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ELECTRICAL ENGINEERING DEPARTMENT

STANDARD SPECIFICATIONS FOR

MATERIAL AND WORKS

VOLUME II

ELECTRICAL WORKS

29 January 2015

(Including A&C 4 dated 28.11.2018)

RVNL

Specifications- Volume II (Electrical Works) RVNL

Dated 28 Nov 2018 of 429

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Standard Specifications for Materials and Works

Volume II-Electrical Works INDEX

Chapter No.

Specification No.

Description Page Nos.

PART A- GENERAL SERVICES ELECTRICAL WORKS

A-0 GENERAL- Scope, Standards, site conditions, Safety Instructions, Man-Power, Inspections of Equipments/materials. Pre Commissioning tests on Equipment, Approval of Drawings, Completion Plan and Completion Certificate

7-16

A-1 RVNL/Elect/GS/01 Internal Electrification Works 19-34

A-2 RVNL/Elect/GS/02 Luminaries/Equipments for Indoor/Outdoor Electrifications Works

35-44

A-3 RVNL/Elect/GS/03 Overhead Works & Steel/GI Tubular Poles 45-56 A-4 RVNL/Elect/GS/04 Cable Laying 57-66 A-5 RVNL/Elect/GS/05 High Mast Lighting System 67-72

A-6 RVNL/Elect/GS/06 Pre-Stressed Cement Concrete Poles for Modification of Power Line Crossings 73-76

A-7 RVNL/Elect/GS/07 Modification of Power Line Crossing on Railways Tracks 77-84 A-8 RVNL/Elect/GS/08 Medium Voltage Switch Board (for Sub- Station) 85-90

A-9 RVNL/Elect/GS/09 Medium Voltage Feeder Pillar & Switch Board (Other Than Sub-Station Work)

91-96

A-10 RVNL/Elect/GS/10 Distribution Board 97-100 A-11 RVNL/Elect/GS/11 Earthing System 101-106 A-12 RVNL/Elect/GS/12 Electrical Driven Sub-mersible Pumps 107-112 A-13 RVNL/Elect/GS/13 Power Distribution Transformer 113-120

A-14 RVNL/Elect/GS/14 Water Cooled Silent Diesel Engine Driven Alternator Set with AMF Panel (30 Kva and above up To 500 kVA) 121-128

A-15 RVNL/Elect/GS/15 11 KV VCB HT Panel 129-134 A-16 RVNL/Elect/GS/16 Auto Power Factor Correction (APFC) Panel 135-138 A-17 RVNL/Elect/GS/17 Battery Chargers for Coaching Applications 139-142 A-18 RVNL/Elect/GS/18 Battery Charging and Pre-Cooling Points 143-146

A-19 RVNL/ Elect/GS/19 Solar Home and Street Lighting System 147-152

A-20 RVNL/ Elect/GS/20

Solar Water Heater 153-158

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Lightening Arrester 159-172


Control Switch Board for A.T 173-176


Specification for LED Type Luminaries 177-180

A-24 RVNL/ Elect/GS/24 Variable Refrigerant Flow (VRF) System for Building

Centralised Air-conditioning 181-188

A-25 RVNL/ Elect/GS/25 Machine Room Type Electric Traction Passenger Lift for

Buildings 189-216

A-26 RVNL/ Elect/GS/26 Machine Roomless & Gearless Version Electric

Passenger Lift 217-242

A-27 RVNL/ Elect/GS/27 Miscellaneous Specifications

243-248


Approved Makes of Equipments and Materials 249-268


Important Indian Standards 269-280

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PART B- RAILWAY ELECTRIFICATION WORKS

B-1 General Requirements for 25 kV, AC Overhead Equipment 281-286 B-2 Overhead Equipments 287-300 B-3 Foundations 301-310 B-4 OHE Structures 311-316 B-5 Equipment, Components and Materials-OHE and Switching Stations 317-324 B-6 Design and Drawings for OHE and Switching Stations 325-334 B-7 Erection and Installation of Equipments-OHE

B-7(a) Principles 335-340 B-7(b) Wiring Procedures 341-344

B-8 Inspection and Testing- OHE and Switching Stations 345-348 B-9 Switching Station Building 349-352 B-10 Traction Substation/Feeding Post, General requirements 353-356

B-11 Feeding Stations switching stations, booster transformer stations and L.T supply transformer stations

357-360

B-12 Structures and steel works-TSS 361-364 B-13 Equipment, Components and Materials-TSS 365-370 B-14 Design & Drawings for Traction Sub-Stations 371-376 B-15 Erection & Installation of Equipment-PSI 377-380 B-16 Inspection & Testing of Traction Sub-Stations 381-384 B-17 Earthing 385-390 B-18 High Rise OHE 391-394

B-19 List of Standard Technical Drawings/ Specifications for Traction Sub stations/ Feeding Posts

395-410

B-20 List of Standards Technical Drawings/ Specifications for OHE Works 411-428

B-21 Miscellaneous instructions

429

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PART –A

GENERAL SERVICE ELECTRICAL ENGINEERING

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PART A: General Services Electrical Works

CHAPTER: A-0

GENERAL

1.0 Introduction

All electrification works shall be carried out in accordance with Indian Electricity Rules. Railway Regulations, BIS Specifications and Code of Practices, National Electricity Code, Energy Conservation Building Code (ECBC), National Building Code, Energy Conservation Act 2001with latest amendments. The specifications issued here are meant for guidelines and does not supersede any of the rules/regulations/codes/instructions issued by Railway Board/RDSO/CORE etc from time to time and they shall be followed accordingly. All the equipments and materials to be supplied shall be as per the specified approved makes and laid down specifications with latest amendments.

2.0 Scope of work

The scope of general electrical works broadly consists of:

External electrification works pertaining to cabling/overhead alignment & associated works for extension of power supply, street lighting etc.

Modification to existing electrical installations as per site requirement. Dismantling/relocation of electrical installations as per site requirement. Modification to supply Authority’s power lines, up to & including 33 kV, to

bring them in conformity with the Regulations for Crossing of Railway Track, 1987 Provision of high mast lighting system with luminaries at circulating areas/yards etc. Availing new power supply connections/ augmentation of existing power supply

connections to cater for new facilities including strengthening of power distribution system.

Electrification of un-electrified level crossings. Provision of 11 kV/415 Volts electric sub-stations with equipments, panels etc. Provision of pumping system for water supply. Provision of battery charging and pre-cooling facilities. Provision of temporary arrangements for lights & fans during non-interlocking period. Coordination with supply authorities for modification of power line crossings &

availing/augmentation of load as required. Survey of project section to identify electrical works. Provision of DG sets, air cooling system, escalators, elevators, travelators and lifts etc.

3.0 Standards

The following standards as amended from time to time, shall apply:

i) Bureau of Indian Standards (BIS) specifications and Code of Practices. ii) Indian Electricity Act 2003 and rules framed there under.

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iii) Regulations laid down by the Chief Electrical Engineer of the concerned zonal railway/ Chief Electrical Inspector/local authorities.

iv) Indian Electricity rules, 1956. v) Energy Conservation Act 2001 Vi) Energy Conservation Building Code vii) National Building code viii) Standards/specifications, Guidelines/directions issued by Railway Board/RDSO from

time to time.

NOTE: a) In case of any conflict between the above standards, the decision of Employer shall be final.

b) Henceforth in these Technical Specifications, wherever the BIS specification no. or any other specification, Code of Practice etc. are referred to, they shall apply to the latest version of the relevant standard, unless specifically stated otherwise.

c) Only the latest version of rules/standards/drawings/instructions shall be applicable unless specifically stated otherwise. In case of any conflict between various instructions, decision of the Employer shall be final. In case of any conflict/discrepancy between specifications contained in this book and specifications as per above mentioned authorities, later shall prevail.

Notwithstanding any approval of drawing or work by RVNL, the contractor shall be finally responsible for following correct instructions and drawings as per latest amended details. In case any mistake is found in the work/drawing later on which is not carried out/prepared in accordance with laid down standards, rules and regulations, the Employer shall be free to reject it at any stage of the work. The contractor shall be liable to dismantle/modify/redo the rejected work without any extra cost as per directions of the Employer. The decision of the Employer shall be final in this regard.

d) In this Technical Specification, the latest standards/drawings/instructions/letter/Code of Practice etc. means latest of above issued up to the date 28 days prior to the deadline for submission of bids.

3.1 Ratings of Components: All the equipments/components in the electrical system shall be of

appropriate rating of voltage/current and frequency as required. All the conductors, switches and accessories shall be of such size as to be capable of carrying maximum current which will normally flow through them without getting them over burdened/overheated.

4.0 Earthing

Earthing shall be provided as per Indian Electricity (IE) Rules, 1956.

5.0 Safety Instructions

5.1 Indian Electricity Rules 1956, are to be followed in their entirety. 5.2 The detailed instructions on safety procedures given in BIS Specifications, Indian

Electricity Rules, respective Supply Authority’s regulations and Railway Rules, shall be applicable, all with their latest amendments.

5.3 The Electrical Contractor/ Sub-Contractor shall hold a valid and relevant Electrical

Contractor’s License for LT/HT/EHT Voltage issued by any State Government. All the work on electrical installations shall be done under the direct supervision of persons holding valid certificates of competency issued by any State Government.

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5.4 No inflammable materials shall be stored in places other than the rooms specially constructed for this purpose in accordance with the provisions of Indian Explosives Act.

5.5 Protective and Safety equipments such as rubber gloves, earthing rods, lineman’s safety

belt, high visibility jackets, portable artificial respiration apparatus etc., shall be provided to all the working staff.

5.6 Caution boards such as “Man working on line”, “ Do not switch on” etc, shall be provided on

the HT/LT Panel Boards, for indication that the switch has been put to off position and person has been allowed to work on line.

5.7 “Permit to Work” shall be got issued from the person in-charge of the installation, prior to

start of work, on energized electrical installations. 5.8 No work on live bus bar or switch boards shall be handled by a person below the rank of a

Licensed Wireman and such work shall be done in the presence of a competent Engineer. 5.9 When working on or near live installations, suitable insulated tools shall be used, and

special care shall be taken to ensure that tools do not drop on live terminals causing shock or dead short.

5.10 The electrical switch boards/ distribution boards shall be clearly marked to indicate the

areas being controlled by them.

6.0 Man- Power 6.1 The contractor shall employ competent, licensed, qualified full time electrical engineers to

direct the work of electrical installations in accordance with the applicable specifications, IE Rules, Acts and Railway Regulations. The Contractor’s Engineer(s)/ technician(s)/ Workmen shall possess the necessary license/competency certificate issued by competent authority including RVNL/Railways as required under rules/law etc.

6.2 The Contractor’s Engineer shall possess relevant knowledge/ experience in substation work/ wiring of residential/ service buildings, illumination of streets/ railway yards/ circulating areas, designing of distribution system, mains/ sub-mains/ individual distribution boards, modification of overhead power line crossings, stringing of overhead mains and laying of underground cables etc. as applicable to the works included in the scope of the contract.

7.0 Inspection of Equipments/ materials

7.1 The inspection of various Equipments/ materials as specified in relevant IS/Specifications shall be carried out by the agencies as specified below provided the value of material is more than specified limits as per Railway Board Letter No. 2000/RS(G)/379/2 dt 06/09/2017 (Rs. 5 Lakh as of now). In other cases, inspection shall be arranged by RVNL/its Representative as per 7.3 below:

1 Power Distribution Transformers RITES 2 H.T./ L. T Panels RITES 3 High Mast Lighting Systems RITES 4 Diesel Generating Sets RITES 5 H.T./L.T Cables RITES 6 Battery Chargers RITES 7 APFC Panels RITES

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8 ACSR conductor RITES 9 Tubular Poles RITES 10 Luminaries and Lamps RVNL/ its Representative 11 Fans and Regulators RVNL/ its Representative 12 Wiring Cables and accessories RVNL/ its Representative 13 Feeder Pillar and Switch Boards RITES 14 Meter Board, Meters RVNL/ its Representative 15 G.I. Pipes RVNL/ its Representative 16 HT End Terminations RITES 17 Insulators and Stays RITES 18 Glow Sign Boards RVNL/ its Representative 19 Battery Charging system and Pre Cooling

Points RVNL/ its Representative

20 Pumps RITES 21 All other materials RVNL/ its Representative

7.2 The inspection of the above items will be done at the manufacturer’s works or other

appropriate location decided by RVNL and inspection fees chargeable by Inspecting Authority will be borne by the contractor as per relevant instructions/agreement. In exigency of work or revision in Railway Board/RVNL policy, inspection authority may be changed by RVNL. If the inspection is carried out by other than RDSO/RITES, the inspection charges shall be recovered as per extent policy of RVNL.

