CHAPTER 20: TECHNICAL SPECIFICATION FOR XLPE CABLE WITH TERMINATION

CHAPTER 20: TECHNICAL SPECIFICATION FOR XLPE CABLE WITH TERMINATION

3.1 TECHNICAL SPECIFICATION OF 33KV, 66KV, 132KV, 220KV & 400KV XLPE
CABLE AND TERMINATION

20.1 SCOPE
(i) The specification covers Design, Engineering, Construction, Supply & Delivery, Erection, Laying, Testing &
Commissioning including Transportation & Insurance, Storage of XLPE Cable of different ratings and
their associated works.

20.2 STANDARD & CODES

(ii) The works covered by the specification shall be designed, engineered, manufactured, tested and
commissioned in accordance with the Standards as specified in the table below.

Other internationally accepted standards which ensure equivalent or better performance than that specified in
the standards referred shall also be accepted. Copies of such standards shall be submitted by the bidder along
with the bid.

IS 7098 : Part 3 : 1993 Cross-linked polyethylene insulated thermoplastic sheathed cables:

For working voltage from 66KV up to and including 220KV.
IS 8130 : 1984 Conductors for insulated electric cables and flexible cords
IS 5831 : 1984 PVC insulation and sheath of electric cables.
IS 1255 : 1983 Code of practice for installation and maintenance of power cables upto and
including 33KV rating.
IS 3975 : 1999 Mild steel wires, formed wires and tapes for armouring of cables.
IS 5831 : 1984 PVC insulation and sheath of electric cables.
IS 6380 : 1984 Elastomeric insulation and sheath of electric cables.
IS 8130 : 1984 Conductors for insulated electric cables and flexible cords.
IS10418 : 1982 Drums for electric cables
IS 5 : 1994 Colours for ready mixed paints and enamels.
IS 617 : 1994 Aluminum and aluminium alloy ingots and castings for general
engineering purposes (Superseded IS 20: 1977)
IS 3043 : 1987 Code of practice for earthing.
IS 5578 : 1984 Guide for marking of insulated conductors.
IS 11353 : 1985 Guide for Uniform System of Marking and Identification of
Conductors and Apparatus Terminals.
IS 5216 : Part I : 1982 Recommendations on Safety Procedures and Practices in Electrical Work.
IS 2071 : 1993 High voltage test techniques.
IEC-60540 Power cables with extruded insulation and their accessories and cords
EC 60060 : 1989 High Voltage Test Techniques
IEC-60502 Extruded solid dielectric insulated power cables for rated voltages from
1KV up to 30KV
IEC-60754 : 1991 Tests on gases evolved during combustion of electric cables
IEC-60183 : 1990 Guide to the Selection of High Voltage Cables.
IEC-60230 : 1996 Impulse tests on cables and their accessories.
IEC-60840 / IEC- Testing
62067
IEC-60287 : 1995 Calculation of the continuous current rating of cables (100%load
factor).

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IEC-60304 : 1982 Standard colours for insulation for low-frequency cable and wires
IEC-60331 : 1970 Fire resisting characteristics of Electric cables.
IEC-60332 : 1992 Tests on electric cables under fire conditions.
BS-5468 Cross-linked polyethylene insulation of electric cables
IEC-60228 : 1978 Conductors of insulated cables
IEC-60332 : 1993 Test on electric cables under fire conditions
IEC-60066 Environmental Test
IEC-60117 Graphical Symbols
IEC-60270 : 2000 Partial Discharge Measurements
CSA-Z299.1-1978h Quality Assurance Program Requirements
CSA-Z299.2-1979h Quality Control Program Requirements
CSA-Z299.3-1979h Quality Verification Program Requirements
CSA-Z299.4-1979h Inspection Program Requirements
ASTMD-2863 Measuring the minimum oxygen concentration to support candle like
combustion of plastics (oxygen index)

20.3 COMPLIANCE TO SPECIFICATION & DEVIATION:

Normally the offer should be as per Technical Specification without any deviation. But any deviation felt necessary
to improve performance, efficiency and utility of equipment must be mentioned in the Deviation Schedule with
reasons duly supported by documentary evidence. Such deviations suggested may or may not be accepted by the
purchaser.

As a mark of technical conformance, all sheets of the specification shall be furnished by each bidder with the
signature and company seal affixed thereon. In case of any deviations, the same shall be carried out in the deviation
schedule only. Deviations not mentioned in Deviation schedule will not be considered.

The bidder shall also submit the GTP as per Annexure-1 duly signed with date & company seal for acceptance of the
Technical Bid unless which the bid may be considered as non-responsive.

20.4 CONSTRUCTION
1. For 66KV and above: The cable shall be of applicable EHV grade as per requirement according to price schedule,
single core, unarmored, stranded compacted circular Copper conductor in case of cross section less than or equals to
800 sq.mm or segmental compacted circular (Miliken) Copper conductor in case of cross section over 800 sq.mm, core
screening by a layer of semiconducting tape followed by a layer of semiconducting compound, crosslinked
polyethylene (XLPE) dry cured insulation, insulation screening with semiconducting compound extruded directly
over the insulation, longitudinal sealing by a layer of non woven tape with water swellable absorbent over insulation
screen, followed by radial sealing of corrugated & seamless or seam welded aluminum with asphalt coating &
overall HDPE sheathed (conforming to IEC 60840) & graphite coated and conforming to the technical particulars of
specification.
For 33KV : Untinned annealed copper of class 2 as per IS 8130/1984 and any latest amendments to it. The shape of
conductor shall be compacted, stranded, and circular, shielded with conductor screen of black extruded semi-
conducting XLPE compound , XLPE insulation, shielded with insulation screen of black extruded semi-conducting
compound, black semi-conducting tape and metallic screen of copper tape, Inner sheath extruded PVC type ST2,
single layer of strip/ round steel or round hard drawn aluminium wire armoured as per IS :7098 part II and black
extruded FR PVC (TypeST-2) overall sheathed, conforming generally to IS:7098 (PartII).

Cables used earlier or repaired after damaged shall not be accepted. IS 7098 part 3 shall be followed for
manufacturing of cable along with technical specification.

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2. The construction of cable shall generally conform to the description mentioned above. Bidder may offer necessary
layers such as separation tape, binder tapes etc additionally as per their manufacturing practices for meeting required
performance of the offered cable. The bidder shall enclose with the bid, drawing showing cross section of the cable.
3. The cable shall be suitable for laying underground with uncontrolled back fill and chances of flooding by water and
suitably designed by the addition of chemicals in the outer sheath to be protected against rodent and termite attack.
4. The cables shall be designed to withstand all mechanical, electrical and thermal stresses under steady state and
transient operating conditions.
5. Progressive sequential marking of the length of cable in meters at every one meter shall be provided on the outer
sheath of the cable.
6. The cables shall have outer sheath of a material with an Oxygen Index of not less than 29 and a Temperature
index of not less than 250°C.
7. Allowable tolerance on the overall diameter of the cables shall be plus or minus 2mm.
8. IS 7098 part III shall be followed for cable construction.

20.5 COMPOSITIONS OF CABLES

CONDUCTOR
The conductor shall consist of annealed copper stranded wires. The compacted circular conductor shall consist of
segments wounded up and then compacted. For the cable sizes having cross section over 800 sq.mm, the segmental
compacted circular conductor having minimum four (4) segments should be constructed for the supply under the
scope of bid. When the conductor’s cross-section is less than 800 sq.mm, the compacted circular is applied
generally.
CONDUCTOR SCREEN
The conductor screen shall consist of extruded semi-conducting XLPE. Semi-conducting separator tapes may be applied
between conductor and the extruded semi-conductor XLPE.
INSULATION
The insulation material shall be extruded cross-linked polyethylene. In order to ensure that the screen and insulation
are intimately bonded together and free from all possibilities of voids between layers, the conductor screen, the
insulation and the insulation screen should be extruded simultaneously in one process in single cross-head. The
extrusion process should be carried out under strictly controlled atmospheric conditions.
The thickness of the insulation layer should be maintained as the maximum value figured out from the design of the
impulse voltage and A.C. voltage. The cross-linking process by N2 gas should be preferred instead of conventional cross-
linking process by saturated steam.
INSULATION SCREEN
The insulation screen shall consist of extruded semi-conducting XLPE. Suitable bedding tapes shall be applied over the
extruded semi-conducting XLPE.
MOISTURE BARRIER
The longitudinal water barrier shall be applied over insulation screen by a layer of non woven synthetic tape with
suitable water swellable absorbent.

METALLIC SCREEN:
The metallic screen shall be of Lead Alloy ‘E” as per IS 7098 Part III sheet with asphalt coating. The metallic
screen shall be designed to meet the requirement of the system short circuit rating of 31.5KA for 3 sec (for 33KV
and 66KV), 40KA for 3Sec (for 132KV) and 50KA for 3 sec (for 220KV). Copper wire screening may be used if
required to meet the above ratings.
ARMOURING (FOR 33KV CABLE)
a) The armoring shall be of non-magnetic material.
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b) Armoring shall be applied over the insulation or protective barrier or non-metallic part of insulation
screening, in case of single core cables or inner sheath in case of screened and armoured single core
cables.
c) The armour wires/strips shall be applied as closely as practicable the direction of lay of the armour shall
be left hand. For double wires/strips armoured cables, this requirement shall apply to the inner layer of
wires/strips. The outer layer shall, except in special cases, be applied in the reverse direction to the inner
layer, and there shall be a separator of suitable non-hygroscopic material; such as plastic tape,
bituminized cotton tape, bituminized hessian tape, rubber tape, proofed tape between the inner and outer
layers of armour wires strips.
d) A binder tape may be applied on the armour.
e) The joints in armour wires of strips shall be made by brazing or welding and the surface irregularities
shall be removed. A joint in any wire/strip shall be at least 300 mm from the nearest joint in any other
armour wire/strip in the completed cable, Number of joint in a single wire to be limited.
OUTER SHEATH
The outer sheath shall consist of Extruded black HDPE (TypeST7) grade. The outer sheath shall be designed for
protection against termite and rodent attack and shall be coated with graphite.
20.6 RATING
The bidder shall declare current rating of cable for maximum conductor temperature of 90 degree C under continuous
operation. A complete set of calculation made in arriving at the current rating shall be furnished for laying condition
under present.

20.7 CABLE DRUMS

Cables shall be supplied in wooden or steel drums of heavy construction of suitable size and packed conforming to IS
10418 or applicable internationally accepted standards. Wooden drum shall be properly seasoned sound and free from
defects. Wood preservative shall be applied to the entire drum. A layer of water proof paper shall be applied to the
surface of the drums and over the outer most cable layer.
Each drum shall carry the manufacturer’s name, the purchaser’s name, address and contract number and type, size and
length of the cable, net and gross weight stenciled on both sides of drum. A tag containing the same information shall
be attached to the leading end of the cable. A narrow and suitable accompanying wording shall be marked on one end
of the reel indicating the direction in which it should be rolled.

Packing shall be sturdy and adequate to protect the cables, from any injury due to mishandling or other conditions
encountered during transportation, handling and storage. Both cable ends shall be sealed with hermetically sealed by
means of water blocking compound followed by heat shrinkable caps totally coated inside with mastic so as to
prevent to cable for moisture penetration during transit, storage and laying.

The bidder shall consider supply of cable on returnable drums basis. Contractor shall take back all the cable drums from
site after successful laying, testing and commissioning of cables. If any length of cable remains unused, the same
shall be adjusted by the employer.

Embossing of outer sheet: the following details on the other sheet of cable at a regular interval of 1(one) meter.
(a) Name of Customer i.e. AEGCL
(b) Conductor size, type of insulation and voltage grade.
(c) Manufacturer’s name.
(d) Year of manufacturing

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20.8 TESTS
All routine and acceptance tests shall be conducted as per IEC60840/IEC62067. All type tests conducted during last
five years from the date of NIT as per IEC 60840:1999/ IEC 62067:2001 including its amendments on the XLPE
insulated HT cable should be submitted. The diameter of test cylinder during bending test shall be as per IS:7098
(Part3) or the diameter of drum barrel to be used for dispatch of cables which ever is lower. For accessories type test
reports should be submitted as per Clause 11.3.2 IEC 60840:1999/ Clause12.4.2 IEC62067:2001 & including
amendments.
Following additional type tests shall be carried out on outer sheath of XLPE insulated HT cable.
a. Oxygen index and temperature index test as per ASTMD-2863.
b. Chemical composition test for verifying lead sheath composition.
All tests as prescribed in IEC-60840 shall be performed after installation of cable.
TESTS AFTER INSTALLATION
All tests as prescribed in IEC-60840:1999/IEC 62067:2001 shall be performed after installation of cable.
20.9 TRENCHING
The cable trench work involves earth excavation for cable trench, back filling and removal of excess earth from site.
The work site shall be left as clean as possible.
The trench shall be excavated using manual/ mechanical modes as per field conditions.
Where paved foot paths are encountered, the pavements labs shall be properly stored and reinstated. Identification
markers of other services shall be properly stored and restored.
The sides of the excavated trenches shall wherever required be well shored up.
Suitable barriers should be erected between the cable trench and pedestrian/motor way to prevent accidents. The
barriers shall be painted with yellow and black or red and white coloured cross stripes. Warning and caution boards
should be consciously displayed. Red lights as warning signal should be placed along the trench during the nights.
The excavated material shall be properly stored to avoid obstruction to public and traffic movement.

