110_Technical document of JICA-012.pdf

7/24/2019 110_Technical document of JICA-012.pdf

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INDEX OF 66KV XLPE CABLES

S. No. PARTICULARS

1 SCOPE

2 STANDARDS

3 CLIMATIC CONDITIONS AND LAYING CONDITIONS

4 DESIGN & TECHNICAL DETAILS

5 MATERIAL AND CABLE CONSTRUCTION

6 CABLE JOINTING ACCESSORIES

7 MANUFACTURING PROCESS

8 QUALITY ASSURANCE

9 TESTING

10 TESTS AT MANUFACTURERS WORKS

11 MARKING ON OUTER SHEATH

12 SEALING AND DRUMMING

13 STANDARD LENGTH AND QUANTITY TOLERANCE14 DETAILS OF PAST EXPERIENCE

15 GUARANTEED TECHNICAL PARTICULARS

16 ABSOLUTE GUARANTEES

Annexure-I DESIRED TECHNICAL PARTICULARS OF 66 KV XLPE CABLE


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TECHNICAL SPECIFICATION FOR 66 KV XLPE CABLE

1.0 SCOPE

1.1 Scope includes manufacture, testing before dispatch and delivery FOR destination of66 KV XLPE Power cable of size 1200mm2 as per BOQ conforming to IS 7098 for66kV cable work of LILO of one circuit of 66kV Sector 23- Dhundahera line atproposed 220kV s/stn. Sector 20 enroute proposed 66kV s/stn. HSIDC Udhog Vihar(3.91kms) and LILO of one circuit of Daultabad- Sector 9 line at proposed 66kV s/stn.Sector 4 Gurgaon (3.47kms).

2.0 STANDARDS:

2.1 Unless otherwise stated hereafter, rating, characteristics, test and procedures etc.concerning the 66kV XLPE cable shall be preferably as per IS, IEC standards givenbelow and shall be in compliance with the latest edition or revisions thereof andmeeting the constructional details and testing requirement as stipulated in foregoing

also.

IEC-60228 Conductor for insulated cable.

IEC-60229 Tests on cable over sheaths

IEC-60230 Impulse tests on cables and their accessories.

IEC-60270 Partial discharge measurements

IEC-60287-1-1 Calculation of continuous current carrying capacity.

IEC-60502 Power Cables with extruded insulation and theiraccessories.

IEC- 60840 Power Cables with extruded insulation and their accessoriesfor rated voltage above 30 KV upto 150 KV.

IEC-62067 Tests for power cables with extruded insulation for ratedvoltage above 150 kV upto 500 kV.

BIS: 7098 (Part-3) XLPE Cable specification for working voltages from 66 kVupto and including 220 kV.

IEEE:48 Tests procedures and requirements for high voltage cableterminations.

2.2 The 66 KV XLPE cable may conform to any other authorities standards, whichensures an equal or better quality than the standard mentioned above. The biddermust specifically indicate the standards to which the cable conforms and indicate alldeviations (if any) from the preferred IS/ IEC codes that affect performance and rating.

2.3 Compliance of the 66 KV XLPE cable manufactured with the provisions of thisspecification does not relieve him of the responsibility of furnishing 66 KV XLPE cableand accessories of proper design, electrically and mechanically suited to meet theoperating guarantees at the specified service conditions.

2.4 If there are, in the opinion of the bidder, any conflicts between these codes and thisspecification, these contradictions shall be brought to the attention of the owner.

3.0 CLIMATIC CONDITIONS AND LAYING CONDITIONS

The XLPE Power cable shall be suitable for continuous & satisfactory operation underfollowing conditions:-

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3.1 Climatic Conditions:-

i) Peak ambient temperature in shade 50oCii) Maximum average ambient temperature in 24 hours

period in shade40oC.

iii) Min. ambient air temperature in shade (-) 5 oC.iv) Maximum temperature attainable by an object exposed to

sun55 oC

v) Maximum relative humidity 100%vi) Minimum relative humidity 10%vii) Average number of thunder storm days per annum 40viii) Average number of rainy days per annum 100ix) Average annual rainfall 10 to 100 cmx) Number of months of tropical Monsoons conditions. 4 monthsxi) Maximum wind pressure 100 kg/Sq.mmxii) Altitude not exceeding 1000 M

3.2 Conditions of Laying:-

i) Laid directly in ground / metaled road.ii) Installed outdoor in free air in vertical position.iii) Drawn into underground ducts in RCC trench.iv Laid through special arrangement for crossing of Bridge/Nala

3.3 Condition of installation of XLPE cable:i) Ground Temp. 35oC

ii) Maximum conductor temp. 90oC

iii) Air temperature 50oC

iv) Depth of RCC trench 1.5 m. approx.

v) Formation 1 Ckts. in trefoil with spare

vi) Bonding of metallic sheath Single point/ Both end/CrossBonding (as applicable)

vii) Number of 3 phase circuits Ckt-Iviii) Thermal Resistivity of soil 150oC cm/W or as per site

conditions

4.0 DESIGN & TECHNICAL DETAILS

4.1 Single Core XLPE cable suitable for 66 KV nominal system shall have construction asunder:

The cable shall be made of Segmental type(Milliken as per table2 of IEC:60228) forsize of1200mm

2of 66kV, electrolytic grade Aluminium tapped with semi conductingtape. Conductor screening shall be with extruded semi conducting thermosettingcompound layer. The cable shall be insulated with completely dry cured XLPE

insulation; Insulation screening for non-metallic part shall be with extruded semi-

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conducting thermosetting compound layer. Taping with semi conducting waterswellable tape shall be provided for longitudinal water sealing. Screening for metallicpart shall be with corrugated Aluminum or Lead Alloy E sheathed in combination withbedding of semi-conducting tape(s) followed by annealed copper wires screen andtaped with open helix copper tape binder, if required followed by suitable non-metallictape binder and overall extruded black, PE or PVC sheath with outer conductivecoating. Power cable shall conform to the IS 7098(Part-III)/ IEC and foregoing parasof this specification.

4.2. The covering shall be watertight, electrically insulated, rodent proof and vermin proof.

4.3 The offered XLPE cable for 66 KV earthed system shall meet the technical particularsindicated in Annexure-I

4.4 The XLPE Cable shall be suitable for use where combined ambient temperature andtemperature rise due to load result in conductor temperature not exceeding 90 Deg Cunder normal operation and 250 Deg C under short circuit conditions.

4.5 Offered XLPE cable end termination as well as jointing kits shall be of rated shortcircuit current of 31.5 kA for duration of 1 second for 66 kV system.

4.6 The XLPE cables shall be designed to withstand the mechanical, electrical andthermal stresses under the steady state and transient / fault conditions and shall besuitable for proposed method of installation.

4.7 The cable shall be suitable for underground buried installation with uncontrolled backfill and some of areas to be flooded by water in rainy season.

4.8 The sheath voltage under full load conditions shall not exceed the voltage specified /allowed in relevant standards for safety of personal as well satisfactory working ofcable. Sheath shall be solidly grounded at suitable locations with / without SVL.Bidder must indicate details of configuration proposed along with sufficiencycalculation with the bid so as to limit induced voltage of sheath within 65 V.

4.9 The charging current of the cable shall be as low as possible.

4.10 The XLPE cable shall be capable of withstanding the normal stress associated withtransportation, erection, reeling and unreeling operations without getting deformed.

4.11 The XLPE cable shall be used on System Voltage of 66 KV for 3-phase AC earthedsystem. The cables shall be suitable for continuous operation at a power frequencyvoltage 10% higher than system voltage.

