technical specification document final 23-09-2011x

7/29/2019 Technical Specification Document Final 23-09-2011X

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Tender no. 11000039-HD-11370_Lighting Improvement_6 Gujarat Locations

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1 :GENERAL ANDTECHNICAL SPECIFICATIONS, SCOPE OF WORK &WORKMANSHIP.

1.1SCOPE OF WORK1. Work as listed below, but not necessarily limited to, is included within the scope of this

tender enquiry.2. Installation, connecting, testing and commissioning of all electrical equipment required for

locations e.g. High Mast, Flood Lighting Fixtures, FLP Light fittings, Control Gear Box,

Lighting Distribution Board etc., as per the Bill of Quantities.3. Laying of XLPE insulated cables in excavated / RCC trenches in RCC slits chipped out in

RCC floors and on cable trays as required.

4. Supply of single / double compression / flameproof nickel plated brass cable glands andcrimping type tinned copper cable lugs wherever required. Normally, equipment shall be

received at site with cable lugs and glands. Where these are short supplied or wronglysupplied by equipment supplier these shall be provided by electrical contractor.

5. Excavation and back filling of cable trenches.6. Termination of power, control and lighting cables.7. Supplying, Erection, testing & commissioning of prefabricated High Mast lighting towers

along with foundations and other flood light towers.

8. Fabrication of supports, cable racks, frames with supply of MS materials as required.9. Supply, laying and connection of the complete Earthing system including supply of GI

Earthing strips, connecting earth pits in a grid, testing earth pits, flexible Earthing

conductors, etc.

10.Minor civil work including chipping, grouting, repairing of floor and walls damaged duringelectricalInstallation, as may be required to complete the work in all respect.

11.Supply and installation of any other items not specifically mentioned but found necessaryby the Engineer-in-charge for satisfactory completion of work.

12.Any work not included in this tender but may be required as decided by the Site in- chargewill be carried out. For such items rate shall be worked out at the market prevailing rates.


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1.2 GENERAL INSTRUCTIONS TO TENDERERS1. This is augmentation job and the contractor has to work in a running highly hazardous plant.

As such he has to obtain necessary Electrical work permit/safety work permit/working on

Height permit of appropriate class from the Depot/Terminal I/C or Engineer in chargebefore starting of job and also the contractor and his men shall observe all safety

precautions/ rules/ regulations as generally observed in running depots/terminals.

2. It is possible that contractor may not get shut down on the whole part for doing the erection/Testing / commissioning work for a long stretch of time. They will, therefore, submit

execution plan prior for approval from location where shut down of plant is required.

3. The offer shall be strictly as per specifications/data sheet/drawings/schedule of quantitiesetc.

4. Unfilled blocks/blank space provided in the NIT/specification/data sheet as applicable, to befilled up and furnished with the offer. Any unfulfilled data may lead to disqualification ofthe offer.

5.

Any deviation from the technical details of the enquiry must be spelt out under headingTECHNICAL DEVIATIONS.6. For supply items, certificates, drawings, sketch etc. Showing general arrangement,

equipment layout, electrical scheme etc. should be enclosed to make the offer technically

clear and complete.

7. Every component, material, hardware used in the equipmentmanufacturer/assembly/erection shall be of approved make, with distinct mark of quality

and confirming to relevant Indian/International Standards and codes. The entire job shall be

executed with good workmanship and sound engineering practices.8. All the jobs shall be pre-planned and sketches for installations e.g., High Mast, Flood

Lighting Fixtures, flameproof light fittings, Junction Boxes, Control Gear box, Lighting

Distribution Board etc. Shall be made and submitted to Engineer-in-charge for approval.The entire installation shall be as per the approved erection drawings.

9. Any installation found unsatisfactory/defective/not as per the approved drawings/sketcheshave to be dismantled and re-done without any extra cost to the owner.

10.Stage and final inspection of all supply items like High Mast, Flood Lighting Fixtures,Cables, FLP materials like Junction Boxes, lighting fixtures, Control Gear box, Lighting

Distribution Board etc. including GI strips, earth electrode shall be done at manufacturers

works by TPI representative. Inspection charges shall be borne by Contractor.11.In case specification/data sheet for any item of supply or erection is not enclosed with the

NIT, relevant Indian Standard shall be applicable.

12.All electrical installation shall confirm to the latest Indian Electricity Rules, Factories Actand all statutory rules and regulations.

13.Technical particulars enclosed for Cables, High Mast and flameproof material is only forinformation and need not be filled. However successful tenderer has to fill up and complywith the technical particulars within 10 days from placement of LOI.

14.The territorial clearance from the State Electrical Inspector/CEE/OISD/CEA for newelectrical equipment installed by the contractor shall be in scope of the contractor prior to

commissioning.


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15.Copies of General Arrangement /CMRI & CCOE Certificates, Certificate of tests for degreeof protection for enclosure (IP 55) etc. to be enclosed to make the offer technically completeand clear.

16.Lay out of the components, terminals shall be logical and the enclosure shall be liberallydimensioned so that cable terminations, operation and maintenance can easily be carriedout. All hardware shall be of stainless steel. Paint shall be epoxy, Shade-631 as per IS-5.

17.The quantity indicated in the enquiry is tentative and it may be increased / decreased /deleted without further reference.

18.Wherever applicable, 4 copies of all the drawings shall be submitted by the successfultenderer within two weeks from the date of LOI for approval. Manufacture shall be as per

approved drawings only.

19.Final drawings, test certificates, instruction manuals etc. (all in SIX SETS) with onereproducible of all electrical Schematic Drawing, to be furnished to HPC before dispatch of

the equipment.

20.All the Lighting Fixture should have ISI marking, CMRI & CCOE No. and equipment S.No. punched in main name plate only failing which equipment will not be accepted. Pasting

of plastic sticker are not acceptable.

21.CMRI No., cable size and make should be punched on the cable glands.22.In case of conflicts between description / details of specifications in various clauses of this

tender document higher specifications shall prevail. HPCL will consider the best practices

in the market, IS codes and pertaining of clerical mistakes, etc. HPCLs decision in this

regard shall be final and binding on the vendors.

1.3JOB SPECIFICATION1.3.1 HPSV/HPMV Lamp

1. The lamp to be accommodated in the luminary shall be 250/400 watt tubular clear type HighPressure Sodium Vapor (HPSV) or High Pressure Mercury Vapor 400W HPMV lamp,

flame proof fixture required.

2. The lamp shall comply with the requirements of IEC 60662 together with all currentamendments.

3. The minimum lumen output specifications of the lamp shall be as follows

Lamp

Lamp Cap

Type

Colour Corrected

Temperature CCT

Lumen Output [Lm]

Initial 100 Hrs After 2000 Hrs

250W HPSV E40 2000K-2100K 28000 26500

400W HPSV E40 2000K-2100K 48000 46000400W HPMV E40 3900K-4000K 23000 22000

4. The lamp shall not take longer than 4 minutes after the initial switch on to attain 80% ofits guaranteed lumen output at the rated voltage 240 Volts, +5%, -10% and frequency 50

Hertz. The re-ignition period after an interruption of the supply shall not be longer than 1

minute to attain 80% of its lumen output.


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5. The average luminous flux of the lamp shall not depreciate more than 10% of initial valueafter 10,000 switched operating hours.

6. The average mortality rate for the 250/400 watt HPSV lamp shall not be greater than 10% at12,000 switched operating hours.

1.3.2 Luminary BodyEpoxy grey powder coated single piece die-cast aluminum housing, heat resistant toughenedclear glass fixed to housing with silicone rubber gasket with MS Galvanized clips. Separate

die-cast aluminum top cover hinged to the housing and fixed with state-of-art press fit clips.

Side entry mounting for 50-60 mm OD pipe bracket.

1.3.3 ReflectorElectrochemically brightened, polished and finish computer aided pot optic aluminum

reflector for tubular lamp.

1.3.4 Degree of ProtectionIP 66 (Lamp compartment only).

1.3.5 Lamp holder And Associated Supports and Brackets1. The lamp holder shall be made of non-metallic, heat resistant material and be rigidly fixed

onto the optical compartment.2. The lamp holder shall be an E40 type for the 250/400 W HPSV/HPMV lamp. The lamp

holder shall be complete with an appropriate brake system to prevent loosening of the lamp.

3. The lamp holder together with its supports and brackets shall withstand normal usagethroughout the life of the luminaries.

4. A lamp fully inserted shall be rigidly held with its axis substantially concident with that ofthe lamp holder under the normal conditions of wind, vibration and mechanical shock.

5. The E40 lamp holder shall be rated for 4.5kV pulse.1.3.6 ELECTRICAL CONTROL GEARA. GENERAL

1. The luminaries shall be furnished complete with integral electrical control gear comprisingof inductive ballast, capacitor and ignitor.

2. The electrical control gear shall be mounted on a suitable module unit and shall be easilyremovable and replaceable as a unit without the use of any special tools.

3. Electrical connection and disconnection of the electrical control gear unit from theluminaries shall be through a plug and socket type connection/terminal block such that

incoming supply cables need not be removed when removing the electrical control gear

module.

B. BALLAST1. The ballast shall be solidly filled with polyester compound and enclosed in a sheet steel or

die cast aluminum container or vacuum impregnated with polyester resin of not less than

thermal class H (180 C in accordance with IEC 60085).