7.3 OEM’s certificate and other papers, such as material challans etc. shall be furnished by the

Contractor, to establish the genuineness of the equipment/ material. 7.4 Nominated Inspector shall have free access to visit the manufacturer’s works at all

reasonable times to witness and inspect the testing of equipment/ materials. The contractor shall provide all reasonable facilities and equipments/lab at his cost for proper inspection of the material/equipment.

7.5 Item available as catalogued product in market like MCBs, MCCBs, wiring accessories, light

fittings, fan etc. will be acceptable on factory routine test report for the batch, certificate from authorized dealer and manufacturer and visual inspection at site. However engineer may decide to get any item under the scope of supply inspected by any agency (RITES/RVNL/Rly) at manufacturer’s work if so required. And the cost of such test shall be borne by contractor. If RVNL wants to get any special test done on any item other than at manufacturer’s work, the cost of the same shall be borne by RVNL.

7.6 The Contractor shall ensure that all the equipments/materials supplied are tested as per

relevant BIS/ BS Specification and comply with instructions on energy star rating issued by BEE wherever applicable. At per present RB instructions, all energy consuming equipments should be procured with min 3 star energy rating.

7.7 The Contractor shall ensure that all the equipments/materials supplied is procured from

applicable approved list of sources. In case item is not featuring in approved list or approved itself is not available, prior approval of RVNL/Railway shall be taken before placing order. Detail guidelines of RVNL/Railways issued from time to time shall be applicable in this regard.

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8.0 Pre- Commissioning tests on Equipment 8.1 The pre-commissioning tests on various equipments shall be carried out jointly by the

Contractor with the Engineer. 8.2 The Contractor shall get the electrical installations checked and approved from the

Concerned Chief Electrical Engineer of Railways, Electrical Inspector/ local Authority/ CEA/ any other regulatory authority, as per requirement. The work will not be treated as complete until such clearances are obtained by the Contractor. He shall also obtain any other clearances that may be required from time to time. The installation shall be energized, in the presence of the Engineer, only after the receipt of all such approvals.

9.0 Other Requirements

9.1 Care shall be taken by contractor to avoid damage to the building during execution of his

part of work. He shall be responsible for repairing all damages and restoring the same to their original finish at his own cost. He shall also remove at his cost all the unwanted and waste materials arising out of his work from the site. The Contractor shall dress up/repair the site as per the existing surrounding ground/ floor/walls/ road surface etc. after completion of the work and make good any damages that occurred during the execution of works.

9.2 The work shall be carried out with minimum power shut downs. The required shut downs

from railway/other agencies will be arranged by the Engineer, with the active assistance of Contractor, in consultation with user departments, and the charges if any & not mentioned otherwise, shall be borne by RVNL.

9.3 Coordination with other Agencies:

The contractor shall coordinate with all other agencies so that work is not hampered due to delay in his work. Recessed conduit and other works which directly affect the progress of the main work should be done in time and on priority.

Wherever approval is to be taken from other department (s) of state/central

government, standards of work and approved list of equipments /materials should be followed as per their requirement and approvals obtained.

9.4 Work in Occupied Buildings:

While working in the occupied buildings, there should be minmum inconvenience to the occupants. Work should be programmed in coordination with the engineer and occupying department. If required, work may have to be planned beyond normal working hours.

The contractor shall be responsible to abide by the regulations/restrictions regarding entry into and movement within the premises.

9.5 The rates are deemed to be inclusive of all lead (except as otherwise specifically provided

in the description of the particular item), lifts ascend descend, handling, re-handling, crossing of nullahs/streams/tracks or any other obstructions.

9.6 All enabling works for executing the work e.g. approach road to site, launching arrangements, procuring right of way: arrangement of water and electricity etc. is to be arranged by the contractor at his own cost and is deemed to be included in the quoted rates.

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9.7 Storage of Material: All the material at site shall be property stacked & stored so as to facilitate inspection. The material should be properly protected from detrimental effects of nature, fire, theft etc. The contractor shall be responsible for watch & ward and any loss or deterioration on account of above shall lead to rejection of material. In this eventuality, the contractor shall have to replace the same at this own cost.

9.8 All minor items viz. hardware items, foundation bolts clamps, termination lugs for electrical

connections etc. as required and necessary for proper working of the equipment shall be deemed to have been included in the Bill of Quantities, whether such items are specifically mentioned or not. All hardware & M.S components should be either Galvanized or Electroplated.

9.9 If any activity of work is essential for the satisfactory completion of the work but is not

mentioned specifically in the Bill of Quantities or elsewhere in the bidding documents, the same shall be deemed to be included In the scope of work and shall be executed by the contractor within the accepted cost. The work shall be handed over in a functional manner complete in all respects.

10.0 Approval of Drawings and completion drawings

10.1 On award of contract, the successful bidder shall visit the site and prepare working

drawings as per site requirements. Drawings shall conform to the relevant standards and details given in Indian Railway works Manual and prepared in Auto CAD. The drawings which require prior approval shall be first prepared and submitted in three copies with one soft copy as check drawings. The comments and corrections received back shall be incorporated while preparing the final drawing on RTF sheets for signatures and approval.

10.2 The drawings of all equipments including HT/ LT panels, transformer, DG set, distribution

boards, pre-cooling/battery charging points, battery charger, wiring plan, route of laying of cables, poles , and other items shall be got approved from the Engineer. Manufacturing of the items can be taken in hand only after the approval of the drawings and samples. The Contractor shall supply six copies in addition to one copy on RTF and soft copy of each of these approved drawings before commencement of work.

After completion of the work, as erected completion drawings shall be submitted in four

copies in addition to two copies on RTF and soft copy. 11.0 Commissioning of Completed Works:

11.1 After completion of work, the Contractor shall ensure that the installations have been

commissioned only after due testing and approval of the Engineer. 12.0 Completion Plan and Completion Certificate:

12.1 After completion of works, the Contractor shall submit required sets of ‘As Erected’

drawings as per para 10.2 above in respect of all the electrical installation works. 12.2 Completion Certificate, in the following format, shall be jointly signed by the Engineer and

Contractor.

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Completion Certificate

I/ We certify that the installation detailed below has been installed by me/ us and tested and that to the best of my/ our knowledge and belief it complies with Indian Electricity Rules, 1956, Electrical installation at ----------------------------------------- Voltage and system of supply------------------------------------

Particulars of work:

(a) Internal Electrical installation : No. Total load System of wiring i Light point ii Fan point iii Plug point iv 3 pin 5 Amp. v 3 pin 15 Amp vi Other points

(b) Motors No Total load HP/KW Type of starting i ii

(c) Other Plants

No i ii

(d) Installation of over head line and underground cable

Overhead line Total length and No. of spans. No. of street lights and its description Underground cable Make and Year Total length of underground cable and its size. Number of joints End point Tee Joint St. through Joint

(e) Earthing No. Details Qty with unit a Description of earthing electrode b No. of earth electrodes C Size of main lead

(f) Test results- Insulation resistance I Insulation resistance of the whole system of

conductors to earth in Mega ohms ----- Mega ohms

ii Insulation between the phase conductor and neutral.

------ Mega Ohms

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iii Between Phase R and neutral ------ Mega Ohms iv Between phase Y and neutral ------ Mega Ohms v Between phase B and neutral ------ Mega Ohms vi Between phase R and phase Y ------ Mega Ohms vii Between phase Y and phase B ------ Mega Ohms vii Between phase B and phase R ------ Mega Ohms

(g) Polarity test- Polarity of non-linked single pole branch switches. (h) Earth Continuity test –Maximum resistance between any point in the earth continuity

conductor including metal conduits and main earthing lead---- Ohms.

(i) Earth electrode resistance – Resistance of each earth electrode:

No. i) …….. Ohms ii) …….. Ohms

Signature of the Engineer Signature of Contractor

Note: For obtaining EIG approval for energizing HT installations, the EIG application format of the

concerned Railway shall be followed. 13.0 Concrete and Cement

(a) All the foundations [except as per details given in (b)], for masts of street lighting, solar lighting, LT/HT over head conductors, Guy wires, stays, steel/GI Tubular poles, Battery charging poles and pedestals, protective fencing shall be as per the approved drawings of the RVNL. In these type of foundations, normally M-10 cement concrete (except where specified otherwise) conforming to IS-456 with 20 mm coarse aggregates shall be used. The cement to be used shall be ordinary Portland cement of 43 grade (conforming to IS-8112) or 53 grade (conforming to IS-12269) or PPC conforming to IS 1489(Part 1/Part 2) as approved by RVNL based on requirement and availability and date of manufacturing shall not be older than three months.

(b) Where foundations of equipments are to be laid as per OEM recommendations/standard drawings of the Railway/SEB, grade of cement, size of aggregate, concrete grade and foundation dimensions etc shall be as per their recommended standard such as High mast lighting system, H pole structures used for power line crossings.

The contractor shall use concrete mixer, proper shuttering and vibrators for compaction for foundations of high mast lighting system, large pumping installations etc as directed by Engineer. For smaller foundations detailed at (a) above, manual concrete mixing and compaction may be adopted.

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TECHNICAL SPECIFICATIONS

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Tech. Spec. No. -RVNL/Elect/GS/01

INTERNAL

ELECTRIFICATION

WORKS

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CHAPTER: A-1

Technical Specification No. RVNL/Elect/GS/01

INTERNAL ELECTRIFICATION WORKS

1.0 Scope This specification pertains to internal electrification of residential and service buildings on 3 phase, 415 volts or single phase, 230 Volts, 50 Hz Ac supply system, including provision of conduits with accessories, metal boxes and Boards, wiring, metering, protection, switchgear, UPS, stablizers, energy savers, provision of fans & luminaries, pre-commissioning/ commissioning tests and handing over. Separate conduits shall be laid for:

i) Emergency and non emergency circuits ii) Power and lighting circuits

1.1 Regulations and standards

The system shall be governed by IS:732, I.E. Rules 1956, National Electric Code (NEC), ECBC, National Building code, relevant BIS Standards and Codes applicable to internal electrification and distribution works.

1.2 The definitions of terms shall be in accordance with IS:732-1989 ( Indian Standard Code of Practice for Electrical Wiring), except for the definitions of point wiring, circuit, sub-main and main wiring.

The conventional signs & symbols for technical work shall be indicated in the working and as erected drawings.

1.3 GENERAL CONDITIONS:

a. Before starting wiring work approval of site drawings shall be obtained regarding layout, no. of points to be wired and location of switchboards etc.

b. All switchboards shall be of GI box type/ PVC box compatible with modular switches/plug points. No wooden switchboards shall be used.

c. The wiring shall be done from a distribution system through main and/or branch distribution boards. The system design and location of boards will be properly worked out and approved by site supervisor.

d. Each main distribution board and branch distribution board shall be controlled by an incoming circuit breaker. Each outgoing circuit shall be controlled by a circuit breaker/switch with fuse. All Main/sub distribution boards shall be double door recess type.

e. For non-residential buildings, as far as possible, DBs shall be separate for light and power. Only MCCB/MCB type DBs shall be used. Kitkat fuse, glass fuse, Re-wirable type fuses shall not

be used. f. Three phase DBs shall not be used for final circuit distribution as far as possible. g. 'Power' wiring shall be kept separate and distinct from light wiring, from the level of circuits

(Sub-main), i.e., beyond the branch distribution boards. Conduits for light/power wiring shall be separate.

h. Essential/non-essential/UPS distribution each will have a completely independent and separate distribution system starting from the main, switchboard up-to final wiring for each system.

i. Generally, no switchboard will have more than one source of incoming supply. j. Each MDB/DB/Switch Board will have spare outgoing ways for future expansion. k. All M.S clamps/structures/hardware should be hot dip galvanized. If not possible special

structures cold galvanization paint shall be applied.