4.12 Repaired cables shall not be acceptable.

5.0 MATERIAL AND CABLE CONSTRUCTION:-

5.1 Conductor:

5.1.1The Milliken segmental type shall be made of Aluminium complying to the

requirements of flexibility Class-2 of IEC-60228 / IS: 8130. The conductor shall havehigh compactness & smooth surface finish.

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5.1.2 The minimum number of wires in conductor and D.C. resistance shall be as per table-II of IEC-60228 / IS: 8130. The grade and quality of the Aluminium used for theconductor shall be as per IEC/IS standard.

5.1.3 The material & nominal area of conductor shall be as per BOQ.

5.2 Conductor Screen:

5.2.1 The conductor screen consisting of semi conducting compound layer shall beprovided over the conductor by extrusion which will not only eliminate the risk ofelectric discharge at the interface between conductor and insulation but will alsopresent a very smooth protrusion free interface with the insulation to eliminate anylocalized stress concentration. The screen shall be firmly bonded to XLPEinsulation.

5.2.2 The minimum thickness of extruded conductor screen shall be 1.0 mm. The outersurface of the conductor screen shall be circular and free from irregularities. A non-hygroscopic semi-conducting tape, if required, shall be applied to the conductor

under extruded layer to prevent penetration of compound in to the conductorinterstices.

5.3 Insulation:-

5.3.1 The insulation composed of a special super clean grade layer of cross linkedpolyethylene (XLPE) shall comply with the requirement of IS-7098(Part-III)/ IEC. Theinsulation shall be applied by extrusion over the conductor screen and vulcanizedusing dry curing process to form a compact homogeneous body free from microvoids and contaminants.

5.3.2 The eccentricity of insulation should not be more than 10%.

5.4 Insulation Screening:

5.4.1 The insulation screening shall consist of two parts, namely, non-metallic andmetallic.

5.4.2 Non-Metallic Part (extrusion):-

5.4.2.1 A non-metallic insulation screen of semi-conducting compound similar to conductorscreen (clause 5.2) for similar purpose shall be applied directly over the insulation

core by extrusion and shall be continuous and cover whole surface area ofinsulation. It shall be firmly bonded to the insulation.

5.4.2.2 The minimum thickness of extruded insulation screen layer shall be 0.8 mm, theovality of the core shall be not more than 5%.

5.4.3 Non-metallic part (taped)-Longitudinal water barrier:

5.4.3.1 Under-sheath, water barrier shall consist of a synthetic semi-conducting moistureswellable layer (non woven synthetic tape with suitable water swellable absorbenttape with suitable overlap) covering the whole surface area of the insulation screen.

The barrier shall restrict longitudinal water penetration under the metallic sheath.The nominal thickness of water swellable tape shall be 0.3 mm.

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5.4.3.2 The semi conducting compound and the semi conducting tape shall becompatible with the insulating material and suitable for the operatingtemperature of the cable.

5.4.4 Metallic Part Radial Water Barrier:-

The metallic sheath of Aluminium sheath or Lead alloy E shall be provided overthe non-metallic part of the insulation screening. Metallic sheath, together withcopper screen (if required) shall be able to withstand short circuit current of31.5 kA for duration of 1 second for 66 kV system. The details of metallicsheaths are as under:

5.4.4.1 Lead alloy E Sheath:

i) The lead alloy sheath shall have composition as per IS: 692. The lead alloy ESheath shall be extruded using a continuous screw press and shall be free fromall extrusion defects. The nominal thickness of lead alloy E sheath shall be asper IEC-60502-2 / IS: 7098 (Part-3).

The bedding over the Metallic sheath shall be of semi-conducting tape(s)

Copper wire screen of annealed plain copper wires with gap shall be Helicallyapplied over the Radial Water Barrier lead alloy metallic sheath.

ii) An open helix copper tape binder shall be applied over the copper wire screen.The nominal thickness of the tape shall not be less than 0.1 mm. The minimumthickness shall not fall below the nominal value by more than 10%. Suitablenon-metallic binder tape may also be applied over the copper screen to preventthe penetration of the outer sheath in to the screen.

5.4.4.2 CorrugatedAluminium Sheath:-

i) When the corrugated aluminium sheath is used, it shall be applied byextrusion/seam-weld and then passing through a corrugating head. Thecorrugating head contains rotating dies to form the valleys between the ribslike sine wave and produce to correct diameter of sheath to fit over theinsulation. The sheath shall be free from pinholes flaws and otherimperfections.

ii) Anti-corrosive compound shall be applied over the aluminium sheath.

5.5 Outer Sheath:-

5.5.1 The outer sheath shall consist of an extruded layer of black, PE or PVC typeST-2 as per IEC/IS-7098 (Part-3)

5.5.2 The nominal thickness of outer sheath shall not be less than the valuecalculated as per the recommendation of IEC 60502-2/IS-7098 (Part-3). Theouter sheath shall be of sufficient hardness to discourage termite and rodentattack.

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5.5.3 Outer conductive coating / layer:

The outer conductive layer shall be of Graphite coating applied at works. Thisconductive layer / coating must facilitate testing of the non-metallic outersheath. This test is important to ensure the physical integrity of the cable fromtime to time be it at the factory, after transportation, directly after laying uponcompletion of the installation.

6.0 CABLE JOINTING ACCESSORIES

6.1 The cable jointing accessories shall include the end terminating kits, straightthrough joints. These shall be rated for 31.5KA for 66 kV system. The sheathvoltage under full load conditions shall not exceed 65V specified / allowed inrelevant standards for safety of personal as well satisfactory working of cable.The sheath shall be solidly grounded.

6.2 The cable terminations shall be fire resistant. The components of kits shall haveflame retardant property.

6.3 All the cable sealing end/end termination kits and straight through joints shall beeither pre-molded or Heat shrinkable type upto 66kV level complete withaccessories from reputed manufacturer of proven design which has alreadybeen extensively used and fully type tested. The make of termination kits andstraight through joints shall be got approved from HVPNL before bringing inuse.

6.4 The joint shall preferably be built up from the same material as the main cableand shall have electrical and mechanical withstand capabilities same as orbetter than the main cable. The joints shall be suitable for tropical climatic

conditions. The straight through joints shall be suitable for underground buriedinstallation with incorporated back fill and chances of flooding by water. Thestraight through joints should be absolutely impervious to the entry of water.The manufacturer shall use the proven technology and design to prevent entryof water or any other liquid inside the straight through joints and cables.

6.5 The end termination shall be outdoor anti-fog type and shall be of porcelaintype with accessories. The outdoor terminal should be suitable for heavilypolluted atmospheric conditions with minimum creepage distance of 25 mm/kVand protected creepage distance of not more than 50% of the total creepagedistance. The cable end terminals for terminating the cables shall be fullycompatible with the cables to be supplied. Field tests of sealing end terminalsshall be made in conjunction with the cables after installation of the cables andterminals.

6.6 The testing of cable termination, sealing ends and straight through joints shallbe as per IEC-62067. All the type tests, sample tests and routine tests shall beas per IEC-62067.

6.7 The cable termination and straight through joints shall bear guarantee for five(5) years from the date of commissioning. Any defect noticed in the kit shall be

attended by the bidder immediately but not later than 24 hours on getting thecomplaints and if required shall be replaced and installed free of cost, otherwisethe same will be arranged at the bidders risk and cost.

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7.0 MANUFACTURING PROCESS:

7.1 XLPE cable should be processed in a modern triple head extrusionmanufacturing line. XLPE extrusion and curing through Vertical CataneryVulcanisation system (VCV) or horizontal MDCV or CCV will be used to ensurecircularity and concentricity of the extruded layers around the conductor.

