported to the work spot carefully at contractors cost without
causing any damage.
3. Schedule of Supplies
The construction programme of the civil works of the regulators and escapes and the schedule of
delivery at work spot of the fabricated parts of the gates shall be well coordinated. The contractor
shall furnish and follow a schedule of delivery acceptable to the KBJNL.
4. Erection
Erection of any component of gate shall be commenced only after approval of the component by
the Executive Engineer. Such approval shall be given after due inspection at work spot and without
absolving the Contractor his responsibility to rectify any defects which may be noted subsequently
till the gate is finally handed over after satisfactory erection, commissioning and test operations.
5. The gate shall be provided with two coats of anti corrosive paint of approved quality over
one coat of primer.
6.1.6 TEST OPERATION
Before the work is finally accepted the test operation of gate shall be done in the presence of the
Engineer-in-charge, after due intimation and any defects noticed shall be set right. Test operation
shall be done when the canal is functioning with full depth of flow. However, if for no omission on
the part of the Contractor, the Canal does not commence functioning within 6 months after the
stipulated date of completion of his work the test operation shall be done with such depth of water
as may be available in the canal.
6.2
VERTICAL LIFT SLIDE GATE
The vertical lift slide gates are for the gates of the Distributory head works. The dimensions and the
out-line arrangements shown in the tender drawings are tentative. The department will supply
working drawing of each Distributory head works to the Contractor showing therein the precise
dimensions of the gates and the location, elevation etc., of the hoisting arrangements. The
contractor shall then furnish within 60 days the design and drawings of the gates and the hoisting
arrangements including hoist platform, anchorages etc. for approval of the department. The design
and drawings shall be approved or returned with comments for modificatio n within a period of 60
days from the date of receipt by the department. If the drawings are returned with comments, the
contractor shall furnish the final drawings incorporating all suggested modifications within a period
of 45 days and final approval shall be communicated within 30 days.
The gate shall be manufactured using plates and rolled sections of structural steel. The design
shall be in conformity with IS: 5620-1970 Design criteria for low head slide gates. The gate shall
be with screw gear hoists, the force being transmitted through a screw attached to the Centre of
the gate. On the upper end of this shaft, a square screw thread is cut for the length necessary to
secure required travel of the gate and the screw nut to fit the thread is housed in a box in which it
can freely revolve, the box being fixed to the hoist platform. The nut is revolved by means of a
spanner of capstain head. Guide collars are provided to support the screw shaft at suitable
intervals.
The contractor shall make his own arrangements for procurement of materials. The department will
supply structural steel plates and rolled sections if available in the Departmental stores at the issue
rate. Contractor shall produce necessary I.S.I. test certificate for all materials procured from
sources other than departmental stores.
The gate shall be fabricated in workman like manner and in accordance with relevant I.S.
specification and transported to work site carefully. Erection shall commence only after inspection
and approval by the Engineer-in-charge.
The gate shall be painted with 2 coats of anti corrosive paint of approved quality over a coat of red
oxide primer.
Trial operations of the gate shall be made in the presence of Engineer-in-charge and any defects
noticed shall be set right promptly. If the commissioning of Canal is delayed by more than 6 months
after the agreed date of completion of the gated structure, due to no fault on the part of the
contractor, the test operation will be done with such depth of water as may be availab le in the
canal.
SECTION - VII
7.0
RUBBLE MASONARY:
7.1
SCOPE OF WORK
The work covered under this section consists of furnishing all material, equipment and labour
for providing and laying uncoursed rabble masonry in substructure and superstructure and
performing all functions necessary and ancillary thereto and including pointing of exposed surfaces
and curing. This also includes dewatering if required.
7.2
1. IS : 1121 - 1974
Method of test for determination of strength properties
(All parts) of natural buildings stones

2. IS : 1122 - 1974
Method of test for determination of true specific gravity
3. IS : 1123 - 1975
Method of identification of natural building stones
4. IS : 1124 - 1974
Method of test for determination of water absorption, apparent
specific gravity and porosity of natural building stones.

5. IS : 1125 - 1974
Method of test for determination of weathering of natural building
stones.
6. IS : 1126 - 1974
Method of test for determination of durability of natural building
7. S : 1127 - 1970
Recommendations for dimensions and workman ship of natural
stnvs.
building stone for masonry work.

8. IS : 1129 - 1972
Recommendations for dressing of natrual building stone
9. IS : 1542 - 1977
Sand for plaster.
10. IS : 1597 - 1967
Code of practice for construction of stone masonry
11. IS : 1597 - 1967
Rubble stone masonry
Part I
12. IS : 1706 - 1972
Method of determination of resistance to wear by abrasion of
natural building stones.

13. IS : 2116 - 1980
Sand for masonry mortars.
14. IS : 2250 - 1981
Code of practice for preparation and use of masonry mortars.
15.
IS : 1401 - 1967
Stone facing
Part I
16.
IS : 4121 - 1967
Method of test for determination of water transmission rate by
capillary action through natural building stones.

17.
IS : 4122 - 1967
Method for the surface oftening of natural building stones by
exposure to acidic atmosphere

18.
IS : 4348 - 1973
Method of test for determination of permeability of natural building
IS : 5218 - 1969
Method of test for toughness of natural building stones
stones.
19.
20.
IS : 7779
Engineering properties of building stones
21.
Recommended practice for quarrying stones for construction
IS : 8381 - 1977
purposes.
7.3
MATERIAL
7.3.1
CEMENT
The provisions of sub - para 3.5.1 shall apply.
7.3.2
WATER
The provisions of sub - para 3.5.4 shall apply.
7.3.3
SAND
(a)
Sand to be used in mortar shall conform to IS: 2116 - 1980 and the gradation limits given
below:
I.S. sieve designation
(b)
Percentage by weight passing I.S. sieve
4.75 mm
100
2.36 mm
90-100
1.18 mm
70-100
600 Micron
40-100
300 Micron
5-70
150 Micron
0-15
The provisions of sub-para 3.5.2 shall also apply
(c)
Before collecting the sand required for mortar for the masonry work, the contractor shall
ensure that the sample of sand proposed to be used are supplied to the project laboratory for
casting the mortar cubes, and material shall be collected only after ascertaining the results of the
test on the mortar cubes. During the execution of the work sand collected at site shall also be
tested for all specification requirements.
7.3.4 RUBBLE (STONES)
Stone shall be hard, sound free from cracks, decay and weathering. Stone shall be used
from surplus usable excavated rubble or from the approved quarries, if required. Stone with round
surface shall not be used. Stones when immersed in water for 24 hours shall not absorb water by
more than one percent of their dry weight when tested in accordance with IS: 1125 -1974.
The length of stone shall not exceed three times its height and the breadth on the base shall
not be greater than three fourth of the thickness of wall and in any case not less than 15 cm.
Minimum crushing strength of stones shall not be less than 600 Kg/Sqcm.
7.4
U.C.R. Masonry
7.4.1 MORTAR
The mortar shall consist of cement, sand and water thoroughly mixed in the proportion as
specified. Proportion of cement and sand shall be on weight basis as specified in schedule -B. Due
allowance shall be made for the moisture content in sand. Mixing water shall be added to achieve
required workability.
7.4.2 MIXING
(a)
The mortar shall be mixed in mechanical mixers of tilting type having calibrated water tank
for storing water. The first batch of the mortar at the commencement of work with any mixer shall
be made richer by adding 10 percent more cement over and above that required for the particular
mix. In case of mechanical mixing, the mortar shall be mixed for at least 3 minutes afte r addition of
water. Hand mixing shall not be allowed. However, in exceptional circumstances such as
mechanical break down of mixer, work in remote areas or when the quantity of work is very small,
mixing in hand operated mixers shall be permitted.
(b)
All ingredients shall be fed to the mixer simultaneously. The quantity of water to achieve the
required consistency shall be predetermined by trial mixes, and proportion of water from 5 to 10
percent shall precede and the like quantity shall follow the intro duction of other materials. The
remainder of water quantity shall be added during mixing operation.
(c)
The wet mortar shall be used within 30 minutes of mixing, mortar remaining unused, after
above time shall be rejected and shall not be allowed to be used.

7.4.3 MODE OF LAYING
(a)
The dressing of stone shall conform to the general requirements covered in IS: 1129-1972.
Stone shall be sufficiently wetted before laying to prevent absorption of water from mortar. All
stones shall be laid full in mortar both in bed and in vertical joints and settled carefully in place with
a wooden mallet immediately on placement so that it is firmly bedded in before the same has set.
Clean chips and spalls shall be wedged into the mortar joints and beds wherever necessary to
avoid thick beds or joints of mortar. Whenever foundation masonry is laid directly on rock, the face
stones of the first course shall be dressed to fit into the rock snughly when pressed down in the
mortar bedding over the rock. No dry or hollow space shall be left anywhere in the masonry and
each stone shall have all the embedded faces completely covered with mortar. Vertical joints shall
be staggered. Transverse bond shall be provided by the use of bond stones extending from the
front to the back of the masonry. In case of thick walls beyond 60 cm, bond stones shall overlap
each other in their arrangement. Overlap shall not be less than 15 cms. Bell shaped bond stones or
headers shall not be used.
Bond stone shall be stacked separately and marked to distinguish it from other stones.
Masonry work shall be started after sufficient numbers of bond stones are collected on site as
directed by the Engineer-in-charge. Bond stones shall be inserted at the rate of one per square
meter and shall be staggered.
(b)
At all angular junctions, stones at each alternate course shall be well bonded into the
respective course of the adjacent wall. All connected masonry in structures shall be carried up at
one uniform level throughout as far as possible, but when breaks are unavoidable the masonry
shall be in sufficient long steps to facilitate jointing of new work with old. Stepping shall not be more
than 45 degrees with the horizontal. Masonry work shall be carried out to truly plumb or to the
specified batter. Face work and hearting shall be brought up evenly. The top of each course,
however, shall not be leveled up by use of flat chips. Chips and spalls of stones may be used
wherever necessary to avoid thick mortar beds or joints and it shall also be ensured that not hollow
spaces are left anywhere in the masonry. Chips shall not be used below hearting stones to bring
these up to level of face stones. Use of chips shall be restricted to filling of interstices between the
adjacent stones in hearting and they shall not exceed 20 percent of the quantity of stone masonry.
(c)
Hearting or interior filling of water face shall consist of rubble stones, not less than 15 cm. in
any direction carefully laid, hammered down with a wooden mallet into position and firmly bedded
in mortar. Hearting should be laid nearly level with facing and backing.
(d)
The joint shall not be more than 25 mm thick but shall be sufficiently thick to prevent stone to
stone contact and shall be completely filled with mortar. The total content of mortar in masonry
shall not be less than 40% and not more than 48% of the volume of masonry.
(e)
When fresh masonry is to be placed against existing surface of structure, the old surface
shall be cleaned of all loose material, roughened and wetted as directed b y the Engineer-in-charge
so as to achieve a good bond with the new work.
(f)
The scaffolding shall be sound and strong to withstand all loads likely to come upon it. The
holes, which provide resting space for horizontal members, shall not be left in masonry. The holes
left in the masonry work for supporting the scaffolding shall be filled.
(g)
Green work shall be protected from rain by suitable cover. Masonry work in cement mortar
shall be kept consistently moist on all faces for a minimum period of twenty one days after 24 hours
of construction and continuous for 21 days. Watering should be done carefully so as not to
washout the mortar joints or disturb the masonry in any manner. During hot weather all finished or
partly completed work shall be covered or wetted in such a manner as to prevent drying. The
raking of joints where necessary shall be done at the end of day's work when mortar is green.
7.5
POINTING
7.5.1 GENERAL
(a)
For a surface, which is to be subsequently pointed, the joints shall be squarely raked out to a
depth of 20 mm. While the mortar is still green. The raked joints shall be well brushed to remove
dust and loose particles and the surface shall be thoroughly washed and cleaned.
(b)
Mortar required for pointing shall be prepared in accordance with the provisions of para No.
7.4.1 and 7.4.2. The cement and sand shall be used in proportion as specified in the respective
items or as directed by the Engineer-in-charge.
(c)
For pointing, mortar shall be filled and pressed into the raked out joints before giving the
required finish. Superfluous mortar shall be cut off from the edges of the lines and the surface of
the masonry shall also cleared of all mortar.
(d)
Curing shall be started as soon as the mortar used for finishing has hardened sufficiently not
to be damaged when watered. It shall be kept wet for a period of atleast 21 days. During this period
it shall be suitably protected from all damages.
7.6
TEST FOR MORTAR FOR CONSTRUCTION OF MASONRY
(a)
At least one set of test cubes of cement mortar used shall be taken for each day's work and
it shall be tested for 28 days strength.

(b)
From the design mortar mix, cubes using the material shall be cast in the laboratory at
suitable intervals and their strength is determined. This strength shall deemed as the standard
strength for that mortar. The strength of the test cubes shall be found out and shall not be less than
80% of the standard strength mentioned above. For acceptance, the 28 days strength of test cubes
shall be the criteria, 80 percent of the test cubes should satisfy the above criteria. All laboratory
testing work shall be carried out by the department as per relevant Indian standards and the
contractor shall be permitted to watch the test if he so desires. The Cost of testing be borne by the
Department.
7.7
CONTROLLING PAYMENT
The unit rate in Schedule - B for masonry work shall represent the rate for the work to be
done under the item to its full height. Part payment shall, however, be made on intermediate bills
as shown below:
Percentage of Work done
Percentage of Tendered rate

to be paid for the work
Until 50% of masonry is done more than 50%
95%
but less than 100% of masonry is done

When 100% of masonry is done
100%
The above percentages shall be applied to each component o f individual structure separately .
SECTION - VIII
8.0: REVETMENT AND PITCHING:
8.1
The bed or slope to receive the pitching or revetment shall be prepared true to line and grade
and shall be moistened and well rammed so as to present a clear uniform comp act surface.
8.2
The stones shall be hard, sound and durable and as regular in shape as possible and with
length not less than specified. Each stone shall not be less in size than 0.015 cum unless
otherwise specified or ordered by the Engineer-in-charge, having regard to nature of the stone
obtainable in the approved source. For revetment only the size stones shall be used.
8.3
The stones shall be laid closely in position on the prepared bed and firmly set with their
narrowest end downwards, and level with the finished surface of the pitching. The stones shall be
laid breaking joint as far as possible, in the direction of flow of water. The stones are to be placed
perpendicular to the finished surface. i.e. perpendicular to the slope for revetments and to the
specified thickness.
8.4
The interstices between adjacent stones shall be filled in with stone spalls of the, proper
size, well driven in with crowbars to ensure tight packing and complete filling of all interstices. Such
filling shall be carried on simultaneously with the placing in position of the large stones and shall in
no case be permitted to fall behind. The final wedging shall be done only after obtaining the orders
of the Engineer-in-charge. The final wedging shall be done with the largest sized chips practicable,
each chip being well driven with a hammer so that no chip is possible at being picked up or
removed by hand.
8.5
Profiles of string and pegs are to be put up to ensure that the pitching is done true, straight,
and to the proper slope throughout and revetments in all cases are to be built up from the foot of
the bank to be revetted.
8.6
On completion, the surface presented by the apron or revetment shall be even throughout,
free from irregularities, to the required length, breadth and slope specified as shown in the
drawings.
8.7
When use of rubble of canal spoils is specified, rubble required for the work shall be issued
at the nearest available stacks of the excavated materials of the canal in the reach concerned or in
any of the adjoining reaches if available. The contractor shall sort out useful rubble, hammer dress
to the required size shape and convey the same to the work spot at his cost.
SECTION IX
9.0
SUPPLYING, LAYING AND JOINTING HUME (PRE - CAST) PIPES:
9.1
Pipes and collars of specified classes shall be procured by the contractor at the site of work.
No pipe shall be placed in position until the foundations have been approved by the Engineer-incharge. Where two or more rows of pipes are to be laid adjacent to each other they shall be
separated by a distance equal to at least half the diameter of the pipe subject to a minimum of 450
mm.
9.2
The laying of pipes on the prepared foundation shall start from the outlet proceed towards
the inlet and shall be completed to the specified lines and grades. The pipes shall be fitted and
matched so that when laid in work, they form a culvert with a smooth uniform invert.
9.3
Any pipe found defective or damaged during laying shall be removed and replaced by the
contractor at his cost.

9.4
JOINTING
9.4.1 One collar shall be provided at each joint. The collar shall be of R.C. C. having the same
strength as the pipes to be joined. Caulking space shall be between 13 and 20 mm according to
the diameter of the pipes. Caulking material shall be slightly wet mix of cement and sand in the
ratio of 1:3 rammed with caulking irons. Before caulking the collar shall be so placed that its centre
coincides with the centre of the joint and an even annular space is left between the collar and the
pipe.
9.4.2 All joints shall be made with care so that their interior surface is smooth and consistent with
the interior surface of the pipes. After finishing, the joints shall be kept covered and damp for at
least 14 days.
9.5
BEDDING FOR PIPE

The bedding shall provide a firm foundation of uniform density throughout the length of the
culvert and shall conform to the specified levels and grade. Concrete cradle bedding or first class
bedding shall be provided, as specified in the drawing. The specifications of concrete cradle
bedding and first class bedding shall conform to IS : 783 - 1959 or its latest version
9.6
BACKFILLING
Specification for backfilling shall be as per para 2.10.
Backfilling will be separately paid as mentioned in para 2.10.3.
9.7
OPENING TO TRAFFIC
No traffic shall be permitted to cross the pipe lines unless the earth filling above the latter is
at least 0.6 metre.
9.9
RATE
The rate shall include the cost of pipes and collars, transportation, handling, storing, laying in
position and jointing pipes and also the cost of preparing specified bedding.
SECTION X
10.0 ELASTOMERIC BEARING
10.1 GENERAL
Elastomeric bearing conforming to IRC - 83 (part II) section-I and as per the MOST
specification 2005 is to be used.
10.2 PLACING
Elastomeric bearing pads of required size shall be fixed in position true to Line and level as
directed by Engineer - in charge. It includes cost and conveyance of all materials, labour and
fabrication machinering inputs, gas cutting, straightening, mixing neoprene with respect with
respect to nodules with chemicals, vulcanising of Elastomeric compound with reinforcement plates
etc. as per drawing and as directed by Engineer-in charge.
10.3 TESTING
The cost per cubic centimeters shall be inclusive of one extra bearing for Testing, for which
no separate payment will be made and also for testing.
SECTION XI
11.0 WATER STOPPER
11.1 Water bars are performed strips of impermeable material, which are to be embedded in the
concrete during construction so as to span across the joint and provide a permanent watertight
seal during the whole range of joint movement. The most useful forms of water bars are strip with
a central longitudinal corrugation and a central longitudinal hollow tube with thin walls with stiff
wings.
The material used for the water bar are synthetic rubbers and plastics have very
considerable advantage in handling, splicing and in making intersections.