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1.4 Wiring

1.4.1 (a) Main wiring: Main wiring shall mean the wiring from one main/distribution switchboard to another.

(b) Sub-main wiring: Sub main wiring shall mean the wiring from the distribution board to

the 1st tapping point inside the switch box, from where point wiring starts.

(c) PVC insulated, multi stranded, Heat resistant fire retardant (HRFR), low smoke, flexible copper conductor cables of 1.1 kV grade, conforming to IS: 694/1990, ISI marked shall be used. The size/s shall be as specified in the Bill of Quantities (BOQ).

(d) Minimum size of wiring cable/s for light and power points shall be as below:

Light/ Fan wiring - 1.5 Sq. mm Light plug point - 2.5 Sq. mm Circuit wiring for Light/ Fan Point - 2.5 Sq. mm. Circuit wiring for Light plug point - 4.0 Sq. mm Group Point wiring - 2.5 Sq. mm Power wiring - 4.0 Sq. mm Power wiring with more than 1 kW load – the size shall be assessed by the

contractor based on load calculations and approved by the Engineer. (e) Flexible cable – Copper conductor, 3 core flexible cables shall be used for connecting

single phase appliances etc.

Sizes of single core (copper conductor) cable for point, circuit and sub main wiring, circuits, distribution board/s, etc. for Qrs.

Nos. of points and size of wiring cables Nos. of circuits and size of wiring cables

Size of Sub main wiring cable

Size of point wiring cable (copper conductor)

Size of circuit wiring cable (copper conductor)

For L & F Load

For Power load

LP TLP FP CBP EFP PP5A PP 15A GP PP32A (ACP)

For L&F For 5A Plug

For 15A. Plug

For 32A. AC

For geyser

Phases and neutral

1.5 sq.mm 2.5sq mm

4sq mm

6sqmm

6sq mm

2.5 sq. mm

4sq.mm

4sq.mm

6sq. mm

6 sq.mm 4 sq mm 10 sq mm

Continuous earth

1.5 sq.mm 2.5sq mm

4 sq mm

6 sq mm

6sq mm

2.5sq mm

4 sq mm

4 sq mm

6sq mm

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1.4.2 Point wiring:

(i) Definition: A point (other than plug point) shall include all work necessary in complete wiring to the following outlets from the controlling switch or MCB: a. Ceiling rose or connector (in the case of points for ceiling/exhaust fan points, prewired

light fittings, and call bells). b. Ceiling rose (in case of pendants except stiff pendants). Standard specification for

Electrical (General) Works c. Back plate (in the case of stiff pendants). d. Lamp holder (in the case of goose neck type wall brackets, batten holders and fittings

which are not prewired). e. Main and sub-main wiring as described above. f. Distribution boards of reputed make as required, modular switchboard, RCCBs in Main

distribution board of adequate capacity of ABB/Siemens/Legrand/L&T make.

(ii) Scope: Point Wiring shall include: a. Conduit/channel as the case may be, accessories for the same and wiring cables between

the switch box and the point outlet, loop protective earthing of each fan/light fixture. b. All fixing accessories such as clips, screws, Phil plug, rawl plug etc. as required. c. Metal or PVC switch boxes for control switches, regulators, sockets etc., recessed or

surface type, and phenolic laminated sheet covers over the same. d. Outlet boxes, junction boxes, pull-through boxes etc. but excluding metal boxes if any,

provided with switchboards for loose wires/conduit terminations. e. Control switch or MCB, as specified. f. 3 pin or 6 pin socket, ceiling rose or connector as required. g. Connections to ceiling rose, connector, socket outlet, lamp holder, switch etc. h. Bushed conduit or porcelain tubing where wiring cables pass through wall etc. i. Main and sub main wiring of appropriate size. j. Pre wired MDB and DBs of ABB/Legrand/L&T make as required including MCBs. RCCBs for

MDBs will not be paid separately. k. Earth wire run as per requirements.

(iii) Point wiring for plug points:

a. 16A plug points shall be mounted on separate modular board. 6 A plug point can be mounted on light/fan point switchboard or separately. Not more than 1(one) 6A plug point will be allowed on common switchboard.

b. The 6A plug point wiring shall include, controlling switch, socket and necessary wiring from sub main including earthing of third pin.

c. The 16A plug point wiring shall include separate board as approved consisting of controlling switch, socket, MCB, earthing.

1.4.3 System of wiring : a. Wiring shall be done only by the looping system. Phase/live conductors shall be looped at

the switch box. For point wiring, neutral wire/earth wire looping for the 1st point shall be done in the switch box; and neutral/earth looping of subsequent points will be made from point outlets.

b. In wiring, no joints in wiring will be permitted anywhere, except in switch box or point outlets, where jointing of wires will be allowed with use of suitable connector.

c. The wiring throughout the installation shall be such that there is no break in the neutral wire except in the form of linked switchgear.

d. Colour coding:- Following colour coding shall be followed in wiring:-

Phase Red/Yellow/Blue. (Three phase wiring) Live Red (Single phase wiring) Neutral Black Earth Green/Yellow-green.

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e. Termination of Sub main circuit into switchboard:-Sub-main (Circuit) will consist of phase/neutral/earth wire. Sub-main (Circuit) will terminate in a switch board (first tapping point, where from point wiring starts) & the switchboard will have phase, neutral and earth terminal to receive phase/ neutral/earth wire.

1.4.4 Run of wiring:

a. The type of wiring shall be as specified in the tender documents/detailed at site namely, surface conduit/concealed conduit, MS/PVC, channel (Casing/Capping).

b. Surface wiring shall run as far as possible along the walls and ceiling, so as to be easily accessible for inspection.

c. Above false ceiling, in no case, open wiring shall be allowed. Wiring will be done in recessed conduit or surface steel conduit.

d. In concealed conduit system, routes of conduit will be planned, so that various inspection boxes provided don't present a shabby look. Such boxes can be provided 5 mm above plaster level, and they can be covered with plaster of Paris with marking of junction boxes.

e. Generally conduits for wiring will not be taken in floor slabs.

1.4.5 Passing through walls or floors : When wiring cables are to pass through a wall, these shall be taken through a protection (steel/PVC) pipe of suitable size such that they pass through in a straight line without twist or cross in them on either end of such holes. The ends of metallic pipe shall be neatly bushed with PVC or other approved material.

All floor openings for carrying any wiring shall be suitably sealed after installation. 1.4.6 Joints in wiring :

a. No bare conductor in phase and/or neutral or twisted joints in phase, neutral, and/or protective conductors in wiring shall be permitted.

b. There shall be no joints in the through-runs of cables. If the length of final main or sub-main is more than the length of a standard coil, thus necessitating a through joint, such joints shall be made by means of approved mechanical connectors in suitable junction boxes.

c. Termination of multi stranded conductors shall be done using suitable crimping type thimbles.

1.4.7 Capacity of Circuits ( Sub-main) :

a. Lighting circuit from each sub main shall feed light/fan/call bell/6A outlet points. Each circuit shall not have more than 800 Watt connected load or more than 8 points.

b. Power sub main circuit will have only one 16A outlet per circuit. Not more than 4 Nos. 6A outlets outlet shall be allowed from one sub-main.

c. All Loads more than 1 KW each shall be controlled by suitably rated MCB and cable size shall be decided as per calculations.

1.4.8 Measurements

Measurement of point wiring for light points, fan points, exhaust fan points, group points, light plug points, power plug points & call bell points shall be done on unit basis by counting only. Measurement of twin control point wiring shall be done on unit basis by counting.

1.4.9 Circuit Wiring Circuit Wiring shall mean the wiring from the distribution board to the first tapping point inside the switch Board, from where point wiring starts. Looping of switch boards in the same circuit shall also be measured along the length of conduit for circuit wiring as per relevant BOQ item.

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1.4.10 Sub main Wiring (a) Sub main wiring shall mean the wiring from the meter board or main board/ sub main

board to Distribution board/ Sub distribution board as the case may be. Looping of distribution boards/ sub distribution boards shall also be provided along the length of conduit for Sub Main wiring.

Main Distribution Boards, Sub Distribution Boards shall be double door recess type. MCB and LCCBs of requisite rating should be provided in the distribution board.

(b) Circuit Wiring/ Sub main wiring cable/s along with earth wire cable/s shall be of the

capacity specified in Bid document/RVNL standard. Wiring of each circuit wiring/ sub/ main wiring cable/ s along with earth wire cable/s shall be drawn into an independent conduit. Drawn boxes of suitable size shall be provided at convenient locations to facilitate easy drawing of the circuit wiring/ sub main wiring cable/s. Cost of junction Board/ draw Boxes are deemed to be included in the rates of circuit wiring/ sub main wiring cables along with earth wire cable/s. Single phase circuits shall have single earth wire whereas three-phase circuits shall be provided with two earth wires.

(c) Where sub- main, circuit wiring and point wiring cables are connected to the switch/

switchgear etc, sufficient extra length of cable/s ( not less than 150 mm ) shall be provided to facilitate easy connection and maintenance.

1.5 Joints in the Wiring

All joints in the wiring shall be made at main switch boxes and distribution boards only. No joint shall be made in conduits and junction Boxes or in the length of wiring cable. Wiring cable shall be continuous from outlet to inlet. All joints shall be made by use of connectors and lugs. All wire ends to be provided with lug and connected with requisite fasteners. Lugs should be crimped properly with crimping tools.

1.6 Conduit System 1.6.1 Type and Size of Conduit 1.6.1.1 The Conduit wiring shall be carried out as under:

All the non-metallic conduit pipes and accessories shall be of suitable materials complying with IS-2509:1973 and IS-3419:1989 for rigid conduits and IS-9573 (Part 5):2000 for flexible conduits. Internal wiring in the buildings shall be done with ISI marked PVC rigid conduit of size not less than 25 mm diameter and thickness 2.0 mm (Nominal size). PVC conduit shall be used with all its associated accessories such as bends, couplers, saddles, metal deep boxes (100 mm deep for ceilings), PVC bends etc.

1.6.1.2 Normally, concealed wiring shall be provided in all the buildings. Surface conduit wiring shall

be provided if specifically given in BOQ or where it is not practicable to provide concealed wiring with approval of the RVNL.

1.6.1.3 Limitations

The maximum number of PVC insulated 650/1100 V grade copper conductor cables that can be drawn in conduit pipes shall be limited to 45 % of the capacity of the conduit. Table indicating the capacity is as under:- S. No. Size of Conduit 100 % capacity in Sq mm 45% capacity in Sq mm 1. 25 mm 490 220 2. 32 mm 804 362

1.6.1.4 Conduit joints :

Conduits shall be joined by means of screwed or plain couplers depending on whether the conduits are screwed or plain. For conduit fittings and accessories reference may be made to the good practice (IS : 2667, IS:3419, IS:9537 Pert-I II III).

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1.6.1.5 Fixing of conduits : Conduit pipes shall be fixed by heavy gauge saddles, secured to suitable PVC plugs with

screws in an approved manner at an interval of not more than 600mm, but on either side of couplers or bends or similar fittings, saddles shall be fixed at a distance of 300 mm from the center of such fittings except that the spacing between saddles or supports is recommended to be 600 mm for rigid non-metallic conduits.

1.6.1.6 Bends in conduits :

Wherever necessary, bends or diversions may be achieved by bending the conduits or by employing normal bends, inspection bends, inspection boxes, elbows or similar fittings.

Conduit fittings shall be avoided, as far as possible, on outdoor systems.

1.6.1.7 Outlets : In order to minimize condensation or sweating inside the conduit, all outlets of conduit system shall be properly drained and ventilated, but in such a manner as to prevent the entry of insects.

1.6.1.8 Heat may be used to soften the conduit for bending and forming joints in case of plain conduits. As the material softens when heated, sitting of conduit in close proximity to hot surfaces should be avoided.

1.6.1.9 Fixing of conduit in chase (concealing in plaster of wall): The conduit pipe shall be fixed by means of staples or by means of non-metallic saddles

placed at not more than 80 cm apart or by any other approved means of fixing. Fixing of standard bends or elbows shall be avoided as far as practicable and all curves shall be maintained by sending the conduit pipe itself with a long radius which will permit easy drawing in of conductors. At either side of bends, saddles/staples shall be fixed at a distance of 15 cm from the center of bends.