7.2 The conductor screen, insulation and insulation screen shall be extruded in onesimultaneous triple extrusion process (Clause 14.2.1 of IS: 7098-3) throughcommon triple crosshead. The extruders and triple crosshead shall bedesigned to prevent stagnation of materials to eliminate hot spots and ensuresmoothness of the conductor screen and screen surfaces. Insulation thicknessshould be controlled on-line using X-ray monitoring system.

7.3 The cross linking, curing and cooling shall be carried out in one operation andshall be a dry curing process under high pressure to eliminate the formation ofvoids in the insulation and contaminations in the dielectric.

7.4 Process conditions such as curing and cooling temperature, production speedetc. shall be closely monitored during manufacture to ensure a good degree ofcross-linking through the whole insulation.

7.5 The manufacturing process shall be desired to eliminate irregularities likeprotrusions, voids and contamination etc. to ensure the long-term reliability ofthe cable.

7.6 Loading of the extruder in the manufacturing plant shall be performed entirelyclosed and dust proof. The entire line of processing should be controlled from a

computerized central control console. Contamination shall be avoided by useof a fully enclosed material handling system. To avoid contamination XLPEGranules must be transported using gravitational material feeding system.

8.0 QUALITY ASSURANCE:-

8.1 Raw materials used for manufacture of cable shall be of highest quality andmaterial received by manufacturer should be checked / tested to ensure that itmeets manufacturers material specification. The materials shall be clean andpacked in moisture and dust proof packing.

8.2 As the Quality control of EHV XLPE cables while manufacturing is very criticalso expert supervision is required for raw material testing, in process checks andalso for final testing. A specially trained quality assurance team should be inplace for maintenance of the quality at an optimum level at the plant. Completedetails of manufacturing process along with details of automatic manufacturingplant, shall be furnished by bidder in the bid.

8.3 Quality assurance plan indicating test /checks of raw material, process ofmanufacturer and final inspection with customer hold point shall be submitted tothe purchaser for approval.

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9.0 TESTING:-9.1 GENERAL:-9.1.1 This schedule gives tests to be carried out on 66 KV, single core XLPE type

cables. The schedule of tests to be followed shall be generally as per IS-7098(Part-3)/ IEC 62067/ IEC-60840 (For 66 KV cable).

9.1.2 The facilities available for site tests shall be clearly and implicitly brought out inthe Bid. The site tests shall be carried out during and after laying/installation bythe supplier.

9.1.3 This test schedule can be modified at the discretion of the purchaser to omit orto include additional tests. Power frequency test shall be carried out at afrequency of 50 Hz.

10.0 TESTS AT MANUFACTURES WORKS:-10.1 The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC62067/

IEC-60840 (For 66 KV cable).

10.2 ROUTINE TESTS:-The following shall be carried out as routine test:

a) Conductor Resistance Testb) Partial discharge Testc) High Voltage Test

10.3 ACCEPTANCE TESTS:-The following tests shall be carried out as special tests:a) Conductor Resistance Test

b) Test for dimension of Insulationc) Hot Set Test for Insulationd) Test for thickness of metallic Sheath.e) Partial Discharge Test.f) High Voltage test.g) Measurement of Capacitance.

10.4 TYPE TEST(s):-10.4.1 The cables offered should be fully type tested. Type test reports (not more than

seven years old reckoned from the date of bid opening in respect of all the typetests carried out as per relevant IEC/ IS standards from Govt./ Govt. approved

reputed test house shall be submitted along with the bid.

10.4.2 The bidder must have all testing facilities available at their works for testing thematerial as per clause 8 above. Detailed list of testing equipment along withrelevant tests must be furnished with the tender other wise offers is likely to beignored.

11.0 MARKING ON OUTER SHEATH:-11.1 The following particulars shall be marked on cable outer sheath:

Manufacturers name/ or trade nameVoltage grade viz. 38/66 KV.

Cable size ( no. of core x conductor cross section)Year of manufacture.Purchasers name i.e. HVPNL Page-8


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11.2 The spacing between one set of marking and the beginning of the next on thelegend shall not exceed 150 mm.

11.3 Besides above, progressive sequential marking of length shall also be providedat every one meter, which shall be clear and legible sequential length workingby embossing/ engraving/printing.

12.0 SEALING AND DRUMMING:-

12.1 Immediately after the works tests, both ends of every length of cable shall besealed by means of heat shrinkable end caps.

12.2 Cables shall be wound on metallic drums. All the drums shall be arranged totake a round spindle and be legged with strong closely fitting wooden battensso as to prevent damage in the cable. Each drum shall bear an identificationnumber permanently stenciled or branded on the outside of the flange.

12.3 Cable reels shall be of rugged construction, with a drum diameter of ample

dimensions to accommodate the single conductor. Manufacturer shall beresponsible for any damage to the cables during transit. Changes in the shapeof the cable during transit shall not result in deformation in metallic drum.

12.4 The cable drum/ reel shall carry the following information clearly marked onone flange of the drum.

Manufacturer's name, Brand or trade mark.Conductor of cable.Type of cable and voltage grade.Size of cable.Length of cable on the drum.Direction of rotation of drum (by means of an arrow).Net weightGross weight.Year of manufacture.Confirming to IEC/IS NoPurchase order details.Name of owner.Name of consignee.

13.0 STANDARD LENGTH AND QUANTITY TOLERANCE:-

13.1 The Standard length of cable shall be Minimum 500m. to 750m. However,

based upon the production capacity, the successful bidder may offer the largerlength of the cable in order to optimize the No. of Mid-span joints (subject tosafety & ease of cable during wounding on drum, transportation & itserection). Also the delivery length of cable shall match with the location ofjo inting bays as described in Erection part. The line-wise detailed surveyshall include the loops in between the route & at both ends of s/stns. Thesuccessful bidder shall give an undertaking in this regard for the offered length.No negative tolerance in length shall be permitted.

The sufficient loop of 66kV D/C line cables shall be taken at upcoming66kV s/stn. Udhog Vihar (HSIDC), the tentative length of loop for bidding

purpose has been considered as 100m.

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14.0 DETAILS OF PAST EXPERIENCE: -

14.1 The details of past orders executed by the bidder shall be indicated in

the relevant schedule.15.0 GUARANTEED TECHNICAL PARTICULARS:-

15.1 The bidder shall furnish guaranteed technical particulars of cable in the relevantschedule enclosed

16.0 ABSOLUTE GUARANTEES:-

16.1 All commissioning tests and performance tests shall be treated as absoluteguarantee and in the event of failure in any of such test(s) the bidder shall takesteps to rectify/replace/modify at his cost the defective components(s),assemblies. The equipment after such rectification/repair shall be re-tested atbidder cost at site.

16.2 The satisfactory performance of materials supplied shall be Guaranteed asindicated in Commercial bid document. Technical Parameters of the cable shallbe as stipulated in Annexure-I:

Annexure - I

DESIRED TECHNICAL PARTICULARS OF 66 KV XLPE CABLE

S. No. Particulars Technical Details

Cable Single Core, AluminiumConductor XLPE cable

1.Applicable standard Conforming to IEC 60502,60840/

IS 7098(part-3) amended up todate.