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2. The ballast shall be reactor type and comply fully with IEC 60922 - Ballast for DischargeLamps: General and Safety Requirements and IEC 60923 - Ballast for discharge lamps(excluding tubular fluorescent lamps) - Performance Requirements.

3. The rated voltage of the ballast shall be 240 Volt, 50 Hz (Nominal) and shall be suitable foroperation on a 240 Volt, +5%, -10%, 50 Hz supply system. All terminals shall be of screwconnector type.

4. The lamp current crest factor of the ballast shall not exceed 1.8 for 6% voltage variations.5. The rated maximum operating temperature of the ballast winding (tw) shall not be less than

130 C whereas the maximum winding temperature rise (t) shall not be more than 70 C.

C.IGNITOR1. The ignitor shall be solid state, fully electronic, timed, superimposed multiple-pulse type

which does not require the use of tapped ballast to ignite the HPSV/HPMV lamp.

2. The ignitor shall be fully encapsulated and totally sealed against the ingress of moisture.3. The ignitor shall have a casing temperature rating of not less than 90 0C.4. The case of the unit shall carry a label showing the connections and listing the operating

voltage and the precautions to take during its removal. The ignitor shall be mounted with

nut and lock washer.5. The ignitor shall comply with and be tested to IEC 60926 and IEC 60927 together with all

current amendments.

D. CAPACITOR

1. The capacitors shall comply with and be tested to IEC 61048/61049.2. The capacitors shall have a minimum voltage rating of 250 Volt and a casing temperature

rating not less than 850C and shall be of sufficient capacity to raise the power factor of the

circuit to not less than 0.85 lagging. The capacitors shall be housed in extruded aluminum or

thermoplastic canisters and mounted with nut and lock washer.

3. Capacitors shall not be fused but incorporate a safety discharge resistor.

1.4 LIGHTING SYSTEM1.4.1 FLAMEPROOF LIGHTING INSTALLATIONS:

Lighting Installations in licensed area shall conform to the area classification and surface

temperature considerations.

Fixture shall be firmly supported from roof trusses / structure in sheds. Support clamps /

brackets may be bolted or welded to the existing steel members or inserts (in RCC roofs).

Unless mentioned specifically in drawings, lighting fixtures shall be installed at a minimumheight of 4 meters from the floor level. In the Pump House and TLF Sheds, where it may

not be possible to maintain a minimum height of 4 meters, the lighting fixtures may be

installed above 2.5 meters.

However to the extent possible in each shed all fixtures shall be installed at the same height.

The lighting lay out drawing indicates the requirement of fitting in particular area, but actual


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location of each fixture shall be finalized at site in consideration of lumen requirement for

day to day work, any obstruction, uniformity in lighting distribution and aesthetic look.

Cable glanding and termination in licensed area must be done only by qualified and highly

skilled technicians.

Re-fixing of cover and reassembly of parts, if required, of FLP and IP-55 lighting fittings,

associated junction boxes etc. after cable glanding & termination shall be done in verycareful manner so as to ensure total prevention of water ingress. Every FLP and IP-55

lighting fitting and junction box shall be checked for proper position of gasket, tightness of

all screws, plugs etc. If the lighting fixtures have two cable entries, looping of the cables

shall be done in the terminal box of the fitting and no junction box should be used for thesame purpose. Where only one entry in such fittings is used the unused entry must be

properly plugged with threaded FLP plug.

Where the terminal is anti-vibration type, cable termination shall be done with suitable

crimping type lugs supplied with the equipment. If lugs are not supplied, the contractor shall

supply proper lugs and claim extra charges for the same as per the rate included in the Billof Quantity.

Cable glands for terminating cable at FLP and IP-55 electrical equipment shall be supplied

by the equipment supplier. The cable glands for use with such equipment shall be brass /nickel plated double compression type and certified by CMRS for flame proof ness CMRS

certificate No., Manufacturers name and cable size shall be embossed on the gland. In case

of short supply of cable glands the contractor shall supply the required cable glands asdescribed above and shall not claim extra.

1.4.2 LIGHTING IN SUBSTATION & UNLICENCED AREAAll wiring for lighting in substation, DG Room and Fire Water Pump Hose shall be with

XLPE A PVC (Cu cable, supported on wall, column structure etc.in cable trays) byproviding adequate support at an interval of 250 mm. The wiring shall be neat an in straight

line either horizontal or vertical avoiding criss-crossing. All cable shall be terminated in

junction Box / lighting fixtures (to be supplied by the contactor) through double

compression cable glands. The fixtures and junction boxes shall be earthed internally withthird core of the cable. Circuit numbering of lighting fixtures to be done by the contactor

within the rate quoted for installation.

1.4.3 TESTING AND COMMISSIONINGThe contractor shall be responsible for testing and commissioning of the entire lightingcircuit. No lighting circuit shall be energized without proper testing of insulation resistance

of the circuit with a 500 V meggar.


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1.5 INTERNAL WIRING, TERMINAL BLOCK AND EARTHING TERMINALA. Internal Wiring

1.

The luminaries shall be completely pre-wired, requiring only the connection of the electricalpower supply cables to the terminal and the earth continuity conductor to the Earthing

terminal.

2. The control gear looping cables shall be non-hygroscopic heat resistant copper-core flexiblecable, with a temperature rating of not less than 105 C and marked on the insulation and

securely clipped. The minimum size of the cable shall not be less than 1 sq. mm.

3. PTFE insulation or the equivalent, rated to a minimum of 2500C shall be used for leads tothe lamp holder.

B. Terminal Block

1. A readily accessible barrier terminal block with the live and neutral connections clearlyand indelibly marked for the connection of incoming supply cables shall be provided asclose as possible to the point of entry of the supply cables. The terminal block shall be madeof non-inflammable material.

2. A means of clamping the electrical supply cables shall be provided in the luminaries torelieve the terminations of strain where they are connected to the terminals. The cable clamp

arrangement shall not damage the insulation of the cables.

C. Earthing Terminal

1. A separate terminal for the connection of an earth continuity conductor, clearly andindelibly marked shall be provided.

2. All exposed metal parts and other parts accessible when the luminary is opened formaintenance and liable to become live in the event of an insulation fault shall bepermanently and reliably connected to this Earthing terminal.

1.6 TECHNICAL SPECIFICATION FOR FLP WELL GLASSES LIGHTING FIXTURE& CONTROL GEAR BOX ETC.

1.6.1 SPECIFICATIONS FLAMEPROOF/WEATHERPROOF ROTARY SWITCHi. Designing Standards : IS 2148-2004 IEC 60079-1(2001) & IS 13346-2004 IEC 60079-

0(2000)

ii. Current Utilization : 32 AMP 440 Viii. EX-Protection : Ex-d Typeiv.

Gas Gr. : I, IIA & IIB IICv. Zone Classification : Zone 1 & Zone 2

vi. IP Protection Class : IP65vii. MOC : Pressure Die Cast Aluminium Alloy LM6

viii. Paint : Light Gray Epoxy Polyester Powder Coating Shade No. 631ix. Earthling : Internal-01 No. External-02 Nos.x. Cable Entry : 02 nos. for et

xi. O Ring : Endless Neoprenexii. Hardware : In Stainless Steel


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1.6.2 SPECIFICATIONS FLAMEPROOF CONTROL GEAR BOXDESCRIPTION: Flame proof control gear suitable for 400 W HPMV & 250/400

HPSV/MH LAMP.

i. DESIGNING STANDARDS

: IS 2148-2004 IEC 60079-1(2001) & IS 13346-2004IEC 60079-0(2000)

ii. FINISH : Light Gray Epoxy Polyester Powder Coating Shade No. 631iii. MATERIAL: DieCast Aluminum alloy LM 6iv. CABLE ENTRY: 3 Cable entries 3/4 " B.S. Conduitv. GASKET /O ring: Endless Molded Neoprene.

vi. EARTHING : Internal -01 No. External -02 Nos.vii. IP PROTECTION CLASS : IP 65

viii. GROUPS: I, II A & II B as per IS 2148-1981ix. ZONE CLASSIFCATIONS: ZONE 1 & ZONE 2x. CMRI. CERT. No.: C.M.R.I./T.C./H 1256 dated.- 14 Oct. 1999

CIMFR/TC/SR/H837 Dtd.23.01.08 / CIMFR/TC/S/697 Dtd.19.11.2008

xi. TEMP. CLASS: 400 MV/SV/MH -(T6)xii. CURRENT UTILIZATION : 400 W 220 V

xiii. EX-PROTECTION : Ex-d Typexiv. HARDWARE : In Stainless Steel

1.6.3 SPECIFICATIONS FLAMEPROOF WELL GLASS FITTING:DESCRIPTION: Flame proof weather-proof non-integral well glass suitable for

160/250/400W HPMV/HPSV lamp at 250 V AC (max.)i. MATERIAL: Die Cast Aluminium LM 6.

ii. GLASS: Heat resistant and toughened well glass.iii. CABLE ENTRY: 2 way 3/4" B.S. Conduit.iv. HOLDER: GES Holder is provided as standard.v. SUSPENSION: Eye bolt/Bracket

vi. HINGING: M.S. Chain is provided.vii. GASKET: Endless MouldedNeoprene.

viii. IP RATING: IP 65ix. FINISH: Light Gray Epoxy Polyester Powder Coating Shade No. 631.x. STANDARD: IS 2148-2004

xi. GROUPS: I, II A & II Bxii. ZONE : Zone 1 & Zone 2

xiii. CMRI. CERT. No.: C.M.R.I./T.C./P/H382 dt. 18 AUG. 2006.xiv. TEMP. CLASS: 400W MV `T3, 400W SV/MH`T4, 250W SV/MH`T5

1.6.4 SPECIFICATIONS FLAMEPROOF FLOOD LIGHT FITTINGSDESCRIPTION: Flame proof weather-proof non-integral suitable for 160/250/400WHPMV/HPSV lamp at 250 V AC (max.)

i. MATERIAL: Cast Aluminum Alloy LM6ii. CABLE ENTRY: 02 way for et


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iii. HOLDER: PORCELAIN ES 40.iv. GASKET: Endless MouldedNeoprene.v. IP RATING: IP 65

vi. FINISH: Light Gray Epoxy Polyester Powder Coating Shade No. 631 As per IS:5vii.