The bottom of the excavated trench should be levelled flat and from any object which would damage the cable. Any
gradient encountered shall be gradual.
20.10 PAYING OUT
The excavated cable trench shall be drained of all water and the bed surface shall be smooth, uniform and fairly
hard before paying out the cable. The cable shall be rolled in the trench on cable rollers, spaced out of uniform
intervals. The paying out process must be smooth and steady without subjecting the cable to abnormal tension. The
cable on being paid out shall be smoothly and evenly transferred to the ground after providing the cushion. The
cables shall never be dropped. All snake bends shall be straightened. Suitable size cable stocking pulling eye shall be
used for pulling the cable. While pulling the cable by winches or machines, the tension loading shall be by tension
indicator and shall not exceed the permissible value for the cable. The cable laying shall be performed continuously at a
speed not exceeding 600 to1000 meters per hour.
The cable end seal shall be checked after laying and if found damaged shall immediately be resealed. Sufficient number
of heat shrinkable cable end sealing caps shall be stocked at site stores for testing and jointing work. The integrity of
the outer sheath shall be checked after the cable is laid in position.
20.11 LAYING OF CABLES
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The installation, testing and commissioning work for laying of cable in the entire route within the substation,
through the outside cable laying corridor as per designated approved route shall mainly consist of:

a) Route survey for the entire route length under the scope of work. This is also to finalize drum wise cable
length with their tolerances.
b) Clearances from relevant authorities for lying of cables.
c) Formation of buried cable trenches for cables as per specification including supply and installation of warning
tape, protective tiles / brick layer of minimum class designation 50 (50kg./sq.cm.) cable protection covers
for entire route, construction of jointing bays, back filling of trenches and restoration as per specification.
d) Road, rail and canal crossings through HDPE pipe for each cable and restoration as per specification.
e) Cable markers as per statutory requirements shall be provided all along the route at a maximum distance
of 500 meters and other important locations. Also the location of underground cable shall be clearly
indicated on the marker.
f) Supply and installation of straight through joints for complete route.
g) Design, supply and installation of suitable hangers and other necessary structures for running the cable at
over head road bridge.
h) Supply and installation of all critical installation materials like trefoil clamps, neoprene cushions, support
brackets etc. as required for complete route to avoid damages of the cable. Neoprene cushion shall be
provided at road and rail bridge crossings to avoid damage of cable due to vibrations during movement
of trains and vehicles.
i) Termination of cables, bonding of screen/sheath to the earth station through disconnecting type link
boxes and SVL (sheath voltage limiter) at cable conductor junction-point etc. Bidder shall adopt ends
bonding for route under scope as per STP or as per detailed Engineering. Earthing stations/ Earthing pits,
earthing materials and earthing conductors wherever applicable for complete route including outdoor
equipment, structure, cable terminating structure and earth link box at the locations mentioned above
shall be in contractors’ scope.
j) Design, fabrication, supply and erection of galvanized steel structures (including its civil foundation) for
cable end terminations (with all necessary accessories) for cable sat cable–conductor junction point. At
cable-conductor junction point terminal connectors offered by bidder shall be suitable to terminate with
ACSR conductors.
k) For termination at GIS substation end the cable should be laid up to GIS building. Necessary design
construction of cable duct etc. in the GIS Sub-Station including all supply is within the scope of this
contract.
l) Design, supply and installation of LA sat cable–conductor junction point for both the circuits including
its mounting structure and Las & Isolator sat Sub-Station.
m) Termination, bonding, earthing etc. at GIS sub-station end is not within the scope of this work.

20.12 LAYING OVER PRE-CONSTRUCTED TRENCH

For lay of the cable on a pre-constructed trench below the road in any planned township area, Bridge, switchyards
etc., cable shall have to be accommodated in the space allotted in the trench for laying the cables. Sufficient clamping
arrangement shall have to be done for fixing the cable properly. Cables may be placed in trefoil arrangements or flat
arrangements as per allotted width of the trench. Any damages occurred in the trench during lay of the cable shall
have to be repaired properly.

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20.13 CLAMPS
Clamps shall be pressure die cast aluminium (LM-6) or Nylon-6 or fiber glass and shall include neoprene rubber lining
wherever the cable touches the clamps and below the clamp base and necessary fixing non magnetic nuts, bolts,
washer etc. The thickness of neoprene rubber shall not be less than 10 mm inside around the inner surface of the
trefoil clamp and minimum 20 mm thick below the base of trefoil clamp. The neoprene shall be tested as per
ISIII49-1984. Clamps shall be provided at every one meter of cable runs. The contractor shall submit drawings of trefoil
clamps and arrangements for Employer approval.
20.14 CABLE HANDLING
The inspection of cable on receipt, handling of cables, paying out, flaking, cushioning with sand or sieved
compacted soil, back-filling, reinstatement of road surface, providing and fixing joint markers, route indicators,
precautions of joint holes, sump holes and all necessary precautions that are required shall be carefully planned and in
general conform to IS1255- 1983 or its equivalent.
DAMAGE TO PROPERTY
The contractor shall take all precautions while excavation of trench, trial pits etc., to protect the public and private
properties and to avoid accidental damage. Any damages caused shall be immediately repaired and brought to the
notice of the concerned and to the Employer.
- The contractor shall bear all responsibilities and liabilities and shall bear all costs of the damages so caused by
him or by his workman or agents.
- At places where the cables cross private roads, gates of residential houses or buildings, the cables shall be laid in
HDPE pipes of adequate strength using HDD technology.

20.15 CABLE ROUTE MARKERS / CABLE JOINT MARKERS

Permanent means of indicating the position of joints and cable route shall be fabricated supplied and erected as per
drawings supplied by Employer.
Markers provided shall be as per the field requirement, if the route passes through open fields, markers should be
conspicuously visible above ground surface.
The marker should incorporate the relevant information, The name of the owner, voltage, circuit and distance of
cable from the marker.
20.16 DEPTH OF LAYING OF CABLES
Depth of lay shall be normally at 1.5 m. below ground but variation of depth of lay to1 meter may be considered at
the time of detailed engineering on the characteristics of the laying zone.
20.17 SAND BEDDING
The cable shall be completely surrounded by well-compacted cables and to such a thickness and of such size that the
cable is protected against damage. The thickness of the cable sand should normally be a minimum of 10 cm in all
directions from the cable surface.
20.18 THERMAL BACK FILL
Based on the evaluation of soil thermal resistivity along the cable route and after approval from the Employer the
contractor shall design, specify, supply, lay and monitor the installation of thermal back fill surrounding the cables.
20.19 IMMEDIATE ENVELOPE TO CABLE

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The option on the use of the material that immediately envelopes the cable viz., thermal back fill or sand or sieved
native soil rests with the Employer. The contractor shall seek prior approval on the use of the envelop material from
the Employer before execution of the works.
20.20 BACKFILLING
Normally back filling shall consist of the material earlier excavated. However, bigger stores or pieces of rock should be
removed.
20.21 WARNING TAPE
A pre-warning, Red colour plastic/ PVC tape, 250 mm wide100 microns thick, shall be laid at approx. 0.4m above
the cable specified depth, throughout the cable route. The tape shall carry the legend printed in black continuously as
under
CAUTION: AEGCL ….. KV CABLES.
20.22 PREVENTION OF DAMAGE DUE TO SHARP EDGES
After the cables have been laid in the trench and until the cables are covered with protective covering, no sharp metal
tool shall be used in the trench or placed in such a position that may fall into the trench.
Straight and curved rollers used shall have no sharp projecting parts liable to damage the cable.
While pulling through pipes and ducts, the cable shall be protected to avoid damage due to sharp edges.

The cables shall never be bent, beyond the specified bending radius.
20.23 ROAD, RAIL & CANAL CROSSINGS
The road cutting, whether cement concrete asphalt or macadam road surface, rail crossing and canal crossing shall be taken
after obtaining approval from the concerned authorities i.e. Railway authorities, irrigation deptt., civic authorities traffic
police, telephone authorities etc. and work should be planned to be completed in the shortest possible time. Where
necessary, the work shall be planned during night or light traffic periods. HDPE pipes shall be used for cable. HDPE pipes
diameter should not be less than1.5 times the cable diameter.
20.24 TRENCHLESS DIGGING

It is envisaged that trenchless digging shall be used for crossing National highways, Rail line and canal and this shall be in
the scope of bidder. Trenchless digging shall also be used where the concerned authorities do not permit open cut
method and it is essentially required to carry out for installation of underground cables. The trenchless digging
methods shall generally conform to ITU-T 1.38. The various methods of trenchless digging such as hand/ manual
auguring (upto15m.) impact moulding (from 16m to about 40-50m.).HDD (above40-50m) shall be adopted based on
the soil/ site conditions and the requirement and exact method for trenchless digging shall be finalized during detail
engineering as per actual site/ soil condition. The equipment used for HDD shall be capable of drilling at least 100m at
one go. The contractor shall propose the exact methods and procedures for implementation of trenchless digging at various
crossings taking into consideration the following guidelines, for approval by the Employer.
1. Guided boring/drilling technology is to be used.
2. Radio or any detection system should be used for avoiding damage to existing
underground utilities.
3. The depth of boring should be such as to clear any underground utilities/obstacles.
However in no case the depth of boring shall be less than 1.65m from the road surface.
4. In horizontal and vertical boring, the system should be capable of going up to 10 meter
below ground.

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5. The span of HDD will be decided in charge as per site requirements.

6. Excavation and back filling of trial pits and verification of soil condition.
7. Excavation of entry and Exit pits.
8. Erection of drill machined. Drilling of pilot hole.
9. Placement and driving hand augur.
10. Placement and carrying out impact moling.
11. Reaming and widening of bore holes in steps (if required).
12. Pulling of product pipe.

20.25 FOOTPATH CUTTING

The slabs, curb stones on the roads shall be removed and reinstated without damage.
20.26 REINSTATEMENT
After the cables and pipes have been laid and before the trench is backfilled all joints and cable positions should be
carefully plotted and preserved till such time the cable is energized and taken over by the Employer. The protective covers
shall then be provided the excavated soil riddled, sieved and replaced. It is advisable to leave a crown of earth not less
than 50mm and not more than 100mm in the centre and tape ring towards the sides of the trench.
The temporary reinstatement of roadways should be inspected at regular intervals, more frequently in rainy season and
immediately after overnight rain for checking settlement and if required the temporary reinstatement should be done.
After the subsidence has ceased the trench may be permanently reinstated and the surface restored to the best possible
condition.
20.27 MANHOLES
Manholes shall be provided at every proposed joint location for jointing bays. The bidder shall identify the location
of the joint bays after carrying out detailed survey of the cable route and excavation of the trial pits. The delivery
lengths of the cables shall match the location.
The Contractor shall get inspected by a representative of the Employer, all manholes before carrying out the backfilling.
Pipe and cable sealing, installation of joint bus and cable service loops as per approved drawings shall be visually
inspected and checked for tightness.
The contractor shall submit design and drawing of Jointing bay including manholes in the buried cable trench
portion for withstanding a live load of 20 tons vehicle plus 30% for impact from moving vehicle. The Contractor
shall propose a suitable procedure for testing the manhole for approval by the Employer. Manholes type approved
by the Employer only shall be acceptable. The manhole shall include sufficient number of suitable entries.
All works shall be carried out under supervision of the engineer in charge of his representative.
20.28 TOOLS AND PLANTS
The successful bidder shall have all necessary tools, plant and equipment to carry out the survey and cable
installation work.
The bidders are instructed to give all the details of equipment at their disposal to carryout the work successfully and
speedily.
20.29 BENDING RADIUS:
The minimum bending radius of XLPE insulated cables are as follows :

Cable Bending radius

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Single Core 25 X D
“D” means the overall diameter of the completed cable.

20.30 CABLE END TERMINATIONS & JOINTING

The cable jointing accessories shall include the end terminating kits, straight through joints and also any special
tools and tackles required for making these joints.
The straight through joints shall be either Pre-molded Heat Shink type complete with all accessories. The joint
shall preferably be built up as per the construction of the main cable and shall have electrical and mechanical
withstand capabilities same as or better than the main cable. The joints shall be suitable for tropical climatic
conditions.
The outdoor end termination up to 245 KV XLPE Cable shall be Anti-fog, Pre-molded type Silicon Rubber stress
cone. Torque controlled mechanical shear head bolted connector with polymeric composite housing (resin cast body
with silicon shed housing), dry type self-supporting with Plug-in / Plug-out facilities. The termination base plate
and the cable's metallic sheath shall be electrically insulated from the self supporting structure by means of stand-
off epoxy insulators designed to withstand both mechanical and electrical stresses in services. The Polymeric
insulator in grey colour shall be used. In addition upon, arcing horn and shield ring shall have to be supplied as
required for 245 & 420 KV XLPE cables.
The outdoor end termination for 400kV shall be based on the Silicon / EPR-based stress relief cone with the epoxy
housing and the oil-impregnated cylindrical capacitor cone (so called condenser cone type) to secure the uniform
longitudinal voltage distribution all along the termination. Pre-molded type Silicon Rubber sleeve outdoor end
termination for 400kV may be offered by the manufacturer if the same is available.
The outdoor terminals should be suitable for heavily polluted atmospheric conditions with total creepage distance of
31 mm/ kV and protected creepage distance of not more than 50% of the total creepage distance. The cable end
terminals for terminating the cables shall be fully compatible with the cables to be supplied.
The Indoor Termination at GIS SF6 Housing shall be based on the Silicon Rubber based stress relief cone and the
epoxy resin housing. There shall be mechanical devices to maintain the interface pressure. Stress relief cone and
mechanical devices shall be designed to fit with controlled interference over the cable insulation and shall follow
the cable's diameter variations still guaranteeing under any service condition a sufficient positive pressure to control
the electric field concentration. There shall be epoxy insulating plate to isolate between cable sheath and GIS
chamber. The SVLs (Sheath Voltage Limiter) shall be installed to protect epoxy insulating plate from switching
impulse. Plug-in type leading conductors shall be supplied though at the time of detailed engineering confirmation
shall be given for selection of plug-in type. Design and scope of delivery shall be fully complying with IEC-60859,
IEC-62271-209 and possibly adjusted to various needs of project. The main insulation components shall be fully
examined and tested in the factory.
The detailed description on jointing procedure shall be furnished during detailed engineering.
The details of the performance of end terminations / straight through joints as offered with the period in service in
reputed Indian Utility should be furnished for 145 KV & 245 KV and reputed International/ Indian utility for 420
KV Cable accessories for evaluation of the techno-commercial offer.
The accessories shall be Type Tested as per relevant IEC 60840 & Type test report shall have to be furnished for
technical evaluation.