2. System voltage & frequency 66 KV 10% kV, 50 Hz 3%

3. Highest System Voltage 72 kV

4. Suitable for earthed system YES

5. CONDUCTORi) Material Milliken segmental type

ii) Nominal cross-sectional area 1200mm2

iii)Construction of conductor/flexibilityclass

Class-2, IEC 228 / IS: 8130

iv) Shape and formation Very well compacted

v)Approx overall diameter ofconductor

to be indicated

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6. CONDUCTOR SCREENING

i)Material & type Extruded, semi conducting

compound layer.

ii) Grade As per IEC/IS

iii) Thickness 1.0 mm

7. INSULATION

i) Material Cross linked polyethylene(XLPE)

ii) Nominal thickness of insulationAs per 7098 (Part 3)

8. INSULATION SCREENING

A Non-metallic part(extruded)

i)Material Extruded semi conducting

Compound layer.

ii) Grade As per IEC/IS: 7098 (Part 3)

iii) Min. thickness. 0.8 mm

Non-metallic part (taped)

longitudinal water barrier overinsulation screen.

i)Material Synthetic Non-woven semi

conducting Water swell-able tape

ii)Min. thickness As per standard.

C METALLIC SHEATH

i)Material Corrugated Aluminium / Lead alloy

E sheath IS 692

ii)Min. Thickness(mm) Conforming to IEC 60502/ IS: 7098

(Part 3)

iii)Short Circuit Current Withstand[Metallic sheath, together withcopper screen (if required)]

31.5 kA for one Second

D Bedding over lead sheath Semi conducting tape(s)

ECONCENTRIC COPPER WIRESCREEN (IF REQUIRED)

i)Material and type Annealed plain copper wires applied

helically with gap followed by openhelix of copper tape binder

ii)

Min. area (Sq. mm) This and lead alloy E sheath shall

meet earth fault current of 31.5kA fora duration of 1 second.

9. OUTER SHEATH

i)Material Extruded Layer of Black PE or PVC

type ST-2 as per IEC-60502 / IS:7098 (Part 3)

ii) Min. thickness of outer sheath As per standard

10.Conducting layer over outersheath

Graphite coating

11.Approx overall diameter of cable(mm)

To be indicated

12.Approx. weight per meter of cable(kg/m)

To be indicated

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13.Recommended minimuminstallation radius.

To be indicated

14.Maximum D.C. Resistance ofconductor at 90 deg C in ohm/km.

As per standard

15.

Continuous current rating for eachcircuit when laid in ground in trefoilformation and other conditiongiven in specification.

To be indicated

16.Maximum allowable temperaturefor cable and accessories.

i)At rated full load and at siteconditions.

90 Deg C

ii)

The conductor temperature after ashort circuit for one second shallnot exceed (with conductortemperature at start of shortcircuits as 900 C).

250 Deg C

17.Basic impulse insulation level

(1.2/50 micro second wave)

As per Standard

18. Power frequency withstand voltage As per Standard

19.

Symmetrical Short circuit rating forone second duration for leadsheath and copper screenedcombined/ Aluminium Sheath

31.5 kA for 1 Sec.

20. Drum Length AS per Clause No.-13.0

21. Expected cable life. 35 years.

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INDEX OF ERECTION OF 66KV XLPE CABLES

S. No. PARTICULARS

1 SCOPE

2 ROUTE SURVEY

3 STATUTORY CLEARANCES

4 CABLE HANDLING

5 DAMAGE TO PROPERTY

6 CABLE ROUTE MARKERS / CABLE JOINT MARKERS

7 DEPTH OF LAYING OF CABLES

8 PAYING OUT THE CABLE

9 SAND BEDDING

10 BACK FILLING

11 WARNING TAPE

12 PREVENTION OF DAMAGE DUE TO SHARP EDGES

13 ROAD, RAIL & CANAL CROSSINGS

14 TRENCH LESS DIGGING

15 JOINTING BAY

16 TOOLS & PLANTS

17 BENDING RADIUS18 JOINTING AND TERMINATION OF CABLES

19 SUMPHOLES

20 TENTS/ COVERS

21 PRECAUTIONS BEFORE MAKING A JOINT

22 MEASUREMENT OF INSULATION RESISTANCE

23 IDENTIFICATION

24 MAKING A JOINT

25 CABLE TERMINATIONS

26 CABLE TERMINATING STRUCTURES

27 EARTHING

28 TESTS AFTER INSTALLATION

SPECIFICATION FOR CIVIL AND STRUCTURAL WORKS


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ERECTION PART

TECHNICAL SPECIFICATION OF LAYING, ERECTION, TESTING & COMMISSIONINGOF CABLES:-

1.0 Scope: -

1.1 Complete installation, laying, testing and commissioning of the cable of the D/C lines shall

be the responsibility of the bidder. Four runs of the cable per circuit shall be laid as perthe tentative route plan enclosed. The scope for installation work shall, therefore include,

but not limiting to: -

1. Route survey for the entire route length under the scope of work.

2. Clearances from relevant Local Authorities for laying of cables. All the protective

measures for laying, protection and for smooth working of all the cables as per statuary

norms/standards to be followed/ensured by the bidder for its safe and smooth operation

in future.

3. Laying of cables under scope as per specification. At most of the route length, the

cables shall be laid through Trench-less technology at depth of 2.5m to 3.0m.

4. Measurement of Thermal resistivity of soil. The value of thermal resistivity will be

intimated to field office.

5. Transportation of cable drums & other material.

6. All civil works required for laying of the cables, which shall include design, construction

materials and labours. 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.

7. Laying & installation of cables in ducts, in HDPE pipes and through Trench less method of

required strength for various crossings, in air at terminations at the tower, at varying

depths due to obstructions, construction of cable jointing bays.

8. Supply of HDPE pipe of required strength of ISI mark shall be 1.5 times of Cable. The

HDPE pipes are required for crossing of roads/ Bridge/Railways/culverts/water courses/

Nala/ Sewerage pipe lines/Oil /Gas pipe lines and for Trench-less system. The pipes to be

filled with sand/suitable material after cabling in Road crossing .

9. Supply & Erection of terminal structures including foundations between the line for

supporting cable end terminations, it shall include the supply of Earthing material,

Earthing of each cable, post insulators for cable support, civil foundation design,

construction material and labours etc.

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10. The cables will be terminated on the cable termination structures in the s/stn. premises

and the cable will be terminated on the tower at the point of connection with Over-

head line.

Where the cable is to be terminated on the tower (tower will be erected

departmentally), the LAs will have to be mounted on the tower by making suitable

arrangement and the independent earthing of LAs mounted on the tower and of eachcable shall be got done to the satisfaction of Engineer-incharge. The size of

galvanised flat to be used for earthing of LAs shall be 75X12mm.

11. Termination of cables at both ends. Suitable loops shall be provided at both ends.

12. It shall be the responsibility of the contractor to terminate the fourth (spare) run of the

cable at the terminal structures in such a way that it shall be possible to connect it to

all the three phases of conductor by changing jumpers only. However this spare cable

shall be connected to nearest conductor to avoid theft/moisture in-gress. Necessarybonding of the cable screen shall be done by the supplier.

13. Tentative Quantity of LAs shall be as per BOQ attached. The drawings of LAs shall be

got approved from HVPNL .

14. Cable markers as per statutory requirements shall be provided all along the route at a

maximum distance of 100 metersand other important locations. Also the location of

the underground cable shall be clearly indicated on the marker.

15. The bidder shall make his own arrangement for boarding & lodging of his men

engaged in the work.