1.6.1.10 Inspection boxes (for concealed wiring): Suitable inspection boxes to the nearest minimum requirements shall be provided to permit

periodical inspection and to facilitate replacement of wires, if necessary. The inspection/junction boxes shall be mounted flush with the wall or ceiling concrete. Where necessary deeper boxes of suitable dimensions shall be used. Suitable ventilating holes shall be provided in the inspection box covers, where required.

Table 1

Maximum No. of single core cables in Rigid metallic/non metallic conduit

Size of wires Size of conduit (dia in mm) mm2 no. & dia 16 20 25 32 40 50 60 1.5 1/1.4 3 5 10 14 2.5 3/1.06 2 5 8 12 4 7/0.85 2 3 8 10 6 7/1.06 2 5 8 10 7/1.40 3 5 16 7/1.70 3 6 25 7/2.24 2 6 35 7/2.50 4 6 7 50 19/1.80 3 5 6

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Table 2

Maximum Number of Single-Core Cables that can be Drawn into Casing and Capping

Size of wires Size of Casing Mm2 no. &dia 10/15mm

x 10 mm 20mm x 10 mm

25mm x 10mm

30mm x 10mm

40mm x 20mm

50mm x 20mm

1.5 1/1.4 3 5 6 8 12 18 2.5 3/1.06 2 4 5 6 9 15 4 7/0.85 2 3 4 5 8 12 6 7/1.06 2 3 4 6 9 10 7/1.40 1 2 3 5 8 16 7/1.70 1 2 4 6 25 7/2.24 1 3 5 35 7/2.50 2 4 50 19/1.80 1 3 70 1 2

1.6.2 Surface Conduits a) Surface or open conduit pipes shall be fixed by heavy gauge saddles, secured to suitable

approved plugs embedded in walls/ firmly secured with tresses etc. with screws in an approved manner at an interval of not more than 60 cm on either side of the coupler or bends or similar fittings. The saddles shall be fixed at a distance of 30 cm from the center of such fittings. Open conduit wiring shall be laid parallel/ perpendicular to the walls and suitable clamps shall be fixed properly. For 25 mm diameter conduit, width of clamp shall be 19 mm and of 20 SWG wall thickness. For conduits of 32 mm and above, width of clamp shall be 25 mm and of 18 SWG wall thickness.

b) Where conduit pipes are to be laid along trusses, steel joints etc., the same shall be secured by means of special clamps made of mild steel. Where it is not possible to drill holes in the truss members, suitable clamps with bolts and nuts shall be used.

c) Where conduit pipes are to be laid above false ceiling, conduit pipes shall not be clamped to false ceiling frame work and shall be suspended with suitable supports from the suffix of slab. For conduit pipes to run along with wall , the conduit pipe shall be clamped to wall above false ceiling in uniform pattern with special clamps approved by the Engineer at site.

1.6.3 Installation of Conduit system : 1.6.4 Common aspects for both concealed and surface conduit works:

a. The erection of conduits of each circuit shall be completed before the cables are drawn in.

b. All joints shall be sealed/ cemented with approved cement. Damaged conduit pipes/fittings shall not be used in the work. Cut ends of conduit pipes shall have neither sharp edges nor any burrs left to avoid damage to the insulation of conductors while pulling them through such pipes.

c. Bends in conduit : All bends in the system may be formed either by bending the pipes by an approved method of heating, or by inserting suitable accessories such as bends, elbows or similar fittings, or by fixing non-metallic inspection boxes, whichever is most suitable. Where necessary', solid type fittings shall be used.

d. Radius of bends in conduit pipes shall not be less than 7.5 cm. No length of conduit shall have more than the equivalent of four quarter bends from outlet to outlet.

e. Care shall be taken while bending the pipes to ensure that the conduit pipe is not damaged, and that the internal diameter is not effectively reduced.

f. Outlets: All switches, plugs, fan regulators etc. shall be fitted in flush pattern. The fan regulators can be mounted on the switch box covers, if so stipulated in the tender specifications, or if so directed by the Engineer.

g. Painting: After installation, all accessible surfaces of metallic accessories shall be painted.

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1.7 Casing and Capping: PVC casing and capping shall conform to BIS Specification No.14927 Part 2 and for wiring

application with the required accessories viz. bends and tees etc., as per site conditions. They should be properly fitted along with the required accessories viz. couplers, junction box, bends, tees, PVC round blocks, sockets, clamps, bolts, nuts, screws etc., as per the site conditions. They shall be used in suitable size to accommodate the wiring and shall be laid straight horizontally/vertically on the wall/roof etc.

1.8 Accessories 1.8.1 Control Switches for lights/ fans etc.

a) All 5/6 and 15/16 Amp switches/ sockets ( 5 pin/6 pin) including bell push shall be modular type suitable for use on 230 Volts A.C. supply system. Switch plate shall be matching with modular switches/sockets. All switches, sockets, etc., shall normally be of white finish or as approved considering matching with the colour of walls/surface.

b) All the switches controlling the lights/fans etc. shall be connected to the phase wire of the circuit. Switches for lights and 5/6 Amp & 15/16 amp outlets shall be located at 1250 mm above finished floor level and the sub distribution boards (SDB), distribution boards (DB) shall be at 1500 mm above finished floor level, unless otherwise instructed by the Engineer.

1.8.2 Ceiling Rose

The ceiling rose shall be of Bakelite, 5 amps, 250 volts, conforming to latest version of IS:371/1999(ISI marked). The colour shall normally be of white finish or as approved considering matching with the colour of wall.

1.8.3 Lamp Holder The lamp holder shall be Polycarbonate of model as approved (ISI Marked). The colour shall normally be of white finish or as approved.

1.8.4 Call Bell Call bell shall be fixed on metal box of approved size with 3mm Phenolic laminated sheet on top ( conforming to IS: 2036:1995) fixed with brass screws and brass cup washers and shall be suitable to work on 230 V AC, single phase 50 cycle. Piano type bell push shall be fixed at the entrance door.

1.8.5 Attachment of fittings and accessories : a. Conduit wiring system: All accessories like switches, socket outlets, call bell pushes and

regulators shall be fixed in modular sheets in boxes. Accessories like ceiling roses, brackets, batten holders etc. shall be fixed on outlet boxes.

b. Steel/iron screws shall be used to fix the accessories to their bases. c. Fixing to walls and ceiling: Wooden plugs for fixing to wall/ceiling will not be allowed. Fixing

will be done with the help of PVC sleeves/Rowel plugs/ dash fasteners as required. d. Drilling of holes shall be done by drilling machines only. No manual drilling of hole will be

allowed. e. PVC spacers shall be provided during fixing of fittings and other items on wall.

1.9 For termination of cables, crimping type cable socket/lugs shall be provided and soldered if

necessary/ instructed. 1.10 Load Balancing:

Balancing of circuits in three–phase installation shall be planned before the commencement of wiring and shall be strictly adhered to.

1.11 Colour code for Wiring: Colour code for wiring installation shall be maintained as Red, Yellow and Blue for three phases, Black for neutral and green only for earth in case of insulated earth wire.

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1.12 Earthing of Non- current Carrying Part All the non-current carrying metal parts of electrical installations shall be earthed properly. All metal enclosures, cable armour, switchgear, distribution boards, light fittings and all other parts made of metal shall be bonded together and connected by means of specified earthing conductors to an efficient earthing system.

1.13 Earth Conductor Every earthing conductor shall be of copper single core pvc wire / G. I of suitable size.

1.14 Testing of Wiring: Wiring system shall be tested as per IS:732 for: i) Continuity of all circuits, ii) Earthing after the wiring is completed and before energizing, iii) Polarity test of switches etc. 1.15 Testing

After completion of work, the entire installation shall be subjected to the following tests: Insulation Resistance Test. Earth Continuity Test. Earth Resistance Test.

Besides the above, any other tests specified in BIS Standards or as required by the local Authority/ Engineer shall also be carried out.

1.15.1 Insulation Resistance Test

a) The insulation resistance shall be measured by applying between earth and the whole system of conductor or any section thereof with all fuses/MCB in place and all switches closed and except in earthed concentric wiring, all lamps in position of both poles of the installation otherwise electrically connected together, a direct D. C. Voltage not less than twice the working voltage, provided that it does not exceed 500 Volts for medium voltage circuits. Where the supply is derived from 3 wires (AC or DC) or polyphase system, the neutral pole of which is connected to earth, either direct or through added resistance the working voltage shall be deemed to be that which is maintained between the outer or phase conductor and the neutral.

b) The insulation resistance in mega ohm of an installation measured as in ‘a’ above, shall not be less than 50 divided by the number of points on the circuit, provided that the whole installation need not be required to have a insulation resistance greater than one meg ohm.

c) The entire installation shall be tested and shall comply with the requirements of specifications, IS code and IE norms.

1.15.2 Testing of Earth Continuity Path:

The earth continuity test of metallic envelopes shall be done for electrical continuity. Electrical resistance of the same, along with the earthing lead, excluding any added resistance of earth leakage circuit breaker, measured from the connection with the earth electrode to any point in the earth conductor in the completed installation, shall not exceed one Ohm.

1.15.3 Polarity Test of switch

In a two-wire installation, a test shall be made to verify that all switches in every circuit have been fitted in the same conductor through out, and such conductor shall be labeled or marked for connections to the phase conductor or to the non-earthed conductor of the supply. In a three or four wire installation, a test shall be made to verify that every non-linked single pole switch is fitted in a conductor which is labeled or marked for connection to one of the phase conductors of the supply.

1.15.4 Earth Resistance Test Earth Resistance Test shall be carried out in accordance with Indian Standard Code of Practice for earthing IS 3043 – 1966. All tests shall be carried out in the presence of the Engineer.

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1.15.5 After testing of installation, test results shall be recorded and jointly signed by the Contractor and the Engineer.

1.16 SCALE OF ELECTRICAL FITTINGS FOR QUARTERS

Details of Points as Sanctioned by Railway Board Type

of Quart

er

LP Tube Total

FP PP 5A

PP 15A

Call Bell

Exh. Fan

Geyser AC (32A)

Total Points

1 2 3 4 5 6 7 8 9 10 11 12 13 I No. of

Points 6 2 8 2 2 2 0 0 0 0 14

II 6 2 8 2 3 2 1 0 0 0 16 III 7 3 10 3 3 3 1 0 0 0 20 IV 11 5 16 3 4 4 1 1 1 1 31 V 15 6 21 5 6 5 1 1 2 2 43

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Nos. of points

Nos. of circuits Single phase Double Door Distribution board (4 incomer +8 outgoing)

Earth Electrode

Qty Details

Type of Quater

LP TLP FP CBP EFP PP 5A

PP 15A

GP

PP32A

(ACP)

For

Lights

Fa

ns

&

c

all bel

l

For

5A P

lug

For

15A.

Plug

For

32A

AC

For

gey

ser

Tot

al C

kt.

I 6 2 2 0 0 2 2 0 0 2 1 2 0 0 5 1 Incoming MCB DP-20 Amp with RCCB 100 mA and O/G --- 6-16amps. MCB

SP -5 Nos.

(a) Single unit Quarter --- 1 No (b) two units Quarter - 1 No,

(c)Three/four units quarter - -2 Nos.

II 6 2 2 1 0 3 2 0 0 2 2 2 0 0 6 1 Incoming MCB DP-20 Amp with RCCB 100 mA and O/G --- 6-16amps. MCB

SP -6 Nos

III 7 3 3 1 0 3 3 0 0 3 2 3 0 0 8 1 I/C MCB DP-20 Amp with RCCB

100 mA and O/G --- 6-16amps. MCB

SP - 8 Nos.