With all water bars, it is important to ensure proper compaction of the concrete. The bar
should have such shape and width that the water path through the concrete round the bar should
not be unduly short. The water bar should either be placed centrally in the thickness of the wall or
its distances from either side of the wall should not be less than half the width of the bar. The full
concrete cover to all reinforcement should be maintained.
11.2 Joint sealing compound: Joint sealing compounds are impermeable ductile materials,
which are required to provide a watertight seal by adhesio n to the concrete throughout the range of
joint movement. The commonly used materials are based on asphalt, bitumen, or coal tar pitch
with or without filters, such as lime stone or slate dust, asbestos fibre, chopped hemp, rubber or
other suitable material.
These are usually supplied after construction or just before the
reservoir/delivery chamber is put into service by pouring in the hot or cold state. These may also
be applied during construction such as by packing round the corrugation of water bar. For detailed
specification refer IS 3370 (Part-I) 1965.
SECTION - XII
12.0
G.I.PIPE HAND RAILS
12.1
G.I. Pipes of approved quality, confirming to the relevant IS code of 40mm dia. in three
rows shall be fixed to RCC posts of CC M-15 grade of size 100mm x 100mm at top and 150mm x
150mm at bottom placed at a distance of 2 mtr. intervals at a height of 750mm. including curing,
finishing etc. as directed by Engineer-in-charge
Handrails shall be properly jointed and installed and painted with two coats of p aint as approved by
Engineer-in-charge.
SECTION XIII
13.0 PRESSURE RELIEF VALVES/DRAINAGE SPOUTS:
13.1 Scope of work
Item includes providing and fixing properly pressure relief valves at suitable intervals and
Drainage spouts near at structure locations as per drawings and I.S. 455850 mm in dia pressure
relief valve of G.I. pipe of approved quality of the required length with suitable sealing ring, bush,
and hinged lids as per drawing so as to release water from bed/sides. It includes drilling 25mm di a
holes one meter deep in rock. It includes fixing the pipe in concrete 1 U.C.R. masonry with
anticorrosive painting as directed by the Engineer-in-charge.
13.2 Materials
Metal, sand shall be as per Para of specifications for materials, Lid shall be of aluminum plate
of approved quality, Hinges, bushes and pin of gun metal of approved quality. G.I. pipes 50 mm
dia shall be of approved quality.
13.3 Mode of Construction
Pressure relief valves of G. 1 pipes length required for the bed sides with necessary fittings
are to be fixed in concrete. U.C.R. masonry including, painting with anticorrosive paint as per the
directions of the Engineer-in-charge, The lengths are only approximate and may vary during
execution for which no extra payment will be made. Be fore fixing the pipe a hole of 25 mm dia one
metre deep should be bored beneath the pipe. Before fixing the pipe the hole should be got
inspected by the Engineer-in-charge.
The pipes should be fixed so that it will be complete in flush with the finished slopes of the
canal sides and the bed without any projections whatsoever. The fixing of pipe should be done
simultaneously with laying the concrete for the bed, U.C.R. masonry for the sides.
13.4 Mode of payment
Full payment will be made on Number of pipes, fixed upto satisfaction of Engineer-in-charge
that the work has been carried out as described above according the specification.
SECTION XIV
14.0 FILTER DRAINS:
14.1 Scope of work
Item includes providing constructing vertical/inclined-graded filter drains behind bed and side lining.
This item includes for providing and fixing 50 mm pressure relief valves with perforated G.I. pipe 30
cm long for properly at suitable intervals behind P.C.C. lining. This item includes the excavation of
pits of size 35cm x 35 cm x 40 cms and filling the same with filter material of graded sand and
graded metal of size 10mm to 40mm so as to satisfy the filter criteria between adjacent layers as
specified in paragraph 6.00 to 6.11. The filter material shall be hand pack ed and compacted The
perforated G.I. pipe shall be fixed in the filter pockets. The gradation of each filter layer shall meet
the following requirements with respect to the materials to be protected and also with respect to the
adjacent filter layers. The specifications of sand and aggregates for the filter shall conform to para
2.2 to 2.4 of materials.
1.
D 15 of the filter should be less than 4 times the D 85 of the material to be protected.
2.
D 15 of the filter should be greater than 5 times the D 15 of the material to be protected and
that the filter does not contain more than 5% of material finer than 0.075 mm.
3.
The grain size curve of the filter should be roughly parallel to that of the base material in the
filter range.
14.2 Materials
1)
Metal, and sand shall be as per para of specification for materials.
2)
Lid shall be of aluminum plate of approved quality
3)
Perforated G.I. pipe ot 50 mm dia shall be of approved quality
4)
Hinges, bushes and pin of Gun metal of approved quality.
14.3 Mode of construction

The drain pit of required size shall be excavated with the side vertical in bed drains normal to the
side slopes for sides and the excavated stuff shall be disposed off as directed by the Engineer-incharge. Any loose or disturbed material on the sides shall then be well compacted. The graded
filter material satisfying filter criteria shall then be carefully placed and compacted in layers as per
drawings or as directed by the Engineer-in-charge. The approved pressure relief valves and
perforated G.I. pipe with hinges, lids as per drawings and specifications shall be supplied by the
contractor and the same embedded with filter materials. The entire exposed surface of the filter
material shall be covered with tarpaper so as to prevent the water from the bed concrete entering
into the filter. No extra payment will be made on this account. The pressure relief valves should
be so fixed that it will be completely true with the finished slope of the canal sides and bed without
any projections whatsoever.
SECTION XV
15.0 GUARD STONES/BOUNDARY STONES/CHAINAGE STONES:
15.1 All stones shall be quarried from the approved quarry only. The stones shall be clean, hard,
durable, dense, tough and shall be free from decay, whethered portions, skin, veins, flaws, cracks,
cavities, vescicules and other defects. Stone shall be as far as possible uniform in colour and
texture. Stones shall be of fine medium grained and shall give ringing sound when struck with a
hammer. They shall be of the required size and shall be dressed neatly on the exposed faces.
The guard stones shall be hammer dressed.
15.2 The stones shall be fixed on both the sides of canal at intervals as directed by the Engineerin-charge. The size of stones shall be 75 cm x 20 cm x 20 cm
and the portion above
the ground level shall be dressed to the required size and directed by the Engineer-in-charge.
Arrow marks shall be engraved for boundary stones as directed. The stones shall be fixed by the
excavating a pit and back filled with excavated material. The stones shall be white washed
as directed. The rate quoted by contractor for this item shall includes cost and conveyance
of all material, with all leads and lifts, dressing to the required size and shape including engraving
arrow mark (for boundary stones) and white washing as directed by the Engineer-in-charge fixing
in position by excavating a pit of required size and refilling with excavated materials including
consolidation, watering etc., complete.
SECTION XVI
16.0 EXPANSION JOINTS AND CONTRACTION JOINTS:
16.1 Pre moulded expansion joint filter to be used in the expansion joints shall be of approved
quality prepared strips of fibre mastic and bitumen and having a thickness of 20mm and depth
equal to the thickness of the concrete where it is used. The prepared filler must be of such quality
that it will have the necessary adhesive properties which will not be deformed by ordinary handling
during the hot-summer months prior to placing and contain sufficient filler incorporated in the
bitumen in order to reduce to a minimum its brittleness at freezing temperature. The filler shall be
cut to conform to the cross section of the canal lining. The pre moulded joints can be prepared in
the following manner.
Composition: The mastic used should be composed of:
Very fine sand 60% by wt;
Suitable grade of Asphalts 30% by wt;
Cement 8 % by wt;
Chopped hemp 2% by wt;
16.2 Mixing
The sand should be heated in a large flat pan to a temperature of 400 . F. The binder should be
heated separately, in a suitable container, to a temperature of about 360 o F. The requisite quantity
of binder should then be added to the heated sand and thoroughly stirred. The weighed quantities
of cement and chopped hemp are to be added again mixed thoroughly and mixture should be
immediately poured in to moulds before it has time to cool appreciably.
16.3 Mould and method of Filling
The mould should consist of a plane board about 30 cm longer if necessary. The board should be
about 30 cm wide, which is usually sufficient for most expansion joints. Wooden battens should be
made to the exact thickness of the expansion joint required and clamped to the board, the distance
between the battens corresponding to the width of expansion joint. A strip of brown paper of
preferably waxed or oiled paper cut to the width of the expansion joint should be laid between the
battens. The inner faces of the battens should then be painted with the solution made of soft soap
and water to prevent the bitumen adhering to them. Mastic is then filled in between the battens
and struck off smooth with a wide and heavy spatula. Another piece of brown or oiled paper
should then be spread over the mastic and gently pressed into it. When the mastic has cooled the
clamps are loosened and battens removed. The expansion joint material is then ready to be cut
into requisite Lengths with a sharp hot knife. The purpose of the oiled brown paper is to prevent
the mastic from becoming sticky.
16.4
Mode of Construction
Premoulded expansion joint filler of 20mm thickness shall be properly hammered into the joint
between adjacent bed concrete, slabs and finished flush with the surface of bed concrete.
Care shall be taken to seen that no cavities are left in the joints. The premoulded expansion joint
filler shall be such size and shape as to exactly fit in the joint. In case there are any small cavities
left they are to be filled properly; with suitable liquid bituminous mixture as directed by the
Engineer-in-charge. Any premoulded filler joints sold in the market under different pattern and
found suitable to this work may be used with the specific approval of the Engineer-in-charge.
Similarly 12mm thick filler to be used for UCR masonry as directed by the Engineer-in-charge.
DETAILED SPECIFICATIONS OF ROAD

PREPARATION OF SITE
CLEARING THE SITE
(a)
The contractor shall clear the entire area, required for setting out, of all tree stumps, roots,
bushes, rubbish of all kinds, loose stones and all other objectionable materials. The ownership of
the useful materials so removed from clearing site and / or excavation shall rest with the KBJNL.
Cutting of trees, covered under this item shall not be resorted to without the permission of the
Engineer-in-charge. The contractor shall remove all the stumps and roots of trees for which no
additional payment will be made. The roots of trees shall be grubbed to a depth of 100 cms. The
contractors shall dispose off all such materials as directed by the Engineer-in-charge.
(b)
No separate payment will be made to the contractor for complying the requirements of this
paragraph and all cost shall be deemed to have been included in the price quoted by the bidder.
1.1
BORROW AREAS
1.1.1 GENERAL
(a)
All materials required for the construction of impervious or pervious zones of embankment
and back fill for cut-off trech and structures which are not available from canal excavation,
excavation for structure or from excavation of other ancillary works, shall be obtained from the
designated borrow areas or as designated by the Engineer-in-charge in consultation with field
laboratory. The depth of cut in all borrow areas shall be designated by the Engineer-in-charge and
the cut shall be made to such designated depth only. Each desig nated borrow area shall be fully
exploited before switching over to the next designated borrow area. Haphazard exploitation shall
not be permitted. The type of equipment used and the operations in the excavation of materials in
borrow areas shall be such as to produce the required uniformity of the mixture of materials for the
embankment.
1.1.2 STRIPPING OF BORROW AREAS
(a)
Borrow areas shall be stripped of topsoil and any other objectionable materials to the
required depth. Stripping operations shall be limited only to designated borrow areas. Materials
from stripping shall be disposed of in the exhausted borrow areas or in the approved adjacent
areas.
(b)
Stripping of borrow area shall not be measured and paid for separately. The cost of stripping
is to be included in the unit rate for the respective embankment.

1.1.3 BORROW AREA WATERING
(a)
Borrow areas watering shall be done by the contractor wherever necessary and in the
manner specified by the Engineer-in-charge.

(b)
The initial moisture content of the material in the borrow areas shall be estimated with the
help of laboratory test. The optimum moisture content for the material in the particular borrow
areas shall be determined by field tests. The additional moisture requirements if any shall be
introduced into the borrow areas by watering well in advance of the excavation to ensure uniformity
of moisture content.
All care shall be taken to reduce excessive moisture in any of the locations of a borrow area before
or during excavation to secure the materials with moisture contents close to the optimum to avoid
formation of pools in the borrow areas during excavation operation. Drainage ditches from borrow
areas to suitable outlets shall be excavated, wherever necessary. On exhausting all useful
materials or abandoning borrow areas the pits shall be fully drained to ensure no ponding of water.
1.2
EMBANKMENT
1.2.1 GENERAL
The embankment may comprise of different zones viz.
(i)
Semi-pervious/pervious earth fill of controlled compaction at controlled moisture
content, and
(ii)
All in fill of controlled compaction at random moisture content.
12.2 EARTH FILL

1.
Bushes, roots, sods or other organic or unsuitable materials shall not be place in the
embankment. The suitability of each part of the foundation for placing embankment materials
thereon and of all materials for use in embankment construction will be determined by the
Engineer-in-charge on the basis of field laboratory tests. As for as possible levels of embankment
along with the cross-section shall be the same. any difference in levels between zones if un
avoidable shall not exceed the thickness of one layer .. Placing of the layers for the embankment
portion programmed for construction in the season shall be continuous and approximately
horizontal.
2.
Placement of fill within the zones as shown on the drawings shall be performed in an orderly
sequence and in an efficient and workmanlike manner.

3.
Chemical and physical tests of the soil in the embankment shall be carried out by the quality
control organization of the department to ensure that the soil does not contain soluble lime, soluble
salts or cohesionless fines and unsound materials in quantities harmful to the embankments.
Useful materials from canal excavation and excavation of structure s and from borrow areas shall
be classified, transported and placed in the specified zones of embankment as directed by the
Engineer-in-charge.
4.
Normally, the contractor shall utilize not less than 80% of suitable excavated material from
the canal and structures to construct embankment, whenever such utlisation is economical in the
opinion of the Engineer by conveying from the spoil heaps with all leads and lifts as mentioned in
schedule B and he will not be authorized to obtain material from borrow areas until he does so.
The balance of soils shall be obtained from borrow areas approved by the Engineer-in-charge. If
the contractor fails to utilize atleast 80% of the usable excavated materials from the canal and
structures and obtains instead material from the borrow area, payment for this material shall be
made as if obtained from canal excavation within the leads mentioned in schedule -B. The decision
of Engineer about the usability of soils available from the canal excavation is final and binding upon
the contractor.
5.
Embankment materials shall be spread in successive horizontal layers extending to full width
of the embankment plus 45 cms on either side to facilitate satisfactory compaction in the full
designed width. No payment shall be made for placing the additional 45 cms. widths or for their
subsequent removal. No addition shall be allowed to the slopes of the bank after the bank is raised.
Trimming of inside slopes to final dimensions, lines and grades shall precede the lining work. This
shall be done not more than two days prior to lining.
6.
Thickness of embankment layers may be adjusted by the Engineer-in-charge if the
contractor by carrying out trial compaction and requisite tests satisfies the department that the type
of compactors used by him provide required density. The thickness of loose layers in embankment
shall be normally as under:
Sl. No. Type of compaction Machine
Weight
Thickness of loose layer
1. 1.5 mts. Dia.drum sheep foot rollers
6000 kgs./running mrts.
25cms. to 30 cms
2.
1 mtrs. Dia drum sheep foot rollers
3000 kgs/running mrts.
20cms to 22 cms.
3.
Pneumatic Tamper
................................
7.5cms to 10 cms.
4.
D. R. R.
10,000 kgs.
20cms to 25 cms.
5.
Vibratory roller
................................
30cms to 45 cms.
7.
No embankment layer shall be laid until the previous layer is properly watered, compacted
and tested as per requirement. The work of spreading and compaction shall be so adjusted as not
to interfere with each other and in such a way that neither of the operations is held up because of
non-completion of the rolling and watering. If the work is held up due to failure of machinery, no
claim whatsoever will be entertained even in case of machinery is supplied by the department. The
surface of embankments shall at all time of construction be maintained true to required cross
section.
8.
The distribution of materials in each layer shall be such that the compacted materials will be
homogeneous and free from lenses, pockets or other imperfections The excavating and placing
operations shall be such that the materials when compacted will be blended sufficiently to secure
the best practicable degree of compaction, impermeability and stability.
9.
The material of the earth fill zones of controlled compaction and moisture content shall be
compacted to a density as specified on the drawings but not less than 95% of the standard proctor
density.
10.
In the above zones, no lumps or stone or pebbles having larger dimension than 7.5 cms in
impervious core and 13 cms. in pervious/semipervious zones shall be permitted. The total
percentage of lumps or stones or pebbles of permissible size shall not exceed 5% in the case of
impervious core and 15% elsewhere. The percentage is in respect of every 3 cubic metre of batch
material conveyed to the site of placement.
11.
The homogeneous section for canal embankment shall be provided in the reaches where
design requirements are met with without hearting. The soil for the embankment shall generally be
in accordance with recommendations contained in IS : 8826-1978 (para 8). The available coarser
and more pervious material shall be placed near the outer slopes in order to have increasing
permeability from inner to outer side.
12.
The casing zone shall consist of material which provides support to impervious core under
various conditions of saturation and draw down. The distribution of material shall be suc h that the
compacted material shall be homogeneous, free from cracks, pockets or other imperfections. The
excavating and placing operations shall be such that the material when compacted shall be
blended sufficiently to secure the best practicable degree of compaction, impermeability and
stability. The casing material should normally have a standard Proctor density not less then 1.75
gms/cc.
13.
All suitable material with dry density greater than 1.35 gms/cc. Shall be used in all -in-fill
zone. Suitable sub-zones shall be formed within the all-in-fill if so directed by the Engineer-incharge, by depositing materials of different type, texture and particle size in different sub -zones. In
general, fragments of smaller size shall be deposited towards the inner slope and larger fragments
towards the outer slope of all-in fill. Formation of service roads and inspection paths in reaches of
full cutting will be treated as all-in-fill and will be paid for accordingly.
14.
The top surface of the bank shall be leveled with a gradient of 1 to 80 away from the inner
edge to facilitate proper drainage. The canal embankment shall be constructed to the top width
and height equal to designed height shown on the drawing, plus 2.5% of the designed height to
allow for settlement. The embankment width, at various levels should be regulated accordingly.
However, the bottom width of embankment shall as shown on the drawing or as directed by the
Engineer-in-charge.
15.
For proper bond between embankment placed in a previous se ason with the current
embankment, work shall be carried out and finished as under :

i.
Where an existing embankment is to be extended hoizontally it shall be cut to a slope
not steeper than 1 in 3 and the surface so prepared shall be scarified loosened atleast to a depth of
15 cms and wetted. Following, the embankment material shall be laid in layer and compacted to
the required degree of compaction.
ii.
If the old bank is to be raised vertically, vegetation shall be cleared followed by
scarifying, and watering and placing of the new earth layer as specified above. Raising shall be
done after the bottom layer is tested. No extra payment will be made in this regard for the
operations of clearing, scarifying and watering etc.
iii.
The surfaces which are damaged due to rain shall be repaired by filling with proper
material duly compacted by tampers.