WORKING PROCEDURE FOR TERMINATION

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(i) At cable terminating end sufficient length of spare cable shall be left in the ground and at cable tray
also at GIS, for future needs.
(ii) The rise of the cable immediately from the ground shall be enclosed in PVC/ PE pipe of suitable diameter
to protect against direct exposure to the sun.
(iii) The cable shall be properly fastened using non-metallic clamps.
(iv) Appropriate labels shall be fixed identifying the phase circuit, voltage and date of commissioning etc.,
on the cable supporting structure.
(v) The sealing end shall be mounted on pedestal insulators to isolate them from their supporting steel
work.
(vi) Protection from contact with the exposed metal work at the termination shall be provided by resin
bonded glass fiber shroud.
(vii) Providing earth stations with all required materials, like leads, connectors etc. Earth pits shall conform
to IS-3043:1987 (Code of practice for earthing).

WORKING PROCEDURE FOR JOINTING

(i) The cable jointing personnel and his crew shall have good experience in the type of jointing and
terminations that are used. The jointing works shall commence as soon as two or three lengths of
cable have been laid. All care should be taken to protect the factory-plumbed caps/ seals on the cable
ends and the cable end shall be sealed whenever the end is exposed for tests.
(ii) Jointing of cables in carriage ways, driveways under costly paving, under concrete or asphalt surfaces and
in proximity to telephone cables and was mains should be avoided wherever possible.
(iii) Sufficient overlap of cables shall be allowed for making the joints.
(iv) The joint bay should be sufficient dimensions to allow the jointers to work with as much freedom of
movement and comfort as possible. Sufficient space should be kept below the cable to be jointed. 3
ph link box for cross bonding to be placed inside the bay with provision for easy access for
maintenance purpose.
(v) The joints of different phases shall be staggered in the jointing bay.
(vi) Comprehensive jointing instructions should be obtained from the manufacture of jointing kits and
meticulously followed.
(vii) The materials used in the joints like ferrules, screen/ sheath continuity bonds, lugs etc. shall be of
good quality and conform to standards.
(viii) The jointing tools shall be appropriate and as per the requirement of jointing HVXLPE cables.
(ix) SUMPHOLES
When jointing cables in water logged ground or under unforeseen rainy conditions, a sumphole should
be made at one end of the joint bay, in such a position so that the accumulated water can be pumped
or drained out by buckets, without causing interference to the jointing operation.
(x) TENTS/COVERS
An enclosure or suitable protection cover shall be used in all circumstances wherever jointing work is
carried out in the open irrespective of the weather conditions. The joint shall be made in dust free,
moisture free and clean atmosphere.
(xi) PRECAUTIONS BEFORE MAKING A JOINT
The cable end seals should not be opened until all necessary precautions have been taken to prevent
circumstances arising out of rainy/ inclement weather conditions which might become uncontrollable.
If the cable end seals of cable ends are found to have suffered damage the cables should not be
jointed, without tests and rectification.

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(xii) MEASUREMENT OF INSULATION RESISTANCE

Before joining, the insulation resistance of both sections of cables shall be checked.
(xiii) The identification of each phase shall be clearly and properly noted. The cables shall be jointed as per the
approved design. Each cable shall have identification for phase at joint bays.

20.31 BONDING OF SCREEN/ SHEATH

The screens at both ends, shall be brought out and bonded to the earth station through disconnecting type link boxes
or through SVL wherever applicable.
On the basis of the length of the cable and rise of sheath Voltage the bonding maybe required as follows:
1. Single End Bonding
2. Double End Bonding
3. Cross Bonding
4. Mid point bonding

All accessories and consumables used in the termination should be of good quality and compatible with the cable.
At the time of single end bonding parallel copper conductor along the length of the cable shall have to be provided
between the two ends of the cable. Bonding cable of 6.6KV copper shall be provided for bonding of metallic sheath/
Screen.
20.32 CONNECTION OF RADIAL WATER BARRIER AND CABLE SCREEN

If the metallic radial water barrier is insulated from the metallic wire screen a connection suitable to carry the
currents occurring during operation must be installed between metallic radial water barrier of the cable and metallic
wire screen in joints and sealing ends.
20.33 STATUATORY APPROVAL OF WORKS
Contractor shall make an application on behalf of the owner for submission to the Electrical Inspectorate along with
copies of required certificates complete in all respects and submit to the engineer-in-charge for onward transmission
well ahead of time so that the actual commissioning of system/ equipment is not delayed for want of inspection by
the Inspector. Contractor shall arrange the actual inspection of work by the Electrical Inspector. Necessary
coordination and liaison work in this respect shall be the responsibility of the contractor.
The Inspection and acceptance of work as above shall not absolve the Contractor from any of his responsibilities
under this contract.
Any other statutory approval of works required for the electrical installation (such as Factory Inspector, CCOE, etc.)
is also included in contractor’s scope.
Supply & execution of job is subjected to regulations time to time framed by the AERC; approval Govt. Of Assam,
and NOC from Assam Pollution Control Board. Contractor shall complete the entire job in compliance with the
same.
20.34 INSPECTION, TESTING AND COMMISSIONING
Inspection of Supplied materials and Site works time to time during execution: Inspection of AEGCL and clearance
from AEGCL will be in Contractor responsibility. Expenditure related to this inspection will be in contractor
account. Site inspection, testing and commissioning of electrical installation shall be carried out as per enclosed
Specification and Inspection and Test Plans included or referred in this BID. All the equipment installed by the
contractor shall be tested and commissioned, as required and no separate payments shall be made unless otherwise
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specified in the Schedule of Rates. Contractor shall carefully inspect all equipment and submit the manufacturer’s
Certificate before installation. Any damage or defect noticed shall be brought to the notice of the engineer-in-charge
at that time and same shall be rectified or replaced by CONTRACTOR on his OWN RISK AND COST within
TIME FRAME. Complete testing of power transmission system would be carried out under the supervision of the
Employer.

Any work not conforming to the execution drawings, specifications or codes shall be rejected forthwith and the
contractor shall carry out the rectification at his own cost.
The contractor shall carry out all the tests as enumerated in the tender and technical specifications and technical
documents which may be furnished to him during performance of the work.
Before the electrical system is made live, the electrical contractor shall carry out suitable tests to establish to the
satisfaction of the Employer that the installation of equipment, cabling/ wiring and connections have been
correctly done and are in good working condition and that the system/ equipment will operate as intended.
All tests shall be conducted in the presence of Employer/ Engineer-in-Charge or his authorized representative
unless he waives this requirement in writing. Contractor shall arrange testing equipment, as required to carry out
the tests. Test results shall be recorded on approved Performa and certified records of the tests shall be submitted
to the Employer/ Engineer-in-Charge.
Prior intimation to be given to the Employer before finalizing of date of scheduled inspection at least 15 days in
advance.
Clearance in favour of contractor for dispatch of equipment/material from respective works of manufacturer will
be covered by the Employer after physical inspection and witnessing satisfactory routine and acceptance tests.
Contractor will have to arrange physical inspection and witnessing of Routine and Acceptance Test of
materials/equipments at respective manufacturer’s works by two engineer of the Employer and cost of such
inspection shall have to be borne by contractor. Clearance for dispatch of equipments & materials from
respective works of manufacturers will be conveyed by the Employer after verification and acceptance
thereafter.
After the completion of all tests and rectification of all defects pointed out during final inspection, plant start-up
trials shall commence. During the start-up trials, contractor shall provide skilled/ unskilled personnel and
supervision round the clock at his own cost. The engineer-in-charge/Employer will decide the number and the
category of workmen and their duration. Any defects noticed during the start-up trials relating to the equipment
supplied and work carried out by the contractor, shall be rectified by the contractor at his own cost.
The Employer shall have the right to get the defects rectified at the risk and cost of the contractor if he fails to
attend to the defects immediately as desired.
Contractor shall also inform the Employer/ Engineer-in-charge, well in advance in case services of any OEM
(Equipment manufacturer) are required and same shall be arranged by Contractor at the time of commissioning
on his own cost.
Contractor shall furnish site acceptance test (SAT) procedures from the equipment supplier and get it approved
from the Employer/ Engineer-in-charge before carrying out the same at site.
Contractor shall prepare detailed testing, pre-commissioning and commissioning procedures for the entire
installation. These shall include Performa for defining activities and recording of test results.
It is the responsibility of the contractor to coordinate and provide all necessary assistance to other contractors /
agencies/ vendors involved in the complex for proper and timely execution of the works. Further contractor shall

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do all the liaisoning, documentation or other related formalities with respective authorities/agencies for
successfully charging/commissioning of system.
The following equipment/ items as included in Contractor’s scope of supply shall be tested and inspected by the
Employer or his authorized representative before dispatch at the manufacturer’s works. Test certificates duly
signed by the Employer or his authorized representative shall be submitted by the contractor as part of the final
document:
a) EHV cable & optical fiber cables.
b) Jointing & termination kits for above items
20.35 ENGINEERING DATA AND DRAWINGS
The Bidder shall necessarily submit all the drawings/ documents unless anything is waived. The Bidder shall submit
4(four) sets of drawings/ design documents/ data/ test reports as may be required for the approval of the Employer.
All drawings submitted by the Bidder including those submitted at the time of bid shall be in sufficient detail to
indicate the type, size, arrangement, material description, Bill of Materials, weight of each component, break-up
for packing and shipment, dimensions, internal and the external connections, fixing arrangement required and
any other information specifically requested in the specifications.

All engineering data submitted by the Bidder after final process including review and
approvalbytheEmployershallformpartoftheContractDocumentandtheentireworks performed under these
specifications shall be performed in strict conformity, unless otherwise expressly requested by the Employer in
Writing.

20.36 INSTRUCTION MANUAL

(i) The instruction Manuals shall contain full details of drawings of all equipment being supplied under this
contract, their exploded diagrams with complete instructions for storage, handling, erection,
commissioning, testing, operation, trouble shooting, servicing and overhauling procedures.
(ii) If after the commissioning and initial operation, the instruction manuals require any modifications/
additions/ changes, the same shall be incorporated by the bidder in the final submission.
(iii) The Bidder shall furnish to the Employer catalogues of spare parts.

20.37 QUALITY ASSURANCE PROGRAMME

a. To ensure that the equipment and services under the scope of this Contract whether manufactured or
performed within the Bidder’s Works or at his sub-bidder’s premises or at the Employer’s site or at any other
place of work are in accordance with the specifications, the Bidder shall adopt suitable quality assurance
programme to control such activities at all points necessary. Such programme shall be outlined by the Bidder
and shall befinally accepted by the Employer after discussions before the award of Contract.
b. Quality Assurance Documents

The Bidder shall be required to submit the following Quality Assurance Documents within three weeks before
laying/ erection of the equipment.

(i) All Non-Destructive Examination procedures, stress relief and weld repair procedure actually used during
fabrication and reports including radiography interpretation reports.
(ii) Welder and welding operator qualification certificates.

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(iii) Welder’s identification list, listing welder’s and welding operator’s qualification procedure and welding
identification symbols.
(iv) Raw material test reports on components as specified by the specification and/or agreed to in the quality
plan.
(v) Stress relief time temperature charts/ oil impregnation time temperature charts.
(vi) Factory test results for testing required as per applicable codes/ mutually agreed quality plan/ standards
referred in the technical specification.
(vii) The quality plan with verification of various customer inspection points (CIP) as mutually agreed and
methods used to verify the inspection and testing points in the quality plan were performed satisfactorily.

20.38 EQUIPMENTS & STRUCTURES FOR CABLE TERMINATION

1. The terminating structure being provided should be designed as per the requirement of the cable end sealing,
porcelain bushing etc. The mounting structure shall be fixed on the cement concrete foundation, the design
and drawings of which shall be submitted to Employer for review and acceptance during the course of
detailed engineering.

After fixing the end termination, the cable shall be fixed to the support, with non- magnetic material
clamps to the required height securely. The mounting structure includes the supports for cable end
boxes, link boxes and any other structure required for the intent of the contract. All steel sections used
shall be free from all imperfections, millscales, slag intrusions, laminations, fillings, rust etc. that may
impair their strength, durability and appearance. All materials shall be of tested quality only unless otherwise
permitted by the Employer.
2. Suitable fencing should be provided at the cable terminating yard at cable conductor junction point. The
fencing will consist of galvanized steel XPM structure over a brick wall of 2(two) feet meeting electrical
requirement (IE). A suitable entry point (gate) has to be provided.
3. Outdoor type 120KV lightning arresters for each cable of both the circuits are to be provided at cable-
conductor junction point. The technical specification of lightning arresters is given separately in this
volume.
4. It is recognized that the Bidder may have standardized on the use of certain components, materials,
processes or procedures different from those specified herein. Alternate proposals offering similar
equipment based on the manufacturer’s standard practice will also be considered provided such proposals
meet the specified designs, standard and performance requirements and are acceptable to the Employer.
Unless brought out clearly, the Bidder shall be deemed to conform to this specification scrupulously. All
deviations from the specification shall be clearly brought out in the respective schedule of deviations. Any
discrepancy between the specification andthe catalogues or the bid, if not clearly brought out in the specific
requisite schedule will not be considered as valid deviation.

5. Equipment furnished shall be complete in every respect with all mountings, fittings, fixtures and standard
accessories normally provided with such equipment and/or needed for erection, completion and safe
operation of the equipment as required by applicable codes though they may not have been specifically
detailed in the Technical Specifications unless included in the list of exclusions. Materials and
components not specifically stated in the specification but which are necessary for commissioning and
satisfactory operation of the work unless specifically excluded shall be deemed to be included in the
scope of the specification and shall be supplied without any extra cost. All similar standard components/
parts of similar standard equipment provided shall be inter-changeable with one another.

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6. STEEL STRUCTURES (GANTRY, EQUIPMENTS ETC.):

A) The contractor shall assume full responsibility for supply, fabrication and detailing, if required of the
steel structures and for their satisfactory performance. All detail drawings for the structures shall be
supplied to the successful bidder by the Employer/Engineer. However, the contractor shall have to
submit the construction drawings to the Engineer/Employer solely prepared on the basis of these
supplied drawings. Equipment Structure drawings, supplied by the employer, shall have to be modified
to suit to the approved GA drawings of the equipment and electrical layout drg. And to be submitted to
Engineer for approval. Employer/ Engineer shall have the right to instruct the contractor to make any
changes in details necessary to make the construction conform to the requirement of the Contract
Document.