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IV

11

5

3

1

1

4

4

1

1

4

2

4

1

1

12

1 ( for L&F)

I/C MCB DP-32Amp with RCCB 100 mA and Outgoing - (i) MCB SP 6-16amps ---6 Nos,

One Number for each quarter

1 ( for power circuit)

I/C MCB DP-32Amp with RCCB 100 mA and Outgoing - (i) MCB SP 16amps ---4 Nos,(PP15A) (ii) MCB SP 20 amps -- 1 No.(Geyser) (iii) MCB SP 32 amps -- 1 No(AC/WC)

V

15

6

5

1

1

6

5

2

2

6

3

5

2

2

18

1 (for L&F)

I/C MCB SPN-32Amp with RCCB 100mA and Outgoing –(i) MCB SP 6-16 amps – 12 Nos,

Two Numbers for each quarter

1 (for Power circuits)

I/C MCB TPN-40 Amp with RCCB 100 MA mA and Outgoing – (i) MCB SP 16amps -6 nos, (PP15A) (ii) MCB SP 20 amps – 2 nos (Geyser) (iii) MCB SP 32 amps – 2 No (AC)

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Abbreviations

LP Light point with 18 watt CFL with inbuilt choke.

PP5A Light plug point complete with socket and switch

TLP Tube light point with 1x28 watt T-5 Luminary complete with electronic choke and T-5 lamp.

PP15A Power plug point complete with socket and switch

FP Ceiling Fan point with 1200/1400 mm fan with 300 watts electronic regulator

PP32A (ACP)

Air Conditioner point with Industrial type iron clad plug 32 amps & 20A DP MCB in metal clad box

CBP Call bell point with ding dong type call bell GP Geyser point with 25 liters storage geyser.

EFP Exhaust fan point with 300 mm Exhaust fan

------------------------------------------------------------------------------------------------------------------

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Tech. Spec. No. RVNL/ELECT/GS/02

LUMINARIES & EQUIPMENTS

FOR

INDOOR/OUTDOOR

ELECTRIFICATION WORKS

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CHAPTER: A-2


LUMINARIES & EQUIPMENTS FOR

INDOOR/OUTDOOR ELECTRIFICATON WORKS 2.0 Scope

This specification covers supply and fixing of various electrical luminaries and other equipments for installing inside/outside the service buildings, staff quarters, platforms, passenger shelters, sheds, foot-over bridges (FOB) etc. The luminaries to be provided include compact fluorescent lamps (CFL), LED Lighting System, T-5 type energy efficient luminaries, metal halide luminaries etc. Electrical equipment includes fans, geysers, water coolers, Meter boards etc.

2.1 Ceiling Fan

a) Ceiling fans shall be provided with suspension hook arrangement in the concrete slab/roof members at appropriate stage before casting of roof at locations indicated on the working drawings prepared by the contractor. Co-ordination has to be maintained with civil engineering contractor authorities for the dates of casting of roof in order to provide fan box with MS hook as approved.

b) Ceiling fans shall be continuous duty type with double ball bearings, copper wound motor,

complete with canopies, down rod, 3 blades, capacitor etc (as per BOQ item) conforming to IS 374/1979, suitable for operation on 230 Volt +/- 10 %, 50 Hz, A. C. supply and star rated. Fans shall be generally off-white.

2.2 Normally 1400 mm ceiling fans shall be provided in service buildings/ passenger

shelters/waiting halls or rooms and 1200 mm sweep ceiling fans in residential buildings.

2.3 Stepped type electronic regulator (as per BOQ item) shall be provided for control of speed of fan at locations other than passenger shelters/ sheds as per Engineer’s decision.

2.4 Exhaust fans 2.4.1 Exhaust fans shall be heavy-duty type, suitable sweep (as specified in BOQ.) , 900 rpm (as

per BOQ item), noise free with fibre/steel body, star rated (if available in India), double ball bearing and conforming to IS 2312-1967. Exhaust fan shall be complete with copper wound motor, capacitor and louver/shutter, frame and mounting bracket and shall be suitable for operation on 230 volt +/- 10 %, 50 Hz, single phase AC supply system. The color of the exhaust fan shall be preferably matching with the wall or as decided by engineer.

2.4.2 A suitable hole shall be provided in the wall to suit the size of the frame, which shall be fixed

by means of rag bolts embedded in the wall. The size of the rack bolt and spacing shall match with the holes on the frame of exhaust fans. The hole shall be neatly finished to the original shape of the wall.

2.5 Light fittings Light fittings shall conform to IS-10322 and RDSO specification RDSO/PE/SPEC/PS/0100(REV.1)-2011. Light fittings shall be fixed on 3mm thick round

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phenolic laminated cover provided on conduit junction Board. Adequate length of copper conductor PVC insulated cable shall be provided for pendant fittings connections and earthing.

2.6 Surface type T-5, Energy Efficient Luminary with Tube/s 2.6.1 The surface type luminary shall be epoxy white powder coated, CRCA sheet housing with

reflector, pre-wired, indoor type, single/double 28 watts ( as per BOQ item) suitable to operate on 230 volts, 50 c/s AC supply system. Luminary shall be complete with T-5 tube/s, electronic ballast/s, holder/s, etc. conforming to IS-15111.

2.6.2 The connections and earthing of the fitting shall be done with 1.5 sq. mm single core, PVC

insulated, multi stranded, flexible copper conductor cable/s of 1.1 kV grade with FR properties as per IS: 694/1990.

2.6.3 The fitting shall be fixed to the wall by suitable approved arrangement. The fitting, if required

to be suspended from the roof, shall be suspended with 2 numbers of 19.0 mm diameter 16 SWG MS conduit pipes ( conforming to relevant latest IS) with ball and socket arrangements, double check nuts to hold the luminary in position, non-metallic bushing at cable entry to prevent damage to the flexible cable. The other end of the conduit tubes shall be fitted with the luminary.

2.6.4 Where false ceiling is being provided, the luminaries shall be recess type with mirror optic

reflector and LED / CFL / T5 lamps with complete fittings of 1 feet/ 2feet/ 4 feet length as approved by engineer.

2.7 Street Light Type T-5 Energy Efficient Luminary with T-5 Fl. Tube Light/s 2.7.1 Weather proof, street light luminary shall be of aluminium housing with epoxy white powder

coated CRCA sheet steel tray, clear acrylic cover, pre-wired, outdoor type with degree of protection not less than IP-54. It shall be provided with T-5 tubes and electronic ballast (as per BOQ item) suitable to operate on 230 volt 50 c/s, AC supply system. The luminary shall also be provided with holder/s, etc. as required and shall conform to the latest version of the relevant BIS specification.

2.7.2 The connections of the fitting shall be done with 1.5 sq. mm single core PVC insulated, multi

stranded, flexible copper conductor cable/s of 1.1 kV grade, with FR properties as per IS: 694/1990.

2.7.3 The earthing to the fitting shall be done with 1.5 sq mm single core PVC copper conductor

cable of 1.1 kV grade, flame retardant as per IS: 694/1990.

2.7.4 The luminary shall be mounted on the pipe bracket of pole/wall and connection to luminary shall be done from junction box of pole/over head line/ ceiling rose of point wiring etc., as the case may be.

2.7.5 In case, the luminary is to be provided on a wall, 450/600 mm long shaped G.I. pipe bracket

of class ”B” ISI marked of diameter matching with the inlet hole of the luminary shall be provided.

2.8 Street Light Metal Halide (MH) Luminary with Lamp

a) The metal halide luminary shall be single piece, deep drawn aluminium housing, POT optics with toughened heat resistant glass cover. The lamp compartment shall consist of electrochemically brightened and anodized aluminium reflector with center ribs for better uniformity and high optical efficiency. It shall consist of stainless steel toggles for fixing cover with housing. It shall have degree of protection not less than IP 54 for lamp and gear compartments and conform to the relevant BIS specifications.

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b) The metal halide luminary shall be suitable for operation on 230 volt AC, single phase, 50 Hz supply and complete with all accessories, toughened heat resistance glass including copper wound polyester ballast, power factor improvement capacitor, electronic ignitor, terminal block, lamp holder and metal halide lamp etc (as per BOQ item).

2.9 Low Bay Metal Halide (MH) Luminary with Lamp

The housing of the luminary shall be fabricated from CRCA MS sheet and finished in white stove enamel both from outside and inside with scientifically designed aluminium reflector. The control gear compartment shall house a removable gear tray prewired with a copper wound polyester ballast, power factor improvement capacitor and mains connector. The housing shall be fitted with a toughened heat resistant clear glass cover. It shall be suitable for operation on 230 volt AC, single phase, 50 Hz and shall be complete with metal halide lamp etc.

2.10 High Bay Metal Halide (MH) Luminary with Lamp

The housing of the luminary shall be of cast aluminium, LM6 with spherical control gear housing, finished in stove enamel gray and shall be provided with a spun aluminium reflector. The control gear housing shall be prewired with replaceable copper wound VPIT ballast, power factor improvement capacitor etc. mounted on a serviceable gear tray for ease of maintenance. For suspension, an eye bolt shall be provided on capsule cover with anti-loosening arrangement with a rubber bushing to damp vibrations. The luminary shall be suitable for operation on 230 volt AC, single phase, 50 Hz and shall be complete with Metal Halide lamp etc. Reflector shall be electrochemically brightened and anodized for longevity and high photometric performance.

2.11 LIGHTING on PLATFORMS: 2.11.1 All the luminaries having light spread more than 75 degree angle from vertically down outside

COP shall be provided with additional 1.2 mm Stainless / 2 mm thick Anodised Aluminium reflector outside covering luminare with top surface painted black as per approved design.

2.11.2 The orientation of luminaries outside COP shall be perpendicular to track whereas the luminaries inside COP shall be parallel to track to avoid bright glare to loco pilots of approaching trains.

2.12 LED type luminaires: The LED luminaires with lamp should generally be in line with the RDSO draft Specification No.

RDSO/PE/SPEC/PS/0123 (Rev’0’)-2009 enclosed separately. The luminaire should be suitably fitted based on the type of LED fitting such as lamp type, recess type, street light type as per details given for respective type fitting given above. The electrical connections etc also shall be as per respective fitting details mentioned above.

2.13 Solar Photovoltaic LED based Street light system: Refer detail specifications in relevant chaptor of this specification. 2.14 Geyser

a) Geyser (storage type water heater) shall be suitable to operate on 230 V AC, single phase, 50 Hz supply. Geysor shall have copper/SS inner shell and fibre body outer shell. Geyser orientation shall be of vertical / Horizontal type as per site requirement and shall be of specified capacity (as per BOQ item) conforming to IS:2082, ISI marked of approved make and star rated. It should be provided with inlet and outlet PVC (with steel mesh) water connections. The geysers shall be provided with a suitable thermostat control on which the range of temperature is indicated. The thermostat control shall have an adjusting knob for setting the temperature of water to the desired level. The water temperature indicator shall be available on geyser body. At the set temperature, the thermostat shall cut off the power supply automatically. The geyser shall be provided with an LED/ LCD lamp to indicate that the power supply is ON/ OFF. The body of the geyser shall be provided with an earth connection to protect leakage of current.

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b) The geyser shall be mounted vertically /horizontally on the wall by providing rack bolts embedded in the wall. The water connection shall be provided to the inlet port from the nearest water pipe line in order to maintain water supply to the geyser continuously. The outlet of the geyser shall be connected to water pipe line for drawing hot water.

c) The geyser shall be provided with suitable length of 3 core flexible cord and power plug of

16 A. The power supply shall be through MCB provided in the SDB to protect the geyser from overloads and short circuits.

2.15 Water Cooler a) Water cooler conforming to IS-1475 (Part-I)/2001 shall be complete with hermetically

sealed type, suction cooled compressor (conforming to IS 10617/Part-I/2013), with overload protection and and star rated and all connected standard fittings, accessories, etc. It shall be suitable to operate on 230 volt AC, single phase, 50 Hz supply.

b) Cooling capacity of water shall be 150 liter per hour or as specified in the relevant BOQ

item. The tank shall be manufactured from stainless steel of minimum 0.8 mm thickness. The cabinet of the water cooler shall be made of stainless steel sheet not less than 1.0 mm thick. The front panel below the water outlet & drain pan shall be made of stainless steel of 0.8 mm thickness. The bottom pedestal shall be made of thickness not less than 2.65 mm. Power factor of water cooler shall not be less than 0.85 at the rated capacity of the cooler. The thermostat shall conform to IS 113338/1985 and the setting shall be adjustable through rotary switch from 10 to 25 degree C which shall be marked suitably. The thermostat control shall have an adjusting knob for setting the temperature of water to the desired level. At the set temperature, the thermostat shall cut off power supply automatically. The body of the water cooler shall be distinctly provided with an earth connection to protect from leakage of current.

c) The water cooler shall be provided with a suitable length of 3 core flexible cord and a

power plug of 16 A and earthing. The power supply shall be through MCB provided in the SDB to protect the water cooler from overloads and short circuits.

d) The water cooler shall be placed on brick masonry platform. The water connection to be

given shall be provided to the inlet port from the nearest water pipe line in order to maintain water supply to the water cooler continuously.

e) Water cooler shall be provided with 5 KVA electronic auto voltage stabliser, suitable for operation on single phase 160 to 260 volts input supply,with provision for time delay start, voltmeter, instant start etc.