16.
The finished fill shall be free from lenses, pockets, streak of layers of materials differing
substantially in texture or gradation from the surrounding materials. Successive loads of the
materials shall be dumped on the earthfill so as to produce best practicable distribution of the
materials subject to the approval of the Engineer-in-charge.
1.2.3 MOISTURE CONTROL
..
Prior to and during compacting operations the material in each layer of earthfill zones of
controlled compaction and moisture content shall have optimum moisture content. The permissible
variation in the OMC is +or-3%.
ii.
As far as possible, the material excavated from the borrow area shall have adequate
moisture content. If additional moisture is required, it shall be added preferably at the borrow area
and only to a limited extent, if required, on the embankment by sprinkling water before placement.
If moisture content is more than required, the material shall be allowed to dry before compaction.
The moisture content shall be uniform throughout the layer of material for which plough, disc
harrowing or other methods of mixing shall be applied. If the moisture content is more than the
required moisture content specified above or if it is not uniformly distributed throughout the layer,
rolling shall be stopped and shall be started again only when the above conditions are satisfied.
1.2.4 COMPACTION
i.
Material shall be placed in layers of specified thickness as shown in the table under
Para 2.6.2(6). the proper moisture content where prescribed shall be uniformly distributed through
out the material, before it is compacted. Compaction shall be done in strips overlapping not less
then 0.30 m. The compacting equipment shall travel in a direction parallel to the axis of the canal.
Turns shall be made carefully to ensure uniform compaction. Each layer of soil placed in the bank
as specified above shall be compacted with 8 to 10 tonnes power rollers or suitable crawler tractor
drawn, heavy sheep foot rollers. The compaction shall have to be uniform over the full width of the
bank. The roller shall be made to travel overt the entire designed width of each layer so that the
soil is uniformly compacted to the required degree and it leaves no visible marks on the surface.
Where flat roller are used, the surface of each layer of compacted materials shall be roughened
with a harrow or thoroughly furrowed/pick-marked as directed before depositing the succeeding
layer of materials and care shall be exercised to avoid the occurrence of horizontal seams.
ii.
In those parts of the structure which are inaccessible to the specified rolling
equipments, or around and in contact with structures and in proximity to structures, where the
rolling equipment is not permitted to operate, compaction shall be accomplished by mechanical or
pneumatic rammers of approved type as directed. Rollers shall not be permitted to operate within
0.60 metre of concrete or masonry structures and the earth fill within this distance shall be tamped
by mechanical or pneumatic rammers. All materials to be so tamped shall be spread in layers.
7.5cms to 10 cms. thick when loose and the moisture content of the material and the amount of
tamping shall be such as to produce a degree of compaction equal to the specified degree of
compaction for rolled fill portion Special care shall be exercised to obtain good contact and bond
with surface of concrete or masonry structures.
iii.
Where canal embankment covers barrels of cross drainage structure first 45 cms. of
the embankment shall be compacted with pneumatic hand tempers in loose layers 7.5 cms. to 10
cms. thick. Further fill shall be compacted by using suitable light rollers to avoid d amage to the
structures, by adjusting the thickness of layers until sufficient height is achieved to permit
compaction by heavy rollers. Density test shall be conducted from time to time on site to ascertain
whether the compaction is attained as specified above. Separate tests shall be conducted for each
layer of hearting and casing zone of embankment at least one field density test shall be taken in
each zone for every 30 mtrs. or less of compacted earth work. A minimum of three density tests
one is hearting one in inner casing and one on outer casing shall be taken per day. IN case the
specified densities are not attained, suitable measures shall be taken by the contractor either by
moisture correction or by removal and relaying of layer or by additional rolling so as to obtain the
specified density which shall be checked again at the same locations. In addition, tests shall also
be carried out at the limits of the embankment and adjacent to filters at the discretion of the
Engineer-in-charge.
Necessary unskilled labour required for collection of samples shall be
provided by the contractor at his cost. However, testing charges shall be borne by the department.
iv.
Atleast three standard proctor tests shall be carried out at regular intervals for hte
material to be used to account for variation in the borrow area material as well as excavated
material. Wherever material from different sources are used for embankment i.e. material from
borrow areas or from excavation, atleast three tests shall be carried out to determine standard
proctor density of each material.
v.
The department might review the design if necessary on examination of density and
other test results and the contractor shall have no claim arising out of such a review and
consequent change if any in the design.
vi.
Where compaction of cohesionless free draining materials such as gravel is required,
the materials shall be deposited in horizontal layers and compacted to the specified relative
density. The excavating and placing, operations shall be such that the material, when compacted,
shall be blended sufficiently to secure the highest practicable unit weight and best stability. Water
shall be added to the materials as may be required to obtain the specified density by method of
compaction being used.
1.2.5 COMPACTION OF ALL-IN FILL
The all-in-fill zone of the bank wherever shown in the drawings or instructed to provide, shall be
formed in layers of uniform thickness and for the full width of zone. The thickness of loose layer
shall not be more than that given in the table in para 7 in clause 2.6.2. When construction of
controlled earth fill zone proceeds the formation of the all-in-fill zone, the slope of the earth fill zone
at the junction shall be stepped if so directed to ensure prop er bonding between the two zones.
All clods and lumps of soil shall be broken to a size not exceeding 7.5 cms. The finer of the
materials available shall be deposited on the inner side and the coarser materials towards the
outside of the embankment. Each layer shall be well compacted by the flat rollers, sheep foot roller
vibratory rollers, crawler tractor or by combination of any of the above as is best suited to the type
of the fill material, as directed. The minimum relative density of the compacted m aterial shall not
be less than 70% of the dry density as determined in laboratory tests in the case of cohesionless
materials. In the case of cohesive materials, the degree of compaction should not be less than
95% of the proctor's density. A minimum number of passes of the compacting equipment would be
prescribed and followed to obtain optimum compaction.
1.2.6 WEATHER CONDITIONS
(a)
Embankment material shall be placed only when weather conditions are satisfactory to permit
accurate control of the moisture content in the embankment material. Before closing the work on
embankment, in any continuous reach prior to monsoon, the top surface shall be graded away from
the canal and rolled with a smooth wheeled roller to facilitate runoff. Prior to resuming wo rk, the top
surface shall be scarified and moistened or allowed to dry as the case may require.
(c)
The contractor shall provide suitable protection works to protect the slopes from erosion due
to rain. No payment whatsoever shall be made for providing such protection work and repairing any
monsoon damages.
1.2.7 INSPECTION AND TESTS
1.2.7.1 GENERAL
(a)
The Engineer-in-charge would exercise thorough check on the quality of fill material delivered
to the embankment and on the degree of compaction. He would further arrange to obtain and
record the data of in-situ properties of the high banks after compaction, for comparison with design
assumptions. To achieve these objectives, a programme of field testing and inspection shall be
planned.
(b)
The scope of testing and inspection is as under:

i)
The quality of materials used for bank work will be checked periodically.
ii)
Checks on the effectiveness of placement and compaction procedures shall be made
by field density tests at prescribed intervals.

iii)
Record tests of compacted fill shall be made at regular intervals
1.2.7.2 BEFORE COMPACTION

(a)
Material delivered to the fill shall be visually examined and their properties estimated by way
of inspection.
Borrow Area
i)
Excavation of borrow areas shall be limited in extent and depth as indicated on plans.
ii)
Estimation of moisture content of materials shall be made by visual examination and
feel.
iii) Sample shall be taken for laboratory analysis in case of soil is of different characteristics.
(d)
These inspection /checks shall be supplemented by sampling the materials at prescribed
intervals and by testing the samples in the laboratory for gradation and moisture content etc.
Embankment
iv.
Moisture content tests shall be carried out in the laboratory while placing the fill materials.
v.
Moisture content shall be controlled by adding water or allowing the soil to dry up to the
extent required.
vi.
It shall be ensured that the methods of dumping, spreading and moisture conditions are such
as will result in reducing segregation and variation of moisture content to a minimum.

1.2.7.3 DURING COMPACTION
Inspection during compaction shall ensure:
iv.
That the layer thickness of the material is as specified.
v.
That the fill is compacted at least upto 90% of Standard Proctor dens ity or as otherwise
specified or 70% relative density as the case may be.

vi.
That no excessive rutting, waving or scaling of the fill occurs during compaction.
1.2.7.4 AFTER COMPACTION

The condition of the fill after compaction shall be observed and recorded particularly with
respect to rutting or waving. However, the properties of materials after compaction shall be
determined primarily by field density tests. Routine tests on samples taken from constructed
embankment shall include, density tests, and moisture content tests. The record tests shall include
grain size distribution Atterburg limits, permeability & consolidation characteristics.
1.2.8 FREQUENCY OF TESTING
(a) Before and after compaction, the sampling and testing of materials shall be do ne at
sufficient frequencies so that effective checks on the full operations are maintained. Testing
frequencies shall be as per standards prescribed by the department. However, the actual
frequencies shall be adjusted to suit to the nature and variability of materials placed and the rate of
fill placement as per the directions of the Engineer-in-charge.
(b) Testing shall be performed at higher frequencies than those specified above during initial
stages of construction in order to establish control and testing techniques. Testing shall be
conducted additionally, as and when required in case of special problems such as variation in the
construction materials, in equipment performance and weather.
(c) In addition, these tests shall be made
iii.
In areas where the degree of compaction is doubtful and
iv.
In areas where embankment operations are concentrated.
(c)
Locations of likely insufficient compaction shall cover the following or any other areas
so determined by the Engineer-in-charge.

vi.
The junction between areas of mechanical tamping and rolled embankment along structures.
vii.
Areas where rollers turn.
viii.
Areas where improper water content has been encountered.
ix.
Areas where dirt clogged rollers have been encountered.
x.
Areas containing materials differing substanti ally from the average.
1.2.9 RECORD AND REPORT

The Contractor shall maintain chronological and location wise record of the source of
materials and the embankment placing operations in order to have a continuous check on the
works. Thus, it should be possible to have a complete description of materials that has gone into in
any portion of the embankment.
1.2.10 PROTECTION
The Contractor shall take all precautions necessary for the protection of all works by
diversion of adjacent streams, surface drainage, rain water etc. Any damage to earth work due to
any reason whatsoever shall be repaired by the contractor at his cost till the work is certified as
completed and taken over by the Department.
WATER BOUND MACADAM SUBBASE / BASE

Note: The Specifications for the item shall be as per Karnataka Roads and Bridges
Specifications (KRBS) and Karnataka Building Specifications (KBS) of Belgaum Circle SR
2013-14. They are reproduced below. The clauses referred in the following specifications refer to
relevant clauses in the Karnataka Roads and Bridges Specifications (KRBS) and Karnataka
Building Specifications (KBS) of Belgaum Circle SR 2013-14, and they also form the part of the
specification of the item.
400.4. SPECIFICATIONS FOR WATER BOUND MACADAM SUBBASE / BASE
400.4.1. Scope
400.4.1.1. This work shall consist of clean, crushed aggregates mechanically interlocked by rolling
and bonding together with screening, binding material wherever necessary and water laid on a
properly prepared subgrade/sub-base / base or existing pavement, as the case may be and
finished in accordance with the requirements of these specifications and in close conformity with
the lines, grades, cross-sections and thickness as per approved plans or as directed by the
engineer.
400.4.1.2. It is, however, not desirable to lay water bound macadam on an existing thin black
topped surface without providing adequate drainage facility for water that would get accumulated
at the interface of existing bituminous surface and water bound macadam.
400.4.2. Materials
400.4.2.1. Course aggregates - Coarse aggregates shall be either crushed or broken stone,
crushed slag, over burnt (Jhama) brick aggregates or any other naturally occurring aggregates
such as Kankar and Laterite of suitable quality. Materials other than crushed or broken stone and
crushed slag shall be used in sub-base courses only. If crushed gravel/ shingle is used, not less
than 90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall have at
least two fractured faces. The aggregates shall conform to the physical requirements set forth in
Table 6. The type and size range of the aggregate shall be specified in the contract or shall be as
specified by the engineer. If the water absorption value of the coarse aggregate is greater than 2
per cent, the soundness test shall be carried out on the material delivered to site as per IS: 2386
(Part 5)- copy enclosed as Annexure.
400.4.2.2. Crushed or broken stone - The crushed or broken stone shall be hard, durable and free
from excess flat, elongated, soft and distinguished particles, dirt and other deleterious material.
Table 6 Physical requirements of coarse aggregates for water bound macadam for sub base
courses
1
2
Test
Test Method
Requirements
* Los Angeles Abrasion value or
IS:2386
40 percent (Maxi.)
*Aggregate impact value
IS:2386 (Part-4) or IS;5640**
30 percent (Maxi.)
Combined Flakiness and Elongation
IS:2386 (Part - 1)
30 percent (Maxi.)
indices (Total)***
*
Aggregate may satisfy requirements of either of the two sets.
**
Aggregates like brick metal, kankar, laterite etc. which get softened in presence of water
shall be tested for Impact value under wet condition in accordance with IS: 5640.
***
The requirement of flakiness index and elongation index shall be enforced only in the case
of crushed broken stone and crushed slag.

400.4.2.3. Crushed slag - Crushed slag shall be made from air-cooled blast furnace slag. It shall
be of angular shape, reasonably uniform in quality and density and generally free from thin,
elongated and soft pieces, dirt or other deleterious materials. The weight of crushed slag shall not
be less than 11.2 KN per m3 and the percentage of glossy material shall not be more than 20. It
should also comply with the following requirements:
(i)
Chemical stability
To comply with requirements of appendix of BS :

1047
(ii)
Sulphur content
Maximum 2 per cent
(iii)
Water absorption
Maximum 10 per cent
400.4.2.4. Over burnt brick aggregates - Brick aggregates shall be made from over burnt bricks or
brick bats and be free from dust and other objectionable and deleterious materials.
400.4.2.5. Grading requirement of coarse aggregates - The coarse aggregates shall conform to
one of the Gradings given in Table 7 as specified, provided; however, the use of Grading No. 1
shall be restricted to sub-base courses only.
Table 7, Grading requirements of coarse aggregates

Gradation
Size range
I.S. Sieve
designation
Percent by weight passing
63 to 45 mm
90 mm
100
63 mm
90-100
53 mm
25-75
45 mm
0-15
22.4 mm
0-5
63 mm
100
53 mm
95-100
45 mm
65-90
22.4 mm
0-10
11.2 mm
0-5
53 to 22.4 mm
Note: The compacted thickness for a layer with Grading 1 shall be 100 mm while for layer with
other gradings i.e., 2 & 3, it shall be 75 mm.
400.4.2.6. Screenings - Screenings to fill voids in the coarse aggregate shall generally consist of
the same material as the coarse aggregate. However, where permitted, predominantly non-plastic
material such as moorum or gravel (other than rounded river borne material) may be used for this
purpose provided liquid limit and plasticity index of such material are below 20 and 6 respectively
and fraction passing 75 micron sieve does not exceed 10 per cent. Screenings shall co nform to the
grading set forth in Table 8. The consolidated details of quantity of screenings required for various
grades of stone aggregates are given in Table 9. The table also gives the quantities of materials
(loose) required for 10 sq.m for sub-base / base compacted thickness of 100/75 mm. The use of
screenings shall be omitted in the case of soft aggregates such as brick metal, Kankar, Laterites,
etc. as they are likely to get crushed to a certain extent under rollers.
1. Table 8 Grading for screenings

Grading
classification
A
Size of
screenings
13.2 mm
11.2 mm
IS Sieve
designation
13.2 mm
11.2 mm
5.6 mm
180 mcn
11.2 mm
5.6 mm
180 mcn
Per cent by weight

passing the IS sieve
100
95-100
15-35
0-10
100
90-100
15-35
Table 9, Approximate quantities of coarse aggregates and screenings required for 100 / 75 mm
compacted thickness of water bound macadam (Wbm) sub -base / base course for 10 sq.m area
Classifica
Size
Compact
Loose
Screenings
tion
Range
thickness
Qty.
Crushable type such