B) The contractor shall supply all materials, deliver the same to site, and provide all labour, erection plant and
equipment, fixtures, fitting and all temporary and permanent works necessary for satisfactory completion
of the job in all respects.

C) No omissions or ambiguities on the drawings or in specifications will relieve the contractor from
furnishing best quality of materials and workmanship. Should any inaccuracies be found, the contractor
shall promptly notify the Employer/Engineer without carrying out the job and no further work shall be
done before these discrepancies are corrected. Continuation of further work shall be done only after such
discrepancies are rectified at contractor's risk and responsibility.

D) MATERIALS: The materials shall conform to the following requirements:

All Structural Steel Materials to be used in construction within the purview of the specification shall comply
with :IS:2062 –Structural Steel (Grade-A) (fusion welding quality) and manufactured by Prime Rollers e.g. SAIL/
TISCO/ IISCO/ RINL. In case of MS sections not manufactured by prime rollers or such sections are not
available with prime rollers the same is to be procured from approved conversion agents of prime
manufacturer(s).In such case, prior approval of the Engineeris to be obtained by the contractor.

Successful bidder on receipt of structural drawing from department shall submit within 15 days, a detailed raw
material procurement plan indicating MS sectionwise producers name to the Engineer for approval. On according
approval in this aspect, work for fabrication protos shall be taken up in hands.

Entire fabrication job of MS structural shall not be entrusted to more than two sub- vendors. Further, a list of
bonafide fabricators, not exceeding 6 (six) shall be furnished to the Engineer for according approval within
15(fifteen) days from the date of handing over of drawings.
All electrodes to be used under the contract shall comply with any of the following Indian Standard
Specifications as may be applicable.
i) IS:814: Covered electrodes for metal arc welding of Structural Steel.

ii) IS:815: Classification and coding of covered electrodes for metal arc welding of mild steel and low alloy
high tensile steel.

iii) IS:144: Covered electrodes for the metal arc welding of high tensile structural steel.

All bolts and nuts shall be of grade 5.6HRH and shall conform to the requirements of IS:6639 and IS:1367 and
galvanizing quality shall be as per IS:1367. All bolts and nuts shall be of minimum diameter of 16mm unless
otherwise stated. All mildsteel for bolts and nuts when tested in accordance with the following Indian
Standard specification shall have a tensile strength of not less than 44Kg/Sq.mm. and a minimum elongation

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of 23 percent on a gauge length of 5.6A, where `A' is the cross sectional area of the test specimen-

i) IS:1367: Technical supply conditions for threaded fasteners.

ii) IS:1608: Method for tensile testing of steel products other than sheet, strip, wire and tube.

Washers shall be made of steel conforming to IS:226, IS:961 as may be applicable under the provisions of the
contract and shall be electrogalvanized.
7 FASTNERS & CONNECTIONS:
a) BOLTS: All connections shall be bolted with 16mm bolts.

b) SPLICES: Splicing shall be avoided unless the length of a member exceeds 6.0 m or so. The member of
splices shall be limited to a practical minimum. No credit shall be allowed for bearing on a butting areas.
Lap joints in leg members shall be preferred to butt joints.

c) STEP BOLTS: Step bolts shall be of 16mm diameter and shall have round or hexagonal head. Each step bolt
shall be provided with two hexagonal nuts. The minimum bolt length and length of unthreaded portion shall
be 180 and 125mm respectively. Step bolts shall not be used as connection bolts. The step bolts shall be
spaced alternately on the inner gaugelineoneachfaceoftheangleabout40cmcenters.Theyshallbefurnished for
one leg of each steel structure column from its base elevation.

d) U – BOLTS: U-Bolts shall be suitable furnished or steel structures to suspend or terminate insulator strings
or ground wire assemblies. Size of U-bolt shall withstand all loads acting on it.

e) BILL OF MATERIAL: Bill of material shall give the size, length and weight of each member and the
total weights of steel structures. It shall also include the number of bolts, nuts and washers per structure.

20.39 MATERIAL/ WORKMANSHIP

Where the specification does not contain references to workmanship, equipment, materials and components of
the covered equipment, it is essential that the same must be new of highest grade of the best quality of their kind
conforming to best engineering practice and suitable for the purpose for which they are intended.
In case where the equipment, materials or components are indicated in the specification as “similar” to any
special standard, the Employer shall decide upon the question of similarity. When required by the specification
or when required by the Employer the Bidder shall submit, for approval, all the information concerning the
materials or components to be used in manufacture, Machinery, equipment, materials and components supplied,
installed or used without such approval shall run the risk of subsequent rejection, it being understood that the
cost as well as the time delay associated with the rejection shall be borne by the Bidder.
The design of the Works shall be such that installation, future expansions, replacements and general maintenance
may be undertaken with a minimum of time and expenses. Each component shall be designed to be consistent
with its duty and suitable factors of safety, subject to mutual agreements. All joints and fastenings shall be
devised, constructed and documented so that the component parts shall be accurately positioned and restrained
to fulfill their required function. In general, screw threads shall be standard metric threads. The use of other
thread forms will only be permitted when prior approval has been obtained from the Employer.
Whenever possible, all similar part of the Works shall be made to gauge and shall also be made
interchangeable with similar parts. All spare parts shall also be interchangeable and shall be made of the same
materials and workmanship as the corresponding parts of the Equipment supplied under the Specification. Where

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feasible, common component units shall be employed in different pieces of equipment in order to minimize
spare parts stocking requirements. All equipment of the same type and rating shall be physically and
electrically interchangeable.
All materials and equipment shall be installed in strict accordance with the manufacturer’s recommendation(s).
Only first-class work in accordance with the best modern practices will be accepted. Installation shall be
considered as being the erection of equipment at its permanent location. This, unless otherwise specified, shall
include unpacking, cleaning and lifting into position, grouting, leveling, aligning, coupling of or bolting down
to previously installed equipment bases/ foundations, performing the alignment check and final adjustment
prior to initial operation, testing and commissioning in accordance with the manufacturer’s tolerances, instructions
and the Specification.
Provision for Exposure to Hot and Humid climate: Outdoor equipment supplied under the specification shall be
suitable for service and storage under tropical conditions of high temperature, high humidity, heavy rainfall
and environment favourable to the growth of fungi and mildew.
20.40 PACKAGING & PROTECTION

a. All the equipment shall be suitably protected, coated, covered or boxed and crated to prevent damage or
deterioration during transit, handling and storage at Site till the time of erection. On request of the
Employer, the Bidder shall also submit packing details/ associated drawing for any equipment/ material
at a later date, in case the need arises. While packing all the materials, the limitation from the point of
view of availability of Railway wagon sizes in India should be taken into account. The Bidder shall be
responsible for any loss or damage during transportation, handling and storage due to improper packing.
Any demurrage, wharf age and other such charges claimed by the transporters, railway etc. shall be to the
account of the Bidder. Employer takes no responsibility of the availability of the wagons.
b. All coated surfaces shall be protected against abrasion, impact, discoloration and any other damages. All
exposed threaded portions shall be suitably protected with either a metallic or a non-metallic protecting
device. All ends of all valves and piping and conduit equipment connections shall be properly sealed
with suitable devices to protect them from damaged. The parts which are likely to get rusted, due to
exposure to weather should also be properly treated and protected in a suitable manner.

20.41 FINISING OF METAL SURFACES

a.All metal surfaces shall be subjected to treatment for anti-corrosion protection. All ferrous surfaces for
external use unless otherwise stated elsewhere in the specification or specifically agreed shall be hot-dip
galvanized after fabrication. High tensile steel nuts and bolts and spring washers shall be electro galvanized
to service condition. All steel conductors including those used for earthing/grounding (above ground level)
shall also be galvanized accordingtoIS:2629.

b. HOT DIP GALVANISHING

The minimum weight of the zinc coating shall be 610gm/sq.m and minimum thickness of coating shall be
85 microns for all items thicker than 6mm. For items lower than 6mm thickness requirement of coating
thickness shall be as per relevant ASTM. For surface, which shall be embedded in concrete the zinc coating
shall be 610gm/sqm minimum.
The galvanized surfaces shall consist of a continuous and uniform thick coating of zinc firmly adhering to the surface
of steel. The finished surface shall be clean and smooth and shall be free from defects like discoloured patches bare
spots, unevenness of coating, spelter which is loosely attached to the steel globules, spiky deposits, blistered surface,
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flaking or peeling off etc. The presence of any of these defects noticed on visual or microscopic inspection shall
render the material liable to rejection.
After galvanizing no drilling or welding shall be performed on the galvanized parts of the equipment excepting
that nuts may be threaded after galvanizing. Sodium dichromate treatment shall be provided to avoid formation
of white rust after hot dip galvanization.
The galvanized steel shall be subjected to six one minute dips in copper sulphate solution as per IS-2633.
Sharp edges with radii less than 2.5mm shall be able to withstand four immersions of the Standard Preece test.
All other coatings shall withstand six immersions. The following galvanizing tests should essentially be
performed as per relevant Indian Standards
- Coating thickness
- Uniformity of zinc
- Adhesion test
- Mass of zinc coating

Galvanized material must be transported properly to ensure that galvanized surfaces are not damaged during transit.
Application of zinc rich paint at site shall not be allowed.
c. PAINTING
All sheet steel work shall be degreased, pickled, phosphate in accordance with the IS-6005 “Code of practice for
phosphating iron and sheet”. All surfaces which will not be easily accessible after shop assembly shall be
forehand be treated and protected for the life of the equipment.
The surfaces, which are to be finished painted after installation or require corrosion protection until installation
shall be shop painted with at least two coats of primer. Oil, grease, dirt and swaf shall be thoroughly removed by
emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid followed by washing with running
water, rinsing with slightly alkaline hot water and drying.
After phosphating, thorough rinsing shall be carried out with clean water followed by final rinsing with dilute
dichromate solution and oven drying. The phosphate coating shall be sealed with 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.
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 inspection of first coat of painting.
The exterior color of the paint shall be as per shade no: 697 of IS-5 and inside shall be glossy white for all
equipment, marshalling boxes, junction boxes, control cabinets, panels etc. unless specifically mentioned under
respective sections of the equipments. Each coat of primer and finishing paint shall be slightly different shade to
enable inspection of the painting. A small quantity of finishing paint shall be supplied for minor touching up
required at site after installation of the equipments.
In case the Bidder proposes of follow his own standard surface finish and protection procedures or any other
established painting procedures like electrostatic painting etc. the procedure shall be submitted along with the Bids
of Employer’s review and approval.
20.42 HANDLING, STORING AND INSTALLATION

a.In accordance with the specific installation instructions as shown on manufacturer’s drawings or as directed by
the Employer or his representative, the Bidder shall unload, store, erect, install, wire, test and place in to
commercial use all the equipment included in the contract. Equipment shall be installed in a neat, workman

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like manner so that it is level, plumb, square and properly aligned and oriented. Commercial use of switchyard
equipment means completion of all site tests specified and energization at rated voltage.
b.Bidder may engage manufacturer’s Engineers to supervise the unloading, transportation to site, storing, testing
and commissioning of the various equipment being procured by them separately. Bidder shall unload, transport,
store, erect, test and commission the equipment as per instructions of the manufacturer’s supervisory
Engineer(s) and shall extend full cooperation to them.
c.In case of any doubt/ misunderstanding as to the correct interpretation of manufacturer’s drawings or
instruction, necessary clarifications shall be obtained from the Employer. Bidder shall be held responsible for any
damage to the equipment consequent to not following manufacturer’s drawings / instructions correctly.
Where material/ equipment is unloaded by Employer before the Bidder arrives at site or even when he is at
site. Employer by right can hand over the same to Bidder and there upon it will be the responsibility of
Bidder to store the material in an orderly and proper manner.
d.The Bidder shall be responsible for making suitable indoor storage facilities to store all equipment, which
require indoor storage.
e.The words ‘erection’ and ‘installation’ used in the specification are synonymous.
f.Exposed live parts shall be placed high enough above ground to meet the requirements of electrical and other
statutory safety codes.
g.The design and workmanship shall be in accordance with the best engineering practices to ensure satisfactory
performance throughout the service life. If at any stage during the execution of the Contract, it is observed
that the erected equipment(s) do not meet the above minimum clearances as given in clause 4.7.1 the Bidder
shall immediately proceed to correct the discrepancy at his risks.

20.43 QUALITY CONTROL:

The contractor shall establish and maintain quality control procedures for different items of work and materials
to ensure that all work is performed in accordance with the specifications and best modern practice.
In addition to the Contractor's quality control procedures, materials and workmanship at all times shall be
subjected to inspection by the Engineer. As far as possible all inspection by the Engineer or Engineer's
representative shall be made at the Contractor's fabrication shop whether located at site or elsewhere. The
contractor shall cooperate with the Engineer in permitting access for inspection to all places where work is being
done and in providing free of cost of all necessary help in respect of tools and plants, instrument, labour and
material required to carry out the inspection. Materials or workmanship not in reasonable conformance with the
provisions of this specification may be rejected at any time during the progress of the work.
The quality control procedure shall cover but not be limited to the following items of work :
i)Steel: Quality, manufacturer's test certificates, test reports including procurement in-voice of representative
samples of materials from unidentified stocks if permitted to be used.

ii) Bolts, nuts & Washers: Manufacturer's certificate, dimension check, material testing

iii) Electrodes: Manufacturer's certificate, thickness and quality of flux coating.

iv) Welds: Inspection, X-ray, ultrasonic test, magnetic particle tests as required

v) Paints: Manufacturer's certificate, physical inspection reports.

vi) Galvanizing: Tests in accordance with IS:2633 – Method of testing uniformity of coating on zinc coated

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articles and IS:2629 Recommended practice for hot - dip galvanizing of iron and steel. Raw zinc & samples
collected from bath shall be tested at third party laboratory as per direction of the Engineer.