2.16 Meter Board a) The meter Board shall be suitable to operate on 230/415 volts Ac, single / three phase,

50 Hz supply system (as per BOQ item) and complete with all equipments including meter/s, MCB’s etc. (as per BOQ item).

b) The meter Board shall be out door type, weather proof, fabricated with 1.6 mm CRCA

sheet & compartmentalized for accommodating each unit. It shall be flush mounting type with degree of protection not less than IP-54. Each compartment shall have its own door with insulated thumb screw. MCB compartment shall be suitable to accommodate each MCB directly mounted on DIN channel in its own chamber. Meter compartment shall be suitable to accommodate each energy meter in its own chamber and have provision of concealed lock for sealing the individual compartment. Suitable provision shall be made on the front of the door to record the meter reading by providing a glass window 6 mm thick. The provision to be made for padlock/ seal. Meter and meter box should be provided with anti temper single use seal with sr no. Provision of suitable glass/fiber window shall be made for meter reading with out opening the meter board.

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c) The meter compartments shall be with vertical formation and cable alley shall be in the centre of the meter Board. Bus bar compartment shall be on the lower side of accommodate incoming cable for termination on incoming MCB. Outgoing MCB compartment/s for each quarter shall be on upper side (on top).

d) Connections from bus bars to meters and from meter to MCB shall be housed in flexible

MS/ PVC conduit through cable alley. e) The meter Board shall be provided with detachable gland plates on top & bottom with

knock outs and earthing terminal etc. as required. Bottom plate shall be provided with cable gland for incoming cable. Suitable knock outs shall also be provided on upper portion and on back side of MCB compartment to connect outgoing wiring/conduit.

f) The bus bar chamber, incoming and each outgoing MCB chamber shall have double

doors. It shall be possible to operate the MCBs only after opening of the outer door. g) Neutral supply to be provided with link in the all distribution boards. No MCB or fuse

should be provided in the neutral circuit.

Meter board shall be manufactured to meet the requirement/s as per site conditions i.e. for one/two/three/four unit blocks etc.

NOTE: Prior to bulk manufacturing, one sample of each type of meter Board shall be got approved from the Engineer.

2.17: Air Circulators: Air circulators shall be Heavy duty wall mounting, oscillating type fan 600 mm sweeps (24”)

complete with guard without regulator. Air-circulators should be supported on wall, pillars/poles with suitable mounting arrangements like brackets, clamps and hardware as approved by employer with all connected accessories viz. pipes, brackets, hook/clamps, bolts, nuts, washers, split pins, rubber pads etc. The fan shall be electrically connected to 3 terminal ceiling rose and from the ceiling rose to the Air Circulator by 3 core flexible copper cable run in suitable size PVC flexible hose.

2.18 Evaporative Air Coolers: Air coolers should be evaporative type fibre body conforming to IS 3315:1994 (Reaffirmed

2004) Edition 3.2 incorporating Amendt.Nos 1&2, ISI Marked, to operate on 230V, 1 50Hz AC supply, with all connected accessories viz. clamps, bolts, nuts, washers, rubber packing, honeycomb cooling pads and full function remote. It should have arrangement for water level indicator, low water alarm, air direction control in horizontal and vertical directions, indication for power ON with independent switches for exhaust fan and pump. The fan shall have three speed control viz low/medium and fast. Fan, filter pads, water pump etc. should conform to IS 3315:1994(Reaffirmed 2004) admt 1&2., The water pump shall conform to IS: 11951:1987(Reaffirmed 2007) with admt 1 to 4.

Depending on need, these can be room, window or tower type.

2.19 Window and Split Air Conditioners: Window and split type AC shall conform to IS-1391 pt I/1992 (amdt 1,2) and IS-1391 pt-

II/1992 (Amdt-1) respectively and star rated, remote control suitable to operate on 230V 1 50Hz AC supply and includes all connected accessories viz. clamps, bolts, nuts, washers, angulars, iron stand/frame, rubber packing, brackets, copper pipe etc. The AC shall be fitted

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with adequate length of copper pipe which should be covered with insulation of suitable thickness. Suitable draw pipes should be provided for draining out condensate water in PVC pipes or G.I / Plastic / Fibre trays as per site conditions and as per instructions of employer.

The AC shall be installed with suitable rated voltage stabilizer. The windows shall be properly sealed with insulating material after installation of AC.

2.20 Cassette type Air Conditioner: These ACs are designed to be installed on ceiling. They should operate on 230V 1 or 440V, 3 50Hz AC supply depending on its rating. AC should be star rated, remote controlled with suitable mounting arrangements on ceiling. The AC shall be fitted with adequate length of copper pipe which should be covered with insulation of suitable thickness. Suitable draw pipes should be provided for draining out condensate water in PVC pipes or G.I / Plastic / Fibre trays as per site conditions and as per instructions of employer. The AC shall be installed with suitable rated voltage stabilizer to protect it from voltage fluctuations.

2.21 Package type Air Conditioner: These ACs are designed to be installed inside room on the floor. The AC should be suitable to work on 440V, 3 50Hz AC supply and shall be suitably rated. AC should be star rated, remote controlled. The AC shall be fitted with adequate length of copper pipe which should be covered with insulation of suitable thickness. Suitable draw pipes should be provided for draining out condensate water in PVC pipes or G.I / Plastic / Fibre trays as per site conditions and as per instructions of employer. The package units may be air/water cooled type as specified in BOQ.

2.22 AIR COOLING SYSTEMS

(a) The air-cooling system is provided in the waiting halls, station buildings, service buildings, running rooms and rest houses etc.

(b) The air cooling system in Waiting Room and Lounge at stations shall conform to RDSO

Specification No. RDSO/2009/EM/SPEC/0001, (Rev.‘0’)Amdt-1.

(c) The air cooling system in other places like service buildings, running room and rest house shall also generally conform to above RDSO Specification. Prior approval of RVNL should be taken for any changes in the RDSO specification suiting to local requirement and specific to the building.

2.23 ENERGY SAVERS:

The ENERGY SAVERS consists of Street light /High Mast controller complete with infrared sensors, contactors and MCB, terminal board etc. for 25 KW load. Energy Pack, should be a lighting control device for outdoor luminaries. It should optimize the switching ON/OFF cycle, automatically, using Nature Switch having space grade infra red sensor, as per seasonal variation of daylight. It should be suitable for automatic, group control of outdoor luminaries, eliminating the need for any manual operation. Auto switch ‘ON’ of light at dusk Auto switch ‘OFF’ at dawn or after selected duration. No clock setting or clock tuning should be required. It should have operating voltage range from 185 to 275 V. the enclosure shall be IP 54 protected.

2.23.1 Constructional Features

Metallic/plastic molded housing to accommodate power contactor, overload protection devices, terminal blocks, MCB for three phases etc. Front opening door shall be with clear transparent window for sensing variation of daylight by the nature switch.

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MS plates should be fixed to the housing for pole mounting. Front door shall be provided with unique lock and key arrangement for safety.

2.23.2 Technical Specifications

Sr No Parameter Details

1 Operating Voltage Range 185 - 275V AC, 50-60 Hz

2 Maximum Load 15KW (3 Phase)

3 Endurance at rated load Minimum 5000 cycles

4 Operating Illuminance Levels

a) For Switching ON <60 lux for >30 sec (per Std. Test Procedure)

b) For Switching OFF >10 lux for >30 sec (per Std Test procedure)**

5 Max. Device Power Consumption 1 Watt at 230V AC

6 Insulation Resistance Minimum 5 Mega Ohms

7 Operating Temperature Range -10 C to +60 C

8 Operating Humidity Range Up to 95% RH at 40 C

9 Over Voltage trip levels

A) Auto High Voltage Sense and Trip

B) Auto High Voltage Sense and Reset

Above 270V

Below 255V AC AC

10 Under Voltage trip levels

(a)Auto Low Voltage Sense and Trip

(b)Auto Low Voltage Sense and Reset

Below 150V AC

Above 165V AC

11 Selectable res. for switching off from dusk 4 Hrs to 8 Hrs with a resolution of half an hour

12 Override facility for continuous ‘ON’ and continuous ‘OFF’ for maintenance

Yes

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Tech. Spec. No. RVNL/Elect/GS/03

OVERHEAD WORKS

& STEEL/GI TUBULAR POLES

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CHAPTER: A-3


OVERHEAD WORKS & STEEL/GI TUBULAR POLES

3.0 SCOPE

The scope covers overhead power lines, including stays and poles, MS cross arms (brackets), ACSR conductors, insulators, earth wire (GI wire), guarding etc. All materials, fittings, etc, used In the installation shall conform to relevant BIS specifications, wherever they exist. In those cases, where there are no BIS specifications available, the items shall conform to specifications approved by the Engineer.

3.1 Route of overhead Line

3.1.1 As far as possible, the route of distribution line as well as the location of stay sets shall be decided taking into consideration the present and future requirements of other agencies and utility services affected by it.

3.1.2 The route of distribution line shall generally follow the route of roads. 3.1.3 Poles for distribution lines may be located alongside the road on the road berm, a little

away from the road edge and drain. 3.1.4 Normally there shall be a pole located at road junction. 3.1.5 The route shall be so chosen as to avoid use of struts and continuous curve as far as

possible. 3.1.6 Junction of main road and service lane shall be preferred for location of pole to

facilitate street light of service lane as well. 3.1.7 Front of entrance to building shall be avoided for locating poles. 3.1.8 The clearances shall be in accordance with the Indian Electricity Rules. 1956. 3.1.9 Normally, no road crossing shall be done by overhead lines in Railway Area. Road

crossing by cable is given in chapter 4.

3.2 Spacing of Poles Spacing shall be in accordance with Indian Electricity Rules 1956. Normally poles shall be erected at distances as indicated below *:-

i For platform lighting 20 meters ii For street /Road lighting 30 to 35 meters iii For distribution line 35 meters iv For other location as decided by the Engineer and approved by employer

* Note:-These are general guidelines. However spacing of poles should be chosen judiciously

so as to ensure specified lux levels is achieved and lighting is uniform as per RB letter no-2004/Elect(G)/109/1 dt 18/5/2007 for station area and as per the requirement of the Division.

3.2.1 Where distribution line and street lighting fixtures are erected on the same support, the span shall not normally exceed 40 m.

3.2.2 Spans shall be chosen such that in a residential area adequate street lighting is

provided as per IS and as approved by Railway/Employer.

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3.3(a) Excavation and back filing for foundation 3.3.1 General

3.3.1.1 The excavation work shall be taken up after the locations of poles/stays are decided. 3.3.1.2 Every care shall be taken to see that the pits are not oversized while digging. 3.3.1.3 Suitable caution signals/boards, red lights and other protective measures, as decided

by the Engineer, shall be provided near the pit to warn the pedestrians/vehicular traffic till such time the pit is back filled and surface leveled.

3.3.1.4 The size of the pit shall be made as per approved drawing of the foundation OR as

specified in the standard tables given below. Wherever specific depth of foundation is not specified, the depth of the pit shall be such that normally 1/6th of the length of pole is buried in the ground as specified in IS: 2713.

3.3.1.5 The foundation pit shall be generally excavated in the direction of the lines.

3.3.1.6 All supports shall be correctly aligned before concreting or the back filling of the pit

with excavated earth. 3.3.1.7 The pit for support/stay/strut shall be filled up or concreted only in the presence of the

Engineer.

3.3 (b) Foundation (i) While erecting the poles on platforms and within station limit/area, the latest

schedules of dimensions (SOD) as per IRSOD-2004 with latest ammendments shall be strictly followed.