STANDARD: IS 9900viii. GROUPS: I, IIA & IIB

ix. ZONE : Zone 1 & Zone 21.6.5 DISTRIBUTION BOARDS

For Distribution Boards the contractor shall level and grout foundation channels in the floor

when the clearance is obtained from Engineer-in-charge. The Distribution Boards shall beassembled on leveled foundation, and aligned. Items recorded as short supply / damaged on

transit shall be supplied and installed by contractor.

1.7

SPECIFICATIONS FOR 30m HIGH MAST

1.7.1 SCOPEThis specification covers the technical requirements of design of system, manufacture,

testing at works, supply in well packed condition of high masts lighting structure, lightfittings, lamps, control gears for movement / maintenance of light fitting, Earthing /

lightning protection of units, aviation lights for towers / supply of spares for one year

maintenance free operation and commissioning etc. for Cochin Terminal, Kochi in Kerala.The scope shall also include the erection including testing and commissioning of the system

and also the supervision for erection, testing and commissioning of the system.

The lighting fixtures given in the tender schedule are based on design done with a particularmake (Crompton Greaves). The drawing showing illumination levels for the 3 locations is

enclosed with the tender. In case the vendor supplies mast/fixtures of another approved

make (as stated in approved vendor list), they should submit lighting design using software

of that manufacturer for approval of HPCL. However, the type of fixtures proposed shouldbe equivalent to the type(s) specified in the tender and the payment will be made for actual

number of fixtures provided on item basis as per schedule of rates of tender.

1.7.2 INSTRUCTION TO BIDDERA. The average illumination levels to be maintained in different areas be according to the

following. The areas to be illuminated are as marked in the plot plan drawings:

a) Truck movement Area - 20 luxb) Tank Farm Area/roads - 20 luxc) Other Area - 10 lux

The illumination levels as mentioned shall be uniform as far as possible.

B. The supplier is to consider the followings for Supply.a) Masts shall be of unipolar (single pole) structure. Special consideration shall be

taken in respect of lamp replacement, operation and maintenance.

b) Number of masts, their locations are indicated in layout are tentative.


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c) Number of fixtures has been decided based on the area, lux level and theobstruction in the considered area.

d) 400 W HPSV lamps shall be used.e) The height of mast shall be 30 M.

C.Manufacture of masts and components, light fittings, lamps, control gears for fittings,control gears for lantern carriage movement (i.e., raise / lower) with self-sustaining winch /

stainless steel wire rope / flameproof motors / control PB stations and flexible cables, shall

be as per relevant Indian / International Standards. Winch motor shall be in flameproofenclosures and the control gears shall be in flameproof enclosure. The FLP enclosures shall

conform to groups IIA/IIB. Masts shall be hot dip galvanized, polygon shaped and

sectionalized. Necessary Earthing and lighting protection of mast shall be provided.

D. Routine tests shall be carried out on the supplied items at manufacture's works as perrelevant standards. For imported items of masts, relevant routine test certificates need to be

produced for the purpose. However, testing shall not absolve the supplier from his

responsibility for making good any defect, which may be noticed subsequently. Site testingto demonstrate working & performance of the system shall also be carried out.

E. The following documents shall be supplied with offer / for approval.a)Technical data of mast : With offer/For Approval/Final.b)Scheme diagram : With offer/For Approval/Final.c)Technical data of light fittings : With offer/For Approval/Final.d)Technical literature / Catalogues: With offer/For Approval/Final.e)Civil foundation data / details : With offer/For Approval/Final.f) Test Certificates : With offer/For Approval/Final.g)Guarantee Certificates : With offer/For Approval/Final.h)Earthing & Lightning Protection drg: With offer/For Approval/Final.

F. 2 nos. earth pits shall be provided near each mast for lightning protection and Earthing. Theconnection from each pit to the mast shall be arranged by the Vendor by GI strips of size 50

X 6 mm. The earth pit shall be within 10 M of the mast.

G. All Flameproof equipment being used shall be approved by CMRI, Dhanbad & CCOE,Nagpur,for use in hazardous area.

H. This specification is to be read in conjunction with enclosed "Detailed TechnicalSpecification for 30 M High mast lighting.

1.7.3 DETAILED TECHNICAL SPECIFICATION FOR 30 M HIGH MAST LIGHTING:A. SCOPE:

The scope of this specification covers supply, installation, testing and commissioning of the

complete lighting system, using Raising and Lowering type of High mast towers, includingthe civil works in foundation. All items required for the safe and efficient operation and

maintenance of the lighting system, including the high mast, whether explicitly stated

hereunder or not, shall be included by the Contractor. Control Panel at base including timer,cabling from control panel to the control gears / fittings as per price bid and aviation lamp /

lightning protection shall be part of high mast item. Control Panel shall have facility toterminate two numbers of cables as specified in SLD.

B. APPLICABLE STANDARDS:


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The following shall be the Reference Standards for the loading of the high mast:-

a. BS Code of Practice, CP-3, Gradient of wind related to height Chapter-V, Pt-IIabove ground.

b.

BS 4360 Grades of MS Platesc. BS 5135 Weldingd. BD 729 Galvanizinge. Technical Report (TR) No.7 1996 Specification for Mast and Foundation.f. IS-875 (Pt-III) 1987 Code of Practice for Design Loads for structure.

C. HIGH MASTSTRUCTURE:The High mast shall be of continuously tapered, polygonal cross section, at least 16 sided,

presenting a pleasing appearance and shall be based on proven In- Tension design conforming

to the Standards referred to above, to give an assured performance and reliable service.

The mast height shall be 30 meters, with minimum diameters of 152mm at the top and

612mm at the bottom. Minimum plate thickness of bottom section shall be 5mm and Othersections 4mm. The PCD of the mast flange shall be minimum 740 mm. The structure shall be

suitable for wind loading as per IS-875, pt-3, 1987.

D. CONSTRUCTION:The mast shall be capable of safely withstanding the strong winds prevailing at site. The

deflection at the top during heavy monsoon periods shall therefore be considered in the

design and the mast designed in such way that the above deflection during worst periods iskept to a minimum value. The mast shall be fabricated from special steel plates, conforming

to BS-EN10-025, cut and folded to form a polygonal section as stated above and shall be

telescopically jointed and fillets welded. The welding shall be in accordance with BS:5135.The procedural weld geometry and the workmanship shall be exhaustively tested on the

completed welds. The 30 meter size mast shall be delivered only in three sections, and shall

be jointed together by slip-stressed-fit method at site. No site welding or bolted joint shall bedone on the mast. The minimum over lap distance shall be 1.5 times the diameter at

penetration.

The mast shall be provided with full penetrated flange which shall be free from any

Lamination or incursion. The welded connection of the base flange shall be fully developed tothe strength of the entire section. The base flange shall be provided with supplementary

gussets between the bolt holes to ensure elimination of helical stress concentration. For the

environmental protection of the mast, the entire fabricated mast shall be hot dip galvanised,internally and externally, having a uniform thickness of 65 microns.

E. DOOR OPENING:An adequate door opening approximately 1000 mm x 300 mm shall be provided at the base of

the mast and the opening shall be such that it permits clear access to equipment like winches,cables, plug and socket, etc. and also facilitate easy removal of the winch. The door opening

shall be complete with a close fitting, vandal resistant, weather proof door, provided with a

heavy duty double internal lock with special paddle key. The door opening shall be carefully


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designed and reinforced with welded steel section, so that the mast section at the base shall be

unaffected and undue buckling of the cut portion is prevented.

F. DYNAMIC LOADING FOR THE MAST:The mast structure shall be suitable to sustain an assumed maximum reaction arising from awind speed as per IS 875 (three second gust), and shall be measured at a height of 10 meters

above ground level. The design life of the mast shall be a minimum of 25 years.

G. LANTERN CARRIAGE:Fabrication:

A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fitting

and control gear boxes. The Lantern Carriage shall be of special design and shall be of steeltube construction, the tubes acting as conduits for wires, with holes fully protected by

grommets. The Lantern Carriage shall be so designed and fabricated to hold the required

number of flood light fittings and the control gear boxes, and also to have a perfect self-balance.

The Lantern Carriage shall be fabricated in two halves and joined by bolted flanges with

stainless steel bolts and plastic lock type stainless steel nuts to enable easy installation orremoval from the erected mast. The inner lining of the carriage shall be provided with

protective PVC arrangement, so that no damage is caused to the surface of the mast during

the raising and lowering operation of the carriage. The entire Lantern Carriage shall be hot

dip galvanizedafter fabrication.