The contractor shall submit a detailed material inspection plan on the basis of various IS codes & standard
practices in respect of structural fabrication, galvanization, bolts, nuts, anchor bolts etc. much prior to
commencement of the job.
20.44 FABRICATION WORKMANSHIP:
All workmanship shall be equal to the best practice in modern structural shop and shall conform to the
provisions of IS:800/ IS:802.
Rolled materials before being laid off or worked, must be clean free from sharp kinks, bends, or twists and straight
within the tolerances allowed by IS:1852. If straightening is necessary it may be done by mechanical means or by
the application of a limited amount of localised heat not exceeding 600 oC.
Cutting shall be effected by shearing, cropping or sawing. Use of mechanically controlled Gas Cutting Torch may be
permitted for mild steel provided special care is taken to leave sufficient metal to be removed by machining, so
that all metal that has been hardened by flame is removed. To determine the effective size of members cut by
gas, 3mm shall be deducted from each cut edge.
The erection clearance for cleated ends of members connecting steel to steel shall preferably be not greater than
2mm at each end. The erection clearance at ends of beams without cleats shall not be more than 3mm at each
end, but where for practical reasons greater clearance is necessary, suitably designed clearance shall be provided.
All members shall consist of rolled steel sections.
Holes for bolts shall not be more than 1.5mm larger than the diameter of the bolt passing through them unless
otherwise stated.
All members shall be cut to jig and all hole shall be punched and drilled to jig. All parts shall be carefully cut
and holes accurately located after the members are assembled and tightly clamped or bolted together.
Drifting or rimming of holes shall not be allowed. Holes for bolts shall not be formed by gas cutting process.
Punching of holes will not be permitted for M.S. members upto 8mm thick and in no case shall a hole be
punched where the thickness of the material exceed the diameter of the punched hole.
Minimum bolt spacing and distances from edges of members shall in accordance withthe provisions in the
relevant Indian Standard Specification.
Built members shall, when finished, be true and free from all kinds of twists and open joints and the material
shall not be defective or strained in any way.
All bolts shall be galvanized including the threaded portion except the foundation bolts for which galvanizing
work shall be done for a length of 100mm (min) to 175mm (max) measured from the tip of the treaded portion.
The threads of all bolts shall be cleared of smelter by spinning or brushing. A die shall not be used for cleaning
the threads unless specially approved by the Engineer. All nuts shall be galvanized with the exception of the
threads which shall be oiled. In case of foundation bolts the same shall be galvanized excepting the length of
embedment.

When in position all bolts shall project through the corresponding nuts but not exceeding 10 mm. The nuts of all
bolts attaching insulator sets and earth conductor clamps to the structure shall be carefully positioned as directed
by the Engineer.
Bolts and nuts shall be placed in such a way so that they are accessible by means of an ordinary spanner.

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Foundation bolts shall be fitted with washer plates or anchor angles and flats, nuts etc. and shall be manufactured
from mild or special steel.
Washers shall be tapered or otherwise suitably shaped, where necessary to give the heads and nuts of bolts a
satisfactory bearing. The threaded portion of each bolt shall project out through the nut at least by 3mm. In all
cases the bolt shall be provided with a washer of sufficient thickness under the nut. In addition to the normal
washer, one spring washer or lock nut shall be provided for each bolt for connections subjected to vibrating
forces or otherwise as may be specified in the drawings.
The thickness of spring washer shall be 3.5 mm for bolt diameter 16 mm and 4 mm for bolt diameter 20 mm.
20.45 CLEANING & GALVANIZING: CLEANING:
After fabrication has been completed and accepted, all materials shall be cleared off rust, loose scale, dirt, oil
grease and other foreign substances.

GALVANIZING:
All materials shall be hot-dip galvanized after fabrication and cleaning. Re tapping of nuts after galvanizing is
not permitted.

Galvanizing for structural mild steel products shall meet the requirements of IS:4759. All holes in materials shall
be free of excess spelter after galvanizing.
Galvanizing for fasteners shall meet the requirements of IS:1367. The spring washers shall be electrogalvanized as
per IS:1573.
Finished materials shall be dipped in to the solution of dichromate after galvanizing for white rust protection during
transportation.
All galvanizing shall be uniform and of standard quality. Quantity of zinc shall meet the requirement of IS:209.
Mass of Zinc Coating:
The mass of zinc coating for different class of materials, as given in Table below, shall be followed:
MASS OF ZINC COATING
Sl. No. Product Electro meter Minimum value of
reading (micron) average mass of
coating
i) Casting - gray iron, malleable iron 610 (gm/m2)
ii) Fabricated steel articles :
a) 5 mm thick and over 86 610
b) Under 5 mm, but not less than 2 mm 65 460
c) Under 2 mm, but not less than 48 340
1.2mm
Threaded work other than tubes and
iii)
tube fittings :
a) 10 mm dia and over 43 300
b) Under 10 mm dia 39 270

STRAIGHTENING AFTER GALVANIZING:

All plates and shapes which have been warped by the galvanizing process shall be straightened by being rerolled
or pressed. The materials shall not be hammered or otherwise straightened in a manner that will injure the

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protective coating. If, in the opinion of Employer/ Engineer the material has been forcibly bent or warped in the
process of galvanizing of fabrication, such defects shall be cause for rejection.
REPAIR OF GALVANIZING:
Materials on which galvanizing has been damaged shall be acid stripped and re-galvanized, unless, in the opinion of
Engineer, the damage is local and can be repaired by zinc spraying or by applying a coating of galvanizing
repair compound. Where re-galvanizing is required, any member which become damaged after having been
dipped twice shall be rejected.
SHOP ASSEMBLY:
One of each type of steel structures shall be assembled in the shop to such an extent as to ensure proper field
erection in order to facilitate inspection by the Engineer.
SHOP TEST:
The following shop tests shall be performed with relevant provisions of I.S. Codes :
a) General Inspection
b) Material test.
c) Assembly test.
d) Galvanizing test.

The contractor shall furnish four certified copies of reports of all tests to the Engineer.
20.46 FOUNDATION WORKS:
GENERAL REQUIREMENT:
The design of RCC foundation for gantry and other equipment structures to be constructed shall be the
responsibility of the contractor. All design of RCC foundation works shall conform to IS: 456 (2000) unless
otherwise mentioned herein. All designs and details shall be subject to approval of the Engineer. Effect of
additional surcharge due to earth filling shall duly be taken into account during design.

However, detailed foundation design shall be based on the actual soil parameters which shall be ascertained by
the intending bidder. Any variation in design of foundations due to change in soil parameters during execution of
work shall not affect the terms of the Contract. No extra payment on account of any change what so ever in soil
parameters will be entertained.
20.47 DESIGN OF FOUNDATIONS:

20.48 STEEL STRUCTURE FOUNDATIONS:

The foundations shall be designed such that the upper structure shall be securely supported. Any unequal
displacement that may cause harmful effect to the upper structures shall not be allowed. The safety factors for
strength and stability of the foundations shall be as per relevant code.
The overload factor shall be taken as 1.1 for designing foundations of all gantry and equipment. The loads, shear
and moment values shall be multiplied with this overload factor, so as to obtain the design values.
20.49 ELECTRO-MECHANICAL EQUIPMENT FOUNDATIONS:

The foundation shall be so designed that the upper equipment shall be securely supported. The effect of vibration of
the equipment, impact load when in operation and over turning force due to abnormal condition of equipment
shall be considered in foundation design. The safety factor for stability of the foundations shall be as per relevant
code with an overload factor of 1.1.

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Following minimum values shall be used while designing foundations :

20.49.1 Minimum base slab thickness of footings : 200mm
20.49.2 Minimum bar dia for foundation : 10 mmTOR
20.49.3 Minimum bar dia for columns :12mmTORwith binder
spacing limited to 190 mmc/c
iv. Clear cover to: Main bars in base slab : 50 mm
Main bars in columns : 40 mm
Main bars of beams : 40 mm

v. Minimum reinforcement for base slab shall be 0.2 percent of cross-sectional area, depth to be
considered as effective depth and where beam slab mechanism will be deployed 0.12
percent of gross cross-sectional area shall be considered.
20.50 OTHER DETAILS

A) DETAIL DESIGN CALCULATION:

Detail design calculations for each type of foundation shall be submitted for approval of Engineer. Such
details shall show the following requirements.

i) Detailed calculation of loads acting on foundation under different loading conditions.

ii) Calculated safety factor for each type of stability and other conditions.
iii) Maximum stresses in concrete and in steel reinforcement at any critical section.

B) LINE AND GRADE:

The contractor shall set all lines and grades or elevation of the ground at all footings and set the necessary
stakes that are required for the work and will be responsible for their accuracy. Employer/ Engineer may
check lines and levels set by the Contractor from time to time, and inadequacies if any, shall be rectified by the
contractor as per the direction of the Engineer, but the responsibility for their accuracy shall rest entirely
with the Contractor.
C) DETAIL DRAWINGS:

Details of each type of foundation submitted for Employer's/ Engineer's approval shall be as shown on the approved
design drawings and shall conform to the requirements described hereafter. No change shall be made without the
written approval of Employer/ Engineer. The detail drawings shall include but not limited to the following:
i) Detail dimensions of foundation.
ii) Details of setting dimensions of foundation.
iii) Details of placing of all reinforcing steel which shall conform to the Building Code
Requirements for Reinforced Concrete (IS:456) and the Manual of Standard Practice for
Detailing Reinforced Concrete Structure unless otherwise specified herein.
iv) Details of type size and length of each reinforcing steel including schedule of bar
bending to be submitted to the Engineer at site

20.51 WEIGHT OF SUB-STATION STRUCTURES:

Self-weight of line tower, A-frame and equipment structures for different gantry and equipment structures shall
be provided at the time of detail engineering.
20.52 Technical Specification for Underground Fibre Optic Cable

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This section describes the functional requirements, major technical parameters and Type testing, Factory
Acceptance Testing & Site Acceptance Testing requirements for underground fibre optic cables and HDPE
pipes. Marking, packaging, transportation & installation requirements have also been described. The payment
will be made for the executed route length only. However, specified service loops and lengths for wastage,
installation/working for FO cable & HDPE ducts shall be considered as required by the bidder for which no
additional payment will be made.
20.52.1 General
The underground fibre optic cable shall be armoured and shall be suitable for direct burial as well as for
underground installation in pipes. The cable should be of low weight, small volume and high flexibility. The
mechanical design and construction of each unit shall be inherently robust and rigid under all condition of
operation, adjustment, replacement, storage and transport. The fibre optic cable shall be a UV resistant, rodent
proof. The underground fibre optic cable (UGFO) shall be offered from a manufacturer who has been
manufacturing UGFO for the last five (5) years and UGFO manufactured & supplied by such manufacturer shall
have been in satisfactory operation.
20.52.2 Applicable Standards
The cable shall conform to the standards named below and the technical specifications described in the
following sections.
i). ITU-T Recommendations G.652
ii). Electronic Industries Association, EIA/TIA 455-78A, 455-3A/33/41/25A / 81A / 82B, 455-
62A, 455-164A/167A/174, 455-168A/169A/170/175A, 455-176, 455-59, EIA/TIA 598, EIA
455- 104.
iii) International Electro technical Commission standards, IEC60304, IEC60794-1-2, IEC60811-
5-
iv) Bellcore GR-20
v) Indian Railways standard specification no IRS:TC55(Oct 96) (including all amendments)
vi) ASTM:A167-92,ASTM:751-92b,ASTM:A751-92,ASTM:A370-82,ASTM:D2581-
91,ASTM:D2287-81, ASTM:D 638 for FRP, ASTM :D 217,556, 93-IP-34 for Jelly, ASTM:D
570,211 for PBTP, ASTM:D1505for Poly Carbonate, ASTM:D1633,150 for HDPE.
20.52.3 Fibre Type(s) and Counts
The Cable shall consist of 24 fibres Dual-Window Single mode (DWSM), G.652 optical fibres and shall meet
the requirements stipulated in Table 1
DWSM Optical Fibre Characteristics(Table-1)

Fibre Description: Dual-Window Single-Mode

Mode Field Diameter: 8.6 to 9.5 µm (± 0.6 µm)

Cladding Diameter: 125.0 µm +/- 1 µm

Mode Field concentricity error ≤0.6%

Cladding non-circulatory ≤ 1%

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Cable Cut-off Wavelength λcc ≤ 1260 nm

1550 nm loss performance As per G .652

Proof Test Level ≥ 0.69 Gpa

Attenuation Coefficient: @ 1310 nm ≤ 0.35 dB/km

@ 1550 nm ≤ 0.21 dB/km

Chromatic Dispersion; 18 ps/(nm x km) @ 1550 nm

Maximum:
3.5 ps/(nm x km) 1288-1339 nm
5.3 ps/(nm x km) 1271-1360 nm

1300 to 1324 nm
Zero Dispersion Wavelength:
0.092 ps/(nm2xkm) maximum
Zero Dispersion Slope:

Polarization mode dispersion ≤0.2 ps/km^1/2

Coefficient

Temperature Dependence: Induced attenuation ≤ 0.05 dB (-60 0C - +

850C)

Bend Performance: @ 1310 nm (75±2 mm dia Mandrel), 100

turns;
Attenuation Rise ≤0.05 dB
@ 1550 nm (30±1 mm radius Mandrel)
100 turns;
Attenuation Rise ≤ 0.05 dB
@ 1550 nm (32±0.5 mm dia Mandrel, 1
turn;
Attenuation Rise ≤ 0.50 dB

20.52.4 General Cable Construction

Consist of a central fibre optic unit protected by one or more layers of helically wound anti-hygroscopic tape or
yarn. The central fibre optic unit shall be designed to house and protect the fibres from damage due to forces
such as crushing, bending, twisting, tensile stress and moisture, wide temperature variations, hydrogen
evolution etc. The fibre optic unit shall be of loose tube construction. The inner polyethylene jacket and outer
sheath jackets shall be free from pinholes, joints, splits or any other defects. All fibre optic cable shall have a
minimum service life span of 25 years. The cable construction and mechanical parameters for the Armoured
OFC shall be as specified in the Table 2 below.