(ii) Foundation for erection of pole shall be constructed at the approved location. Drawing of pole foundation shall be got approved from the Engineer prior to casting of the foundation and erection. However, the responsibility of adequate design & drawing shall rest with the contractor.

(iii) After excavation of pit of suitable size, cement concrete bed of approx. 50mm thickness, using cement concrete of M-10 grade shall be first provided at the bottom of the pit. Square foundation shall be made with cement concrete of M-10 grade of size given below: (a) For hot dip Galvanized Pole- as specified in the table of standard dimensions of

pole given below. The foundation shall be made up to 150mm above ground level

(b) For Steel/GI Tubular poles- as per approved drawing. If approved drawing is not available, square foundation of such size where edge of foundation shall not be less than 150mm from edge of the pole. The depth of the foundation shall be 1/6th of the length of pole. Circular muffing of 150 mm thickness around the mast shall be made for 300 mm height above ground and sloped at the top.

(iv) It shall be ensured that the GI/HDPE pipe/s for the cable/s entry is/are placed in position. Muffing shall be plastered, finished and also cured.

(v) After foundation work, the pit shall be filled with excavated earth. During back filling of earth, ramming and watering shall be done.

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3.3 (c) ERECTION OF POLE: (i) The pole shall be erected in plumb and top of all the poles shall be at the same level to

maintain uniformity. (ii) The Hot Dip Galvanized poles shall be erected and bolted on casted foundation with a

set of four bolts. 3.4 Stays and Staying Arrangement

3.4.1 A stay shall consist of stay rod, anchor plate, bow tightener, thimbles, stay wire and strain insulator. The entire stay assembly shall be galvanized. The stay wire shall be hard drawn galvanized of 7/3.15 mm dia GI (as specified in the relevant BOQ item) conforming to IS 2141-2000. The anchor plate shall be of galvanized MS and not less than 30 cm x 30 cm x 8 mm thick and the size of stay rod shall be not less than 1.80 m (6 ft.) long and 19 mm dia.

3.4.2 The position of pit shall normally be such that the stay makes an angle within the

range of 45 degree to 60 degree with the ground. If the site conditions are such that the angle as stated may not be possible, special stays such as foot stays, flying stays or struts may be used.

3.4.3 The depth and size of the pit shall be suitable for the foundation of stay.

3.4.4 A stay shall be provided at all angle or terminal poles.

3.4.5 The stay rod shall be set in position in the excavation pit.

3.4.6 Stay rod shall be embedded in cement concrete of M-10 grade vertically with square

foundation 300 mm x 300 mm above the anchor plate lying over 15 cm thick cement concrete base. The stay rod shall be bent only at the unthreaded portion such that the stay wire and the bent portion of stay rod are in correct alignment. Care must be taken to avoid sharp bend or danger to galvanization.

3.4.7 After concrete has set, back filling shall be done with excavated earth and ramming in

layers of 20 cm using water as required.

3.4.8 The surface of foundation above ground shall be finished and cured.

3.4.9 The stay clamp shall be located near about the centre of gravity of the load of the overhead conductors.

3.4.10 One end of stay wire shall be fixed to the bow tightener of the stay grip of the stay

rod and the other end to the stay clamp fixed to the pole. By means of well spliced joint units, GI thimbles. A strain insulator shall be provided at a height of 3 meters above ground level. For high voltage lines, however, the stays may be directly anchored.

3.4.11 The stay wire shall also be connected and bonded properly to the continuous earth

wire.

3.4.12 Normally one stay shall be provided at angle pole.

3.4.13 Double stays shall be provided at all dead ends and at any other place as required by the Engineer. In such cases, these shall, as far as possible, be set parallel to each other at a distance of approx. 600 mm or as approved by the Engineer.

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3.4.14 If the stay rod cannot be erected in accordance with the above clauses due to roadways or obstructions of buildings etc. bow stay, fly stay or strut whichever is suitable to the location, shall be used.

3.5 Cross Arm (Bracket)

3.5.1 Cross arm shall be made of MS angle iron of size not less than 50 mm x 50 mm x 6

mm thick ( for LT overhead)/ MS channel iron of size not less than 75mm x 40 mm x 6.4 kgs per meter/100x50x6.4 mm for V-type cross arm ( for modification of power line track crossings/HT lines) as specified in the BOQ item. The length of the cross arm shall be suitable for accommodating the required number of insulators with the spacing of the conductors being in accordance with the clearances required. A minimum distance of 8 cm for LV/ MV lines and 10 cm for HT lines shall be left from the centre of the extreme insulator pin hole to the end of the cross arm. The cross arm shall be complete with clamp made of MS flat of size not less than 50mm x 6mm with necessary bolts of 16 mm and nuts & washers. The cross arm shall have holes as required to accommodate insulator pin etc.

3.5.2 The length of cross arm for carrying guard wire shall be such that the guard wire shall

always run not less than 30 cm beyond the outer most conductor of the configuration. 3.5.3 The cross arm and the pole clamp shall be treated with one coat of red oxide primer

before erection and finished with two coats of approved paint after erection along with other hardware. Iron nuts and bolts shall be used for fixing of clamps.

3.5.4 The cross arms shall be clamped to the support properly, taking into consideration the

orientation of the lines. 3.6 Insulators

3.6.1 The porcelain insulator shall conform to IS 1445-1977 suitable for overhead power lines below 1000 volts and IS 731-1971 for overhead power lines with a nominal voltage greater than 1000 volts. The insulator shall be complete with galvanized iron hardware etc. as required.

3.6.2 The insulators shall be of the following types as specified in the relevant BOQ item:

a) Pin and shackle insulator for LT & MV lines. b) Pin and disc type for HV lines.

3.6.3 The minimum size of shackle insulator shall be 90 mm dia x 75 mm high and shall be complete with GI clamps, nuts & bolts etc.

3.6.4 The minimum size of pin insulator shall be 65 mm dia x 100 mm high and complete

with GI pin, nuts and bolts etc.

3.6.5 Pin insulator/ shackle insulators/disc insulators shall be erected on the cross arms, as specified in the BOQ or as directed by the Engineer.

3.6.6 Shackle insulators shall be erected on cross arms at intermediate support in case of

long lines, deviation from straight line, terminal positions, junction poles etc.

3.7 ACSR Conductors

3.7.1 All conductors shall conform to IS: 398/pt. II/1996. Conductors shall be strung with permissible sag and the profile shall be got approved from the Engineer.

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3.7.2 Jumpers 3.7.2.1 Sufficient length of conductor shall be kept at shackle termination and Parallel Groove (PG) clamp shall be used for making jumper connections.

3.7.2.2 Jumpers used shall be of the same material as the line conductor and be of adequate current carrying capacity.

3.7.3 Binding of Conductors

3.7.3.1 The binding of conductor to insulator shall be sufficiently firm and tight to ensure

that no intermittent contacts develop.

3.7.3.2 The ends of binding wire shall be tightly twisted in a closely spaced spiral around the conductor to ensure good electrical contact and to strengthen conductors.

3.7.4 Binding Material

The insulators shall be bound with the line conductors with the help of aluminum binding wire or tape for ACSR/Aluminium conductors. The size of binding wire shall not be less than 2 mm dia and it shall be of galvanized iron conductors for galvanized conductors.

3.7.5 Guarding 3.7.5.1 General At all road crossings, crossing of overhead lines, crossing with other lines ( telephone

lines etc) and between HV and LV/ MV lines carried on the same support, guard shall be provided.

3.7.5.2 The guard wires shall be bonded to earth wire. 3.7.6 Earth Wire

3.7.6.1 The size of the continuous earth wire shall not be less than 8 SWG GI. 3.7.6.2 All metal supports and all reinforced and pre-stressed cement concrete supports of

overhead and metallic fittings attached there to shall be permanently and efficiently earthed.

3.7.6.3 The continuous earth wire shall be connected to an earth. There shall be not less

than 3 connections with earth (earth electrode) per kilometer spaced equi-distantly, as far as possible.

3.7.6.4 Where continuous earth wire cannot be provided, every pole shall be earthed and all

metal parts shall be bonded. 3.7.6.5 Junctions at terminal locations and all special structures shall be connected to earth. 3.7.6.6 The lead from earth electrode shall be suitably bonded to the continuous earth wire.

3.8 Danger Notice Plate and Anti- Climbing Devices

3.8.1 Danger Notice Plate

All supports carrying HV lives shall be fitted with danger notice plates conforming to IS: 2551-1982 at suitable height from ground indicating the voltage of lines.

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3.8.2 Anti Climbing Devices.

For preventing unauthorized persons from ascending any of the supports carrying HV lines without the aid of a ladder, arrangement for special appliances shall be made as directed by the Engineer. Barbed wire conforming to IS 278-1978 having 4 point barbs spaced 75+/-12 mm apart shall be wrapped helically with a pitch of 75 mm around the limb of the support and tied firmly, commencing from a height of 3.5m up to a height of 5 meters or as directed by the Engineer.

3.9 Steel/GI Tubular Poles

3.9.1 Steel/GI tubular poles shall be swaged type with single/double bracket/s for

platform/road/level crossing lighting etc. The constructional details shall be as per IS 2713/Pt 1 to 3. The length and designations shall be as per the relevant BOQ item. The diameter of bracket for mounting of luminary shall match with the inlet diameter of the luminary. In case of GI pole, the pole with base plate along with the bracket shall be hot dip Galvanized 80 to 90 microns thickness after the frabrication, as per I.S 2629. The pole shall be with single/double arm bracket of length 1.0mtr and with base plate complete. Dimensions of the pole shall be as per IS, reproduced in table given at 3.9.4. Foundation bolts and base plate sizes shall be:

Base plate of size 300 X 300 X 16 mm Foundation Bolts: 700x20mm- 4 Nos. with double nut, washer & template.

3.9.2 General (a) The uncovered platform/road etc. shall be provided with swaged type stee/GI

tubular pole/s and the luminary shall be weather proof, outdoor type as specified in the relevant BOQ item. Luminary shall be complete with control gear, lamps, accessories, fixing arrangements etc. The make and type of luminary & lamp shall be as specified in the BOQ item.

(b) Single core FR, PVC insulated copper conductor cable ( 2 x 1.5 sq mm size for connections to each luminary and 1 x 1.5 sq.mm for earthing), multi stranded, conforming to IS 694 (latest), ISI marked shall be supplied and provided for connections from junction box/overhead/light point as the case may be. Each luminary and junction box shall be suitably earthed.

(c) Separate wiring shall be provided for each luminary from junction box.

3.9.3 Steel Tubular pole with Canopy Type Single/Double Bracket/s (7 m for

platform lighting and 9m for Level Crossing/ circulating area Lighting/Road lighting etc)

3.9.3.1 (a) Steel tubular pole shall be swaged type made from steel of ultimate tensile strength 410 MPa (42 kg/mm. sq) as per IS: 2713(Pt. I,II and III) 1980 amended up to date. The pole shall be as per IS designation 410 SP-3 for 7 meter and 410 SP-30 for 9 meter length. The portion to be inserted in the ground shall be about 1/6th of total length as per IS: 2713. Pole shall be supplied with canopy type brackets, base plate etc. A hole of 25 mm dia and a rubber bush at required height from the bottom of the pole shall be provided in the lower limb (above the muffing) for drawing/taking the PVC wire from junction box to inside the pole for the

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connection of luminary. Each pole shall be provided with 16 mm dia GI earth terminals of suitable length for earth connection.

(b) MS square base plate of size 300 x 300 mm and 10 mm thick shall be welded at

the bottom of the pole. The base plate shall have a hole of dia. Approx. 50 mm in the centre, for draining out of water.

(c) Hot dip galvanised double arm Conicle poles with foundation bolts, base plate and

bracket can also be used in above place. The pole with base plate along with the bracket shall be hot dip Galvanized 80 to 90 microns thickness after the fabrication, as per I.S 2629.

3.9.3.2 Bracket

Bracket for accommodating of luminaries shall be canopy type with single/double G.I. pipe class ”B” 200 mm long (ISI marked), welded at an angle of 15 degree ( horizontal plane). Bracket shall be removable type and adjustable in horizontal plane. Fixing arrangement with pole shall be with 4 nos. bolts & nuts of dia not less than 10 mm. Fixing Arrangements shall be suitable to bear the wind pressure. The dia. Of the bracket pipe shall match with the inlet hole of proposed luminary to be provided on the pole.