H. Junction Box:Weather proof junction box with IP55 enclosure, made of Cast Aluminium shall be providedon the Carriage Assembly as required, from which the interconnections to the designed

number of the flood light luminaries and associated control gear fixed on the carriage shall be

made.

I. Raising and Lowering Mechanism:For the installation and maintenance of the luminaries and lamps, it will be necessary to lowerand raise the Lantern Carriage Assembly. To enable this, a suitable Winch Arrangement shall

be provided, with winch fixed at the base of the mast and the specially designed head frame

assembly the top.

J. Winch:The winch shall be of completely self-sustaining type, without the need for brake shoe,

springs or clutches. Each driving spindle of the winch shall be positively locked when not inuse, gravity activated PAWLS. Individual drum also should be operated for fine adjustment

of lantern carriage. The capacity, operating speed, safe working load of the recommended

lubrication and serial number of the winch shall be clearly marked on each winch. The gearratio may be according to manufacturers standard.

However, the minimum working load shall be not less than 750Kg. The Winch shall be Self-

lubricating type by means of an oil bath and the oil shall be readily available grades of

reputed producers. The winch drums shall be grooved to ensure perfect seat for stable and


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tidy rope lay, with no chances of rope slippage. The rope termination in the winch shall be

such that distortion or twisting is eliminated and at least 5 to 6 runs of rope remains on thedrum even when lantern carriage is fully lowered and rested on the rest pads. It should be

possible to operate the winch manually by a suitable handle and / or by an external power

tool. It shall be possible to remove the double drum after dismantling, through the dooropening provided at the base of mast. Also a winch gear box for simultaneous and reversible

operation of the double drum winch shall be provided as part of the contract. The winch shall

be type tested in presence of reputed Institution and the test certificate shall be furnishedbefore supply of material. A test certificate shall be furnished by the contractor from the

original equipment manufacturer, for each winch in support of the maximum load operated by

the winch.

K. Head Frame:The head frame which is to be designed as a capping unit of the mast, shall be of welded steelconstruction, galvanised both internally and externally after assembly. The top pulley shall be

appropriate diameter, large enough to accommodate the stainless steel wire ropes and the

multi-core electric cable. The pulley block shall be made of non-corrodible material, and shallbe of die cast aluminium alloy (LM-6). Pulley made of synthetic material such as plastic or

PVC is not acceptable. Self-lubricating bearings and stainless steel shaft shall be provided to

facilitate smooth and maintenance free operation for a long period. The pulley assembly shall

be fully protected by a canopy galvanised externally and internally.Close fittings guides and sleeves shall be provided to ensure that the ropes and cables do not

dislodged from their respective positions in the grooves. The head frame shall be provided

with guides and stops with PVC buffer for docking the lantern carriage.

L. Stainless Steel Wire Ropes:The suspension system shall be essentially be without intermediate joint and shall consist of

any non-corrodible stainless steel of AISI 316 or better grade. The stainless steel wire ropes

shall be of 7/19 construction, the central core being of the same material. The overalldiameter of the rope shall not be less than 8 mm. The breaking load of each rope shall not be

less than 2350kg individually, giving factor of safety or over 5 for system at full load, the

minimum recommended value as per the TR-7 referred to in the beginning of the

specification. The end construction of rope to winch drum shall be fitted with talurit. Thethimbles shall be secured on ropes by compression splices. Two continuous lengths of

stainless steel wire ropes shall be used in the system and no intermediate joints are acceptable

in view of the required safety. No intermediate joints, either bolted or else is provided on thewire ropes between winch and lantern carriage.

M. Electrical System, Cable and Cable Connection:The electrical connections from bottom to top shall made by special trailing cable. The cableshall be EPR insulated and PCP sheathed to get flexibility and endurance. Size of the cable

shall be 5 core, 4 mm, copper conductor. The cable shall be of approved make.


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A suitable FLP socket arrangement shall be provided at the bottom section of the Mast. The

trailing cable also shall have FLP plug connected at the bottom end. Also suitable provisionshall be made at the base compartment of the Mast to facilitate the operation of externally

mounted, electrically operated FLP power tool for raising and lowering of the lantern carriage

assembly. The trailing cables at the top shall be terminated in the weather proof junction box.Control Panel at the base shall be suitable to terminate cables as specified in SLD & cable

schedule. Control Panel shall be flameproof. Control Panel shall be provided with timer, Auto

manual off switch, start push button. The fittings including control gear shall be supplied byHigh Mast supplier. The wiring from control panel upto lighting fitting shall be done by High

Mast supplier. Junction box shall be provided at the top of Mast. 3 core x 2.5 mm2 FRLS

cable shall be used from junction box to lighting fitting.

N. POWER TOOL FOR THE WINCHA suitable, high powered, electrically driven, externally mounted, flameproof (FLP) powertool, with manual operating handle, together with an operating stand shall be supplied for

raising and lowering of the lantern carriage for maintenance purpose. The speed of power tool

may preferably be of slow speed, of 1.5 to 1.8 mtr / minute, so that vibrations associated withhigh speed are avoided.

The power tool shall be single speed, provided with a motor of required rating, suitable for

trolley mounting. The power tool shall be supplied complete with flame proof push button

type remote control switch, together with 6 (six) meters of power cable, so that the operationcan be carried out from a safe distance of 5 (five) meters. The capacity and speed of the

electric motor used in the power tool shall be suitable for lifting of the designed load installed

on the lantern carriage.The power tool trolley shall be so designed that it will not only be self-supporting but also

align the power tool perfectly with respect to the winch spindle during the operations. Also, a

handle for the manual operation of the winches, in case of problems with electrically operatedtool, shall be provided and shall incorporate a torque limiting device.

There shall be a separate torque limiting device to protect the wire ropes from over stretching.

It shall be mechanical with suitable load adjusting device. The torque limitor shall trip theload when it exceeds the adjusted limits. There shall be suitable provision for warning the

operator once the load is tripped off. The torque limitor is a requirement as per the relevant

standards in view of the overall safety of the system. Internal built -in type power tools shall

not be acceptable. It is utmost importance that the complete power tool, including trolley,motor, PB station and lead etc. shall be designed, assembled / built and supplied as one unit

by the original equipment manufacturer (OEM), to the Depot, through the Contractor. Locally

assembled / built make-shift contraption, in lieu of the above, to be called as power tool bythe Contractor, shall under no circumstances be accepted.

O. LIGHTNING CONDUCTOR:One number heavy duty, hot dip galvanised lightning finial shall be provided for each mastThe finial shall be minimum 1.2 M in length and shall be provided at the centre of the head-

frame. It shall be bolted solidly to the head frame to get a direct conducting path to the earth

through the Mast body. The lightning finial shall, under no circumstances, be provided on the


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lantern carriage, in view of the safety of the system. Other lightning arrestor of the installation

shall take into existence of these lightning arrestors and cone effect to be taken into account.

P. LUMINAIRES:The number of fittings on each mast shall be as per schedule given. A set of Two Neon

Aviation Obstruction shall be provided on top of each mast.

Q. EARTHING TERMINAL:Three numbers Earthing terminals, using 12mm dia stainless steel bolts, shall be provided

At a convenient location on the base of the mast, one exclusively for the lighteningconductor and other two for Earthing the mast.

R. TESTS:Routine tests shall be carried out as per relevant Indian Standards. Following routine tests

shall be carried out on all components as per relevant standards.Functional test.

Checking of dimensions, paint shade, bill of materials, circuit diagram etc.

The measuring instruments used during the shop testing of panels shall be calibrated and

their calibration must be valid. The calibration should be got done from any Govt. approvedtest house. The calibration reports must be furnished before conducting the shop test for our

approval.

S. TEST & GUARANTEE CERTIFICATE:Test certificate shall be furnished by the contractor, obtained from the original equipmentmanufacturer (OEM), for each winch including wire rope, in support of the maximum load

operated by the winch. A separate guarantee certificate shall also be furnished by the

Contractor, obtained from the OEM, for the quality and reliability of the total Mast systemincluding the mast, accessories and associated civil works in foundation.

T. TECHNICAL DATA FOR 30 MTR HIGH MAST AND COMPONENTS1. HIGH MAST LIGHTINGS STRUCTURE

a. Cross section of mast in polygon (no of sides)b. Overall height of mast (mm)

c. No. of sections of mast

d. Individual section, thickness /dia /length(mm)i. Top

ii. Middleiii. Bottom

e. Type of joints & length of overlap joints

f. Weight in Kgs of mast (including base plate, door and head frame etc.,)


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g. Material construction

h. Pollution treatmenti. Thickness of galvanisation (min)

j. Size of base opening door

k. Locking arrangement of base opening doorl. Size of base plate dia. / thickness

m. Lighting protection device

n. Aviation lighting deiceo. Make / Enclosed Drawing reference

2. CIVIL DESIGN CONSIDERATION

a. Max. wind speed (as per IS:875 1987)

b. Max. gust speed time

c. Factor of safety for wind loadd. Factor of safety for other load

e. Factor of safety of tower

3. Foundation Detailsa. Type of foundation

b. Size of foundation

c. Designed load bearing capacity

d. Design safety factore. Considered wind pressure (Kg/Mt)

f. Consider wind speed (Km/Hr)

g. Depth of foundationh. Average soil bearing capacity

i. No. of foundation bolts

j. PCD of Foundation boltsk. Type of foundation bolts / dia.