16. Training of HVPNLs Engineers & jointers.

17. The laying of cables shall be through proposed densely populated residential/industrial

area. Therefore, utmost precautions shall be taken for erection of cables by the

contractor for safety of the public. All the bidders are strongly advised to visit the site

through field office and acquaint themselves with the topography, infrastructure,

crossings involved etc. before submitting the bids. Suitable protection of XLPE cables

and Public property shall be ensured to the satisfaction of Engineer-incharge. The

successful bidder shall be fully responsible for providing all equipment, materials,

system and services specified or not, but are required to complete the erection and

successful commissioning of 66 KV cable complete in all respects. The cost of

carrying out such works, shall be deemed to be included by the bidders in the last

column of Supply & Erection portion. Nothing Extra shall be paid later-on on this

account except for the variation in the quantities of the items shown in Supply &

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18. Erection portion. After award of contract, its Design/Drawings will be got approved

before execution of work.

19. The design of all type of crossings is in the scope of the bidder and work shall be

started only after getting the design / Drawings approved from HVPNL.

2.0 Route Survey

The bidder shall fully familiarize himself with the site and route conditions etc. Thecomplete design and detailed engineering shall be done by the contractor. The surveyshall be conducted for underground routes to finalize the route and paths for theunderground cable. Contractor shall arrange information about existing under groundfacilities for the proposed routes. To do so as built drawings or route index diagramfor various services viz water works, electric supply utilities, telecom services, publichealth, Gas/oil authorities etc. may be collected from the concerned authorities. Incase details are not available, the contractor shall assess suitably by conductingenquiries and surveys. The contractor shall prepare and submit the final survey reportshowing all the details enroute for HVPNL approval.

3.0 Statutory Clearances

The contractor shall coordinate on behalf of owner, for obtaining necessary clearancesfor laying of cable and carrying out excavation/ digging work from the authorities onbehalf of the Employer and provide requisite copies of information maps, survey reportetc. to the authorities. The employer shall assist the contractor in obtaining suchclearances by providing the authority letter or any other relevant document. Thecontractor shall ensure quick and speedy clearances in order to implement the projectwithin stipulated schedule. In case the authorities have some objections on certainsections of routes proposed and are unwilling to provide clearances, the contractor

shall propose an alternate route, promptly carrying out the survey and submit specificsurvey report for that and reapply for clearance after taking into account thecomments/objections of the authority. The clearance of the Chief Electrical inspectorunder Electricity laws shall solely be in contractors scope.

4.0 CABLE HANDLING

The inspection of cable on receipt, handling of cables, paying out, flaking, cushioningwith sand or sieved compacted soil, back-filling, providing and fixing joint markers,route indicators, and all necessary precautions that are required shall be carefullyplanned and in general conform to IS 1255-1983 or its equivalent.

5.0 DAMAGE TO PROPERTY

The contractor shall take all precautions while excavation of trench, trial pits & drill fortrench-less laying etc., to protect the public and private properties and to avoidaccidental damage. Any damage so caused shall be immediately repaired and broughtto the notice of the Employer.

The contractor shall bear all responsibilities and liabilities and shall bear all costs ofthe damages so caused by him or by his workman or agents.

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6.0 CABLE ROUTE MARKERS/CABLE JOINT MARKERS

Permanent means of indicating the position of joints and cable route shall befabricated supplied and erected.

Markers provided shall be as per the field requirement, if the route passes throughopen fields, markers should be conspicuously visible above ground surface.

The marker should incorporate the relevant information. The name of the owner,voltage, circuit & Danger sign. The drawing of marker is enclosed with the bid.

7.0 DEPTH OF LAYING OF CABLES

Depth of laying of cables shall be 1.5mfor directly buried cables ( trench method) and2.5m-3.0m in Trench-less method Laying at varying depths due to obstructions/siteconditions may be accepted subject to field office approval during detailed

Engineering. The typical cross-section drawing of trench is enclosed with thisspecification.

8.0 LAYING OUT THE CABLE

The excavated cable trench shall be drained of all water and the bed surface shall besmooth, uniform and fairly hard before laying out the cables. The cables shall be rolledin the trench on cable rollers, spaced out at uniform intervals. The laying out processmust be smooth and steady without subjecting the cable to abnormal tension orscratches. The cable being laid out shall be smoothly and evenly transferred to theground after proving the sand cushion. The cables shall never be dropped. Suitablesize 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 andshall not exceed the permissible value for the cable..

The cable end seals shall be checked after laying and if found damaged shallimmediately be resealed. Sufficient number of heat shrinkable cable end sealing capsshall be stocked at site stores for testing and jointing work. The integrity of the outersheath shall be checked after the cable is laid in position.

The sealing of power cable ends during the storage, execution & completion of jointingwork shall be in the scope of successful bidder. Under no circumstances, the cableends shall be kept open. The amount due to damages done because of

water/moisture ingress OR penetration in the cable / conductors during execution shallbe recovered form successful bidder. It shall be responsibility of successful bidder torepair OR replace free of cost without affecting the completion schedule.

9.0 SAND BEDDING:

The cable shall be completely surrounded by well-compacted sand (River bed sand) tosuch a thickness and of such size that the cable is protected against damage.

Precast RCC slabs in M-20 of size 500X300X65mm for 66kV and shall be provided forprotection of the cable by covering the cable as per drawing enclosed. Every pre-castslab shall carry the engraved words as- HVPNL 66kV.

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10.0 BACK FILLING:

Normally back filling shall consist of the material earlier excavated. However, biggerstones or pieces of rock should be removed & shifted at approved locations of LocalAuthority. The compaction of Earth filling shall be ensured by the contractor 95% ofthe Proctor density.

11.0 WARNING TAPE:A pre-warning, Red colour plastic/PVC tape, 250 mm wide 100 microns thick shallbe laid at approx. 0.4 m above the cable specified depth, throughout the cable route.The tape shall carry the legend printed in black continuously as under CAUTIONHVPNL, 66000 V CABLES.

12.0 PREVENTION OF DAMAGE DUE TO SHARP EDGES

After the cables have been laid in the trench and until the cables are covered withprotective covering, no sharp metal tool shall be used in the trench or placed in such aposition that may fall into the trench.

Straight and curved rollers used shall have no sharp projecting parts liable to damagethe cable.

While pulling through pipes and ducts, the cable shall be protected to avoid damagedue to sharp edges.

The cables shall never be bent, beyond the specified bending radius.

13.0 ROAD, RAIL & CANAL CROSSINGS

The road, Rail & Canal crossing should be done by HDPE pipes of required strengthof diameter not less than 1.5 times the cable diameter.

14.0 Trench less Digging:

If required, trench-less digging shall be used for all roads crossings and throughcongested Urban streets of HUDA/industrial area. The various methods of trench lessdigging such as hand/manual auguring (up to 15m), impact moling (from 16m to about40-50m). HDD (above 40-50m) shall be adopted based on the soil/site conditions andthe requirement and exact method for trench less digging shall be finalised during

detailed engineering as per actual site/soil condition.

The contractor shall propose the exact methods and procedures forimplementation of trench less digging at various crossings taking intoconsideration the following guidelines, for approval by the Employer:-

a) Excavation and backfilling of trial pits and verification of soil condition.b) Excavation of entry and Exit pits.c) Erection of drill machined drilling of pilot hole.d) Placement and driving hand augur.e) Placement and carrying out impact moling.

f) Reaming and widening of bore holes in steps (if required).g) Pulling of product pipe.