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Table 2
Armoured Cable Construction and Mechanical Parameters

Parameter Units Description

No of fibres in the cable 24

Type of fibres in the cable G.652

No. of loose tubes Minimum 2

Cable design life More than 25 years

Colour Coding & Fibre Identification

Individual optical fibres within a fibre unit, and fibre units shall be identifiable in accordance with EIA/TIA
598 or IEC 60304 or Bellcore GR-20 colour-coding scheme. The colour coding system shall be discernible
throughout the design life of the cable. Colouring utilized for colour coding optical fibres shall be integrated
into the fibre coating and shall be homogenous. The colour shall not bleed from one fibre to another and shall
not fade during fibre preparation for termination or splicing. Each cable shall have traceability of each fibre
back to the original fibre manufacturer’s fibre number and parameters of the fibre. If more than the specified
number of fibres are included in any cable, the spare fibres shall be tested by the cable manufacturer and any
defective fibre shall be suitably bundled, tagged, and identified at the factory. The colouring scheme shall be
submitted along with the cable DRS/drawing for Employer’s approval.

Strength Members
The armoured optical fibre cable shall have solid non-metallic strength member(s)/ Solid metallic member(s)
or the combination of both. The metallic strength member shall be of high grade steel wire, music spring
quality as per ASTM-A228/A228M-93 and shall have suitable chemical coating for proper adhesion with
sheath material. The central fibre optic unit should include a central strength member of non-metallic Fibre
Reinforced Plastic (FRP) only. Peripheral strength members and aramid yarns are also acceptable. The central
FRP strength member may be of slotted type with SZ lay (reverse oscillation lay) of fibre units or it may be
cylindrical type with helical or SZ lay of fibre units. The construction of the central strength member shall be
such as to meet the mechanical strength requirements specified in this specification.
Filling Compound
The interstices of the central fibre optic unit and cable shall be filled with a suitable compound to prohibit any
moisture ingress or any longitudinal water migration within the fibre optic unit or along the fibre optic cable.
The water tightness of the cable shall meet or exceed the test performance criteria as per IEC60794-1-2-F5.
The filling compound used shall be a non-toxic homogenous waterproofing compound that is free of dirt and
foreign matter, anti-hygroscopic, electrically nonconductive and non-nutritive to fungus. The compound shall
also be fully compatible with all cable components it may come in contact with and shall inhibit the generation
of hydrogen within the cable. The filling compound shall remain stable for ambient temperature up to +70°C
and shall not drip, flow or leak with age or at change of temperature. Reference method to measure drip point
shall be as per IEC 60811-5-1 and drip point shall not be less than 70°C.
The Sheath / Inner jacket

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The Sheath shall be made of High Density Polyethylene-HDPE (Red /Black) and shall be smooth, concentric,
and free from holes, splits, blisters and other surface flaws. The sheath shall be extruded directly over the
central fibre optic unit and shall also be non-hygroscopic. The cable sheath design shall permit easy removal
without damage to the optical fibres or fibre units. The sheath shall be made from good quality of weather
resistant polyethylene compound HDPE and thickness shall be > 1.5mm including the strength member if used
in the sheath.
Armouring of cable
Over the inner PE sheath armouring and outer sheath shall be provided to make the cable termite and rodent
proof. The thickness of the stainless steel alloy armour shall be > 0.125mm. The steel armour shall be both side
coated with a copolymer of thickness > 0.05mm so as to bond the armouring to the outer jacket and make a
unitary construction. Stainless steel shall be armouring corrugated transversely for lateral strength and bending
flexibility to be applied longitudinally with an overlap of 10% (minimum) over the inner PE sheath. The
corrugation over the entire length of the tape used in the cable shall be uniform, electrically continuous
(applicable to all metallic elements used in the cable) and bonded to the outer sheath. The force of adhesion of
the armour to the outer sheath shall be minimum 14 Newton and shall be tested as per ASTM:4565 test
method. Suitable glue adhesive should be provided in between overlap portion of cable armouring for bonding
to avoid ingress of moisture (below the armour). The height of the corrugation shall be 0.6mm (min.) and the
pitch shall be 2.5mm(max.). Height and pitch of corrugation shall be measured between crest and tough base
line. The corrugated armouring of stainless steel shall offer excellent corrosive resistance and shall be AISI
Alloy no. 304 and the chemical composition and mechanical properties of steel shall be as specified in table 1
& 2 of ASTM : A167-92b for AISI 304 respectively.
The Outer Jacket
A non-metallic moisture barrier sheath (Red or Black in colour) shall be applied over the armour, which shall
consist of tough weather resistance made of HDPE. The thickness shall be uniform and shall not be less than
2.0mm (Red in colour) for the cable having inner and outer HDPE sheath. The outer jacket shall have smooth
finish and shall be termite resistant. The raw material and additive used to make the outer sheath termite proof
shall be clearly mentioned by the manufacturer of the cable.
In case of HDPE material black in colour is used, the material from finished product shall be subjected to the
following tests mentioned in Table 3 below;

Table 3

1.Density 0.94 to 0.965 gm/cc

2.Melt flow index < 0.8 gm/10 minutes at 1900 C

3.Carbon black content (2.5+0.5)%

4.Carbon black Dispersion Uniform dispersion

5.ESCR No crack till 48H in 10% Igepal solution

500C

6.Moisture Content <0.3% for 24H, ASTM D570

7.Tensile strength and Elongation at >2 Kg.mm2 and > 500% respectively
break

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Rip Cord: Suitable rip cord(s) shall be provided to open the outer sheath of the cable. The rip cord(s) shall be
properly waxed to prevent wicking action and shall not work as a water carrier.
20.52.5 Mechanical Parameters & Tests: The offered cable shall meet requirement of mechanical
characteristic & tests specified in this specification.
20.52.6 Cable drums, Marking, Packaging and Transport
All optical fibre cable shall be supplied on strong wooden drums provided with lagging with adequate strength,
constructed to protect the cabling against all damage and displacement during transit, storage and subsequent
handling during installation. The cable drum shall be suitable to carry underground fibre optic cable of
required length. However, the exact lengths for drums to be supplied for each link shall be determined by the
Contractor during detailed engineering/survey. Drum schedule shall be approved by the Employer before
manufacturing the FO cable. Both cable ends in the drum shall be sealed and shall be readily accessible. The
drum shall be marked with arrows to indicate the direction of rotation. Both the ends of the cable shall be
provided with pulling eye. The pulling eye and its coupling system should withstand the same tensile load as
applicable to the cable. The following marking shall be done on each side of the cable drums.

i) Drum number
ii) Consignee’s name and address
ii) Contractor’s name and address
iv) Type of cable
v) Number of fibres
vi) Type of fibres
vii) Year of manufacturing, month & batch no
viii) Name of manufacturer
ix) Total cable length
x) Inner end marking and Outer end marking
Packing list supplied with each drum shall have all the information provided on marking on the respective
cable drum and following additional information: OTDR length measurement of each fibre and Ratio of fibre
and cable length.
20.52.7 Optical fibre cable marking
A suitable marking shall be applied in order to identify this cable from other cables. Marking on the cable shall
be indelible, of durable quality, shall last long and shall be applied at regular interval of one-meter length.
Marking shall be imprinted and must clearly contrast with the surface and colours used must withstand the
environmental influences experienced in the field. The accuracy of the sequential marking must be within +
0.5% of the actual measured length. The sequential length marking must not rub off during normal installation.
In case laser printing is used the marking shall not exceed 0.15 mm depth. The optical fibre cable shall have
the following markings in every meter.
i) Type of Cable
ii) Running meter length
iii) Number of fibres
iv) Type of fibre
v) Laser symbol & caution notice
vi) Year of manufacture and batch no.
vii) Manufacturer’s name
viii) Owner’s Name

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20.52.8 Operating Instructions

Complete technical literature in English with detailed cable construction diagram of various sub-component
with dimensions and test data of the cable shall be provided. All aspects of installation shall also be covered in
the handbook.
20.52.9 Test and Inspection:
`Type Testing
The Bidder shall offer only the type tested cable and submit along with their bid the earlier carried out type test
reports for the offered fibre optic cable meeting the requirement. The Contractor shall submit the previously
carried out type test report for the same design of cable for the tests listed in Table below. The fibre should
have been type tested as per relevant International standards for the tests listed in Table below and the Bidder
shall submit the test reports and certificates along with the bid. The Contractor shall submit the type test
reports of fibres meeting the minimum requirement specified in Tables below.

Type Tests Fibre Optic Cable

TABLE-4

S. No Test Name Test Procedure

Type Tests Fibre
1 Water Ingres Test (IEC 60794-1-F5/EIA 455-82B) Test duration:24
Optic Cable
hours
TABLE-5
2 Seepage of filling (EIA 455-81A) Preconditioning: 72 hours,
S. No compound
Test Name Acceptance Criteria Test Procedure
Test duration: 24 hours
1 Attenuation IEC 60793-1-40 or EIA/TIA
3 Crush test IEC 60794-1-E3/EIA 455-41)
455-78A
4 Impact test (IEC-60794-E4/ EIA 455-25A)
2 Attenuation Variation IEC 60793-1-40 or EIA/TIA
5 with wavelength
Stress strain Test (EIA 455-33A) 455-78A

3 6 Attenuation at wavelength
Water As per TS IEC 60793-1-40 or EIA/TIA
Cable Cut-off (EIA 455-170)
Peak 455-78A
7 Temperature Cycling Test (IEC60794-1-F1/EIA-455-3A)-2 cycles
4 Temp Cycling (Temp IEC 60793-1-52 or EIA/TIA
dependence of 455-3A, 2 cycles
5 Attenuation)
Attenuation with Bending IEC 60793-1-47 or EIA/TIA
(Bend Performance) 455-62A

6 Mode Field dia. IEC 60793-1-45 0r EIA/TIA

455-164A/167A/174

7 Chromatic dispersion IEC 60793-1-42 or EIA/TIA

455-168A/169A/175A

8 Cladding Diameter IEC 60793-1-20 or EIA/TIA

455-176
As per TS
9 Point Discontinuities of IEC 60793-1-40 or EIA/TIA
attenuation 455-176
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10 Core-Clad concentricity IEC 60793-1-20 or EIA/TIA
error 455-176

11 Fibre Tensile proof testing IEC 60793-1-30 or EIA/TIA

455-31B
 CHAPTER 20: TECHNICAL SPECIFICATION FOR XLPE CABLE WITH TERMINATION

Factory Acceptance Testing

The tests listed in Table below shall be carried out as Factory Acceptance Test for Underground fibre optic cable
meeting the requirements specified in this section.

Factory Acceptance Tests on Underground Fibre Optic Cable

Sl No Factory Acceptance Test

1 Attenuation Coefficient (1310, 1550): By EIA/TIA 455-78A or OTDR

2 Point discontinuities of attenuation: By EIA/TIA 455-78A or OTDR

3 Visual Material verification dimensional checks as per approved

drawings

20.52.10 PLB HDPE PIPE and ACCESSORIES

The following paragraphs describe the functional requirements, major technical parameters and Type and Factory
Acceptance Testing requirements for Permanently Lubricant High Density Polyethylene (PLB HDPE) Pipe. PLB
HDPE pipe shall be suitable for underground fibre optic cable installation by blowing as well as conventional pulling.
The PLB HDPE pipe shall be suitable for laying in trenches by directly burying, laying through G.I/RCC hume pipe
and laying through trench less digging. The expected service life of HDPE pipe and accessories shall not be less than
50 years. The unit rates quoted in the price schedule shall be the composite price of PLB HDPE pipe along with all
accessories.
Construction of PLB HDPE pipe
The PLB HDPE pipe shall have two concentric layers viz. outer layer and inner layer. The outer layer shall be made of
HDPE material and the inner layer of solid permanent lubricant. These concentric layers shall be co-extruded and
distinctively visible in cross section under normal lighting conditions and generally conform to IS-9938. The colour of
the PLB HDPE pipe shall be finalized during detail engineering. In the finished PLB HDPE pipe, the co-extruded
inner layer of solid permanent lubricant shall be continuous and integral part with HDPE outer layer and preferably be
white in colour. The inner layer of solid permanent lubricant shall not come out during storage, usage and throughout
the life of the pipe. The pipe shall be supplied in a continuous length of 1000 (one thousand) meter in coil form,
suitable for transportation, installation and handling purposes. The finished pipe shall be of good workmanship such
that the pipe is free from blisters, shrink holes, flaking, chips, scratches, roughness, break and other defects. The pipe
shall be smooth, clean and in round shape, without eccentricity. The ends shall be cleanly cut and shall be square with
axis of the pipe.
General
The HDPE pipe shall conform to the following standard and the technical specifications described in the following
sections.
a) IS: 4984 / IS: 2530/IS:14151/(part1)/ IS:9938/IS:7328/IS12235(Part-9)/IS:5175
b) ASTM D 1693/ ASTM D 638/ ASTM D 648/ ASTM D 790 / ASTM D 1712/
ASTM D 2240/ ASTM D 4565 / ASTM F 2160/ ASTM G 154