3. BOLT DIAMETER

For tender purpose, the tenderer shall consider a Safe Bearing Capacity of 5 Tons/sq.m

and depth of foundation of maximum 3 meters. The soil investigation

report/recommendations shall be made available to the successful tenderer for designingthe foundation. Any special treatment of soil required as per the soil investigation report

such as providing hard core, sand layer, PCC, backfilling with imported earth, including

piling etc. as required shall be carried out at no extra cost.

4. LANTERN CARRIAGE

a. Material of constructionb. Type of construction

c. Diameter of carriage ring (m)

d. Number of joints


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e. Buffer arrangement for carriage and mast

f. Load carrying capacity (kg)g. Total weight of assembly with fittings(kg)

h. Number of fittings

i. Type of fittings/fixture

5. WINCH

a. Make of winch & No. of winch / drums

b. Gear ratio

c. Capacity (kg)

d. Operating Speed on full loade. Individual drum rotation

f. Method of Operation

g. Lubrication arrangement / type of lubricanth. Tested load per drum (kg) i. Kgs per drum ; ii. Kgs per winch

i. SWL of winch at 200 rpm (Kg)

6. STAINLESS STEEL WIRE ROPE

a. Make

b. Gradec. Number of ropes

d. Material and construction

e. Centre core materialf. Diameter (mm)

g. Thimbles & Terminals

h. Breaking load capacity (kg)i. Factor of safety (specified not less than 5)

7. CABLE

a. Conductor, insulation/No. of cores

b. Type

c. Maked. Conductor Size / Current Capacity

8. POWER TOOL

a. Mode / Type

b. Input Supply (Volts)

c. KW / HPd. Operating speed

e. i) Remote control switch PB stationii) Length of control cable provided

f. Max. Time taken for:

i) Raising


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ii) lowering

9. TORQUE LIMITER

a. Model

b. Lifting capacity (kg)c. Adjustability / non-adjustable

10. AVIATION FITTINGS

a. Type

b. Type of lamps

c. No. of Lamps/fittings.

1.8 EARTHING SYSTEMSA. EARTHING ELECTRODE

Earthing electrode and accessories shall be as per drawing enclosed.a. Size of the copper plate - 600x600x3mmb. GI (galvanized) pipe of 50 mm diameter is to be used. This will have a funnel at the

top of the earth pit chamber.

c. The earth pit to be dug for a depth of 3.75 mts.d. Copper plate is to be properly fastened with nuts and bolts to the copper wire ofsize

14 SWG. This copper strip/copper wire is laid upto Switch board.

e. 50 Kg. of salt and approx. 100 Kg. of coal are to be filled in the pit, in layers, afterthe plate and the pipes are laid in the pit.

f. Measure the earth resistance at the pit which has to be less than 2 Ohms.g.

Cover be of CI with 750X750 mm size. Chamber should be 1000X1000 mmbrickwork and bottom with PCC.

B. EARTHING CONDUCTOR:The size and type of the Earthing conductors for main grid and equipment Earthing shall beas per drawings and specifications.

C. EARTHING NETWORK MAIN GRID:The location of earth pits (electrodes) earth conductors, earth bus, earthing points on the

equipment shall be determined at field, in consultation with the site- in- charge. Any

changes in the arrangements, routes, size of conductors shall be made only with approval ofEngineer-in-charge.

Each earth pit shall be connected to the grid at least by two distinct connections.

Where cable trays are available earth conductors may be laid on the tray, but the same shall

be clamped firmly to the side of the tray.

Joints and tapping of the earth conductors shall be made in such a way that reliable and

good electrical continuity is permanently ensured. All joints below ground shall be welded


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and suitably protected with two coats of bitumen paint given immediately after welding and

cleaning of welding slag. Welding must be with overlap of twice the width of GI strip andall four side of the overlap.

All joints using Earthing cables shall be by means of lugs / connectors only.

Excavation and filling the earth necessary for laying the underground earth conductors / grid

shall be the responsibility of the contractor.

D. EARTHING PRACTICES:Following codes of practice must be followed strictly:

a) Minimum distance between two electrodes shall be twice the length of the electrode.b) Minimum distance of the electrode from any building or foundation or structure shall

be equal to the length of the electrodec) For all electrical equipment minimum number of connection from earth grid :

External Earthing

Up to 250 Volts : OneAbove 250 Volts : Two

Internal Earthing

Flameproof equipment / lighting fixtures located in licensed area shall have anadditional Internal Earthing done with extra core available. All lighting fixtures and

associated junction boxes in unlicensed area earthed internally need not have external

Earthing.

E. TESTINGAll earth electrodes shall be individually tested by disconnecting from the grid with proper

earth tester. The test shall be conducted during dry season and results shall be recorded.

After connecting all electrodes to the ground resistance of the grid to earth shall also betested with proper earth tester.

1.9 CABLES/WIRES FOR ILLUMINATION WORKSa) Cable Laying And Termination

The scope of the contract shall include laying of power and lighting cables, which shall be

laid in trenches, cable trays or conduits as drawing and cable schedule or as per site

conditions. Fabrication and erection of cable trays, supports as required shall be theresponsibility of the Contractor.

Power and control cables shall be separated by adequate spacing or taken through separate

pipes.


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Cable schedule indicate the most desirable route of each cable. The routes are marked on the

plant lay out. However, there may be some obstruction or other problems at site. The mostconvenient route shall be decided in consultation with the Engineer-in-charge. Cable shall

not be cut from a drum until the actual length required is ascertained. The lengths given in

the cable schedule is only indicative.

To the extent possible one length without any joint shall be laid from one terminal to the

other. Wherever joint cannot be avoided, only Tropolin jointing kit of CCI / MahindraChemical or approved equivalent shall be used.

Cables shall be neatly arranged and dressed in trenches, trays avoiding criss-crossing.

Cables on the trays shall be clamped. Arranging the cables in the trenches / trays shall beresponsibility of the contractor. Cables from trench to the equipment shall be taken through

GI pipes of adequate size. Pipe shall be laid at angle of 45 max. to the trench for pulling of

the cables with ease. Bends shall have large bending radius (> 12 times of cable OD).

All cables will have identification tags close to their termination points bearing Run No. and

cable size shall be punched on Aluminium sheet (100 X 25 X 2 mm) and fastened to thecable by nylon tie locking type. For the underground cable tag shall also be provided at each

end before entry into the ground and at an interval of 30 meters.

Routes of the underground cables in the yard shall be marked with the markers at interval of30 meters and in turnings as well. Location of cable joints shall also be marked with

markers.

All temporary ends of cables must be protected against moisture / dirt to prevent damage to

insulation. For this purpose, ends of all PVC insulated cables shall be sealed with cable

compounds / PVC tape / rubber tape etc.

Cable shall be handled carefully to avoid damage. Screw jacks and rollers shall be used for

laying the cables.

Cables shall be laid in the trenches as per the code of practice. Before the cables are placed

the trench bottom shall be made level and covered with a 100 mm thick layer of sand.

Cables shall be dressed avoiding crossing and making separate groups for power cables,control cables etc. Cables shall be covered with 100 mm of sand on top of the cable of

largest OD. Class B Red bricks shall then be laid flat. The remainder of the trench shall then

be back filled with soil, rammed and leveled.

Cables shall not be cut from the drum without measuring the insulation resistance. After

laying one layer of cables and before covering with sand for second layer, if required, all thecables shall be meggared again in presence of site-in- charge and results to be recorded.

All wall opening / cable trenches, at the point of entry into a building shall be sealed

effectively to prevent seepage of water into a building.


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Where cables rises from the trenches / underground pipes to equipments, they shall be taken

through GI pipes of adequate size up to a minimum of 300 mm above the floor level or asdirected by the Engineer-in-charge. Cable shall be pulled carefully through the pipes so that

there is no damage to the cables. If required cable lubricant shall be used.

Where cables pass through foundation wall of any underground structure, necessary ducts or

opening shall be provided. However, should it be necessary to cut holes in existing

foundation or structure the contractor shall obtain permission of Engineer-in-charge beforecutting it.

The contractor shall examine each drum on receipt and record discrepancies, if any, in

respect of length, size, damages etc. The cable in drum shall be meggared and insulationresistance values shall be noted. In case of any discrepancy, the same shall be sorted out

with the Engineer-in-charge before cable from such a drum is utilized. Proper account of all

cables received and laid shall be maintained indicating Run No., Drum No., Length as perCable Schedule, Actual length laid, insulation resistance w.r.t. Earth and between the cores

with date of test and megger number and make.

Cables laid above ground shall be run on trays, fixed on walls, ceiling or structures and shall

be run parallel or at right angle to beams, walls or columns. Cable dressing is important and

must be approved by Engineer-in-charge. In case the above conditions for exposed cables

are not maintained, the site-in charge may direct to rectify / modify the same without anyextra cost to the HPCL.

Individual cables, group of cables, which run along a structure, may be directly clamped tostructure by means of 16 SWG Al clamps on 25 X 6 mm MS saddle bars. The rates for

cable laying should include consumable like saddle, saddle bar, binding straps nylon tie

locking type etc. and no separate payment shall be made for such items. Proper nylonlocking type or temporary fastening etc., Steel wires, cable armors etc. shall never be

allowed for such purposes. Cables shall be supported adequately to avoid unsightly sagging.