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15.0 JOINTING BAY

Manholes shall be provided at every proposed joint location for jointing bays. Thebidder shall identify the location of the joint bays after carrying out detailed survey ofthe cable route and excavation of the trial pits. The delivery lengths of the cables shallmatch the location.In case of underground portion, the joint bays should have a flat and level surfacelined with bricks and properly plastered. The retaining walls on all sides to the requiredheight shall be of brick/stone masonry. The top of the wall shall have a cementconcrete band 1:2:4 with 20mm size aggregate all-round. The top shall be coveredwith pre-fabricated RCC slabs and with an inspection cover. Al the bottom in a corner,a sump-pit shall be made for bailing out water.

The contractor shall submit design and drawing of Jointing bay for HVPNL approval.All works shall be carried out under supervision of the engineer in charge or hisrepresentative.

16.0 TOOLS AND PLANTS

The successful bidder shall have all necessary tools, plant and equipment to carry outthe survey and cable installation work.

The bidder are instructed to give all the details of equipment at their disposal, to carryout the work successfully and speedily.

17.0 BENDING RADIUS:

The minimum bending radius of XLPE insulated cables are as follows:

Cable Bending radius

Single Core 20 x D

D means the overall diameter of the completed cable.

18.0 JOINTING AND TERMINATION OF CABLES

The cable jointing personnel and his crew shall have good experience in the type ofjoints and terminations that are used. The jointing work shall commence as soon astwo or three lengths of cables have been laid. All care should be taken to protect thefactory-plumbed caps/ seals on the cable ends and the cable end shall be sealed

whenever the end is exposed for tests.

Jointing of cables in carriage ways, drive ways under costly paving, under concrete orasphalt surfaces and in proximity to telephone cables and water mains should beavoided whenever possible.

Sufficient over lap of cables shall be allowed for making the joints.

The joint bay should be of sufficient dimensions to allow the jointers to work with asmuch freedom of movement and comfort as possible. Sufficient space should be keptbelow the cable to be jointed.

The joints of different phases shall be staggered in the jointing bay.Page-6


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19.0 SUMPHOLES

When jointing cables in water logged ground or under unforeseen rainy conditions, asumphole should be made at one end of the joint bay, in such a position so that theaccumulated water can be pumped or baled out by buckets, without causinginterference to the jointing operation.

20.0 TENTS/ COVERS

An enclosure or suitable protection cover shall be used in all circumstances whereverjointing work is carried out in the open irrespective of the weather conditions. The jointshall be made in dust free, moisture free and clean atmosphere.

21.0 PRECAUTIONS BEFORE MAKING A JOINT

The cable end seals should not be opened until all necessary precautions have beentaken to prevent circumstances arising out of rainy/ inclement weather conditions,which might become uncontrollable.

If the cable end seals or cable ends are found to have suffered damage, the cablesshould not be jointed, without tests and rectification.

22.0 MEASUREMENT OF INSULATION RESISTANCE

Before jointing, the insulation resistance of both sections of cables shall be checked.

23.0 IDENTIFICATION

The identification of each phase shall be clearly and properly noted. The cable shall be

jointed as per the approved design. Each cable shall have identification for phase atjoint bays.

24.0 MAKING A JOINT

Comprehensive jointing instructions should be obtained from the manufacturer ofjointing kits and meticulously followed.The materials used in the joints like ferrules, screen/sheath continuity bonds, lugs etc.,shall be of good quality and conform to standards. The jointing tools shall beappropriate and as per the requirement of jointing HV XLPE cables.

25.0 CABLE TERMINATIONS

The preparation of the cable end for installing the terminations and the precautions tobe taken before fixing the terminations shall be followed as in the case of the cablejointing procedures.

The instructions furnished by the termination manufacturer shall be strictly followed:

At cable terminating end, the following provisions for supply and erections are to beincluded:

A sufficient length of spare cable shall be left in the ground, for future needs.

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The cable shall be properly fastened using non-metallic clamps.

The spare cable shall be connected to its nearest cable on load so as to avoid its theft

and moisture ingress.

Appropriate labels shall be fixed identifying the phase circuit, voltage and date ofcommissioning etc., on the cable supporting structure.

26.0 CABLE TERMINATING STRUCTURES

The terminating structure being provided shall be of bidders standard design as per

requirement of 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 approval 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, post insulators, link boxes and any other

structure required for the intent of the contract. All steel sections used shall be free

from all imperfections, mill scales, slag intrusions, laminations, fillings, rust etc. that

may impair their strength, durability and appearance. All materials shall be of tested

quality only.

27.0 Earthing:-

Bidder shall carry out the earthing of sheath/ screen at the cross bonding points as

well as at the ends of cable using insulation sheath bonding (earthing) cable of

required size through link boxes with/ without surge voltage limiter at cross-bonding

points and terminal substations. Earthing shall be as per relevant standards. The

sheath /screen shall bound in the earth station through disconnecting type link boxes.

Screen continuity by using tinned copper mesh and earth continuity by tinned copperbraids of appropriate size shall be provided for transfer of screen/earth in straight

through joints.

All the LAs to erected on the towers shall be properly earthed through 75X12mm GI

strip to the satisfaction of field office.

28.0 TESTS AFTER INSTALLATION

All tests as prescribed in IEC-60840: 1999 shall be performed after installation ofable.

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SPECIFICATION FOR CIVIL AND STRUCTURAL WORKS

1.0 EXCAVTION

1.1 The specification covers excavation for cable trenches, ducts, structural foundation,

jointing bays.

1.2 The contractor shall control the grading in the vicinity of all excavations so that the

surface of the ground will be properly sloped or diked to prevent surface water from

running in to the excavated area during construction.

1.3 The excavation shall include the removal of all materials required to excute the work

properly and shall be made with sufficient clearance to permit the placing, inspection

and setting of forms and completion of all works for which the excavation was done.

1.4 The sides and bottoms of excavation shall be cut sharp and true. Under cutting shall

not be permitted. Earth sides of excavations shall not be used in lieu of form work for

replacement of concrete unless authorized by the Engineer where the limititations of

space for large excavation necessitate such decision.

1.5 When machines are used for excavation th last 300 m,m before reaching the required

level shall be excavated by hand or by such equipment that will leave the soil at

required final level in its natural condition.

1.6 The bottom of the excavation shall be trimmed to the required level and when carried

below such level by error, shall be brought to level, by filling with lean concrete of 1:4:8

Mix at contractors cost.

1.7 All excavation for installation of underground facilities shall be open cuts.

1.8 The excavations for foundation where specified shall be carried out at least 75 mm or

as specified in relevant drawing below the bottom of the structure concrete and then

be brought to the required level by placing lean concrete of 1:4:8 mix or as specified

with aggregate of 40 mm nominal size.

1.9 When the excavation requires tracing, sheeting, shoring strutting etc. the contractor

shall submit to the Engineer in charge drawings showing arrangement and details of

proposed installation and shall obtain the approval from the Engineer in charge beforeproceeding with the work.

1.10 The contractor shall have to constantly pump out the water collected in the pits,

trenches due to rain, sub soil, springs etc. and maintain dry working conditions at no

extra cost to the owner.

2.0 DISPOSAL OF EXCAVATED EARTH

2.1 The contractor shall arrange to transport the surplus excavated earth by mechanical

transport. It shall however be ensured that no stacked/disposed shall be as directedby the Engineer-in-charge.

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2.2 However the contractor shall take all precautions at the site of excavation for keepingthe free flow of vehicular and human traffic and to avoid inconvenience in general. Thesoil transported for disposal shall be stacked, leveled and dressed neatly.

3.0 BACK FILLING MATERIALS

3.1. The backfilling of excavated trenches around foundation shall consist of one of the

following materials as the Engineer-in-charge may direct in each location.i) Selected sieved earth from excavated soil.ii) Selected sieved earth brought from borrows area.iii) Sand filling (sieved).