Stone screening
as moorum or
gravel
Grading
For WBM
Grading
classific
sub-base/
classific
ation
base
ation
Loose
and size
course
and
Qty.
(loose
size
Qty)
Grading 2
63mm
to
75 mm
45
0.91
1.07m3
mm
- do -
- do -
to
Type A 0.12 to
13.2
- do -
0.15 m3
0.22
to
0.24 m3
mm
- do -
- do -
Type B 0.20 to
11.2
- do -
- do -
- do -
- do -
0.22 m3
mm
Grading 3
53mm
75 mm
to 22.4
- do -
- do -
0.18 to
0.21 m3
mm
400.4.2.7. Binding material - Binding material to be used for water bound macadam as a filler
material meant for preventing raveling, shall comprise of a suitable material approved by the
engineer having a Plasticity Index (PI) value of less than 6 as determined in accordance with IS :
2720 (Part 5). The quantity of binding material where it is to be used will depend on the type of
screenings. Generally, the quantity required for 75 mm compacted thickness of water bound
macadam will be 0.06 0.09 cu.m / 10sq.m and 0.08 0.10 cu.m/ 10 sq.m for 100 mm compacted
thickness. The above mentioned quantities should be taken as a guide only, for estimation of
quantities for construction etc. Application of binding materials may not be necessary when the
screenings used are of crushable type such as murum or gravel.
400.4. Construction operations
400.4.3.1 Preparation of bases - The surface of the subgrade /sub-base/base to the specified
lines and crossfall (camber) and made free of dust and other extraneous material. Any ruts or soft
yielding places shall be corrected in an approved manner and rolled until firm surface is obtained if
necessary by sprinkling water. Any sub-base /base / surface irregularities, where predominant,
shall be made good by providing appropriate type of profile corrective course (levelling course) to
clause 500.1 of these specifications.
As far as possible, laying water bound macadam course over an existing thick bituminous layer
may be avoided since it will cause problems of internal drainage of the pavement at the interface of
two courses. It is desirable to completely pick out the existing thin bituminous wearing course
where water bound macadam is proposed to be laid over it. However, where the intensity of rain is
low and the interface drainage facility is efficient, water bound macadam can be laid over the
existing thin bituminous surface by cutting 50 mm x 50 mm furrows at an angle of 45 degrees to
the centre line of the pavement at one metre intervals in the existing road. The directions and
depth of furrows shall be such that they provide adequate bondage and also se rve to drain water
to the existing granular base course beneath the existing thin bituminous surface.
400.4 3.2. Inverted choke - If water bound macadam is to be laid directly over the subgrade,
without any other intervening pavement course, a 25 mm course of screenings (Grading B) or
coarse sand shall be spread on the prepared subgrade before application of the aggregates is
taken up. In case of a fine sand or silty or clayey subgrade, it is advisable to lay 100 mm insulating
layer of screening or coarse sand on top of fine grained soil, the gradation of which will depend
upon whether it is intended to act as a drainage layer as well. As a preferred alternative to
inverted to act as a drainage layer as well. As a preferred alternative to inverted choke, appropriate
geosynthetics performing functions of separation and drainage may be used over the prepared
subgrade as directed by the engineer. Section 700 shall be applicable for use of geosynthetics.
400.4.3.3. Spreading coarse aggregates - The coarse aggregates shall be spread uniformly and
evenly upon the prepared subgrade/sub-base/base to proper profile by using templates placed
across the road about 6 m apart, in such quantities that the thickness of each compacted layer is
not more than 100 mm for Grading 1 and 75 mm for Grading 2 and 3, as specified in clause
400.4.2.5. Wherever possible, approved mechanical devices such as aggregate spreader shall be
used to spread the aggregates uniformly so as to minimise the need for manual rectification
afterwards. Aggregates placed at locations which are inaccessible to the spreading equipment,
may be spread in one or more layers by any approved means so as to achieve the specified
results.
The spreading shall be done from stockpiles along the side of the roadway o r directly from
vehicles. No segregation of large or fine aggregates shall be allowed and the coarse aggregate as
spread shall be of uniform gradation with no pockets of fine material.
The surface of the aggregates spread shall be carefully checked with te mplates and all high or low
spots remedied by removing or adding aggregates as may be required. The surface shall be
checked frequently with a straight edge while spreading and rolling so as to ensure a finished
surface as per approved drawings.
The coarse aggregates shall not normally be spread more than 3 days in advance of the
subsequent construction operations.
400.4.3.4. Rolling - Immediately following the spreading of the coarse aggregate, rolling shall be
started with three wheeled power rollers of 80 to 100 KN capacity or tandem or vibratory rollers of
80 to 100 KN static weight. Type of roller to be used shall be approved by the engineer based on
trial run. Except on superelevated portions where the rolling shall proceed from inner edge to the
outer, rolling shall begin from the edges gradually progressing towards the centre. .The
edge/edges shall be compacted with roller running forward and backward. Roller shall then move
inward parallel to the centre line of the road, in successive passes uniformly lapping preceding
tracks by at least one half width.
Rolling shall be discontinued when the aggregates are partially compacted with sufficient void
space in them to permit application of screenings. However, where screenings are not to be
applied, as in the case of crushed aggregates like brick metal, laterite and kankar, compaction
shall be continued until the aggregates are thoroughly keyed. During rolling, slight sprinkling of
water may be done, if necessary. Rolling shall not be done when the subgrade is soft or yielding or
when it causes a wave-like motion in the subgrade or sub-base course.
The rolled surface shall be checked transversely and longitudinally, with templates and any
irregularities corrected by loosening the surface, adding or removing necessary amount of
aggregates and re-rolling until the entire surface conforms to desired crossfall (camber) and grade.
In no case shall the use of screenings be permitted to make up depressions.
Material which gets crushed excessively during compaction o r becomes segregated shall be
removed and replaced with suitable aggregates. It shall be ensured that shoulders are built up
simultaneously along with water bound macadam courses as per clause 400.7.4.1.
400.4.3.5. Application of screenings - After the coarse aggregate has been rolled to clause
400.4.3.4. Screenings to completely fill the interstices shall be applied gradually over the surface.
These shall not be damp or wet at the time of application. Dry rolling shall be done be damp or wet
at the time of application. Dry rolling shall be done while the screenings are being spread so that
vibrations of the roller cause them to settle into the voids of the coarse aggregates.
The screenings shall not be dumped in piles but be spread uniformly in successive thin layers
either by the spreading motions of hand shovels or by mechanical spreaders, or directly from tipper
with suitable grit spreading arrangement. Tipper operating for spreading the screenings shall be so
driven as not to disturb the coarse aggregate. The screenings shall be applied at a slow and
uniform rate (in three or more applications) so as to ensure filling of all voids. This shall be
accompanied by dry rolling and becoming with mechanical brooms, hand -brooms or both. In no
case shall the screenings be applied so fast and thick as to form cakes or ridges on the surface in
such a manner as would prevent filling of voids or prevent the direct bearing of the roller on the
coarse aggregate. These operations shall continue until no more screenings can be forced into the
voids of the coarse aggregate. The spreading, rolling, and brooming of screenings shall be carried
out in only such lengths of the road which could be completed within one days operation.
400.4.3.6. Sprinkling of water and grouting - After the screenings have been applied, the
surface shall be copiously sprinkled with water, swept and rolled. Hand brooms shall be used to
sweep the wet screenings into voids and to distribute them evenly. The sprinkling, sweeping and
rolling operation shall be continued, with additional screenings applied as necessary until the
coarse aggregate has been thoroughly keyed, well-bonded and firmly set in its full depth and a
grout has been formed of screenings. Care shall be taken to see that the base or s ubgrade does
not get damaged due to the addition of excessive quantities of water during construction.
In case of lime treated soil sub-base, construction of water bound macadam on top of it can cause
excessive water to flow down to the lime treated sub -base before it has picked up enough strength
(is still green) and thus cause damage to the sub -base layer. The laying of water bound
macadam layer in such cases shall be done after the sub -base attains adequate strength, as
directed by the engineer.
400.4.3.7. Application of binding material - After the application of screenings in accordance
with clauses 400.4.3.5. And 400.4.3.6. The binding material where it is required to be used (clause
400.4.2.7.) shall be applied successively in two or more thin layers at a slow and uniform rate.
After each application, the surface shall be copiously sprinkled with water, the resulting slurry
swept in with hand brooms, or mechanical brooms to fill the voids properly, and rolled during which
water shall be applied to the wheels of the rollers if necessary to wash down the binding material
sticking to them. These operations shall continue until the resulting slurry after filling of voids,
forms a wave ahead of the wheels of the moving roller.
400.4.3.8. Setting and drying - After the final compaction of water bound macadam course, the
pavement shall be allowed to dry overnight. Next morning hungry spots shall be filled with
screenings or binding material as directed, lightly sprinkled with water if necessary and rolled. No
traffic shall be allowed on the road until the macadam has set. The engineer shall have the
discretion to stop hauling traffic from using the completed water bound macadam course, if in his
opinion it would cause excessive damage to the surface. The compacted water bound macadam
course should be allowed to completely dry and set before the next pavement course is laid over it.
400.4.4. Surface finish and quality control work
400.4.4.1. The surface finish of construction shall conform to the requirements of clause 900.2.
400.4.4.2. Control on the quality of materials and works shall be exercised by the engineer in
accordance with section 900.
400.4.4.3. The water bound macadam work shall not be carried out when the atmospheric
temperature is less than 0 deg. C. in the shade.
400.4.4.4. Reconstruction of defective macadam - The finished surface of water bound

macadam shall conform to the tolerance of surface regularity as prescribed in clause 900.2.
However, where the surface irregularity of the course excee ds the tolerances or where the course
is otherwise defective due to subgrade soil mixing with the aggregates, the course to its full
thickness shall be scarified over the affected area, reshaped with added material or removed and
replaced with fresh material as applicable and recompacted. In no case shall depressions be filled
up with screenings or binding material.
400.4.5. Arrangement for traffic - During the period of construction, the arrangement of traffic
shall be done as per clause 100.12.
400.4.6. Measurements for payment - Water bound macadam shall be measured as finished
work in position in cubic metres.
400.4.7. Rate - The contract unit rate for water bound macadam sub -base/base course shall be
payable in full compensation for all components liste d in clause 400.1.8 (I) to (v) including
arrangement of water used in the work as approved by the engineer.
PRIME COAT
Specifications (KRBS) and Karnataka Building Specifications (KBS) of Belgaum Circle SR 201112. They are reproduced below. The clauses referred in the following specifications refer to
500.2. SPECIFICATIONS FOR PRIME COAT OVER GRANULAR BASE.
500.2.1. Scope - This work shall consist of the application of a single coat of low viscosity liquid
bituminous material to a porous granular surface preparatory to the superimposition of bituminous
treatment or mix.
500.2.2. Materials
500.2.2.1. Primer - The choice of a bituminous primer shall depend upon the porosity
characteristics of the surface to be primed as classified in IRC: 16, (Annexure 500-A.2) these are:
(i) Surfaces of low porosity, such as wet mix macadam and water bound macadam, (ii) Surfaces of
medium porosity; such as cement stabilised soil base, (iii) Surfaces of high porosity; such as a
gravel base.
500.2.2.2. Primer viscosity - The type and viscosity of the primer shall comply with the
requirements of IS 8887, as sampled and tested for bituminous primer in accordance with these
standards. Guidance on viscosity and rate of spray is given in Table 1.
Table1. Viscosity requirement and quantity of liquid bituminous primer
Kinematic viscosity of Primer at
Quantity of Liquid Bituminous
Type of surface
600C (Centistokes)
Material per 10 Sq.cm. (kg)
Low porosity
30-60
6 to 9
Medium porosity
70-140
9 to 12
High porosity
250-500
12 to 15
500.2.2.3. Choice of primer - The primer shall be bitumen emulsion, complying with IS 8887 of a
type and grade as specified in the contract or as directed by the engineer. The use of medium
curing cutback as per IS 217 (Annexure 500- A.3) shall be restricted only for sites at sub-zero
temperatures or for emergency applications as directed by engineer.
500.2.3. Weather and seasonal limitations - Bituminous primer shall not be applied to a wet surface
(see 500.2.4.2) or during a dust storm or when the weather is foggy, rainy or windy or when the
temperature in the shade is less than 100C. Surfaces, which are to receive emulsion primer, should
be damp, but no free or standing water shall be present.
500.2.4. Construction
500.2.4.1. Equipment - The primer distributor shall be a self-propelled or towed bitumen pressure
sprayer equipped for spraying the material uniformly at specified rates and temperatures. Hand
spraying of small areas, inaccessible to the distributor, or in narrow strips shall be sprayed with a
pressure hand sprayer, or as directed by the engineer.
500.2.4.2. Preparation of road surface - The surface to be primed shall be prepared in accordance
with clauses 500.1.8 and 900.2 as appropriate. Immediately prior to applying the primer the
surface shall be carefully swept clean of dust and loose particles, care being taken not to disturb
the interlocked aggregate. This is best achieved when the surface layer is slightly moist (lightly
sprayed with water and the surface allowed to dry) and the surface should be kept moist until the
primer is applied.
500.2.4.3. Application of bituminous primer- The viscosity and rate of application of the primer shall
be as specified in the contract or as determined by site trials carried out as directed by the
engineer. Where a geosynthetic is proposed for use, the requirements of clauses 700.4.3. and
704.4.4. shall apply. The bituminous primer shall be sprayed uniformly in accordance with clause
500.1. The method for application of the primer will depend on the type of equipment to be used,
size of nozzles, pressure at the spray bar and speed of forward movement. The contractor shall
demonstrate at a spraying trial, that the equipment and method to be used is capable of producing
a uniform spray, within the tolerances specified.
500.2.4.4. Curing of primer and opening to traffic - A primed surface shall be allowed to cure for at
least 24 hours or such other period as is found to be necessary to allow all the volatiles to
evaporate before any subsequent surface treatment or mix is laid. Any unabsorbed primer shall
first be blotted with an application of sand, using the minimum quantity possible. A primed surface
shall not be opened to traffic other than the necessary to lay the next course. A very thin layer of
clean sand may be applied to the surface of the primer, to prevent the primer pricking up under the
wheels of the paver and the trucks delivering bituminous materials to the paver.
500.2.4.5. Tack coat - Over the primed surface, a tack coat should be applied in accordance with
clause 500.3.
500.2.5. Quality control of work - For control of the quality of materials supplied and the works
carried out, the relevant provisions of section 900 shall apply.
500.2.6. Arrangements for traffic - During construction operations, arrangements for traffic shall be
made in accordance with the provisions of clause 100.12.
500.2.7. Measurement for payment - Prime coat shall be measured in terms of surface area of
application in square metres
500.2.8. Rate - The contract unit rate for prime coat with adjustments as described in clause
500.2.7. shall be payment in full for carrying out the required operations including full compensation
for all components listed in clause 401.8(I) to (v) and as applicable to the work specified in these
specifications. Payment shall be made on the basis of the provision of prime coat at an application
rate of 0.6 kg per square metre, with adjustment, plus or minus, for the variation between this
amount and the actual amount approved by the engineer after the preliminary trials referred to in
clause 500.2.4.3.
TACK COAT
500.3. SPECIFICATIONS FOR TACK COAT (UV-NOV 2000)
500.3.1 Scope - This work shall consist of the application of a single coat of low viscosity liq uid
bituminous material to an existing bituminous road surface preparatory to the superimposition of a
bituminous mix, when specified in the contract or instructed by the engineer.
500.3.2. Materials
500.3.2.1. Binder - The binder used for tack coat shall be bitumen emulsion complying with IS 8887
(Annexure 500-A.4) of a type and grade as specified in the contract or as directed by the engineer.
The use of cutback bitumen as per IS 217 (Annexure 500-A.3) shall be restricted only for sites at
sub-zero temperatures or for emergency applications as directed by the engineer.
500.3.3. Weather and seasonal limitations - Bituminous material shall not be applied to a wet
surface or during a dust storm or when the weather is foggy, rainy or windy or when the
temperature in the shade is less than 100 C. Where the tack coat consists of emulsion, the surface
shall be slightly damp, but not wet. Where the tack coat is of cutback bitumen, the surface shall be
dry.
500.3.4. Construction
500.3.4.1. Equipment - The tack coat distributor shall be a self propelled or towed bitumen
pressure sprayer, equipped for spraying the material uniformly at a specified rate. Hand spraying
of small areas, inaccessible to the distributor, or in narrow strips, shall be sprayed with a pre ssure
hand sprayer, or directed by the engineer.
500.3.4.2. Preparation of base - The surface on which the tack coat is to be applied shall be clean
and free from dust, dirt, and any extraneous material, and be otherwise prepared in accordance
with the requirements of clauses 500.1.8 and 900.2 as appropriate. Immediately before the
application of the tack coat, the surface shall be swept clean with a mechanical broom, and highpressure air jet, or by other means as directed by the engineer.
500.3.4.3. Application of tack coat - The application of tack coat shall be at the rate specified in the
contract, and shall be applied uniformly. If rate of application of tack coat is not specified in the
contract then it shall be at the rate specified in Table 2. The normal range of spraying temperature
for a bituminous emulsion shall be 200C to 700C and for a cutback, 500C to 800C if RC-70/MC-70 is
used. Where a geosynthetic is proposed for use, the provisions of section 700 shall apply. The
method of application of the tack coat will depend on the type of equipment to be used, size of
nozzles, pressure at the spray bar, and speed of forward movement.
The contractor shall
demonstrate at a spraying trial, that the equipment and method to be used is capable of producing
a uniform spray, within the tolerances specified.
Where the material to receive an overlay is a freshly laid bituminous layer that has not been
subjected to traffic, or contaminated by dust, a tack coat is not mandatory where the overlay is
completed within two days.
Table 2. Rate of application of tack coat
Sl.
No
Type of Surface
Quantity of liquid bituminous

material in Kg.per sq.m.area
i.
Normal bituminous surfaces
0.20 to 0.25
ii.
Dry and hungry bituminous surfaces
0.25 to 0.30
iii.
Granular surfaces treated with primer
0.25 to 0.30
iv.
Non bituminous surfaces

a) Granular base (not primed)
0.35 to 0.40
b) Cement concrete pavement
0.30 to 0.35
500.3.4.4. Curing of tack coat - The tack coat shall be left to cure until all the volatiles have
evaporated before any subsequent construction is started. No plant or vehicles shall be allowed on
the tack coat other than those essential for the construction.
500.3.5. Quality control of work - For control of the quality of materials supplied and the works
carried out, the relevant provisions of section 900 shall apply.
500.3.6. Arrangements for traffic - During the period of construction, arrangements for traffic shall
be made in accordance with the provisions of clause 100.12.
500.3.7. Measurement for payment - Tack coat shall be measured in terms of surface area of
application in square metres.
500.3.8. Rate - The contract unit rate for tack coat shall be payment in full for carrying out the
required operations including for all components listed in clause 400.1.8 (I) to (v) and as applicable
to the work specified in these specifications. The rate shall cover the provision of tack coat at 0.2
kg per square metre, with the provision that the variance in actual quantity of bitumen used wi ll be
assessed and the payment adjusted accordingly.
CLOSE- GRADED PREMIX SURFACING