Normally the distance between two supports shall be 300 mm for cables of diameter up to25 mm. For cable of higher sizes the distance may be up to 450 mm. However uniform

distance shall be maintained for aesthetic consideration.

All cables shall be supported near the glands, so that there is no undue stress on the gland.All exposed cables must be protected against accidental damage.

b) TERMINATION:All cables shall be terminated at flameproof equipment through FLP double compressioncable glands only. In case, the contractor is required to supply the cable glands the same

shall be of approved make, bearing CMRS certificate No., Name of make and cable sizemust be punched on the cable gland. Threads of the nipple of cable gland must match the

thread at the cable entry of the equipment. Cable OD and diameter under armor must match

the neoprene rings.


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All flameproof equipments are provided with the internal Earthing point and there is anextra core available in the cables for connecting the internal Earthing. Earth connection shall

be taken from earth bus in the Electrical Panel.

Al utilized cores of a control cable shall be identified at both ends by wire numbers

indicated by PVC ferrules or self-sticking cable markers. Wire numbers shall be as per

schematic / terminal wiring diagrams. Cable markers / ferrules shall be as per the sampleapproved by Engineer-in-charge. Cable leads shall be terminated at the equipment terminals

with tinned copper lugs (CUS type) of Dowells or approved equivalent make. The lugs size

is the same as cable size. The lug hole diameter shall match the stud or fastener size. For all

power cable termination proper plain and spring washer must be used. Where anti-vibrationterminals cable termination proper plain is provided the special lugs for such terminations

are to be provided. In no case ordinary lugs shall be used with ant vibration terminals.

In PCC the part of the cable between the gland and the terminal shall be properly clamped

in the cable alley. No cable or wire shall be left hanging loose in the cable alley. All the

unused cable entry in cable alley of PCC should be plugged after completion of cablelaying.

General

1 All the luminaries shall be designed, manufactured and tested in accordance with

relevant IS specifications so far as they are applicable.

2 All the luminaries shall be commercial / industrial type as per specific requirement.

Specification for the various types of incandescent, mercury vapour, sodium vapour and

fluorescent fittings mentioned in the schedule of quantities shall be followed. All thelighting fixtures shall be complete with all parts, including earthing arrangement and

accessories for efficient performance whether specifically asked in the specification orin the schedule of items or not.

3 Individual light fittings shall be provided with suitable arrangements for GI threaded

conduit entry of 19 mm dia unless otherwise specified. Terminals of all fittings shall be

suitable for taking 2.5 sq. mm flexible, copper conductor PVC insulated, PVC sheathedcable.

4 Fittings shall be supplied with all inter connections made and fully wired upto the

terminal block and shall be suitable for mounting on wall / column / ceiling / suspension

(from the ceiling including suitable bracket).

5 All types of light fittings shall be supplied with lamps.

6 All live parts shall be provided with suitable sleeves to prevent accidental contacts. Theearthing terminal in the fitting shall effectively earth the body of the entire luminaries.

7 The clearance between the live parts and the enclosures earthing and other safety factorsshall be governed by the latest revisions of the relevant IS specification and IE rules.

8 The fixing arrangement of various components and lamps shall be in such a way that the

maintenance and replacement jobs can be easily carried out.

9 The luminaries shall be suitably designed to provide economically the required level ofillumination on the working plane when mounted at normal standard height in

accordance with the type of fixtures.


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10 The luminaries shall be suitable for operating at normal supply voltage of 240 V, single

phase, 50 Hz with voltage variation of +/- 6% or at voltages as specified.

11 The lamp holders of the fittings shall be suitable to take the lamp supplied.

12 All types of Fluorescent lamp fittings shall be supplied with necessary controlgear

housing polyester filled electronic ballast. P.F improvement capacitor spring loadedrotary lamp holders starter holders metallic starters all pre wired to suitable terminals

13 All types of fluorescent and well glass fittings shall be suitable for mounting on wall /

column or suspension from ceiling/false ceiling as required.

14 The light fittings shall include the mounting accessories like chain, down rods for

fittings mounted in false ceilings anchor bolt and all erection accessories required forcomplete installation.

15 Only energy efficient electronic ballast shall be used. In case the same is notmanufactured for a particular type of lighting fixture then copper ballast shall be used as

the next option.

16 Wherever inserts are available in the roof slab/column/wall, the same shall be used for

supporting the mounting accessories like down rod/brackets/chains etc., and in otherplaces where there are no inserts. Anchor bolts shall be used for supporting themounting brackets from the ceiling and grouting on wall / column shall be provided for

mounting the fitting on wall / column in consultation with the site engineer.

17 GI/MS/PVC conduits shall be complete with all accessories as required.

18 Due to the highly corrosive atmosphere the fittings shall be provided with two coats anticorrosive epoxy painting over two coats of primer.

19 Bulk head Luminaries suitable for Compact Flourescent fittings.

20 Anti-Corrosive Type Fluorescent Light Fitting

21 Industrial Fluorescent Light Luminaries With Stove/Vitreous Enamelled Reflectors

22 Compact Fluorescent Lamp & Fittings

23 Flame proof well glass & bulkhead luminaries suitable for HPMV/CFL fitting.

1.9.1 SPECIFICATION FOR CABLESa) INSTRUCTIONS TO BIDDERS:

1. The cables covered under this specification shall confirm to ES-8160.2. The tenderer shall submit cable data of the cables offered as per the Technical Particulars

enclosed.3. The Routine and Acceptance tests as per ES-8160 shall be conducted in presence of TPI

representative at venders works before dispatch of cables.

4. The drum lengths of various cables indicated in the enclosed Specification Sheet shall becomplied with subject to tolerance as indicated in ES-8160.

5. Any deviation from specification shall be clearly indicated.6. The following details to be embossed on the outer sheath of the cables :

i) Make / Trade Markii) Voltage Gradeiii) Size of cableiv) Sequential Marking


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All materials to be used shall be new, unused and of the best quality.

i. Conductors : The power cables shall be of stranded Aluminium / copper round orshaped conductors and control cables shall be of annealed high conductivity stranded

copper round conductors. The conductors shall comply with the requirements of IS:

8130.ii. Insulation : The conductor insulation shall be type A/C as indicated in specificationsheet and shall comply with relevant IS.

iii. Fillers : The cables shall have suitable fillers wherever required, laid up withconductors to provide substantially circular cross section before the inner sheath is

applied.

iv. Inner Sheath : Inner sheath, wherever applicable shall be ST1/ ST2 type compoundapplied by extrusion process except for paper cables for which it shall be of lead orlead alloy.

v. Armouring : All power and control cables shall be armoured as specified inspecification sheet. The single core cables shall be armoured with hard drawnAluminium taps/ wires or any other suitable nonmagnetic material. All other cables

shall have galvanized steel wire / strip armouring.

vi. Outer Sheath : The outer sheath shall be ST1/ ST2 type compound applied byextrusion process and suitable to withstand atmospheric pollution, resistance to

termites, fire retardant and coloured black.

vii. Screening : Screening over conductor and insulation shall be provided as per relevantstandard unless specified otherwise. The screening for control cables if specified shallbe of Aluminium, Mylar or equivalent and provided with tinned drain wire which

shall be continuous and permanently connected to the screen.

viii. Identification : The individual cores of cables shall be coloured as per relevant IS.Where it is not possible to distinguish the cores by colour, coloured strip shall be

applied on the cores or core nos. shall be marked on each core at regular intervals. All

cables shall carry the manufacturers name or trade mark, the cable size, voltage ratingand year of manufacture at intervals not exceeding 100 meters. Running meter

markings shall also be provided throughout the length of the cable.

ix. Dimension : The overall dia. and dia. under armour of the cables shall be indicated bythe vendor in the technical particulars. These shall be guaranteed with a tolerance of

5% but not exceeding 2 mm.

The cut ends of the cables shall be sealed by means of non-hygroscopic materials.

f) SPECIAL PURPOSE CABLESa) Flame Retardant Low Smoke Cables (FRLS) : Flame retardant low smoke cables, where

specified in specification sheet, shall have outer sheath of PVC having following values.

- Minimum oxygen index - 29%

- Minimum temperature index - 250C- Maximum acid gas generation - 20%

- Maximum smoke density rating - 60%b) Heat Resistant Cables

Heat resistant cables, where specified in specification sheet, shall be of silicon rubber

insulated laid circular with asbestos worming and overall glass fibre braided and varnished.