3.2 Filling shall be done after the concrete or measonry work has fully set and its curingcompleted.

3.3 The contractor shall fill in and around any work until it has been properly reinstated andapproved by the Engineer-in charge.

4.0 BACK FILLING FOR CABLE TRENCH

4.1 Back filling shall be done in horizontal layers of thickness not exceeding 300 mmthickness, free from pockets with careful watering where necessary for compaction. Thebackfill shall be riddled earth free from materials likely to cause damage to the cables.

4.2 The thermal backfill surrounding the cable shall be as per the design approved by the

owner.

5.0 SPECIFIATION FOR CEMENT CONCRETE

5.1 For the cement concrete, plain or reinforced for general use, requirement of concrete fornominal mix, strength and quality pouring at all levels, from works, protection covering,

finishing, admixture, inserts, curing etc. the provision of the latest revision of IS:456 shallbe complied with, unless permitted otherwise by any other Indian Standard codes, shallform the part of the specification to the extent applicable within specification. The cementused shall comply with IS:12269 (OPC).

6.0 CURING AND PROTECTION OF CONCRETE

All fresh concrete shall be covered with the layer of an absorbent material and keptconstantly wet for a period of seven days or more from the date of placing concrete.The immature concrete shall be protected from the damages and contamination that

would impair the strength of the concrete.

7.0 PRECAST RCC ITEMS

7.1 The concrete mix for the various types of pre-cast units shall confirm to IS: 456. Theaggregate shall be mixed by weight and water cement ratio shall be controlled toobtain the dense concrete and the strength required. The reinforcement shall be asper the design approved. The curing shall be carried out for the period of minimumseven days from the date of casting and precast element shall be cured by floodingwith water of minimum 25 mm depth over the element for the period mentioned above.

7.2 All the pre-cast element shall be marked, appropriately as specified.

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8.0 FOUNDATION

Foundations for mounting structures in cement concrete shall be casted by bidder asper approved drawings.

9.0 BOLTS, NUTS AND WASHERS

Standard bolts, nuts an washers shall be used in all works. These should begalvanized in accordance with IS: 5358.

10.0 PAINTING

Outdoor Kisok for link boxes etc., shall be painted with anticorrovise paint and redoxide as primer and two coats of enamel paint. The boxes should be appropriatelylabeled as per installation at site regarding the S.No., location, type cautionboard/danger.

11.0 MATERILAS USED IN CABLE LAYING

Specification in brief on the materials used in installations of the underground cables,like RCC precast cable protection covers, precluded cement concrete blocks for cableroute. Joint indication, cable and mounting structures joints bays, earthing and othermiscellaneous materials are given below. All materials shall conform to relevantstandards and shall be approved by the Engineer in charge.

12.0 RCC PRE CAST CABLE PROTECTION COVERS

These should be fabricated as per the design supplied by the contractor and approvedby HVPNL. The reinforcement cement concrete should be in the proportion 1:1.5:3 of20 mm and down size aggregate and steel reinforcement of 8 mm diameter conform toIS 1786 for deformed and cold twisted steel rods should be used and cured as perCivil Engineering standards. The covers should carry the legends HVPNL 66 KVCables as the case may be. The covers should be free from burrs and projectingedges so that may be easily laid to butt.

13.0 CABLE ROUTE MARKERS/JOINT MARKERS

13.1 Permanent and durable type, cable route markers/joint indicating blocks should beprovided as per the design approved by the purchaser.

13.2 The Reinforced cement concrete block should be made by the wet process and all theconcrete shall consists of one part cement, one and a half part sand, three partsaggregates of size 20 mm and down.

13.3 The marking block should be given a smooth cover surface or cement mortar and shallhave the appropriate legends, 5 mm deep engraved on them as HVPNL 66 CABLECkt.- I OR HVPNL 66 KV CABLE Ckt.- II, HVPNL 66 KV CABLE or as the case maybe.

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14.0 PIPES

14.1 HDPE pipes of ISI mark, of approved diameter and thickness, of good quality shall beused for formation of cable ducts. All sundry materials like coupling, collars, and capsto cover the pipe ends before cable is pulled in shall be provided.

14.2 The bidder shall furnish the design drawings of foundations, foundation anchor bolts,

and design calculations etc. of these structures.

15.0 SAND

15.1 Sand supplied for backfill shall be river sand, free from flakes, dust, earth, organicmatter and large pebbles and stones and should be free from any chemicalcontaminats likely to have corrosive action on the cable coverings. The sand shouldbe sieved through a mesh to remove all large stones and pebbles. The sand shall beproperly graded and shall conform to IS:383 for concreting work.

15.2 The owner will decide on the requirement of the use of sand depending on the

availability of the excavated earth to be used for backfill. The sand should be usedwith the approval of the owner as a backfill.

16.0 QUANTITIES

16.1 The quoted price shall also include supply of all material transportation charges, taxes,duties, Octoroi and tole tax, labour, construction, plant and equipment and fixture,fittings and all temporary and permanent works necessary for satisfactory completionin all respects.

16.2 If the owner is directed by the Engineer in charge to excavate to a lower level than that

indicated in the drawing, such additional excavation shall not be paid for & will bedeemed to be included in the quoted rates.

16.3 LEAD AND LIFT

The rates quoted for all items of works shall include all lifts and leads whereverapplicable unless otherwise specified.

16.4 BY MECHANICAL TRANSPORT

The rate for this item shall include loading, carriage, unloading, stacking and dressingetc. complete. In no case the excavated soil shall be stacked up to the distance of 1.5Mtrs. From the edge of excavation or one third the depth of excavation whichever ismore.

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16.5 The contractor shall be responsible for estimates, assumptions and conclusionsregarding the nature of the materials to be excavated and difficulty of making andmaintaining of required excavations and performing the work required as shown on thedrawing and in accordance with these specifications. Cofferdams, sheeting, shoring.Draining, dewarering etc. shall be furnished and installed as required and the costtherof shall be included in the rate quoted. The contractor shall be held responsible forany damage to any part of the work and property caused by collapse of sides ofexcavation. The materials can be salvaged if it can be done with safety for the workand structure and as approved by the Engineer in charge.

16.6 However, no extra claim shall be entertained for material not salvaged or any otherdamage to contractors proper as the results of the collapse. He shall not be entitled toany claim for redoing the excavations as a result of the same.

17.0 ROAD CUTTING

The road cutting, whether of cement concrete/ asphalt or macadam road surface shallbe taken after obtaining approval for cutting from the civic authorities, traffic police,telephone authorities and work should be planned to be completed in the shortestpossible time. Where necessary work shall be planned during night or light trafficperiods.

18.0 ROAD CROSSING

HDPE pipes shall be used for cable. Pipes diameter should not be less than 1.5 timesthe cable diameter.

19.0 FOOTPATH CUTTING

The slabs, kerb- stones, on the roads shall be removed and reinstated withoutdamage.

20.0 REINSTATEMENT

After the cables and pipes have been laid and before the trench is backfill all joints and

cable positions should be carefully plotted and preserved till such time the cable isenergized and taken over by the Engineer. The protective covers shall then beprovided, the excavated soil riddled, sieved and replaced. It is advisable to leave acrown of earth not less than 50 mm and not more than 100 mm in the centre andtapering towards the sides of the trench.

20.1 The temporary reinstatement of roadways should be inspected at regular intervals,more frequently in rainy season and immediately after overnight rain for checkingsettlement and if required the temporary reinstatement should be done.