Building Specifications (KBS) of Belgaum Circle SR 2011 -12, and they also form the part of the
500.12. SPECIFICATIONS FOR CLOSE- GRADED PREMIX SURFACING/MIXED SEAL
SURFACING.
500.12.1. Scope
500.12.1.1. This work shall consist of the preparation, laying and compaction of a close -graded
premix surfacing material of 20 mm thickness; composed of graded aggregates premixed with a
bituminous binder on a previously prepared surface, in accordance with the requirements of these
specifications, to serve as a wearing course.
500.12.1.2. Close graded premix surfacing shall be of Type A or Type Bitumen as specified in the
contract documents.
500.12.2. Materials
500.12.2.1. Binder - The provisions of clause 500.11.1.2.1. shall apply.
500.12.2.2. Coarse aggregates - The provisions of clause 500.11.1.2.2. shall apply.
500.12.2.3. Fine aggregates - The fine aggregates shall consist of crushed rock quarry sands,
natural gravel/sand or a mixture of both. These shall be clean, hard, durable, un-coated, mineral
particles, dry and free from injurious, soft or flaky particles and organic or deleterious substances.
500.12.2.4. Aggregate gradation - The coarse and fine aggregates shall be so graded or combined
as to conform to one or the other grading shown in Table 26, as specified in the contract.
Table 26 Aggregate gradation
IS: Sieve Designation
(mm)
Cumulative per cent by weight of total aggregate

passing
Type A
Type B
13.2 mm
100
11.2 mm
100
88 - 100
5.6 mm
52 - 88
31 52
2.8 mm
14 38
5 25
0.090 mm
0-5
0-5
500.12.2.5. Proportioning of materials - The total quantity of aggregates used for Type A or
Bitumen close-graded premix surfacing shall be 0.27 cubic metres per 10 square metre area. The
quantity of binder used for premixing in terms of straight-run bitumen shall be 22.0 kg and 19.0 kg
per 10 square metre area of Type A and Type Bitumen surfacing respectively.
500.12.3. Construction operations - The provisions of clause 500.11.1.3.1 through 500.11.1.3.5
shall apply.
500.12.4. Opening to traffic - Traffic may be allowed after completion of the final rolling when the
mix has cooled down to the surrounding temperature. Excessive traffic speeds should not be
permitted.
500.12.5. Surface finish and quality control of work - The surface finish of construction shall
conform to the requirements of clause 900.2. for control on the quality of materials supplied and the
works carried out, the relevant provisions of section 900 shall apply.
500.12.6. Arrangements for traffic - During the period of construction, arrangements for traffic shall
be in accordance with the provisions of clause 100.12.
500.12.7. Measurements for payment - Close-graded premix surfacing, Type A or B shall be
measured as finished work, for the area specified to be covered, in square metres at a specified
thickness. The area will be the net area covered, and all allowances for wastage and cutting of
joints shall be deemed to be included in the rate.
500.12.8. Rate - The contract unit rate for close-graded premix surfacing, Type A or bitumen shall
be payment in full for carrying out the required operations including full compensation for all
components listed in clause 500.1.8.8.2 (i) to (xi).
SHOULDERS
400. 7. SPECIFICATIONS FOR SHOULDERS, ISLANDS AND MEDIAN
400.7.1. Scope - The work shall consist of constructing shoulder (hard/paved/earthen with brick or
stone block edging) on either side of the pavement, median in the road dividing the carriageway
into separate lanes and islands for channelising the traffic at junctions in accordance with the
requirements of these specifications and in conformity with the lines, grades and cross-sections
shown on the drawings or as directed by the engineer.
400.7.2. Materials - Shoulder on either side of the road may be of selected earth/granular
material/paved conforming to the requirements of clause 300.5/400.1 and the median may be of
selected earth conforming to the requirements of clause 300.5.
Median/Traffic islands shall be raised and kerbed at the perimeter and the enclosed area filled with
earth and suitably covered with grass/turf/shrubs as per clause 300.7 and / or paved as per clause
400.9.3.4. or 400.9.3.5.
Paved shoulders shall consist of sub-base, base and surfacing courses, as shown in the drawings
and materials for the same shall conform to relevant specifications of the corresponding items.
Where paved or hard shoulders are not provided, the pavement shall be provided with brick/stone
block edgings as shown in the drawings. The bricks shall conform to clause 1000.3 of these
specifications. Stone blocks shall conform to clause 1000.4 of these spe cifications and shall be of
size 225 mm x 110 mm x 75 mm.
400.7.3. Size of shoulders/median/islands - Shoulder (earthen /hard/ paved)/ median /traffic
island dimensions shall be as shown on the drawings or as directed by the engineer.
400.7.4. Construction operations
400.7.4.1. Shoulder - The sequence of operations shall be such that the construction of paved
shoulder is done in layers each matching the thickness of adjoining pavement layer. Only after a
layer of pavement and corresponding layers in paved and earth shoulder portion have been laid
and compacted, the construction of next layer of pavement and shoulder shall be taken up.
Where the materials in adjacent layers are different, these shall be laid together and the pavement
layer shall be compacted first. The corresponding layer in paved shoulder portion shall be
compacted thereafter, which shall be followed by compaction of earth shoulder layer. The adjacent
layers having same material shall be laid and compacted together.
In all cases where paved shoulders have to be provided along side of existing carriageway, the
existing shoulders shall be excavated in full width and to the required depth as per clause
300.1.3.7. Under no circumstances, box cutting shall be done for construction of shoulders.
Compaction requirement of earthen shoulder be as per Table 300-2. In the case of bituminous
courses, work on shoulder (earthen / hard/ paved), shall start only after the pavement course has
been laid and compacted.
During all stages of shoulder (earthen/hard/paved) construction, the required crossfall shall be
maintained to drain off surface water.
Regardless of the method of laying, all shoulder construction material shall be placed directly on
the shoulder. Any spilled material dragged on to the pavement surface shall be immediately
removed, without damage to the pavement, and the area so affected thoroughly cleaned.
400.7.4.2. Median and islands - Median and Islands shall be constructed in a manner similar to
shoulder up to the road level. Thereafter the median and Islands, if raised, shall be raised at least
300 mm by using kerb stones of approved material and dimensions and suitably finished and
painted as directed by the engineer. If not raised, the median and islands shall be filled with local
earth or granular material or any other approved material and compacted by plate
compactor/power rammer. The confined area after filling with earth shall be turfed with grass or
planted with shrubs and in case of granular fill it can be finished with tiles/slabs as d irected by the
engineer.
400.7.4.3. Brick/stone block edging - The bricks/stone blocks shall be laid on edge, with the
length parallel to the transverse direction or the road. They shall be laid on a bed of 25 mm sand,
set carefully, rolled into position by a light roller and made flush with the finished level of the
pavement.
400.7.5. Surface finish and quality control of works - The surface finish of construction shall
conform to the requirements of clause 900.2. Control on the quality of materials and wo rks shall be
exercised by the engineer in accordance with section 900.
400.7.6. Measurements for payment - Shoulder (earthen/hard/paved), island and median
construction shall be measured as finished work in position as below:
(i) For excavation in cu. m. (ii) For earthwork/granular fill in cu. m. (iii) For sub -base, base,
surfacing courses in units as for respective items. (iv) For kerb in running metres. (v) For turfing
and tile / slab finish in sq. m. (vi) For brick / stone block edging in sq. m.
400.7.7. Rate - The contract unit rate for shoulder (hard/paved/earthen with brick or stone block
edging), island and median construction shall be payment in full for carrying out the required
operations including full compensation for all components listed in clause 400.1.8. (i) to (v) as
applicable. The rate for brick / stone block edging shall include the cost of sand cushion.
GUARD STONES
SPECIFICATIONS FOR PROVIDING GUARD STONES
General - The work comprises of supplying and fixing boundary stones as per designs and
Specifications and at locations indicated in the drawings or as directed by the engineer.
Measurements for payment - The measurement shall be made in number of guard stones fixed at
site.
Rate - The contract unit rate for guard stones shall be payment in full compensation for furnishing
all labour, materials, tools, equipment for preparing, supplying and fixing and all other incidental
costs necessary to complete the work to these specifications.
ALLUMINIUM DOORS AND WINDOWS

SPECIFICATIONS FOR PROVIDING ALLUMINIUM DOORS AND WINDOWS
General
Aluminium Doors, Windows and ventilators shall conform to IS:733, IS:1948, IS:1949, and IS:1081
shall be as per drawings issued by the Engineer. The contractor shall submit for KBJNL Engineer
In-Charges approval the shop drawings covering all dimension details of fabrication, construction
and installation. After approval of shop drawings the contractor shall submit one or more samples
of the fabricated item of each type for the KBJNL Engineer- In-Charges approval before mass
fabrication.
Material
Aluminium Alloy Extruded Sections
Aluminium alloy used in the manufacture of doors, windows and ventilators shall conform to IS
designation HE 9-WP of IS:733. The sectional properties of extruded sections shall be as given in
IS:733 or as manufactured by approved manufacturer such as Indal/Hindalco or equivalent. The
section shall be uniform in appearance, free from die lines and handling marks.
Glass panes
Glass panes shall be clear float glass / Obscure glass panes with 6 mm thick. Glass panes shall
also be free from flaws, specks or bubbles. All panes shall have properly squared corners and
straight edges. The sizes of glass panes for use shall be in accordance with Table I of IS:1948.
Screws, Fasteners
Screws and fasteners shall be of aluminium alloy or brass oxidised. Screw thread of machine
screws used in the manufacture of aluminium doors, windows and ventilators shall conform to the
requirement of IS:4218. Other threads shall be permissible if agreed to between the purchaser and
vendor.
Standard sizes, tolerances and designation
Size
Overall dimension of windows, doors, ventilators, shall be derived from masonry opening minus an
allowance of 1.25 cm clearance on all sides for the purpose of fitting. However, type and overall
sizes shall be in accordance with IS:1948.
Tolerances
The sizes for doors, windows or ventilator frames shall not vary by more than 1.5 mm from
overall size as specified in drawing.
Designation
Doors, windows and ventilators shall be designated by symbol denoting their width, type and height
in succession as per IS : 1948.
Sectional dimensions and weights

Sectional dimensions and weights per unit length of the section s hall conform to design drawing.
However, uses of specific sections for specified units as per manufacturers standard may be used
with prior approval of MMCI/HPCL Engineer-In-Charge.
Fabrication
Frames
Frames shall be square and flat, the corners of the frame being fabricated to a true right angle.
Both the fixed and opening frames shall be constructed of sections which have been cut to length,
mitred and screwed at the corners.
Sub Frames
Sub frame where recommended, shall match the main frame section. The corners of the sub frame
shall be at right angle. All sides of the sub frame adjacent to the masonry/concrete shall be
properly sealed to avoid any water entry inside.
Shutters
All hinges, pivots, etc. shall be provided and fabricated in acco rdance with provisions given in
IS:1948. However, reference standards and drawings are also to be read in conjunction with the IS
Code.
Doors, Windows and Ventilators
The outer fixed frame shall be of section AL-FX8. The shutter frame shall be of either hollow
sections AL-HFX5 and AL-HFX6 or of solid sections AL-FX5 and AL-FX6. All other attachments
and accessories shall be provided in accordance with IS:1948. Alternatively, selection of sections
from Indal/ Hindalco or equivalent manufacturers specification duly approved by KBJNL EngineerIn-Charge is also recommended.
Finishing
The aluminium sections to be used shall be properly buffed, cleaned by using mild acids and water.
Then the same shall be anodised to have average anodic film thickness of 25 microns. To prevent
damage to metal surfaces, a protective tape shall be applied after manufacturing and same shall
be removed at site only after completion of rough trades.
Handling, Storage
The extruded section or the fabricated windows/doors shall be pro tected against abrasions, water
stains and any other damages caused by acids or alkaline chemicals. Cold metal shall preferably
be placed in a dry storage area avoiding contact between it and other metals. Use of wood face
shelving racks is recommended. It shall also be kept away from caustics, nitrates, phosphates,
acids and cement.
Installation
The fabricated and assembled windows or door units (without glazing) shall be fixed in masonry
opening properly plastered and finished. Straightness and diagonal dimensions of the opening
shall not have tolerance more than 2 mm. Aluminium screws or bolts are to be used with teak
wood block on the back of the sections to avoid dents and other mechanical damages during
tightening of screws/bolts. All gaps between the aluminium section and the masonry surface must
be sealed with gun grade polymer based sealant viz., silicone compound, polysulphide compound.
Cement mortar grout or cement mortar finishing of gaps after installation of aluminium units shall
strictly be restricted to protect the surface treatments given to the aluminium like anodising,
precoating etc. All glass panes shall be fixed only after major activities are over in the area.
Hardware
Necessary hardware for aluminium doors and windows shall be compatible with the basic material
and shall be provided along with the doors, windows and ventilators. Minimum hardware to be
provided.
NOTES
1. All the fittings shall be anodised aluminium (finish compatible with original frame) type unless
otherwise specified.
2. Single leaf door shutters and ventilator shutters of more than 0.80 m width shall be provided
with one extra hinge.
3. Where height of window shutter and door leaf exceeds 1.2 m and 2.15 m respectively one
extra
4. hinge shall be provided for every additional height of 0.5 m or part thereof and length of top
bolt shall be increased by the height of the shutter/leaf above 2.15 m from floor level.
5. In double leaf shutters of doors, two tower bolts shall be fixed to the first shutter at top and
bottom and one to the closing shutter at the top.
6. All hardware shall conform to the applicable Indian Standards.
Measurements for payment - The measurement shall be made in number of aluminium doors and
windows fixed at site.
Rate - The contract unit rate for aluminium doors and windows shall be payment in full
compensation for furnishing all labour, materials, tools, equipment for preparing, supplying and
fixing and all other incidental costs necessary to complete the work to these specifications.
SCADA SYSTEM
SPECIFICATIONS FOR PROVIDING SCADA SYSTEM
General - The work comprises of supplying and fixing SCADA system as per designs and
Major components that a SCADA /DMS implementation would include are given as under.
However, the final scope of work will be finalized b y the utilities as per their requirements in the
relevant RFP document.
1. Main Control Centre for SCADA/DMS
2. DR Centre for SCADA/DMS
3. SCADA/Information Storage & Retrieval (ISR) Functions
DMS Functions
Power Flow
Network Connectivity Analysis
Voltage VAR Control
Fault Management and System Restoration (FMSR)
Feeder Reconfiguration, Loss Minimisation, Load Balancing, etc
Operation Monitor
Outage Management
Load Shed & Restoration
State Estimator
4. SCADA/DMS system to supervise Distribution Network

5. SCADA/DMS/ Dispatcher training simulator (DTS)
6. RTUs at all Primary Sub-Stations (DSS) & FRTUs at RMUs, etc.
7. MFTs at Feeder, RMUs
8. Communication
FO Ring/MAR/VPN, Broadband, leased line, etc., connecting all S/S RTUs to Main & DR
Centre
CDMA/GPRS/DLC based communication, etc. for communicating with FRTUs/FPIs with
SS-RTUs (Data Concentrator)/control centres

9.
Protocols for communication
IEC 60870-5-104 RTU, FRTUs, FPI to control centres
MODBUS/IEC62056 MFTs to RTUs/FRTUs
ICCP (TASE.2) between main /DR centre/SLDC
Support /compliance to IEC61850 for RTU/CC
Rate - The contract unit rate for guard stones shall be payment in full compensation for furnishing
all labour, materials, tools, equipment for preparing, supplying and fixing and all other incidental
costs necessary to complete the work to these specifications.
GALVALUME SHEETS
SPECIFICATIONS FOR PROVIDING GALVALUME SHEETS
General - The work comprises of supplying and fixing of Galvalume sheets as per design and
1.
The roofing system should be designed to withstand the wind load (As per IS 875 Part-3).
The design should also comply with any other relevant IS Codes.
2.
The steel sheet shall be 3-0 (914MM) width (tolerance +/- 2 mm) which shall be curved and
molded at site using mechanical press and dies to the desired curves and shape to form 2 -0 (605
MM) wide interlocking panels. These panels shall be erected in position and their seams shall be
interlocked and pressed to close the seam forming a water tight jo int. Minor colour
chipping/scratching should be rectified by applying Epoxy lacquer. Necessary arrangement
including the supply for the installation of fasteners at the end
3.
The installation of sheet should be done by mechanized methods. The agency has to
mobilize required No. of Hydra for transportation of sheets and cranes for the erection of seamed
sheets.
4.
Adequate precaution shall be taken by the agency during the installation process for the
safety of their workers. Safety belts, helmets and other safety equipments for the execution of job
must be used, wherever required. Works in height panel installation process shall not be carried
out in case of wind velocity at site location is above 22 K.M. per hour.
5.
The design and drawing for the roof must be submitted to KBJNL for approval before the
installation of the sheets at site. The agency shall make provisions for hangers and clamps etc. for
providing light fixtures in the roof, wherever required.
6.
The material of Galvalume sheets shall have the following specifications:
Material:
Imported Galvalume sheets with following contents:
55% Aluminum s
43.5% Zinc
1.5% Silicon
Alloy Coated High Tensile steel.
Tensile Strength
Grade 350 MPa. with details as recommended in ASTM 792M.
Coating
Coating Mass of AZ-150 of the shade to be decided by Hafed.
(150 gms /m2-both sides).
Organic Paint Coating System
Regular polymer Coat
20 micron on top coat over

5 micron of primer.
7 micron of back coat (grey colour)
Thickness:
Basic material the thickness (BMT)=1.00 mm
Total Coated thickness (TCT) = 1.09 mm
Testing Of Material
The sheets shall be tested before use to check the following:
Basic Metal Thickness & Coating Mass.
Tensile Strength
Contents of Aluminium, Zinc and Silicon from the laboratory to be decided by Hafed.
Test charges if any, shall be borne by the agency.