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Silicon rubber insulating compound shall conform to IS:6380 and the constructional

features shall conform generally to IS:9968.

g) CABLE DRUMa)

The cables shall be supplied in non-returnable wooden drums (or steel drums ifspecified) of heavy construction. The wood used for construction of the drums shall

be properly seasoned, sound and free from defects.

b) Cables shall be supplied in specified drum lengths. Where no such indication isgiven, standard drum lengths may be offered.

c) The tolerance on each drum of cable shall not exceed 2.5%. However, no negativetolerance on HV cables is acceptable.

d) All cable drums shall have stenciled data as per relevant IS as well as the purchasersorder no., item no. & drum no.

h) TESTS AND INSPECTIONa) The following tests shall be carried out on the cables as per relevant IS.

i) Routine Tests - On all cablesii) Acceptance tests - On representative length of each size

iii) Type tests - Wherever specified on one cable drum of each size

b) In addition, the following tests shall be carried out on all fire retardant low smokecables as per IS or as per the following standards:i) Oxygen and temperature index test as per ASTM-D-2863

ii) Acid gas emission test as per IEC-754 Part-I

iii) Smoke density test as per ASTM-D-2843iv) Flammability test as per IEC-332 Part-I or IS-10810

c) All the above mentioned tests shall be carried out in the presence of Third Party. Inaddition, the cables shall be subjected to stage inspection at works and inspection at sitefor final acceptance.

d) These tests and inspections shall, however, not absolve the vendor from theirresponsibility for making good any defect which may be noticed subsequently.

i) DEVIATIONSi. Deviations, if any, from this standard shall be clearly indicated in the offer with

reasoning.ii. Deviations, if any, from the data furnished in specification sheet shall be indicated

therein beside the data by encircling it.

1.10CONTROL SWITCHESDecorative type

Single pole decorative type, 5A, or 15A switches shall be used for light/fans/socket outlets

points in office premises / non plant buildings and shall be of approved type, make and

color. All branch switches shall be placed in line conductor of the circuit and no singleswitch or fuse shall be inserted in the neutral conductor of the circuit.


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1.11SWITCH BOARDS (FOR DECORATIVE SWITCHES AND SOCKETS)The switch board shall be made of 1.6 mm thick sheet steel & painted including supports for

switches, sockets, fan regulator etc., but excluding front cover in case of decorative switches

& sockets which will be of FRP sheet of approved quality, design and colour. Clear depth ofthe box shall not be less than 60 mm, but adequate for easy mounting of fan regulators. All

fittings shall be in flush pattern in case of concealed wiring. The FRP cover sheet thickness

shall not be less than 3 mm.

1.12HAZARDOUS AREAGeneral

All the equipment's installed and accessories used shall conform to the requirementsstipulated under relevant Indian Standards and STEC regulations for the type / category of

installation. All the equipments and accessories installed in these areas shall be certified by

CMRI, Dhanbad for using in that particular type of hazardous atmosphere like flammablegas / vapor or hazardous dust. All the equipments installed shall not attain more than the

maximum permissible surface temperature specified for that area elsewhere in the

specification, if not the maximum permissible temperature may be assumed as 100 degree

C. It shall be ensured that overheating / sparking whether in normal use or under faultcondition is confined within the approved housing of wiring system and electrical item

concurred. If any equipment is likely to produce more than the prescribed maximum

permissible surface temperature due to abnormal conditions of operation or during faultconditions, all such fittings shall be fitted with a thermal device to disconnect the

appropriate circuit before the maximum safe temperature is exceeded. This bimetal

thermally operated cutout device shall preferably be included in the enclosure containing

choke and other control gears liable to be over heated. THIS THERMAL DEVICE SHALLNOT BE AUTOMATIC SELF-RESETTING TYPE. If control gears are not integral with

the fitting the enclosure for the control gears also shall be suitable for use in that particular

type of hazardous atmosphere and certified by CMRS, Dhanbad. For all the equipmentswhere cast iron body is specified, cast Aluminium alloy (LM-06) is also acceptable. All the

equipments if constructed out of Aluminium alloy, its external surfaces shall be smooth

finished to be free from frictional sparking hazard. All the equipments shall have markings,warning inscriptions and interlocks, specified as per relevant I.S, inscribed either by raised

lettering or cast integrally with or by a plate permanently attached to the body of the fitting.

Copy of CMRS, Dhanbad, and certificate for each type of fitting should be submitted.

Light FittingsFlame Proof Bulk Head FittingThe fitting shall have a cast iron/Aluminium enclosure with integral control chamber

housing the terminal box. The toughened impact resistant clear glass cover provided in the

front shall be cemented to retaining ring. The retaining ring shall be suitable for fixing to the

main body with the help of screws, which can be opened, only with the help of special tools.The ES porcelain lamp holder shall be suitable for the type of lamp specified. The fittings

shall have suitable cable entry provision as required. Suitable plugs to close the non-used

entries shall also be provided along with the fitting. A suitable chrome plated integral


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xiii. All internal wiring (2 sq.mm black PVC-insulated) forms part of this specification.Purchaser will only connect feeder cable(s) and rubber cable inside the pole.

xiv. Boxes and mounting plates shall be easily removable for installation purposes.xv. For explosion proof boxes test certificates with indication of gas-group classification will

be required.

1.14EQUIPMENT HANDLING:The contractor shall make his own arrangements to safe transportation of equipment toerection site including loading / unloading etc. Equipment shall not be taken out of the cases

unless the foundation has been made ready. The cases shall be opened only in presence of

Engineer-in-charge. Any damage / short supply detected shall be recorded in joint report

duly signed by Engineer-in-charge immediately. No dispute shall be entertained on a laterdate.

1.15ERECTION AND INSPECTION:

All supply items shall be third party inspected and Inspection reports to be submitted to

Engineer In Charge. Minor items like hardware MS materials for racks, support etc. shall beinspected at site by HPCL representative. No item shall be installed / used until the same is

approved by HPCL representative. After completion of erection of each piece of equipment

shall be offered for inspection to the owner before testing and commissioning. HPCL onfinding any defect / inconvenience shall point out the same for rectification. The contractor

shall inform the HPCL site in charge in writing the rectification carried out. Any work not

confirming to execution drawings, specifications, standards, or codes shall be rejected andthe contractor shall rework / rectify the same at his own cost.

1.16TESTING & COMMISSIONING:All equipment installed / connected by the contractor shall be tested and commissioned as

per instruction of Engineer in-charge. After completion of erection a check-list indicatingthe checks / tests proposed to be carried out before commissioning of the equipment shall be

submitted to the Engineer-in-charge for his approval. The contractor shall carry out the test

as per technical specification, manufacturers instruction manual, relevant Indian /International standards and instruction of the HPCL. All tests shall be conducted in presence

of the Engineer in-charge. The contractor shall provide all necessary tools, testing

equipment, labour, competent technical personnel, and consumable materials etc. for tests.

All the test results shall be recorded on approved proforma by the contractor and countersigned by the HPCL authorised representative. On successful completion of tests, the test

results shall be furnished in four copies in the form of Test Certificates.


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2 :LIST OF APPROVED VENDORSA. LIST OF APPROVED MAKE / BRAND FOR CIVIL WORKS

S. No. NAME OF MATERIAL APPROVED MAKE

1 Cement Ultratech, Birla, RAMCO, CCI, ACC

2 Reinforcement Steel / Structural steelTISCO, SAIL, TSRM, VIZAG STEEL,JISCO,

JVSL, LLOD STEEL, ESSAR

3 Cement paint Snowcem / Asian paint / Berger / Nitco

4 PVC / UPVC pipe Supreme / Prince / Finolex / Oriplast

5 GI pipe / MS pipe Tata / Zenith / GST / Jindal

6 Gun metal gate valve / check valve Leader / GG (ISI marked)/Audco/IVC/Fludiline7 G.I. Fittings R-Brand, K- Brand, Unik

8 Brass hardware Saifee, tube & hardware

9 Aluminium hardware Nov Bharat ,Jayant, E.C.I.E &Zaofa

10 C.I. Pipes & fittings NECO, BIC

11 MS structural steel small sections asspecified

Conforming IS:2062 as approved by EIC

12 Anchor bolts Conforming to IS:2062 as approved by EIC

13 Nuts & bolts TVS, GKW, UNBREAKO

14 Electrodes Conforming to IS as approved by EIC

Note :Regarding selecting the make against each item among the approved makes as specified abovdecision of HPCL shall be final.


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B. LIST OF APPROVED MAKE / BRAND FOR ELECTRICAL WORKSS. No. NAME OF MATERIAL APPROVED MAKE

1 MCCB L & T

2 SFU / FSU / HRC fuses / MCCB L & T / Havells / Alsthom / Havells

3MCB Distribution Boards MDS / Havells / Standard Electricals Ltd., / Hager

MK SENTRY

4 MCB/ELCBMDS / Havells / Standard Electricals Ltd., / Hager

MK SENTRY

5 PVC Conduits and accessories ISI / FIA approved make

6 PVC insulated copper wire V plast / Finolex

7 Switch / Sockets Anchor Roma / Mk India / Legrand

8 Angle holder / batten holder / ceiling rose Anchor

9 LT cablesCCI / UNIVERSAL / NICCO / FINOLEX /

GLOWSTAR / OMEGA

10 Light fittings / ballast / lamps PHILIPS / BAJAJ / CROMPTON/WIPRO

11 Ceiling fans (double ball bearing) Crompton / Usha / Khaitan / Bajaj

12 Emergency light BPL

13 KWH meter BHEL / SIMCO / India Meter

14 Ammeter / Voltmeter L & T / AE / IMP / MECO

15 Indicating lamps (LED type) L&T, Crompton Greaves, Philips

16 GI pipes / MS pipe Jindal / GST / Tata / Zenith

17 Street light poles Bombay poles or ISI approved make.

18 Change Over Switch LT / Siemens / Havells

19 Cable Gland Gripwel , Baliga , FCG , EMI

20 Lugs Dowells24 Meter Boards / MV panels / MCC CPRI tested Manufacturers

25 Capacitors Universal / Asian

Note :Regarding selecting the make against each item among the approved makes as specified above

decision of HPCL shall be final


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3 : IS CODES & STANDARDSSTANDARDS FOR ELECTRIFICATION JOBS:

Materials and equipment to be supplied by the contractor for this work shall be in accordancewithrelevant IS specifications. The following standards shall be applicable to various instruments.