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c) TEC-spec no. GR/CDS-08/02/NOV-04(including all amendments)-HDPE pipe for

use as duct for optical fibre cable.
Material
The raw material used for the PLB HDPE pipe shall meet the following requirements:
(i) The anti-oxidant establishers, colour master batch and other additive used shall be physiologically
harmless and shall be used only to minimum extent necessary to meet the specification.
(ii) Usage of any additives used separately or together, should not impair the long-term physical and
chemical properties of the PLB HDPE pipe. Under Ground Fibre Optics-Technical Specification Page
13 of 32.
(iii) Suitable Ultra Violet stabilizers may be used for manufacture of the PLB HDPE pipe to protect against
UV degradation when stored in open for a minimum period of 8 months.
(iv) The ash content of the colour master batch shall not be more than 12% when tested as per method
detailed below:
Test Method for ash content: About one gram of the sample under test shall be taken and dried at 105°C
for two hours in a platinum or glazed porcelain or silica or quartz crucible. The weight of the sample
shall be noted. Subsequently, the sample with the crucible shall be transferred to a muffle furnace
maintained at 600±50°C and allowed to remain there for three hours. The ash content may be calculated
as a percentage of the weight of the original sample.
(V) The base HDPE resin used for manufacturing outer layer of pipe shall conform to any grade of IS-7328
or to any equivalent standard meeting the following requirement when tested as per standards referred in
this Section below.
a) Density (outer and inner layer): 940 to 958kg/m3 at 27°C. The density of completed PLB HDPE shall
not be differ by more than 0.003gms/cc by this value when tested as per IS:2530 or IS:7328.
b) Melt Flow Rate (MFR): 0.2 to 1.1 g/10 minutes at 190°C & 5 kg load: when tested as per IS:2530.
The MFR of the outer layer of the completed PLB HDPE pipe shall not differ by more than 30% of
this value.
c) Tensile Strength at Yield: 20 N/mm2 minimum, when tested As per ASTM D 638, Type-IV
specimens
d) Elongation at break: >600%, when tested as per ASTM D638, Type-IV specimens
e) Flexural Modulus at 1% strain: 690 N/mm2 minimum, when tested as per ASTM D
790.
f) Hardness, Shore-D: Between 60 and 65 units, when tested as per ASTM D 2240
g) Heat Deflection Temperature at 45 g/mm2: 65ºC minimum, when tested as per ASTM D 648.
h) Environmental Stress Crack resistance, When tested with 10% Igepal, CO 0630 Solution 50ºC: 96
hrs., when tested as per ASTM D 1693, No cracks.
i) Weathering in artificial (UV) light (Specimens shall be as per ASTM D 638 Type-IV) and cut from
compression moulded sheet. After exposure for 720 hrs., Tensile strength shall be tested. The
variation shall not be greater than 20% compared to tensile strength obtained at above.
j) OIT (in Aluminium Pan): 30 minutes minimum, when tested as per standard

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k) UV Stabiliser Content: Hindered Amine Light Stabliser minimum 0.15%, when analysed as per FT-
IR method.
(VI) In the inner layer of PLB HDPE pipe, the friction reducing, polymeric material to be used as the inner
layer lubrication material shall be integral with HDPE layer. The lubricant materials shall have no toxic
or dermatic hazards for safe handling.
Dimension of pipe
The nominal size of the pipe shall be minimum 40mm for OFC Cable and minimum 160mm for 132KV Cable and
Thickness ,Pressure of the HDPE pipe will be depending as per the requirement of site Condition.
Accessories of PLB HDPE pipe
The following accessories are required for jointing the pipe and shall be supplied along with the pipe. The manufacturers
shall provide complete design details, procedure for method of installation and type of the material used for the
accessories. No part of the accessories shall contain metal part and minimum pulling force of the coupler shall be
330kgf. The accessories shall pass the ageing test at 70+2ºC and there shall be no leakage when tested for 168 hours.
i) Plastic coupler: The coupler shall be used to join two PLB HDPE pipes. The coupling shall be able to
provide a durable airtight and watertight joint between two pipes without deteriorating the strength of
the pipes. The strength of coupler shall match the primary strength of the PLB HDPE pipe and
threaded coupler is not acceptable. The jointing shall meet the air pressure test of 15 kg/cm2 for a
minimum period of 2 hours without any leakage.
ii) End plug: This shall be used for sealing the ends of empty pipe, prior to installation of FO cable and
shall be fitted immediately after laying of the PLB HDPE pipe, to prevent entry of any unwanted
elements such as dirt, water, moisture, insects/rodents etc.
iii) Cable sealing plug: This is used to hold the cable and prevent entry of any unwanted elements, as
specified above.
iv) End cap: This cap is made of hard rubber, shall be fitted with both ends of PLB HDPE pipe to prevent
the entry of any unwanted elements such as dirt, water, moisture, insects/rodents during transportation
and storage.
v) Set of installation/maintenance accessories comprising of C-Spanners for tightening plastic coupler
(4 nos.), Rotary duct cutter (2 nos.), spare cutting wheel (4 nos. Per Rotary Duct cutter), Chamferring
tool for giving slight chamfer to the ends of PLB HDPE pipe shall be used during maintenance
of the PLB HDPE pipes and these items (1set) shall be supplied along with the pipe.
Workmanship
The pipe shall be free of blisters, shrink holes, break and other defects. The PLB HDPE pipe ends shall be cut as
square as possible to longitudinal aspects. The internal and external PLB HDPE pipe surfaces shall be smooth. The
colour should be uniform throughout.
Marking
All the pipe, shall be clearly marked at intervals of 1 meters with the following data which is not less than 5 mm high.
The details of marking on pipe shall be approved by Employer before commencement of manufacturing.
i) Owner’s Name with logo
ii) Manufacture’s name or trade mark

iii)Year of manufacturing
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iv) Type of PLB HDPE pipe and size

v) Running length marking
Tests & Inspection: The general condition of testing & inspection is given in section-03 of technical specification.
Type Test
The PLB HDPE pipes & accessories offered to be supplied should have been type tested as per requirement specified
in relevant TEC specification or equivalent standard. The Bidder shall enclose the previous type test report and/or
type approval certificate from Telecom Engineering Centre (TEC), Department of Telecommunication, according to
relevant TEC for the proposed PLB HDPE duct meeting the specified requirement.
Factory Acceptance Testing:
The following tests shall be carried out during Factory Acceptance Testing (FAT) in Table 2- 4.
20.52.11 Installation of Underground Fibre Optic Cable System
The Underground Fibre Optic Cable shall be installed along the power cable to be supplied & installed under this
Project. This part of the section describes the installation procedures, installation of PLB HDPE pipes, installation of
RCC hume pipes and GI Pipes, marking, backfilling, installation of underground FO cable, construction of manholes,
splicing, termination and site acceptance testing requirements of the underground fibre optic cabling system.
20.52.12 Installation of PLB HDPE Pipe
One PLB HDPE pipe shall be laid at bottom of the trench after making the surface smooth and providing minimum
80 mm sieved, stone free sand bedding. After laying the pipe additional sieved sand shall be added to increase the
height of the sand layer to a total of 200 mm hence positioning the PLB HDPE pipe in the middle of the layer. Other
important steps are described as under:
a. PLB HDPE Pipe shall be laid in a flat bottom trench free from stones, sharp edged debris.
b. The Pipe shall be placed in trenches as straight as possible. Minimum bending radius of pipe and fibre
optic cable shall always to be taken into account.
c. The ends of pipes shall always be closed with end plugs to avoid ingress of mud, water or dust i.e. all
pipe opening shall be sealed to avoid entry of foreign material.
d. The pipes shall be joined tightly & properly through plastic couplers and the joint shall be smooth and
free from steps. The joints shall be made properly so that it passes the duct integrity test specified in this
section. All joints shall be assembled with proper tools only.
e. Coupler shall not be placed along the bend portion of the pipe
f. Cable sealing plugs shall be provided at all manhole locations and at locations cable is coming out of the
pipe and empty pipe ends i.e. all pipe openings shall be sealed to avoid entry of foreign objects.
g. PLB HDPE pipes shall be installed in a manner that fibre optic cable can be pulled, blown, de-blown
without damaging the fibre optic cable due to stresses. The Contractor shall all joints inspected before
carrying out the backfilling, by a representative of Owner/Employer. Joints shall be visually inspected
and checked for tightness.
20.52.13 Reinstatement
The contractor shall be required to carry out reinstatement of the excavated area. Reinstatement shall include all
works necessary (such as reconstruction of metalled/asphalt road, footpath etc) to restore the excavated area to
original quality and shape. Temporary reinstatement of footpath stipulated in this section shall be carried out as a part
of backfilling. The Contractor shall be responsible for carrying out complete reinstatement work irrespective of area
or type of reinstatement without any additional cost implication to Employer.

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20.52.14 Installation of GI Pipe

The GI pipe of nominal bore of minimum 100 mm shall be laid wherever road crossings, bridge crossings, railway
crossings are encountered on the route as well as on wall/floor crossings in a building. PLB HDPE pipe shall be
inserted into GI pipe. Whenever it is not possible to install the FO cable underground due to non availability of the
right of way or any other unavoidable reasons, the HDPE ducts along with FO cable shall be installed in GI pipe on
the wall inside the sewerage pipe and or on the existing rock/concrete/brick wall/surface with suitable fixing
arrangement and concreting, if necessary, with specific approval of the Employer in case to case basis. The GI pipe
shall conform to at least medium class and conform to IS: 1239 (Part – I). In regard to bridge and culvert crossing, GI
pipe may be installed by concreting the GI pipe along the bridge or by using supporting brackets or by laying
underneath the existing footpath etc. The PLB HDPE pipes shall be installed through this GI pipe. Wherever
underground fibre optic cable is required to be spliced to overhead fibre optic cable using the outdoor Joint Boxes
installed on towers, GI pipes shall be used to protect the portion of the cable/duct upto a height of about 6 to 10
meters and shall be extended in the ground up to suitable depth of the trench so that minimum bending radius of the
cable is maintained. The GI pipe shall be properly clamped/ fixed on the tower leg. The Contractor shall supply and
install all necessary accessories as part of the installation work. The Contractor shall propose the exact methods and
procedures for implementation of crossings taking into consideration the following guidelines, for approval by the
Employer:
a. The GI pipe shall be extended at least 5 meters on each side of crossing subject to availability
of space and approval of the Employer.
b. Two GI pipes shall be joined using proper tools, sockets and accessories etc.
c. Proper arrangements shall be made to seal the ends of GI pipe after installation of PLB HDPE
pipes.
d. Minimum bending radius of optical fibre cable shall always be taken into consideration.
e. 1:2:4 concrete shall be used for encasing of the GI pipe, wherever required.
f. The floor of the trench shall be levelled by laying at least 50 mm of soft soil or sieved sand
before installing the GI pipe.
g. The GI pipes shall be supplied in standard lengths of 6m or as approved by Employer.
h. The GI pipe shall be sealed at both ends.
i.The GI pipe of suitable length shall be provided at road crossings, bridge crossings, railway
crossings encountered on the route as well as on wall/floor crossings in a building and also for
protection of fibre optic cable at tower/pole mounted joint boxes.
20.52.15 Underground Fibre Optic Cable Installation
The cable shall be installed inside the 40mm diameter PLB HDPE pipe installed under this package along the route(s).
Generally the cable shall be installed by compressed air blowing technique. However, for spans upto 150 meter, the
Contractor can use pulling method for installation of OFC in HDPE pipe. If any temporary manhole or hand hole is
required for installation of OFC, the same will be done by the Contractor without any additional cost implication.
Adopting pulling method for installation of OFC for spans more than 150 meter, shall be subjected to approval of the
Employer and shall be substantiated by proper justification. Contractor shall take into consideration the following
guidelines, for installation of OFC approval by the Employer.
a. The Optical Fibre Cable Drums shall be handled with utmost care. The drum shall not
be subjected to shocks by dropping etc. They shall not be normally rolled along the ground for
long distance and when rolled, shall in the direction indicated by the arrow. The battens shall
be removed only at the time of actual laying.
b. A blowing machine in association with an appropriate compressor shall be used for blowing.

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c. Temporary blowing chambers (if required) shall be constructed and then backfilled after
blowing operation is completed.
d. Locations along the route, which provide easy access points for blowing machine and
compressor, shall be determined.
e. Before starting the cable blowing, PLB HDPE pipe shall be checked for obstacles or
damage. Checking shall be done by using a proper sized mandrel.
f. Always blow downhill wherever possible.
g. Multiple blowing machines may be used in tandem if so required.
h. Care must be taken not to violate the minimum bending radius applicable for the fibre optic
cable. Tension in the cable during laying shall not exceed tension limit of the OFC. Installation
by pulling may be permitted by the Employer only in specific cases where installation by
blowing is not feasible on specific approval from the Employer. In case pulling is used, the
pulling speed shall be determined considering the site condition. While installing the cable,
excess length of about 10 meters shall be stored at each joint location for each side. Excess
length of 10 m shall be kept at one ends of a road crossing culvert crossing and 20 meters at
one end of bridges. However, exact excess lengths and manhole locations shall be finalised
during detailed engineering depending upon the site requirement.
20.52.16 Trenchless Digging
It is envisaged that trenchless digging shall be used in short section for crossing National highways, important road or
rail crossings etc. Trenchless digging shall be used where the concerned authorities do not permit open cut method
and it is essentially required to carry out for installation of HDPE pipe.
Contractor’s Scope of Work for Trenchless Digging
The Contractor’s scope of work under this contract shall include, but shall not be limited to, the following:
(a) Identify, provide and transport all equipment to the locations along the route as per the
requirement to install PLB HDPE pipe by trenchless digging method.
(b) Excavation and backfilling of entry and exit pits.
(c) Detection and protection of existing underground facilities of other utilities along the route.
(a) Installation of 40 mm PLB HDPE pipe along the specified route by trenchless digging method
and joining of PLB HDPE pipe by plastic coupler and sealing of PLB HDPE pipe at both ends
by end plugs.
(b) Installation of manholes, termination of PLB HDPE pipes into the manholes and sealing of
PLB HDPE pipes at the manhole entry as per approved drawings.
(c) Providing all plants, tools and tackles, consumables, marking and fencing required for the
execution of the work as per the best engineering and safety practices.
(d) Maintain all lights, guards, plates, safety measures, sign boards etc. When and where necessary
and/or required by the Owner/Employer or by any other statutory authority for the protection
of works and/or for the safety and convenience of the public or the workers at the installation
sites.
(e) Arrange electricity by arrangement of generators or other means at the site wherever required.
(f) Arrange construction water at the sites.
(g) Intimation to road maintenance agency, traffic police, other concerned utilities as necessary.
(h) Testing and inspection of installed PLB HDPE pipes and manholes.
(i) Rectifications, re-digging and re-installation of PLB HDPE pipes in case of problem during
testing and fibre optic cable blowing/pulling.