Standards: The agency shall be ISO certified and shall follow
International Standard for Galvalume sheet roofing.
Fixtures The fixtures like fasteners, turbo ventilators (Aluminum)
of size 24 with capacity of 2200 CFM at 30 interval and translucent 2 mm poly
carbonate sheet of size 2 X 14 at 30 interval to be installed for each
compartment.
Rate - The contract unit rate for Galvalume sheets shall be payment in full compensation for
furnishing all labour, materials, tools, equipment for preparing, supplying and fixing and all other
incidental costs necessary to complete the work to these specifications.
SECTION - 10
SCHEDULE - B
SCHEDULE B
Name of work:
Design, Supply, Installation, Testing and Commissioning of Lift Irrigation systems of 4 th B Lift
Pumps coupled to HT Motors with SCADA system (7 working pumps designed for peak discharge
standby) 220 KV Terminal bay and 220 KV /6.6 KV SC line on DC towers, Electrical Sub -Station
norms, O&M staff and watchman quarters at Jack well cum Pump House site, protective fencing to
Jack well and Electrical Sub-Station, Asphalt approach road from Masabinal - Ingleshwar road to
Jack well cum Pump House along Intake canal, Supply of spare parts, tools, operation and
maintenance of system for Five years after successful commissioning on lump sum Turn -Key
basis.
Item
Description of item
No.
Amount in
figure Rs
in crores
1.
Design, Supply, Installation, Testing and

Commissioning of Lift Irrigation systems
of 4th B Lift work in Bijapur District
under Mulwad LIS UKP Stage III
Works off taking from Km - 18.95 of
Basavana Bagewadi Canal comprising
of Intake Canal, Fore bay, Jack well
Cum Pump House, Trash racks, Stop log
gates, Embedded parts, Mono rail
arrangement for operation of gates, VT
Pumps coupled to HT Motors with
SCADA system (7 working pumps
designed for peak discharge with 1
standby provision) EOT Crane, MS
Manifold, necessary transformers ( 1
working + 1 standby) 220 KV Terminal
Amount in words
2.
bay and 220 KV /6.6 KV SC line on DC

towers, Electrical Sub-Station with
Mulsifyre system, comprising of
Electrical
Panel,
Soft
Starters,
Capacitors, Valves, HT Switch Gear, HT
Metering Equipment for KPTCL
metering, Supply and fixing of Control
and Relay Panels, HT Cabling, Earthing
with necessary arrangements to receive
power supply from KPTCL, requisite
number of MS Rising Main with
necessary Air valves, Zero velocity
valves, NRVs, Thrust Blocks, Surge
protection measures, Delivery Chamber,
Structures along Intake Canal and Rising
main if any, Construction of 220 KV / 6.6
KV SC line on DC towers including
Terminal Bays as per KPTCL norms,
O&M staff and watchman quarters at
Jack well cum Pump House site,
protective fencing to Jack well and
Electrical Sub-Station, Asphalt approach
road from Masabinal - Ingleshwar road
to Jack well cum Pump House along
Intake canal, Supply of spare parts,
tools, operation and maintenance of
system for Five years after successful
commissioning on lump sum Turn-Key
basis..
Rs
Operation and maintenance of the
scheme for a period 5 years after
successful
commissioning
including
manpower and spare parts as per

schedule of prices (spares) (A) VT pump
sets and accessories
Rs
Supply of spare parts required after

completion O & M of 5 years as per the
list enclosed
Rs
4.
Prices for supply of a set of tools/special

tools suitable for all electric/mechanical
including EOT crane on lump sum
turnkey basis.
Rs
Total Amount in figure and words
Note
1. Tenderer to submit detailed BOQ with price breakup in support of lumpsum price quoted above
Price include necessary fire extinguisher, first aid box, danger boards. Shock treatment charts one
set and fire buckets as required.
2.
The technical specifications given under section 7, 8 & 9 for electrical, mechanical and civil
works may be generally followed. However all works shall be carried out as per relevant IS codes.
Indian standards
Inspectorate
of electrical
code
and
rule
and
as
directed
by
Engineer-in-charge.
3.
The amount should be quoted both in words and in figures.
4. The break up cost of various components of the lift irrigation scheme given by bidder along
with schedule 'B' shall be subject to approval or such changes as deemed appropriate by KBJNL
for the purpose of intermediate payments.
5.
The lump-sum provision quoted by the bidder shall be exclusive of Excise d uty component
and exemption for Excise duty to be obtained by the bidder directly.

6.
The O & M cost quoted will be paid to the contractor in equal 5 installments after completion
of each year of operation and maintenance.
SCHEDULE OF PRICE BREAK UP IN SUPPORT OF LUMSUMP QUOTED AS

PER SCHEDULE-B
1. CIVIL WORKS.
No.
Component of the work
Amount Amount in words

in lakhs
1.
Construction of Intake Canal of length

700.0 m (approximately) including
structures.
2.
Design and Construction of fore bay,

Jack well cum pump house for housing
7 working + 1 standby pumps, including
electromechanical components,
miscellaneous works such as stores,
watchman quarters, fencing,. approach
road etc with electrical substation
providing Mulsifyre system.
3.
Construction of rising main for a length

of 1140 m ( Approximately)
4.
Construction of Delivery chamber.
5.
Construction of 220 KV Terminal Bay at

existing 220 KV KPTCL Sub station
6.
Construction of 220 KV SC
Transmission line on DC Towers for a
length of 14 Km ( Approximately)
7.
Spares , Tools and Plants
2.
MECHANICAL WORKS: -
Mechanical works
Ex-
CST/KST
Packing
Entry
Any other Cost
Erection
works
(Purchase
forwarding
taxes
taxes
on price per
price
tax)
etc.,
such
per
per
W.C.T per set
unit
set
set
1
Pumps and motors
Valves
valve/NR
(Sluice
valve/air
valve)
Mechanical supports
disconnecting joints
Manifold and piping
suction and delivery
(inside pump house)
Rising
mains dia
length amount
Priming
pump/
booster
pump
cooling arrangement
Freight
Insurance
of
as one
+WCT
Price
Quantity
Amount
11
12
set
10
3.
ELECTRICAL WORKS INSIDE PUMP HOUSE: -
Electrical
works Ex-
inside
pump works
house
Entry
Any other Cost
Erection
taxes
taxes
on price per
etc.,
such
per
per
W.C.T per set
unit
set
set
price
1
1)a)HT panel
b)Power
factor
capacitors
c)Soft starter
2.HT
cable
(incoming)
3.HT cable (pump
feeder)
4.battery
charger
with set of battery

5.Earthing
6..Pump
lighting
Freight
house
CST/KST
Packing
(Purchase
forwarding
Insurance
tax)
of
as one
+WCT
Price
Quantity
Amount
11
12
set
10
Electrical
works Ex-
inside
pump works
house
Entry
Any other Cost
Erection
taxes
taxes
on price per
etc.,
such
per
per
W.C.T per set
unit
set
set
price
1
7.DC
distributor
board
8.remote
control
panel
9.
Miscellaneous
electrical works
10.
Freight
Temperature
scanner panel
CST/KST
Packing
(Purchase
forwarding
Insurance
tax)
of
as one
+WCT
Price
Quantity
Amount
11
12
set
10
SCHEDULE OF PRICES (SPARES)

(A) VT PUMPSETS AND ACCESSORIES TO BE PROVIDED AFTER THE O&M PERIOD
SL.NO.
PARTICULARS
1.
Impellors two no.
2.
Line shaft bearing (two sets ) for pumps provided capacity.
3.
Thrust and guide bearings(two numbers) for pump & motor
4.
Packing (five no.)
5.
Gland packing (five set)
Shaft Sleeve 4 , Int.Shaft Sleeve 22 , Impeller Shaft

Sleeve 4 , Distance Sleeve 2 , Thordon Bearing 24 , O
Ring 2 Sets, Head Shaft 4 , Impeller Shaft 2 , Deflector
2 , Thrust Bearing 2 , Murf Coupling 12 , Split Rings
12 , Nuts & Bolts 2 Sets .
Motor Bearing Driving End & Non Driving End 2 sets ,

Sealed Transformer Oil 6000 ltrs , Breather with Assembly
2 sets , 6.6 KV Vaccum Bottles 6 , 6.6 KV vcb trip coil
with assembly & closing coil with assembly 16 sets , SF6
Gas Cylinders 2 , 220 KV SF6 gas breaker trip coil &
closing coil with assembly 4 sets , 220 KV Isolator
Operating Rod with Blades 2 sets, 6.6 KV Capacitors for
Motor , for bus , for Auxiliary Load 1 set each , fuse units
for above Capacitor Ratings 16 each , 6.6 KV pt Fuse
Units 4 , 6.6 KV HT 3core Power Cable 100 meters , 6.6
KV 3 Core Termination Kits 6
SIGNATURE
NAME
DESIGNATION
DATE
COMPANY SEAL
UNIT
TOTAL
PRICE
PRICE
MAINTENANCE TOOLS AND PLANT FOR SUBSTATIONS EQUIPMENTS
1 Sets
TELESCOPIC LADDER ALUMINIUM 6 MTR. HEIGHT
- 1 No.
RING SPANNER SET
- 1 SET
TUBE SPANNER SET
- 1 SET
PIPE WRENCH 24
- 2 Nos.
PIPE WRENCH 18
- 2 Nos.
HYDRAULIC CRIMPING TOOL UP TO 1000 SQM.
- 1 SET
RUBBER HAND GLOVES (15 KV TESTED)
- 3 PAIRS
HAND TORCH 5 CELLS AND 3 CELLS
- 2 SET EACH
INSULATED CUTTING PLIER 12 & 8 SIZE
- 3 Nos.
10
LINE LIVE TESTER
- 2 Nos.
11
SCREW DRIVER 18 & 12
- 3 Nos. EACH
12
HAMMER 8LBS.
- 2 Nos.
13
HAMMER 2 LB
- 2 Nos.
14. CHAIR PULLEY BLOCK 5 TON
- 1 No.
15
HYDRAULIC JACK 5 TON
- 4 Nos.
16
PIPE DERRICK
- 1 SET
17
ALLEN KEYS
- 1 SET
18
BOX SPANNER
- 1 SET
19
INSULATION MEGGER DIGITAL 2.5 KV/ 5 KV
- 1 No.
20
INSULATION MEGGER 500 V
- 1 No.
21
MULTIMETER ELECTOROMECHANICAL
- 1 No.
22. MULTIMETER ELECTRONIC
- 1 No.
23
RPM METER
1 No
24
FLOW METER
1 No
25
NOISE METER
1 No
26
TEMPREATURE GUN
1 No
27
SF 6 GAS LEAKAGE DETECTOR
1 No
28
SF 6 GAS FILLING EQUIPMENT
1 No
29
OIL TESTING KIT
1 No
30
TRANSFORMER OIL HAND PUMP WITH PIPE
1 SET
31
DC VOLTMETER + 2 V 2V , 0-150 V , AC VOLTMETER 0-500 V
1 SET
32
VIBRATION METER
1 No
33
STEEL TABLE , S TYPE CHAIRS , STOOL , BENCH
1 SET
LIST OF TOOLS EOT CRANE

1.
Portable screw jack mechanical type of suitable cap for withdrawal of wheels
- 2 Nos.
2.
Spanner
- 1 Set
3.
Adjustable spanners
- 1 Set
4.
Screw driver 8 & 6
- 1 Each
5.
Cutting pliers
- 1 No.
6.
Spirit level
- 1 No.
7.
Grease gum
- 1 No.
8.
Hammer 5 lb, 2lb, 1lb
- 1 Each
9.
Oil can
- 1 No.
10.
Pipe Wrench Set 12 /18/24/36
- 1 Each
SECTION - 11
FORMS OF SECURITIES
FORM OF SECURITIES
REVISED MODEL FORM OF BANK GUARANTEE BOND
In consideration of the Krishna Bhagya Jala Nigam Ltd., (herein after called the KBJNL) having
agreed to exempt__________________________(herein after called the said contractor(s) from
the demand, under the terms and conditions of an Agreement said dated ____________________
made between ________________
(herein after called the said agreement) of security deposit for the due fulfillment by the said
contractor(s) of the terms and conditions contained in the said agreement on productions of a Bank
Guarantee for Rs._______________________
(Rupees___________________________________________________ only)
1.
We ________________________________(indicate the name of the bank) (Herein after

referred to as the Bank the request of contractor(s) do hereby undertake to pay to the
KBJNL an amount not exceeding Rs.____________________ against any loss or damage
caused to or suffered or would be caused to or suffered by the KBJNL by reason for any
breach by the said contractor(s) of any of any of the terms or conditions contained in the
said agreement.
2.
We _______________________________(indicate the name of bank) do hereby

undertake to pay the amounts due and payable under this guarantee without any de mur
merely on a demand from the KBJNL, stating that the amount claimed is due by way of
loss or damage caused to or would be caused to or suffered by the KBJNL by reason
breach by the said contractor(s) of the agreement or by reason of the contractors failure to
perform the said agreement. Any such demand made on the bank shall be conclusive as
regards the amount due and payable by the bank under this guarantee. However, our
liability under this guarantee shall be restricted to an amount not exceeding
Rs._________________(Rupees_____________only).
3.
We undertake a pay of KBJNL any money so demanded not withstanding any disputes
raised by the contractor(s) supplier(s) in any suit or proceeding pending before any court
or tribunal. Stating there to out liability under this present being absolute and unequivocal.
4.
We ______________________________(indicate the name of bank) further agree that the

guarantee herein contained shall remain in full force and effect during the period that
would be taken for the performance of the said agreement and that it shall continue to be
enforceable till the dues of the KBJNL under or by virtue or said agreement have been fully
paid and its claims satisfied or discharged for till _______________________office
of KBJNL, certifies out by the said contractors(s) and accordingly discharge this guarantee.
Unless a demand or claims under this guarantee is made on us in writing on or before
_________________we shall be discharged from all liability under this guarantee

thereafter.
5.
We _______________________(indicate the name of the work) further agree with the

KBJNL, shall have the fullest liberty without our consent and without affecting in any
manner our obligation hereunder to vary any of the terms and conditions of the said
agreement or to extend time of performance by the said contractor(s) from time to time or
to postpone for any time from time to time any powers exercisable by the KBJNL against
the said contractor(s) and for bear or enforce any any of the terms and conditions relating
to the said agreement and we shall not be relieved from our liability by the reasons of any
such variation /or extension being granted to the said contractor(s) or any forbearance act
of omission on the part of the KBJNL, or any indulgence by the KBJNL to the said
contractor(s) by any such matter or thing whatever which under the law relating to sureties
would , but for this provision have effect of so relieving us.
6.
This guarantee will not be discharged due to the change in the constitution of the bank or
the contractor(s) / supplier(s).
7.
We __________________________________(indicate the name of the bank) lastly

undertake not to revoke this guarantee during the currency except with previous consent of
the KBJNL in writing.
Dated
________________________
day
of
__________________________to
_________________________________(indicate the name of the bank).
PROFORMA
BANK GUARANTEE EARNEST MONEY DEPOSIT
In accordance with the provisions and conditions of Bid Notice for the work of
_____________________________________________________________
Sri.___________________________________(name & Address of the Contractor) shall
deposit with the Executive Engineer,... Circle....................
bank
guarantee to guarantee his proper and faithful Performance under the said contract an amount of
(Amount
of
Guarantee)
(in
words)
.
We, the ___________________________________________________(Bank or Financial
Institution) as requested by the contractor, agree unconditionally and irrevocably to guarantee as
primary obligatory and as surety merely, the payment to the
Executive Engineer, ................ Circle, . on his demand without what so ever right of
objection on our part and without his first claim to the Executive Engineer,
Division, . for recovery of the whole or part of the E.M.D
from the contractor under the contract.
We further agree to change add to or other modifications of the forms of the contract or of
works to be performed there under or of any of the contract document which may be made between
the Executive Engineer, _________________________________ Circle,
.. and the contractor shall in any way release us from any liability under this guarantee
and we here by waive notice of any such change, addition or modification.
THE CONDITIONS of this obligation are:(1)
If after Bid opening the Bidder withdraws or modifies his Bid during the period of bid
validity specified in the Form of Bid.
(2)
If the Bidder having been notified of the acceptance of his bid by the Department during the
period of validity.
(a)
fails or refuses to execute the Form of Contract in accordance with the Instructions to
Bidders, if required; or
(b)
fails or refuses to furnish the balance EMD and additional performance Security in
accordance with the instructions of Bidders.
We undertake to pay to the Department up to the above amount upon receipt of his
first written-demand, without the Department having to substantiate his demand,
provided that in his demand the Department will note the amount claimed by him is
due to him owning to the occurrence of one or both of the two Conditions, specifying
the occurred condition or conditions.
This Guarantee will remain in force up to and including the date * *
after the dead line for submission of Bids as such deadline is stated in the Instructions
to Bids or as it may be extended by the Department, notice of which extension(s) to
the Bank is hereby waived. Any demand in respect of this Guarantee should reach the
Bank not later than the above date.
Yours truly,
Signature & Seal

(Name of the Bank)
WITNESS .
SEAL ...
.. (Signature, Name and

Address)
.
*
The Bidders should insert the amount of the EMD in words and figures denominated in
Indian Rupee. This figure should be the same as shown in the NIT.
**
6 months from the deadline date for submission of Bid [As specified in NIT].
PROFORMA
BANK GUARANTEE FOR BALANCE E.M.D.
__________________________________________ (name & Address of Department)

____________________________________
WHEREAS______________________________________________________
_______________________ _ (name and address of Contractor) (hereinafter called "the
Contractor") has undertaken, in pursuance of Contract No._________________
dated :
_________________ to execute the work of __________________
[name of work]
AND WHEREAS it has been stipulated by you in the said Contract that the Contractor shall
furnish you with a Bank Guarantee by a Schedule bank for the sum specified therein as balance
EMD I EMD for compliance with his obligations in accordance with the Contract; AND WHEREAS
we have agreed to give the Contractor such a Bank Guarantee; NOW THEREFORE we hereby
affirm that we are the Guarantor and responsible to you, on
behalf of the Contractor, up to a
total of _____________[amount of guarantee] ________________ [in words], such sum being

payable and we undertake to pay you, upon your first written demand and without cavil or
argument, any sum or sums within the limits of _____________ [amount of guarantee] as aforesaid
without your needing to prove or to show grounds or reasons for your demand for the sum
specified therein.
We hereby waive the necessity of your demanding the said debt from the Contractor before
presenting us with the demand.
We further agree that no change or addition to or other modification of the terms of the
Contract or of the Works to be performed there under or of any of the contract documents which
may be made between you and the Contractor shall in any way release us from any liability under
this guarantee, and we hereby waive notice of any such change , addition or modification.
This guarantee shall be valid upto ..i.e., until 28 days from the date of expiry of the
Defects Liability period.
Signature & seal of the

Guarantor_____________________
Name of Bank______________________________
Address ___________________________________
Date_____________________________________
PROFORMA
BANK GUARANTEE FOR ADDITIONAL FURTHER SECURITY
______________________________________________________
(name
&
Address
of
Department)____________________________________
WHEREAS______________________________________________________
_______________________ _ (name and address of Contractor) (hereinafter called "the
Contractor") has undertaken, in pursuance of Contract No._________________
dated :
_________________ to execute [name of contract and brief description of works] (herein after
called the contractor);
AND WHEREAS it has been stipulated by you in the said Contract that the Contractor shall
furnish you with a Bank Guarantee by a Schedule bank for the sum specified therein as Additional
further security bank guarantee for compliance with his obligations in accordance with the Contract;
AND WHEREAS we have agreed to give the Contractor such a Bank Guarantee; NOW
THEREFORE we hereby affirm that we are the Guarantor and responsible to you, on
behalf of
the Contractor, up to a total of Rs. _________________[amount of guarantee] ________________

[in words], such sum being payable and we undertake to pay you, upon your first written demand
and without cavil or argument, any sum or sums within the limits of _____________ [amount of
guarantee] as aforesaid without your needing to prove or to show grounds or reasons for your
demand for the sum specified therein.
We hereby waive the necessity of your demanding the said debt from the Contractor before
presenting us with the demand.
Contract or of the Works to be performed there under or of any of the contract documents which
may be made between you and the Contractor shall in any way release us from any liability under
this guarantee, and we hereby waive notice of any such change, addition or modification.
This guarantee shall be valid upto and until 28 days from the date of completion.
Signature & seal of the Guarantor______________

Name of Bank_____________________________
Address___________________________________
Date____________________________________
PROFORMA
BANK GUARANTEE FOR MOBILISATION ADVANCE
To
___________________________
___________________________
___________________________
(Name & Address of Contract Authority)
Sub :- ________________________________________ (name of the work)
Gentlemen :
In accord ance with the provisio ns of the Co nditions of Co ntract, Mobilization advance
of the above-mentio ned Contract, ___________________
[name
and
address
of
Contractor] (hereinafte r called "the Co ntractor") shall deposit with________________ [name o f

Departme nt] a b ank g uarantee to g uarantee his p roper and faithful perfo rmance under the said
Contract fo r an amo unt o f Rs. _______________
[amo unt o f guarantee] _____________
(in wo rds).
We, the _______________ [bank], as instructed by the Contractor, agree unconditionally
and irrevocably to guarantee as primary obligator and not as surely merely, the payment to
___________________ [name of Department] on his first demand without whatsoever right o f
objection on our p art and without his first claim to the Co ntractor, for the amount no t exceeding
________________(amount of guarantee)______________________
______________________________________ (in words).
Contract or of the Works to be performed there under or of any of the contractor documents which
may be made between ________________________ [name of Departme nt] and the Contracto r,
shall in any way release us fro m any liability under this guarantee, and we hereby waive no tice
of any such change, addition or modification.
This g uarantee shall remain valid - and in full e ffect fro m the date of the advance
payment under the Contract until ___________________
[name of Departme nt] receives
full repayment o f the same amo unt fro m the Contracto r.