S.No. IS Code Job/Equipment

1 IS: 2516 Specification for AC Circuit Breakers

2 IS: 4047 Specification for Heavy duty air break switches and fuse for voltage

notexceeding 1000 V

3 IS: 1818 Specification for AC Isolators and earthing switches

4 IS: 2607 Air Break Isolators for voltages not exceeding 1000V

5 IS: 2208 HRC Cartridge fuses links up to 650V

6 IS: 3072 Code practice for installation and maintenance of Switchgear

7 IS: 3106 Code of practice for selection, installation and maintenance of fuses(Voltagesnot exceeding 650V)

8 . IS: 4237 General requirements for switchgear and control gear for voltagesnot exceeding1000V

9 IS: 375 Marking and arrangement for switchgear busbars, main connection

and auxiliaryWiring

10 IS: 2705 Current transformers

11 IS: 1248 Direct acting electrical indicating instruments

12 IS: 2419 Dimensions of electrical indicating instruments

Erection of equipment and material whether supplied by owner or contractor shall be in accordance

with the best engineering practice, conforming to respective provisions of IS codes. Site testingshall conform to relevant IS code.

In addition the work shall conform to the following:

i) Indian Electricity rules and Acts.ii) Fire insurance regulations.iii) Requirements of Electrical Inspector.iv) Requirements of State Electricity Boards.v) Requirements of Factory Inspectorvi) Requirements of State/Central/Local Authoritiesvii) Requirements of Chief Controller of Explosives Nagpur.

CODES AND STANDARDS FOR CABLES


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The design, construction, manufacture and performance of XLPE insulated cables shall complywith all currently applicable statutes, regulations and safety codes of the locality where cables will

be installed.The cables shall conform to the applicable Indian, IEC.

The relevant Indian standards are: -S.No. IS Code Job/Equipment

1 IS: 613 (1984) Copper rods and bars for electrical purposes

2 IS:1885-(Part32) (1993) Electro Technical vocabulary - electric cables

3 IS: 2633 (1986) Method of testing uniformity of coating on zinc coatedarticles.

4 IS:3961-(Part4) (1968) Recommended current ratings for Polyethylene insulated

cables.

5 IS: 3975 (1988) Mild steel wire, formed wires and tapes for armouring of

cables.

6 IS: 5831 (1984) Specification for PVC insulation and sheath of electric

cables.7 IS: 6474 (1984) Specification for Polyethylene insulation and sheath of

electric cables.

8 IS:7098-(PartI) (1988) Specification for cross-linked Polyethylene insulated,PVC sheathed cables. (For working voltages up to and

including 1100 volts)

9 IS: 8130 (1984) Conductors for insulated electric cables and flexible cords.

10 IS: 10418 (1982) Drums for electric cables.

11 IS: 10462 (Part 1) (1983) Fictitious calculation method for determination of

dimensions of protective coverings of cables

12 IS: 10810 (Pt 58) Methods of test for cables : Part 58 Oxygen Index test

13 IS: 10810 (Pt 61) Methods of test for cables : Part 61 Flame retardant test14 IS: 10810 (Pt 62) Methods of test for cables : Part 62 Flame retardant test

for bunched cables

15 IEC:60540& 60540A Test methods for insulation & sheaths of electric cables

16 IEC: 230 (1966) Impulse tests on cables and their accessories

17 IEC: 60332 (3 parts) Tests on electric cables under fire conditions

18 IEC: 811 (5 parts) Test methods for insulating and sheathing materials of

electric cables.

19 IEC: 840 (1988) Tests for power cables with extruded insulation for rated

voltages above 30KV upto 150KV

20 ASTM: D2863 Standard method for test for flammability of plastics using

oxygen index method21 IECAS-61-402

NEMAWC5

Thermoplastic insulated wire & cable for transmission &

distribution of electrical energy

22 IECAS-66-524

NEMAWC5

Cross linked thermosetting poly ethylene insulated wire &

cable for transmission & distribution of electrical energy

23 IEC: 840 (1988) Tests for power cables with extruded insulation for ratedvoltages above 30KV up to 150KV


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The cables & accessories shall also confirm to the provisions of the Indian Electricity Rules and

other statutory regulations in force in the country.In case of any contradiction between various referred standards/ specifications/ data sheets and

statutory regulations, the following order of priority shall be given:

- Statutory regulations- Data sheets

- Unit Specifications

- This Specification- Codes & Standards

Relevant Indian standards, Acts and Codes for Earth work excavation

Sl.No. IS Code Job/Equipment

1 IS: 383 1970 Specification for coarse and fine aggregates from naturalsources for concrete.

2 IS 2720 (Part- 2)1973 Methods of test for soils-Determination of water content

3 IS 2720 (Part4-4 ) 1985 Methods of test for soils-Grain size analysis

4 IS 2720 (Part-5 ) 1985 Methods of test for soils-Determination of liquid limit & plastic limit

5 IS 2720 (Part-6 ) 1972 Methods of test for soils-Determination of shrinkage factors

6 IS 2720 (Part-7 ) 1980 Methods of test for soils-Determination of water content-Dry densityrelation using light compaction

7 IS 2720 (Part-8 ) 1983 Methods of test for soils- Determination of water content-Dry densityrelation using heavy compaction

8 IS 2720 (Part-14 ) 1983 Methods of test for soils-Determination of dry index(relative density)

9 IS 2720 (Part-21 ) 1977 Methods of test for soils-Determination of total soluble solids

10 IS 2720 (Part-23 ) 1976 Methods of test for soils-Determination of calcium carbonate

11 IS 2720 (Part-24 ) 1976 Methods of test for soils-Determination of cation exchange capacity

12 IS 2720 (Part-27 ) 1977 Methods of test for soils-Determination of total soluble sulphate

13 IS 2720 (Part-29 ) 1975 Methods of test for soils-Determination of dry density of soil in-place by core cutter method

14 IS: 3764 1992 Safety code for excavation work

15 IS: 4081 1986 Safety code for blasting and related drilling operations

16 IS: 4701 1982 Code of practice for earth work on canals

17 IS: 9759 1981 Guide lines of dewatering during construction

18 IS: 10379 1982 Code of practice for field control of moisture and compaction of soilsfor embankment and sub grade Indian Explosives Act 1940 as

updated.


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Relevant Indian Standards for Plain Cement Concrete and Reinforced Cement Concrete:

S.No. IS Code Job/Equipment

1 IS: 73 1992 Specification for paving bitumen

2 IS : 216 1961 Specification for coal tar pitch3 IS: 269 1989 Specification for 33 grade Ordinary Portland cement

4 IS: 280 1978 Specification for mild steel wire for generalConsultanting

Purposes

5 IS: 383 1970 Specification for coarse and fine aggregates from natural

sources for concrete

6 IS:432 (Parts I) 1982 Specification for mild steel medium tensile steel bars and

hard drawn steel wire for concrete reinforcement Mild

steel & medium tensile bars

7 IS: 432(Parts II) 1982 Specification for mild steel medium tensile steel bars and

hard drawn steel wire for concrete reinforcement - Harddrawn steel wire

8 IS: 455 1989 Specification for Portland slag cement

9 IS: 456 2000 Code of practice for plain and reinforced concrete

10 IS: 457 1957 Code of practice for general construction of plain &

reinforced concrete for dams & other massive structures

11 IS: 516 1959 Method of test for strength of concrete

12 IS : 650 1991 Specification for standard sand for testing of cement

14 IS: 702 1988 Specification for industrial bitumen

15 IS : 737 1986 Wrought aluminium and aluminium alloy plate for

generalConsultanting purposes

16 IS: 800 1984 Code of practice for general construction in steel17 IS: 816 1969 Code of practice for use of metal are welding for

generalconstruction in mild steel

18 IS: 1161 1998 Specification for steel tubes for structural purpose

19 IS: 1199 1959 Methods of sampling and analysis of concrete

10 IS: 1200 (Part-II) 1974 Method of measurement of building and civil

Consultanting works- Concrete works

11 IS: 1200 (Part-V)1982 Method of measurement of building and civil

Consultanting works- Form work

12 IS: 1200 (Part-

VIII)1993

Method of measurement of building and civil

Consultanting works- Steel work & iron work

13 IS: 1200 (Part-XVIII)1974

Method of measurement of building and civilConsultanting works- Demolition & dismantling

14 IS: 1322 1993 Specification for bitumen felts for waterproofing and

damp proofing

15 IS: 1363 (Part 1) 2002 Hexagon head bolts, screws and nuts of product grade

C Hexagon head bolts (size range M 5 to M 64)

16 IS: 1363 (Part 2) 2002 Hexagon head bolts, screws and nuts of product grade

C Hexagon head screws (size range M 5 to M 64)


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flooring.

42 IS : 2645 2003 Specification for Integral cement water proofing

compounds for cement mortar and concrete

43 IS : 2722 1964 Specification for portable swing weighs batchers for

concrete. (single and double type)44 IS : 2750 1964 Specification for steel scaffol

technical specification document final 23-09-2011x

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