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As Built Drawings/details
The Contractor shall submit the as built drawings for the whole route indicating the route, depth of digging and
manhole locations for easy maintenance of the installed system.
List of Drawings/documents required to be submitted for Employer’s Approval
The Contractor shall ensure that the required drawings and documents are submitted well in time to avoid any delay
in approval and project execution. The following minimum drawings and documents are required to be submitted by
the Contractor for approval of the Employer:
a. The methods/procedures and the equipment/machines to be used for different types of trenchless
digging techniques

b. Bill of quantities for various items as per contract

c. SAT Reports

d. As built drawings

20.52.17 Site Acceptance Testing (SAT)

The tests, checks, adjustments etc conducted by the Contractor prior to offering the equipment/material for SAT shall
be called Pre-SAT activities. During installation the Contractor shall maintain proper record of measurements in
approved format and shall be given to the Owner/Employer (along with As Built drawing of the routes) for cross
checking during SAT.
SAT for Excavation, Backfilling, Installation of Pipes, Manholes.
The tests shall include but shall not be limited to the following:
a. Depth Check: One sample every 200 mtrs, Contractor shall prepare a sample pit at a location identified
by the Employer. Depth of each item, warning tape, no. Of warning bricks (if applicable), pipes, cable etc.
Shall be measured. Depth shall be as per technical specifications and shall correspond to recorded
measurements.
b. Crossings: 10% of each type, visual inspection for checking conformance with drawings, thickness of
Concrete, RCC Hume Pipe and GI pipe.
c. Manholes: As per technical specifications.
After inspection the Contractor shall backfill and carry out other restoration work at no additional cost to
the Owner/Employer.
SAT for Underground Fibre Optic Cable
SAT for optical fibre cable shall be carried out link by link. Prior to installation, every fibre optic cable segment shall be
tested for continuity and attenuation and measurements shall be recorded. Test requirements are as per table 2-7. Any
discontinuity or attenuation beyond permissible limits in any of the fibres has to be recorded and brought to the notice of
Employer. Upon completion of a continuous cable path, all fibres within the cable path shall be demonstrated for
acceptance of the cable path. Test requirements are indicated in table 2-9 and in no case losses attributed due to other
factors viz. Extra splice, kinks, will be acceptable to the limit determine by the following formula:
Max attenuation @ 1550 nm: 0.21dB/km + 0.05dB x total no of splices + 0.5dB x connector
Max attenuation @ 1310nm: 0.35dB/km + 0.05dB x total no of Splices + 0.5dB x connector

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 CHAPTER 20: TECHNICAL SPECIFICATION FOR XLPE CABLE WITH TERMINATION

Any increase in attenuation or step discontinuity in attenuation shall not be acceptable and shall constitute a cable failure
during installation. The Contractor shall have to either replace the concerned cable span at its own cost or provide
additional splicing, joint box and manholes required to rectify the fault at its own cost. The fibre attenuation shall be
tested again after replacement or rectification of fault. In case it is found that the splices are bad (loss is unacceptable as
per approved test procedures), the Contractor shall have to do re-splicing and provide new Joint Box wherever required
at no additional cost to the Owner/Employer. After re-splicing the end to end testing shall be repeated. The splice testing
requirements are indicated in table below.

Table 6: Fibre Optic Cable Pre-Installation Testing

Item Description

1 Physical Inspection of the cable assembly for damage

2 Optical fibre continuity and fibre attenuation with OTDR at 1550 nm

Table 7 : Fibre Optic Cable Splice Testing

Item Description

Per splice attenuation with OTDR (bi-directional average) at 1550 nm

1

2 Physical inspection of Joint Box for proper fibre routing techniques

3 Physical inspection of sealing techniques, weatherproofing, etc

Table 8: Fibre Optic Cable Commissioning Testing

Item Description

Fibre continuity and link attenuation (bi-directional) for each fibre at 1310
1
&1550 nm by OTDR

Fibre continuity and link attenuation (bi-directional) for each fibre at 1310
2
&1550 nm by Power Meter & Laser Source

Average splice loss (bi-directional) for each splices and average splice loss
3
for the link by OTDR at 1550 nm.

SAT for PLB HDPE pipe

For PLB HDPE pipes, duct integrity tests shall be carried out as described below. The Duct cleaning (Sponge test)
test shall be carried out on all the ducts before blowing/pulling of the cable between two consecutive manholes on
the PLB HDPE pipes.

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Duct cleaning (Sponge test)

Compressed air should be blown through the PLB HDPE pipe in order to remove dirt and water, if any, with the
help of suitable Air Compressor. A short blast of air about 2-3 Bar shall be blown through the PLB HDPE pipe for
about 2 minutes. Sponge shall be blown through the duct to thoroughly clean the duct from inside.
Crush and deformity test
Place a shuttle of length <15cm and O.D. 80% of the inner diameter of the offered PLB HDPE pipe. Connect the
compressor pipe with a suitable flexible wire grip at the other end to catch the shuttle and start blowing operation to
the pipe and check if shuttle reaches at the other end. If shuttle gets stuck the Contractor shall adopt suitable
arrangement at site to locate the deformity/damage in the HDPE pipe, repair the pipe and ensure end-to-end
continuity of the duct in sound condition.
20.52.17 Documentation
Apart from survey reports as mentioned above, the Contractor will submit the following documents after
completion of the job and acceptance by the Employer:
(a) As built drawing of the route indicating the distance from road centre, OFC drum length, location of
other utilities, link Q, OFC loop length, name of the road, sections and positions of PLB HDPE pipes,
couplers, warning bricks/stone, manholes, G.I. pipes, RCC pipes, joint box, conduits, bends, trays,
optical fibre cable loop lengths in manholes etc.
(b) Depth of PLB HDPE pipe in various sections of the route executed through open trenching.
(c) Sections of trenching digging executed through various methods.
(d) Specific deviation w.r.t. the installation and supply items, if any, from the technical specification. If
there is no deviation, either explicit or implicit, the Contractor will provide a certification to this effect.
(e) Without submission of the above documentations, the Site Acceptance Testing of various items as
described above will be deemed to be incomplete.
20.52.18 Miscellaneous Jobs
In order to provide end-to-end connectivity, it may be required to execute some miscellaneous jobs as detailed
below.
Routing of Cables inside building.

In order to route the OFC (Optical Fibre Cable) from the underground trench to the control room building it is
necessary to install the cable on walls inside PLB HDPE pipe over the existing cable tray/raceways inside the
building.
Installation of PLB HDPE pipe on wall
The PLB HDPE pipe may be required to be installed on the wall using steel or G.I clamps. The contractor will
provide the required clamps and other consumables sufficient for such installation. The contractor will take care of
aesthetics while installation. The OFC will be pulled through the PLB HDPE pipe with due care as described in
relevant Para of this specification.
20.52.19 INSPECTION & TESTING
Type Testing

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Bidder shall offer the type tested product meeting the requirement of technical specifications.
Factory Acceptance Tests
Factory acceptance tests shall be conducted on randomly selected final assemblies of all equipment to be supplied.
Visual inspection shall be carried out on 100% basis for all the equipment/items offered. Factory acceptance testing
shall be carried out on Underground fibre optic cable, Joint box, PLB HDPE pipe etc.
20.52.20 System Maintenance
The one year period commencing immediately after the operational acceptance is called the Defect liability
Period/warranty period. Operational Acceptance shall be given on successful completion of SAT. During this
period, the Contractor shall replace or repair all defective parts. The one year period commencing immediately after
the operational acceptance is called the Warrantee Period/Defect Liability Period. During the Warranty
Period/Defect Liability Period, the Contractor shall guarantee that there shall be minimum outage of the supplied
system. During this period, the Contractor shall replace or repair all defective parts and shall have prime
responsibility for maintaining an operational system.
20.52.21 Documentation
The documentation provided shall include the following:
(a) Detailed list of the deliverables
(b) Description of the products
(c) Technical particulars
(d) Installation manuals
(e) Maintenance manuals
(f) Quality assurance manuals, Manufacturing Quality Plan (MQP) & Field Quality

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 Sl.No. Particulars Details

1 Description of Cable ARMOURING: ARMOURED

CHAPTER 20: TECHNICAL SPECIFICATION FOR XLPE CABLE WITH TERMINATION
CORE MATERIAL: COPPER
INSULATION: XLPE
NOMINAL AREA: 1000 SQ.MM.
NO.OF CORE: Single Core
SHEATHING MATERIAL: EXTRUDED
PVC, INNER & OUTER
20.53 SPECIFIC
TECHNICAL VOLTAGE GRADE: 33KV PARTICULARS
FOR 33 KV XLPE CABLE

2 Highest system voltage 36 KV

3 Voltage Grade 19/ 33KV

4 Earthing System Effectively earthed

5 Frequency 50 Hz

6 Size of Cable 1000 sqmm

No. of Core 1C

7 Rated Power Frequency 70 KV (rms)

Withstand Voltage (1 min)

8 Impulse withstand BIL (1.2/ ±170 kVp

50/ micro Sec) Line to earth

9 Rated short time withstand 31.5 KA (rms) for 3 sec

current

10 Rated peak withstand current 50 KA

(1 sec)

11 No of phase per Ckt 3

12 Maxm.Conductor temp 90 degree C at maxm. continuous current

13 Maxm. Permissible short 250 degree C for one second

circuit Temperature

14 End Sealing H.S. Caps

15 CABLE DETAILS :
CONDUCTORS

i Conductor material Plain un-tinned annealed copper

ii Conductor Shape Compacted circular.

iii Conductor Screen Extruded, Cross-linked, semi conducting

compound of suitable thickness. Semi
conducting separator tapes with 50%
overlap to be applied between conductor
and conductor screen.

iv Resistivity of the Maximum 1000 ohm-meter

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16 INSULATION

i Insulation material XLPE

ii Insulation thickness 8.8 mm (Nominal thickness)

CHAPTER 20: TECHNICAL SPECIFICATION FOR XLPE CABLE WITH TERMINATION

20.54 SPECIFIC TECHNICAL PARTICULARS FOR 66KV, 132 KV & 220KV XLPE CABLE

Sl.No. ITEMS PARTICULARS

1 Description of Cable Stranded single core compacted copper core

screening by a layer of semi conducting tape
followed by a layer of semiconducting
compound as conductor screen, XLPE

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insulation, insulation screening with

semiconducting compound extruded directly
over the insulation, (semiconducting
conductor screen, XLPE insulation,
semiconducting insulation screen-all in one
triple extrusion process), longitudinal sealing
by a layer of water swellable semiconducting
non woven tape over insulation screen,
followed by radial sealing (metal sheath of
Corrugated Aluminum),and overall extruded
black HDPE Sheathed (TypeST7).
2 Highest system voltage 72.5KV 145KV 245KV

3 Voltage Grade 36/66KV 76/132KV 127/220KV

4 Voltage variation +10% and -12.5%

5 Frequency 50 Hz

6 Frequency variation ±3%

7 Power frequency withstand voltage 90KV rms for 30 minutes

190 KV rms for 30 minutes

318KV for 30 minutes

8 Lightning impulse withstand ±325KVpeak 650KVpeak 1050peak
voltage

10 No of phase per Ckt 3

11 Earthing system Effectively earthed

12 Size of Cable 240/ 300/ 400/ 630/ 800/ 1000sq.mm

13 Max. in Conductor Temp. 90ºC at maximum continuous current.

14 Fault level 31.5KA for 3 second

40KAfor3second
50KAfor3second (considering parallel path of
lead sheath and screen copper for metallic
screen)
15 Maximum permissible short ckt 250ºC for one second.
temperature.
16 CABLE DETAILS : CONDUCTORS

16.1 Conductor material Plain un-tinned annealed copper.

16.2 Conductor Shape Compacted circular.

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16.3 Conductor Screen Extruded, Cross-linked, semi conducting

compound of suitable thickness. Semi
conducting separator tapes with 50% overlap
to be applied between conductor and
conductor screen.
16.4 Resistivity of the semiconducting Maximum 1000 ohm-meter
screen
16.5 Insulation

a)material XLPE

b)specified insulation resistance 1x1012 ohm cm

at 900C
16.6 Insulation Screen: Type & Extruded semi conducting compound.
Material
16.7 Resistivity of the semiconducting Max 500 Ohm-meter
compound
16.8 Longitudinal water barrier Material Layer of semiconducting tape with suitable
water swellable absorbent with 50% overlap.
16.9 Radial moisture barrier Material Seamless or seam welded Corrugated Aluminum
sheath with anti-corrosive material.
16.10 Overall sheath Extruded black HDPE (TypeST7) with anti
termite and anti rodent treatment.
16.11 Coating of outer sheath A hard baked layer of graphite or semi
conducting layer shall be applied over the
outer sheath as outer electrode for testing the
sheath.
17. Approximate Length of cable in a 500 metres with a tolerance range of ±5% or
drum as per requirement.
18 Bending Radius The minimum bending radius of XLPE insulated
cables as follows:
Cable: Bending radius Single
Core: 25xD
D – diameter of overall conductor.
19 TESTS IEC60840 IEC62067
Applicable standards
19.1 Type Test All tests as per specifications IEC Standards
a)whether previous test reports will Yes, if done on identical cable.
be sufficient No, if done on identical cable.
b)whether sample to be Type tested
against this order.
19.2 Routine Test All tests as per specifications IEC Standards.

19.3 Acceptance Test All tests as per specifications IEC Standards.

19.4 Whether test will be witnessed by Yes. Acceptance test will be witnessed.
purchaser or his representative
20 INSTALLATION, TERMINATION
AND JOINTS
21 Ambient temperature 450C
Ground temperature Thermal

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resistivity of soil 300C

1500C cm/Km
22 Laying Configuration Trefoil formation.

23 Depth 1.5 m below ground level.

24 Termination

25 Type AS per requirement

26 Joints Required No

27 Earth Link Boxes Required Yes. In both end and at joints as per cable
bonding system
28 Surge Suppressor Required Yes

29 Type Bonding ‘ Single end bonding/ cross bonding

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CHAPTER 20: TECHNICAL SPECIFICATION FOR XLPE CABLE WITH TERMINATION

VOLUME II Page 46 of 46