Yours truly,
Signature & seal : ________________________
Name of Bank / Financial Institution :
________________________
Address : ________________________
Date :_________________________
ANNEXURE-I (B)
FORM OF SOLVENCY CERTIFICATE BY BANKS
I, ___________________________________________________Managing Director /
Manger/ General Manger / Agent of ______________________________ Bank Limited do hereby
certify that a____________________________________ [here the Names and addresses of the
contractor] to be solvent to the extent of Rs.__________
[Rupees__________________________________________________
__________________________] as disclosed by the information and reco rd which are available
with the aforesaid bank.
For the ______________________________Bank
Date :
Place:
Signature of Bank Manager
[Authorised to Sign]
JOINT VENTURE AGREEMENT

THIS AGREEMENT made and entered into on the
day of -------------------- by and
between : -------------------------------------- (hereinafter referred to as -------------------------- which
expression shall mean and include its successors and assigns) having its ------------------------- of the
ONE PART,
And
--------------------------------------------, (hereinafter called as ---------------------------------------- which
expression shall mean and include its successors and assigns) having its Registered Office at -------------------------------------------------------------------------------- of the OTHER PART
------------------------- and ----------------------------------- unless specifically referred to shall hereinafter
be referred to individually as a "Party" and collectively as the "Parties" where the context requires.
WHEREAS
1) Krishna Bhagya Jala Nigam Limited (hereinafter referred to as the "Employer") has invited
tender for --------------------------------------------------------------------------------------------------------------------------------------- (hereinafter referred to as the project)
::
2) ------------------------------------------------- is renowned EPC Contractor in
3)
------------------------------------------------ is renowned Pump Manufacturer.
4) The parties desire to form an unincorporated joint venture and jointly submit a proposal for the
Project on the mutually exclusive consortium basis under the name "---------------------------------------------------------------------------- JOINT VENTURE" (hereinafter referred to as the "Joint Venture") and
to execute the contract if awarded to the Joint Venture.
5) Accordingly the parties have agreed to certain commitments and to regulate their rights in
relation to pre-qualification, preparation and submission of bid for the execution of the project,
parties agree in the manner appearing here below :
NOW IN CONSIDERATION OF THE MUTUAL BENEFITS AND UNDERTAKIN -------------------------------------------------------- OF THE PARTIES IT IS HEREBY AGREED AS FOLLOWS CLAUSE I - Purpose of this Agreement
The Parties hereby constitute an un-incorporated Joint Venture for the sole and exclusive purpose
of jointly preparing bid for the Project and in the event that the Contract is awarded to the Joint
Venture, the parties hereto shall jointly execute the contract, under the name of "---------------------------------------------------------------- JOINT VENTURE".
CLAUSE II - Joint Venture Agreement
In the event the Joint Venture is successful in bidding procedure of the project, the parti es hereto
shall enter into a detailed Joint Venture agreement (hereinafter referred to as the "Joint Venture
Agreement") which shall set out in detail the contractual relationship between the parties for the
performance of the contract, before contract agreement signing.
CLAUSE III - Exclusively
None of the parties shall either directly or indirectly submit the pre -qualification and the bid or
perform the works of the Contract or part thereof separately or in combination with third parties
outside this agreement.
CLAUSE IV - Details of Participation
::
The details of scope of work, roles and responsibilities of the parties to execute the Contract shall
be generally as follows :----------------------------------------will be responsible for ---------------------------------------.
-------------------------------------- will be responsible for ------------------------------------------------------.
CLAUSE V - Responsibility
Notwithstanding anything contained in any other Clause of this Agreement, each of the Parties
shall be jointly and severally liable to the Employer for the execution of the project pursuant to the
Contract.
CLAUSE VI - Leader
------------------------- shall be the Leader of the Joint Venture. In the pre -award stage the Leader will
deal with all matters in connection with the bid in consultation with ------------------------------------ .
The Leader shall negotiate or conclude any matter of a binding nature on behalf of the Joint
Venture in respect of any matter affecting the intere st of the Joint Venture or in respect of any
matter affecting ---------------------------------------------------------------------s interest with its participation
or prior consent.
CLAUSE VII - Executive Committee
For the proper management, administration and execution of the Contract an Executive Committee
comprising of the representatives of both the parties is to be formed upon award of the contract or
part thereof to the Joint Venture by the Employer.
CLAUSE VIII - Assignment
Neither party hereto shall assign any of its rights and obligations arising out of or in connection with
this Agreement and/or the Contract to any other company, firm or person without the prior written
consent of the other party.
CLAUSE IX - Duration of the agreement
This Agreement shall be effective for a period of fifteen months from the last date for submission of
proposal with an option to the parties to extend this agreement further as may be decided mutually.
CLAUSE X - Confidentiality
(a)
All information acquired by any Party hereto from the other shall be treated as confidential by
the recipient and shall not be used other than for purpose contemplated by this Agreement unless
prior written consent of the Party had been obtained or such information: (i)
(ii)
Is or has become public knowledge either than by breach of the contract of this clause or
Is in the possession of the recipient with the full right to disclose prior to receiving it from the
respective party, or
(iii)
Is independently received by the recipient from a third party having the full right to disclose.
(b)
The parties shall at all times use its best endeavor to keep confidential (and ensure that its
respective employees and agents shall keep continuously) any confidential information which it or
they may acquire in relation to the Employer's business affairs of the other Party to this Agreement
or of any of its subsidiaries and shall not use or disclose such information except with the consent
of the other party. For the purpose of this clause, the expression "Party" shal l include the
subsidiary companies of any Party and any other company controlled by such other Party and the
employees or agents of that party and of such subsidiary or controlled companies.
(c)
The provisions of this clause shall survive the termination of this Agreement.
CLAUSE XI - Pre-Award Cost

Each party shall bear the cost and expenses incurred by itself in connection with preparation and
submission of bid, negotiation, etc. to the extent of its share of work in the Contract except for the
cost of Bid bonds, Performance Guarantee Bonds, Advance Guarantee Bonds, etc. which will be
borne by the parties according to their Work Sharing Ratio as mentioned in Clause IV of this
Agreement and no expense shall be charged by one Party to the other in any case as m ay be
expressly agreed in advance between the Parties.
CLAUSE XII - Disputes, Applicable Law
In case of any dispute or difference arising between the Parties, which the Parties are unable to
resolve amicably shall be resolved as per the provisions of Arbitration and Conciliation Act, 1996
by one or more Arbitrators appointed in accordance with the Act. The place of arbitration shall be
XXXX and the award shall be final and binding on the parties.
The Courts in Pune shall have exclusive jurisdiction in the matter.

CLAUSE XIV - Effectiveness
This Agreement shall become effective upon the signing of this Agreement by the Parties hereto.
CLAUSE XV - Amendment of Agreement
Any subsequent amendments modification alterations or change in the provisions of this
Agreement for the performance of the Contract shall be made in writing and duly executed by the
Parties. Such amendments shall be an integral part of this Agreement.
The parties mutually covenant that each has the authority and capacity to enter into this Agreement
and will faithfully and diligently carry out its obligations herein in the interests of the Joint Venture
and do its best to secure the Joint Venture's qualification for the Project and success in the Bid.
IN THE WITNESS WHEREOF, the Parties hereto set their respective hands as appearing below
on the day and year above written.
Signed by
For and on behalf of
Signed by
In the presence of
1.
1.
2.
2.
TIE-UP AGREEMENT
THIS AGREEMENT made and entered into on the

by and between :
day of -----------------------------
--------------------------------------------------, (hereinafter referred to as --------------------------------- which

expression shall mean and include its successors and assigns) having its -----------------------------------------------------------------------------------of the ONE PART,
And
---------------------------------------------------, (hereinafter called as -----------------------------------which

expression shall mean and include its successors and assigns) having its Registered Office at -------------------------------------------------------------------------------- of the OTHER PART
XXX and XXX unless specifically referred to shall hereinafter be referred to individually as a
"Party" and collectively as the "Parties" where the context requires.
WHEREAS
1) Krishna Bhagya Jala Nigam Limited (hereinafter referred to as the "Employer") has invited
tender for --------------------------------------------------------------------------------------------------------------------------------------- (hereinafter referred to as the project)
2) -------------------------------------------------------------------- is renowned EPC Contractor in

3) --------------------------------------------------------------------- is renowned Pump Manufacturer.
4) The EPC Contractor desire to have a tie-up with pump manufacturer and submit a proposal for
the Project under the name ----------------------------------------------------------------
(hereinafter
referred to as the bidder) and to execute the contract if awarded to the bidder.
5) Accordingly the parties have agreed to certain commitments and to regulate their rights in
relation to pre-qualification, preparation and submission of bid for the execution of the project,
parties agree in the manner appearing here below :
NOW IN CONSIDERATION OF THE MUTUAL BENEFITS AND UNDERTAKING ------------------------------------------------------ OF THE PARTIES IT IS HEREBY AGREED AS FOLLOWS CLAUSE I - Purpose of this Agreement
The bidder hereby constitute a Tie-Up for the sole and exclusive purpose of supply of pumps for
the Project and in the event that the Contract is awarded to the bidder, the bidder should execute
the contract, under the name of "-------------------------------------------------------------------------------- ".
CLAUSE II Tie-Up Agreement
In the event the Tie-Up is successful in bidding procedure of the project, the parties hereto s hall
enter into a detailed Tie-Up agreement (hereinafter referred to as the "Tie -Up Agreement") which
shall set out in detail the contractual relationship between the parties for the performance of the
contract, before contract agreement signing.
CLAUSE III - Exclusively
None of the parties shall either directly or indirectly submit the pre -qualification and the bid or
perform the works of the Contract or part thereof separately or in combination with third parties
outside this agreement.
CLAUSE IV - Details of Participation
The details of scope of work, roles and responsibilities of the parties to execute the Contract shall
be generally as follows :-----------------------------------------------will be responsible for executing the complete project.
---------------------------------------------------- will be responsible for supply of pumps and connected
electro-mechanical
equipments.
CLAUSE V - Responsibility
Notwithstanding anything contained in any other Clause of this Agreement, the bidder shall be
liable to the Employer for the execution of the project pursuant to the Contract.
CLAUSE VI - Assignment
Neither party hereto shall assign any of its rights and obligations arising out of or in connection with
this Agreement and/or the Contract to any other company, firm or person without the prior written
consent of the other party.
CLAUSE VII- Duration of the agreement
This Agreement shall be effective for a period of completion of work from the last date of
submission of proposal with an option to the parties to extend this agreement further as may be
decided mutually.
CLAUSE VIII - Confidentiality
(a)
All information acquired by the bidder hereto from the other shall be treated as confidential
by the recipient and shall not be used other than for purpose contemplated by this Agreement
unless prior written consent of the Party had been obtained or such information: (i)
Is or has become public knowledge either than by breach of the contract of this clause or
(ii)
Is in the possession of the recipient with the full right to disclose prior to receiving it from the
respective party, or
(iii)
Is independently received by the recipient from a third party having the full right to disclose.
(b)
The parties shall at all times use its best endeavor to keep confidential (and ensure that its
respective employees and agents shall keep continuously) any confidential information which it or
they may acquire in relation to the Employer's business affairs of the other Party to this Agreement
or of any of its subsidiaries and shall not use or disclose such information except with the consent
of the other party. For the purpose of this clause, the expression "Party" shall include the
subsidiary companies of any Party and any other company controlled by such other Party and the
employees or agents of that party and of such subsidiary or controlled companies.
(c)
The provisions of this clause shall survive the termination of this Agreement.
CLAUSE IX - Disputes, Applicable Law

In case of any dispute or difference arising between the Parties, shall be resolved amongst the
parties itself. KBJNL in no way responsible for any disputes that may arise and to solve the issues.
CLAUSE X - Effectiveness
This Agreement shall become effective upon the signing of this Agreement by the bidder hereto.
CLAUSE XI - Amendment of Agreement
Any subsequent amendments modification alterations or change in the provisions of this
Agreement for the performance of the Contract shall be made in writing and duly executed by the
Parties. Such amendments shall be an integral part of this Agreement
The parties mutually covenant that each has the authority and capacity to enter into this Agreement
and will faithfully and diligently carry out its obligations herein in the interests of the Tie -Up and do
its best to secure the Tie-Up's qualification for the Project and success in the Bid.
IN THE WITNESS WHEREOF, the Parties hereto set their respective hands as appearing below
on the day and year above written.
Signed by
Signed by
In the presence of
1.
1.
2.
2.
SECTION - 12
DATA SHEETS
DATA SHEETS D13

TECHNICAL PARTICULARS OF VERTICAL TURBINE PUMPS OFFERED
I
EQUIPMENT AND SERVICES OFFERED
1.
Pump as per specification
Yes/ No
2.
Motor or the prime mover
Yes/ No
3.
Necessary instruments, test connections
Yes/ No
4.
Foundation bolts
Yes/ No
5.
Base plate
Yes/ No
6.
Companion flanges
Yes/ No
7.
Suction strainer
Yes/ No
8.
Prefabricating tank with Accessories
Yes/ No
9.
Spare Parts
Yes/ No
10.
Maintenance & Special erection tools
Yes/ No
11.
Pump set Erection and commissioning
Yes/ No
12.
Operation & Maintenance
Yes/ No
II
PERFORMANCE GUARANTEE
1.
Manufactures name
2.
Type of pump offered
3.
Number of pumps offered
4.
Maximum Capacity of each pumps
5.
Rated capacity of each pump
6.
Maximum head in meter
7.
Duty point parameters
a.
Specified head without losses
b.
Friction loss ion Column assembly
c.
Discharge head loss
d.
Suction loss any other applicable head
Loss component
e.
Bowl assembly head
f.
Bowl input power in KW
g.
Line shaft loss in KW
h.
Thrust bearing loss in KW & any other
Applicable power loss component.

i.
Power input to pump in KW.
j.
Minimum guaranteed pump efficiency at
Specified duty point.

k.
Minimum guaranteed motor efficiency at

Specified duty point
l.
Power input to motor in KW at specified
Duty point (For evaluation purpose)

8.
Range of head at which the pump can work
9.
Pump losses at rated capacity
10.
Discharge head at rated capacity.
11.
Maximum head developed by pump.
12.
Shut off head.
13.
Pump speed in RPM
14.
Critical speed
15.
Efficiency at rated capacity
16.
Range/head curve enclosed
17.
Power requirement at rated capacity in KW
18.
Transmission & thrust bearing losses in KW
19.
Bearing cooling water required in cubic meter/hr
20.
Quality & pressure in KG/ cubic Cm
21.
Number of stages
22.
Type of impeller
23.
Dimension of impeller
24.
Weight of impeller
25.
Clearance between impeller and bowl

Size of the suction bed
26.
Whether intake strainer provided
27.
Type of coupling offered
28.
Type of drive transmission
29.
Type of stuffing box sealing offered.
30.
Location of thrust load on thrust bearing
31.
Hydraulic thrust load on thrust loading
i)
At duty point
ii)
At shut-off condition
32.
Type of pump lubrication
33.
Non reversible rachet provided
34.
Diameter of the water column in mm
35.
Size of suction bell in mm
36.
Discharge pie in mm
37.
Flange drilling standard.
38.
Height at which discharge elbow is provided.
39.
Whether dimension drg. furnished
40.
Peak value of the vibration of the pump motor assembly
41.
Peak value of the noise level of the assembly
42.
Vertical load particulars
a.
Wt., of pump only in (Dry) Kgs
b.
Wt., of water column in Kgs
c.
Wt of pump with water in Kgs
d.
Wt of motor in Kgs
e.
Wt of pump motor assembly (Dry) in Kgs
f.
Vertical Dynamic load of pump assembly with applicable tolerant
g.
Total Vertical dn. Load of pump & motor assembly with
applicable tolerence
h.
Unbalanced dyn. Force at rated head & rated discharge
43.
Point & direction of hydraulic thrust ( to be furnished in

the form of sketch)
44.
Hydraulic thrust load.
a.
At duty point
b.
At shut-off condition
45.
Place where the performance test of the equipment carried out
III
DELIVERY PIPE & MANHOLD
A)
Manifold details
i)
Overall size (L X B)
ii)
Type of steal used
iii)
Type of construction
iv)
Test pressure and duration
v)
Type of coating used to reduce corrosion and also friction
vi)
Type of coating on the outside
vii)
Type of welding
vii)
Type of weld tests proposed to be carried out.
B)
BEFORE MANIFOLD
1. No of runs
2.
Inner diameter
3.
Thickness of plate
4.
Type of steel used
5.
Design velocity
6.
Test pressure & duration
7.
Type of coating used to reduce corrosion & also friction
8.
9.
Type of welding
10.
Type of weld tests proposed to be carried out
11.
Total length
C)
AFTER MANIFOLD
1.
No of runs
2.
Inner diameter
3.
Thickness of plate
4.
Type of steel used
5.
Design velocity
6.
Test pressure & duration
7.
Type of coating used to reduce corrosion & also friction
8.
9.
Type of welding
10.
Type of weld tests proposed to be carried out
IV)
Materials of construction
1.
Base plate
2.
Discharge elbow/discharge head
3.
Column pipe
4.
Suction bell
5.
Impeller bowl
6.
Discharge casing
7.
Impeller
8.
Impeller wearing rings
9.
Head Shaft
10.
Line Shaft
11.
Impeller Shaft
12.
Shaft couplings
13.
Line bearings
14.
Suction strainer
15.
Stuffing Box
16.
Shaft sleeves
V)
MATERIALS OF CONSTRUCTION
1.
Inspection and test certificates as per specification will be
furnished
VI)
DIMENSIONS
VII)
OTHER DETAILS
Maximum duration for which pump can be operated under
a. Shut off condition
b.Failure of bearing lubrication and cooling system