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20.2 After the subsidence has ceased the trench may be permanently reinstated and thesurface resorted to the best possible condition.

20.3 The road surface being cement concrete, asphalt or tarred macadam, resurfacing willbe done by the civic authorities at owners cost. The fixing of markers etc. shall be co-ordinated by bidder.

20.4 All works shall be carried out under supervision of the Engineer in Charge or hisrepresentative.

21.0 MAINTENANCE OF SITE CONDITIONS

The contractor shall be clean the completed cable route and shall remove all surplusand waste materials, empty cable reels etc. preferably the same day but not later thanthe next day after the particular work is completed.

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Bill of material of LILO of one circuit of 66kV Sector 23- Dhundahera line at proposed 220kVs/stn. Sector 20 enroute proposed 66kV s/stn. HSIDC Udhog Vihar .

(Supply Port ion only)

Sr. No. Descrip tion Unit Total Quantity

1. 66kV 1200 mm2 Single Core AluminiumConductor Milliken type , XLPE insulated Cableas per technical specification

Mtrs. 3910X8

2. End Terminations as per technical specificationsuitable for above cable

No. 16

3. Galvanised End Termination Structures with Nuts ,Bolts, washers etc.

No. 8

6 Indicative quantity of Link Box with SVL( to be decided as per requirement)

No 4

7 Indicative quantity of Link Box with-out SVL

( to be decided as per requirement)

No 4

8 1 x 240, Copper Conductor, PVC insulated,Unarmoured, 3.3 KV Sheath Bonding cable

Mtrs 200

9 66kV LAs alongwith earthing material. No. 6

10 Terminal Connectors including Hardware fitting &conductor etc.

No. Lot

11 Supply of HDPE pipes required for variouscrossings including passing of XLPE cable withtrench less in HUDA Sector streets/Industrial area.

Mtr. 3550X8

12 Tentative No. of Straight Through Joints No. 64

12 Spare Straight Through Joints No. 2

12 Any other items not specified above but arerequired to complete the job in all respect.( Break-up to be specified by the bidder)

No. Lot

Note:-

1. It is specific for all the bidders to visi t the office of SE/ TS, Gurgaon to see the site

constraints before finalising / submitting the bids.2. The said work involves the route through residential area/Industrial area for which Trench-

less digging shall be got done as per Technical specif ication.3. The above mentioned length of cable involves the tentative loop of 100m for enrout ing the

said line at proposed 66kV s/stn. HSIDC Udhog Vihar.4. To lessen the no. of Straight through join ts, the length of cable shall be judiciously

selected keeping in view the safety of the cable by the successful bidder during detailedsurvey.

5. The route length / Quantit ies of 66kV line shown above is tentative & may vary.


30/32

Bill of material of LILO of one circuit of 66kV Sector 23- Dhundahera line at proposed 220kVs/stn. Sector 20 enroute proposed 66kV s/stn. HSIDC Udhog Vihar .

( Erection Portion only)

Sr.No. Descrip tion Unit Quantity

1. Detailed Survey, Laying of Double Circuit1200 mm2 Aluminium Milliken Conductor 66KV cable in trefoil formation with one spare foreach Circuit (6+2), installation of StraightThrough joint, and complete Civil works in allrespect on through rate basis as per technicalspecification with trench method (directlyBuried).

RunningcircuitLength(6+2)Mtrs.

360

2 Detailed Survey, Laying of Double Circuit1200 mm2 Aluminium Milliken Conductor 66KV cable in trefoil formation with one spare foreach Circuit (6+2), installation of StraightThrough joint, and complete Civil works in allrespect including using of HDPE pipes &Manholes for jointing Bays on through ratebasis as per technical specification withTrench-less method.


3550

3 Installation End Terminations including linkboxes, earthing, Terminal connectors etc. andtheir Structures / Foundations. This shall alsoinclude erection of Hardware fittings &

conductor

Nos. 16

4 Installation of LAs alongwith their earthing. Nos. 6

7 Testing & Commissioning Lot Lot


LS Lot

Note:-

1. It is specific for all the bidders to visi t the office of SE/ TS, Gurgaon to see the siteconstraints before finalising / submitting the bids.

2. The said work involves the route through residential area/Industrial area for which Trench-less digging shall be got done as per Technical specif ication.

3. The above mentioned length of cable involves the tentative loop of 100m for enrout ing thesaid line at proposed 66kV s/stn. HSIDC Udhog Vihar.

4. To lessen the no. of Straight through join ts, the length of cable shall be judiciouslyselected keeping in view the safety of the cable by the successful bidder during detailedsurvey.



31/32

Bill of material of L ILO of one circui t of Daultabad- Sector 9 line at proposed 66kV s/stn.Sector 4 Gurgaon.

(Supply Portion only)

Sr. No. Descrip tion Unit Total Quantity

1. 66kV 1200 mm2 Single Core Aluminium

Conductor Milliken type, XLPE insulated Cableas per technical specification

Mtrs. 3470X8

2. End Terminations as per technical specificationsuitable for above cable

No. 16

3. Galvanised End Termination Structures with Nuts ,Bolts, washers etc.

No. 8

6 Indicative quantity of Link Box with SVL( to be decided as per requirement)

No 4

7 Indicative quantity of Link Box with-out SVL( to be decided as per requirement)

No 4

8 1 x 240, Copper Conductor, PVC insulated,Unarmoured, 3.3 KV Sheath Bonding cable

Mtrs 200

9 66kV LAs alongwith earthing material. No. 6

10 Terminal Connectors including Hardware fitting &conductor etc.

No. Lot

11 Supply of HDPE pipes required for variouscrossings including passing of XLPE cable withtrench less in HUDA Sector streets/Industrial area.

Mtr. 1000X8

12 Tentative No. of Straight Through Joints No. 56

12 Spare Straight Through Joints No. 2


No. Lot

Note:-


2. The said work involves the route through residential area for which Trench-less diggingshall be got done as per Technical specification.

3. To lessen the no. of Straight through join ts, the length of cable shall be judiciouslyselected keeping in view the safety of the cable by the successful bidder during detailedsurvey.



32/32

Bill of material of L ILO of one circui t of Daultabad- Sector 9 line at proposed 66kV s/stn.Sector 4 Gurgaon.

( Erection Portion only)

Sr.No. Description Unit Quantity

1. Detailed Survey, Laying of Double Circuit 1200mm2Aluminium Milliken Conductor 66 KV cable intrefoil formation with one spare for each Circuit(6+2), installation of Straight Through joint, andcomplete Civil works in all respect on through ratebasis as per technical specification with trenchmethod ( directly Buried).


2470

2 Detailed Survey, Laying of Double Circuit 1200mm2Aluminium Milliken Conductor 66 KV cable intrefoil formation with one spare for each Circuit(6+2), installation of Straight Through joint, andcomplete Civil works in all respect including usingof HDPE pipes & Manholes for jointing Bays onthrough rate basis as per technical specificationwith Trench-less method.


1000

3 Installation End Terminations including link boxes,earthing, Terminal connectors etc. and theirStructures / Foundations. This shall also includeerection of Hardware fittings & conductor

Nos. 16

4 Installation of LAs alongwith their earthing. Nos. 6

7 Testing & Commissioning Lot Lot


LS Lot

Note:-


2. The said work involves the route through residential area for which Trench-less digging

shall be got done as per Technical specification.3. To lessen the no. of Straight through join ts, the length of cable shall be judiciously

selected keeping in view the safety of the cable by the successful bidder during detailedsurvey.


Documents

110_Technical document of JICA-012.pdf