SEAL
SIGNATURE:
DESIGNATION:
COMPANY:
DATE:
TECHNICAL PARTICULARS OF INDUCTION MOTORS

GENERAL
1.
Applications
2.
Manufacturer
3.
Applicable Standard
4.
Number of Units
5.
Type of motor
RATING
1.
Continuous rating in KW
2.
Continuous over load capacity in KW
3.
Rated voltage
4.
Rated frequency
5.
Allowable variation in
a.
Voltage
b.
Frequency
c.
Combined
d.
Permissible unbalance in supply voltage
6.
RPM
DUTY
1.
Type of duty (CI 9.2 of IS 325 or equivalent)
2.
Duty designation (CI 9.3 of IS 325 or equivalent)
3.
Factor of Inertia
4.
Current
a.
Full load
b.
Starting
5.
EFFICIANCY
a.
At Full load
b.
At half load
c.
At quarter load
6.
POWER FACTOR
a.
At full load
b.
At half load
c.
At quarter load
7.
STARTING
1.
Soft starter technical particulars
2.
Maximum torque
3.
Starting torque % full load torque
4.
Pull out torque % full load torque
5.
Ratio of starting current to rated current
INSULATION
1.
Class of insulation
2.
Reference ambient temperature / Deg C
3.
Maximum temperature rise in winding at rated

capacity in Deg C
TERMINAL BOX
a.
Location as soon from non-drive end Right/ Left
b.
Ratings
Short time current KA (RMS)
Duration seconds KA (Peak)
c.
Cable entry
d.
Maximum size of cable that it can take
e.
Phase segregated
f.
Size of box
g.
Faults with stand capacity at rated voltage
EXTERNAL CABLE DETAILS

a.
Type
b.
Number of cores
c.
Size
INSTALLATION
1.
Location
2.
Hazardous area division (IS : 5572 or equivalent)
ENCLOSURE
1.
Type of enclosure
2.
Designation for degree of protection
3.
Normal winding connection
4.
Types and No. Of terminals brought out.
5.
Whether motor is dust proof
6.
Whether motor is vermin proof
7.
Type of cooling
8.
Dimensions
OTHER DETAILS
1.
Shaft orientation
2.
Mounting symbol (IS: 2253 or equivalent)
3.
Type of coupling
4.
Whether half flange required YES/NO
5.
Rotation as seen from top clock wise/ anticlockwise
6.
Type of bearing drive end / non drive end
7.
Whether bed plate provided YES/ NO
8.
Colour shades of paint if special
9.
Pads for vibration pickup YES/NO provided.
10.
Weight of stator
11.
Weight of rotor
12.
Total weight of motor
13.
Whether lifting lugs provided
14.
Whether the starter frame and other metals treated for rust removal and coated with
treated for rust removal and coated with rust resistant primer and three coats of epoxy
paint.
ADDITIONAL DETAILS
1.
Type and frame size.
2.0
Starting time
2.1
With 100% voltage at terminals
2.2
2.3
3.
Safe stall time at 100% rated voltage and under hot condition
4.
Particulars at rated voltage and frequency
5.
a.
Starting time
b.
Pull out torque
c.
Pull up torque
Minimum voltage required under starting conditions to accelerate driven equipment to

rated speed.
6.
Permissible running time at full load at minimum allowable voltage
7.
Locked rotor current with stand time (safe stall time)
8.
Stator thermal time constant
9.
Whether suitable for
10.
a.
3 equally spread starts per hourUnder normal service conditions
b.
2 starts in quick succession with cold machine at room temperature.
c.
One hot restart.
Space heaters
a.
Voltage
11.
b.
Rating (Total)
c.
Separate terminal box provided
Cable gland included in Contractors

Scope of supply.
12.
Type and range of cables that can be

Used with cable glands for
13.
a.
Main terminals
b.
Space heater terminals
c.
Terminal of motor for control valve.
Two earthing pads with nut/ belt

Arrangement provided on opposite
Sides, each suitable to receive
Purchasers conductor (Material and size)
14.
Winding temperature detectors

a)
Type
b)
Number and location where Provided.
c)
Resisting at 0oC
15.
Type of mounting
16.
Sealing arrangement for bearings.
17.
Special features, if any
18.
Total guaranteed losses comprising

Iron loss, copper loss, friction, windage
And stray losses
19.
Break up: Iron loss
KW
Copper loss
KW
Friction windage & stray losses
KW
Motor bearings
a.
Type of bearing & expected life
b.
Permissible temperature rise for bearings.
c.
Design ambient temperature assumed for above.
d.
Manufacturers reference No. of

Catalogues attached here-with.
20.
Motor bearing lubrication system.
21.
Inertia constant of motor
22.
Magnification current of motor at rated Voltage and frequency
23.
Motor Reactances (for each type of Motor)

i)
Sub transient reactance
ii)
Transient reactance
iii)
Steady state reactance
NOTES:
1)
Each bearing shall be insulated to prevent shaft-circulating current.
2)
Each bearing shall be provided with one embedded temperature detector.
3)
Polarization index test shall be carried out as a routine test on each motor.
4)
The local bearing temperature indicator provided for the motor shall be provided at the
highest convenient position for recording maintenance.
5)
If single core cables are to be used, gland plate shall be of non-magnetic material
SEAL
SIGNATURE
DESIGNATION
COMPANY
DATE
:
:
:
:
TECHNICAL PARTICULARS OF POWER TRANSFORMERS, CT, PT, BREAKERS ETC.,
1.0
Design Data
2.0
Guaranteed Performance Data
: To be enclosed
3.0
Technical data
3.1
Power Transformer: 220 KV/6.6 KVA
3.1.1 Name of manufacturer
: To be enclosed
:
:
3.1.2 Standards followed in design,

Manufacturing and testing
3.1.3 Continuous maximum rating MVA
3.1.4 Type of cooling

3.1.5 Transformer No load voltage
a)
High voltage
b)
Low voltage
3.1.6 Vector Group reference
:
:
3.1.7 Temperature rise over specified
Ambient Temp. in degree C

a)
In oil by the rmo meter
b)
In winding by resistance
3.1.8 Maximum hot spot temp. in degree
3.1.9 One minute Dry Power frequency

Test withstand voltage in KV
High voltage
Low voltage
3.1.10 Impulse test withstand voltage with
1.2/50 microseconds wave in KV
High voltage
Low voltage
3.1.11 ON LOAD TAP CHANGER make
No. of plus taps
No. of minus taps
Voltage per step
3.1.12 Iron losses in KW at rated full load
Frequency.
3.1.13 Copper losses in KW at rated full load
Current and frequency at 75 C
3.1.14 Reactance voltage with guaranteed tolerance
In % rated F.L. Current and frequency at 75 C

3.1.15 Impedance voltage with guaranteed tolerance
In % rated F.L. current and frequency at 75 C
3.1.16 Regulation in % of no load voltage @ F.L.
Current at 75 C and
i)
With unity power Factor.
ii)
With 0.95 lagging
iii)
3.1.17 Efficiency in % at 75 C and at unity power
Factor for:
100% load
75% load
50% load
3.1.18 No load current in amps at rated voltage and
Frequency
3.1.19 In rush Magnetizing current in percent of
Normal F.L. current.
Details of winding insulation:
3.1.20
i)
Class of insulation Material
ii)
Turns insulation high voltage in

Mega ohms.
iii)
Turns insulation low voltage in

Mega ohms.
iv)
Insulation core to low voltage in

Mega ohms.
v)
Insulation high voltage to low voltage in

Mega ohms
vi)
Losses: No load (W)

Full load (W)
3.1.21 Details of termination of HV/IV side

3.1.22 Insulating oil Grade and quality
3.1.23 Weight
i)
Core and windings in
Kgs.
ii)
Tank & fitting
Kgs.
iii)
Oil in
Kgs.
iv)
Complete transformer filled
Kgs
With oil
3.1.24
Overall dimensions
Length
Breadth
Height
3.1.23.1 Fittings and accessories
(Refer specifications at 3.1.44)
3.1.26
Tests as per IS 2026
1.
Type test
2.
Routine tests.
3.
Special tests.
3.2
Out door type SF-6 Circuit Break 11

KV-50 Hz set of 3 Nos. Single pole
to be gang operated.
3.2.1 Name of manufacturer

3.2.2 Rated voltage
3.2.3 Continuous current rating
3.2.4 Short circuit current and rating
3.2.5 1.2/50 u sec Impulse withstand KV
Voltage peak.
3.2.6 One-minute power frequency KV
Withstand voltage.
3.2.7 Permissible limit of temperature
i)
Maximum permissible temperature
ii) Temp. rise at a maximum Air
C
C
temperature not exceeding 45 C

3.2.8 Rated operating duty cycle
3.2.9 Minimum closing time
3.2.10
Maximum total break time at rated
breakage Gap.
3.2.11
Breaking capacity
3.2.12
Detailed schematic diagram of
Control circuits, alarms, and indication

Details of monitoring of SF-6 GAS.
3.3
220 KV Air break switch with Earth Switch
3.3.1 Name of the manufacturer

3.3.2 Type of Air break switch
3.3.3 Short time current rating
KA
3.3.4 Rated Voltage
KA
3.3.5 Rated normal current
KA
3.3.6 Temperature rise

3.3.7 Basic insulation level
i) Lightning impulse withstand KV Peak
Voltage to earth.
ii) Rated power frequency KV rms
Withstand voltage to earth.
3.3.8 Minimum creepage distance
mm KV
3.3.9 Phase to phase spacing for
mm
Installation.
3.3.10 Details of earth switch and interlocks
3.4
Instrument transformers: Detected CT/PT of 0.2 Accuracy shall be considered for
incoming supply metery and technical data furnished separately.

3.4.1 1. Current transformers
1.
Make
2.
Rated insulation class
KV rms
3.
3 second insulation level
KV Peak
4.
1 minute dry power frequency
KV rms
Withstand voltage primary.

6.
Power frequency over voltage
( HV rms)
withstand requirement for

secondary winding.
7.
Minimum creepage distance of
mm/KV
Porcelain housing.
8.
Rated short time current
9.
Core details.
V.3.4.2 1.
(KA rms)
Potential transformer
2.
Make
3.
Voltage ratio
4.
Rated Voltage
5.
Basic insulation level
6.
One minute dry Power frequency
i)
Primary terminal
KV rms
ii)
Secondary terminal
KV rms
7. Minimum creep age distance

8.
VA Burden
mm/KV
Core-I
VA
Core-II
VA
VI 3.5 Lightning Arrestor

Make and type of arrestor
5.2
Rated voltage
KV
5.3
Nominal discharge current
KV
5.4
Maximum 1.2/50 Impulse spark over KV Peak

Voltage
5.5
Over head shield wire details
VII 3.6 ITT Capacitor

6.1
Make and type of ITT Capacitor
6.2
KVAR calculations to improve up to
0.95-to be enclosed.
6.3
Dimensions and method of GA
Connection drawings.
3.7
LT Switch gear
Make of MCCB
Capacity
VIII Batteries and Battery charger
8.1
Make & type of battery and battery
Charger.
8.2
Capacity
IX 3.9 L.T. Cable 6.6 KVXLPB

9.1
Make of cable
9.2
Cross section of cable
X 3.10 Auxiliary transformation 6.6 KV / 415 Volts

10.1 Name of transformer
10.2 Continuous maximum rating
10.2 All other informational as per power
Transformer a SL. No.1 except
Tap changer which shall be off load
Type shall be furnished.
10.3
Di-Electric strength of the
Insulation of windings as per

Clause 3.2.17.5 to be furnished.
3.11 LT Panel
KVA
Vacuum circuit breaker

(Incomer, outgoing to be furnished
separately)
1.
Name of manufacturer & type of VCB
2.
Breaking Capacity
MVA
3.
Continuous normal current
KV
4.
Short time current rating
KA
5.
Rated voltage
KA
6.
Protection (details to be enclosed)
7.
Design and drawing details of HT
Panel (to be enclosed)

3.12.0 LT Distribution panel
1.
Name of manufacturer
2.
Make of ACB
3.
Rating ACB
4.
Breaking cap
5.
Single line diagram of L. T. Penal
Amps
Showing various load details

(to be enclosed)
3.13.0 Battery
3.13.1 Make
3.13.2 Capacity
3.13.3 Batter sizing calculations ( to be enclosed)
3.13.4 Accessories provided
3.14.0 Battery charger
3.14.1 Make and capacity with details
3.15.0 DC distribution board
15.1 Make
15.2 Single line diagram showing cap of
MCB (incoming) outgoing MCB feeder
3.16.0 Auxiliary transformer 6.6 kv/4.15 Volts
KV-3 Phase 50 Hz indoor type with
Off load tap changer
16.1 Make
16.2 Capacity
16.3 Details of accessories
16.4 Tests of factory

16.5 Tests to be conducted at site
3.17.0 Remote control panel
17.1 Make of equipment
17.2 Drawing showing mounting
Arrangement and wiring details
Equipments indicated at clause
19.0 Remote control panel
(Depending on selection of pump)
17.3 Testing at manufacture place
3.18.0 Electronic trirouter meter 0.2 Accuracy make and technical data to be furnished.
SEAL
SIGNATURE
DESIGNATION :
COMPANY
DATE
DESCRIPTION OF MILESTONES PHYSICAL IMPLEMENTATION FOR Mulwad L.I.S. 4 th B LIFT

No.
Description of work
10%
20%
30%
40%
50%
60%
70%
Prepare
composite
hydraulic
model
submit reports
Submissions of Design, Drawings approvals of equipments
placing orders on manufacture.
Delivery of equipments at site including spares and tools
Supply, fabrication, testing and delivery of MS pipes
Manifold
Civil Works Intake Canal , Jack cum pump house with all structures,
Rising
Main, Delivery chamber etc
MS rising
Erection of pumps sets, section and delivery pipes, valves,
manifold & delivery pipes upto delivery chamber
Electrical works inside the pump house
Electrical substation with Mulsifyre system
SC Line on DC towers & terminal bay
Construction
Pump sets acceptance test
Submission of documents
i) As built drawings
ii) 0 &M manual
iii) Factory/field test report/acceptance test
iv) Guarantee /Warranty Certificate
v) KPTCL approvals
Within 28 days after issue of Completion certificate
80%
90%
100%

Bid Document of 4th B Lift

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Bid Document of 4th B Lift

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KRISHNA BHAGYA JALA NIGAM LIMITED

(A GOVERNMENT OF KARNATAKA ENTERPRISES)

MULWAD LIFT IRRIGATION SCHEME UNDER UPPER KRISHNA

MULWAD 4th B LIFT IRRIGATION SCHEME

Tender Face Sheet

Invitation for Bids (IFB)

C. Specification for Civil works

Instruction to Bidders (ITB)

Forms of Bid and letter of Acceptance

General Conditions of Contract

Contract Data and Scope of work

Drawings & Annexure

KRISHNA BHAGYA JALA NIGAM LIMITED

DRAFT TENDER PAPERS

KRISHNA BHAGYA JALA NIGAM LIMITED

TENDER FACE SHEET

enrolled in KPWD & KBJNL select List

5. Whether a Joint Venture and if so

whether required conditions are

: ___ - ___- 2014

: ___ - ___- 2014

: ___ - ___- 2014

: ___ - ___- 2014

8. Last date of receipt of tender

TO BE FILLED AT THE TIME OF OPENING THE TENDERS

remitted the required E.M.D.

No. and date and amount of DD/

Bankers Cheque /Bank Guarantee

Whether the contractor fulfills all

the conditions of EMD

Whether the tender fulfills all the

conditions of Tender Notice and

are put by the contractor

ii) No of Over Writings

ABBREVIATIONS ADOPTED IN THE TENDER

Kilogram per square centimeter

Reinforced Cement Concrete

Earnest Money Deposit

National Savings Certificate

Uncoursed Rubble Masonry

Kilo watt Hour

Krishna Bhagya Jala Nigam Limited

Krishna Bhagya Jala Nigam Limited

KRISHNA BHAGYA JALA NIGAM LIMITED

MULWAD 4TH B LIFT IRRIGATION SCHEME

INVITATION FOR BIDS (IFB)

KRISHNA BHAGYA JALA NIGAM LIMITED

fee (Only for

transformers ( 1 working + 1 standby)

The bids should be submitted in two covers apart from EMD.

COVER-1 (Technical bid) shall contain the following documents.

vii) The details in support of pre-qualification criteria as mentioned in Para 4 below.

COVER-II Shall contain the financial bid.

Issue and submission of tender documents.

The entire EMD amount is to be paid in a single transaction.

guarantee for similar work.

Schedule-B before uploading the documents.

FORMAL TENDER NOTICE

Design, Supply, Installation, Testing and Commissioning of Lift Irrigation

where this condition is not complied with, will be rejected. DELETED

evaluation as under : DELETED

in the ORIGINAL shall prevail.

Eligibility and qualification requirements:

The entire EMD amount is to be paid in a single transaction.

: _ - _- 2014

: _ - _- 2014

: _ - _- 2014

: _ - _- 2014