Note: The drawing of canopy with pipe bracket/s, fixing arrangement and

sample shall be separately got approved from the Engineer.

3.9.3.3 Junction Box (a) Pole Mounting Type Ms Junction Box of size 300 x 200 x 125 mm deep, shall

be double doors, outdoor type, weather proof with degree of protection no less than IP54 and conforming to IS:8623 & IS:13032, suitable for operation on single phase, 230 Volts Ac, 50 Hz supply system. The Junction Board shall be manufactured with CRCA sheet steel 1.6 mm thick, duly powder coated and complete with 4 nos. copper bus bars of rating 100 amp (for cable terminations/ loop-out system ) for looping 4 core 3 nos. LT cables, one no. 16 6 amp 10 kA, SP MCB, earthing studs etc. Outer door shall be hinged on top in vertical formation, with provision of holding arrangement horizontally. The front cover of the junction box shall be provided with a lock which can be opened with a special key.

(b) The junction box shall be earthed as instructed by the Engineer. Junction box

shall be mounted with pole with 2 nos. galvanized Ms flat 40 x 5 mm clamps and Nut and bolts not less than 10 mm dia.

(c) Detachable gland plate shall be provided on the bottom of the junction box for

entry of incoming and outgoing cables.

(d) The junction box shall be fixed with the pole at a suitable height above ground level as per instruction of the Engineer.

(e) Holes shall be suitably protected with rubber bushes to prevent entry of rain

water inside the pole.

3.9.3.4 Earthing Earth electrode shall be provided at approved location as per IE rules. Pole/s shall be earthed to an earth electrode with 4 mm dia. G. I. Wire/armouring of laid cable as required.

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3.9.3.5 Painting

Steel Poles shall be given 2 coats of red oxide primer and after erection painted as under:

3.9.3.5.1 The bottom portion of poles up to a height of 1.5 m above the finished muffs shall be painted with superior quality of black ISI marked paint. 3.9.3.5.2 The remaining portion of poles as well as the clamps shall be painted with 2 coats of superior quality of Aluminium Paint (ISI marked).

3.9.4 Table below indicates dimensions of swaged type steel tubular pole as per

IS2713/Pt 1 to 3:

SN Designation Overall length (m)

Length of Sections (m)

Planting depth (m)

Outside diameter & thickness of sections(mm)

L Bottom

Middle

Top D Bottom Middle Top

1 410-SP-3(Wt.85 Kg

7.00 4.00 1.50 1.50 1.25 114.3 x 5.4

88.9 x4.85

76.10 x3.25

2 410-SP-30 (Wt.133 Kg)

9.00 5.00 2.00 2.00 1.50 139.7 x5.4

114.3 x4.5

88.90x3.25

3.10 HOT DIP GALVANIZED OCTAGONAL POLE 3.10.1 GENERAL:

Octagonal Pole shall be manufactured in single section. Manufacturer shall be ISO: 9001/2000 & ISO: 14001 certified. Drawing of pole and bracket/s shall be got approved from the RVNL.

3.10.2 DESIGN:

The structure shall confirm to IS: 875-part 3: 1987(latest version) relating to wind load on structures. Pole shall be designed for wind speed 169Km/hr.

The grade of steel used shall be as per BSEN-10025grade S-355JO. or equivalent standards. Yield strength shall be minimum 355N/mm. sq and tensile strength 490-630N/mm.sq.

3.10.3 POLE SHAFT:

The pole shaft shall have octagonal cross section & shall be continuously tapered with single longitudinal welding. There shall not be any circumferential welding. The welding of pole shaft shall be done by submerged are welding process. The base plate shall be fixed by welding to the pole shall at two locations i.e. from inside and outside.

Bending of the sheet into polygonal shape shall be done through a CNC controlled. Laser aligned will be as per IS : 1367.

3.10.4 DOOR OPENING:

The octagonal pole shall have door of aproximate 500mm length at the elevation of 500mm from the base plate. The door shall be weather proof to ensure safety to inside connections. The door shall be flush with locking facility. There shall also be suitable arrangements for earthing. The pole shall be additionally reinforced with a welded steel section so that the section at door is unaffected and undue bucking of the cut section is prevented.

The base compartment of the built in connector control box shall have provision to have 6 mm thick Bakelite sheet of suitable size to accommodate the required electrical accessories

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with compression gland for termination of incoming & out going supply cables. The connector box shall be provided with 2 Nos. 32 Amp heavy duty connectors (3way) for loop in and loop out of cables, 6 Amp C-Series DP MCB for individual fitting with din channel, earth stud and other required accessories.

3.10.5 GALVANIZING:

Internal and external surface of the octagonal pole shall be single dip, hot galvanized as per IS: 2629 / IS: 2633 / IS: 4759 standards with minimum coating thickness of 65 microns.

3.10.6 BASE PLATE:

Material of base plate shall be Fe 410 conforming to IS: 226/IS: 2062

3.10.7 Standard Dimensions of pole shall be as under:-

STANDARD DIMENSIONS OF Hot Dip Galvanized POLE

Height (Meter)

Top Dia (mm)

Bottom Dia (A/F)

(mm)

Sheet Thickness (A/F) (mm)

Base Plate Dimensions (LxBxT)

FOUNDATION BOLT Anchor Plate Thickness

(mm)

Foundation

Bolt Size (no.xdia) (mm)

Pitch Circle Dia. (mm)

Bolt Length (mm)

Projected Length (mm)

5.00 70 130 3 200X200X12

4X16

200 600 80 3 500x500x1000

(depth)

7.00 70 130 3 220X220X12

4X20

205 700 100 3 500x500x1250

(depth)

3.10.8 BRACKETS:

Bracket for accommodating of luminaries shall be canopy type with Galvanized single / double arm 200mm long to suit the inlet dia of luminary as per requirement of BOQ, welded at an angle of 15 degree (horizontal plane). Bracket shall be removable type and adjustable in horizontal plane. Fixing arrangement with pole shall be with 4 nos. bolts & nuts of dia not less than 10 mm. Fixing arrangements shall be suitable to bear the wind pressure. The dia. of the bracket pipe shall match with the inlet hole of proposed luminary to be provided on the pole.

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Tech. Spec. No. –RVNL/Elect/GS/04

CABLE LAYING

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CHAPTER:A-4


CABLE LAYING

4.0 General

(a) LT XLPE cables shall be of 1/2/3/3.5/4 core/s (as specified in the relevant BOQ Item). With aluminium conductor, armoured/unarmoured (as specified in the relevant BOQ item). PVC outer sheathed, conforming to IS: 7098 Pt.1(ISI Marked).

(b) HT XLPE (earthed) cable shall be of 3 core, aluminum conductor, screened, armoured shielded and PVC sheathed, conforming to IS: 7098/Pt 2 (latest version)(ISI Marked).

(c) IS 1255-1983 shall be followed in general for laying of cables. 4.1 The minimum safe bending radius for all types of cables shall be at least 15 times the

diameter of the cable up to 11 kV grade and 20 times the diameter for cables above 11 KV grade.

4.2 Route

The route of the cable shall be decided before the work of cable laying is undertaken. The drawing indicating the route of the cable shall be prepared by the contractor and got approved from the Engineer. Cable runs/routes shall generally follow the fixed development such as roads, pathways, track etc.

4.3 Cables of different voltage grading shall be generally laid in different trenches. In case it is not possible to lay them in separate trenches, due to site constraint, the same trench may be used, but adequate separation within the trench shall be ensured. Specific approval shall be obtained from the Engineer.

4.4 There shall be adequate distance between HT & LT cables. In case it is unavoidable to

separate HT &LT cables, the high tension Ht cable shall be laid below LT cable. 4.5 Wherever the power and telecom cables are to cross each other the same shall be laid at

right angles to avoid interference. Wherever it is unavoidable to lay them in proximity, horizontal and vertical clearance between the two shall not normally be less than 600 mm

4.6 Laying of Cable

The cable shall be laid in ground, in pipes, under road/railway track, recess in wall/on surface/clamping with erected pole etc. depending upon the requirement and site conditions.

4.6.1 Laying in Ground The cable shall be laid in ground, wherever it is passing through open country/along road/lanes etc.

4.6.2 Laying of Cables under road/ Railway track/Bridge etc. a) Wherever the cable is to cross road/railway track/ Bridge, Nalla etc. the cable shall be

laid through suitable size of pipes as per instructions of the Engineer. b) GI/CI/RCC/HDPE pipe etc as specified in the BOQ item shall be used for the purpose.

Pipes shall be continuous with couplers etc. and clear of any debris. Before drawing of cables, sharp edges at ends shall be smoothened to prevent injury to cable insulation and/or sheathing.

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c) All the road crossings to be done by UG cables with spare cable provision. One spare duct with same size dia HDPE/GI/CI/RCC pipe also to be made along with crossing for future use.

4.6.3 Laying of Cables under Passage/Wall etc.

Passage/wall used for the laying of cables, shall be cut as required and repaired to match with the original finish. In case cable is being laid on the wall, cable should be well supported by J clamp/hooks.

4.6.4 Erection along Erected Pole

For erection of cable along the pole, the cable shall be held vertically with protective G. I. pipe. The diameter of the pipe shall be adequate for the cable size and length of pipe shall be 3 meters. Cable & G. I. pipe shall be clamped with the erected pole with 40 x 6 mm Ms flat clamps, not more than 2m apart. End of the pipe should be sealed with suitable putty to avoid entry of moisture and rodents.

4.6.5 Width of Trench (a) The width of cable trench shall be approx. 350 mm. Wherever one additional cable is laid

in the same trench in horizontal formation, the width shall be increased such that inter axial distance between the cables shall be at least 200 mm. There shall be clearance of 150mm between the end cables and sides of the trench.

(b) In addition to the protective cover over the cables laid in the underground trench, a brick on edge shall be laid in between the two juxtaposed cables along the direction of lay of the cables for providing separation.

(c) Minimum width of cable trench for laying of LT/ HT cable at various locations shall be as indicated here under:

Width of Trench for LT Cables

Location Width of cable trench Width of cable trench for one additional cable

Width Remarks Under-ground 350mm approx. 550 mm approx. Additional bricks on

edge shall be laid in between the two juxtaposed cables.

On platform 350 mm approx. 550 mm approx.

Under Railway Track/road

350 mm approx. -- Through pipe

In wall/floor To be recessed as per instructions of the Engineer

- -

Other than above

As per instructions of the Engineer



Width of Trench for HT Cables.

Location Width of cable trench Remarks Additional cable not permitted in trench Under-ground 350mm approx. On platform 350 mm approx. Under Railway Track/road

Through pipe. With trenchless method/or digging method as decided by engineer

Other than above



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4.6.6 Depth of Trench Normally cables shall be laid in single tier formation and the minimum depth of top of laid

cable/pipe at various locations from the ground surface/bottom of sleeper shall not be less than as indicated here under:

Depth of Trench for LT Cable Location Minimum Depth of top of laid cable/pipe from

the ground surface/bottom of sleeper Remarks

Under road 1000 mm from ground surface Cables to be laid in single tier formation

Under-ground 1000 mm from ground surface --do-- On platform 750 mm from platform level --do-- Under Railway Track Not less than 1200 mm from bottom of laid sleeper at

locations where ground & track formation are in same level (with manual digging)

New Lines

Not less than 3000 mm from ground level at locations where track formation level is above ground surface. ( with trenchless method) Not less than 1200 mm (with manual digging) and 3000 mm ( with trenchless method) from bottom of laid sleeper at locations where ground & track formation are in same level.

Locations other than New Lines (as approved by Engineer)

Not less than 1200 mm (with manual digging) and 3000 mm (with trenchless method from ground level at locations where track formation level is above ground surface.

In wall/floor To be recessed ---do-- Other than above As per instructions of the Engineer ---do--

Depth of Trench for HT Cable (above than 440 V)

Location Minimum Depth of top of laid cable/pipe from the ground surface/bottom of sleeper

Remarks

Under-ground 1100 mm from ground surface Cables to be laid in single tier formation

Under road 1100 mm from ground surface --do-- Under Railway Track Not less than 1200 mm from bottom of laid

sleeper at locations where ground & track formation are in same level (with manual digging)

New Lines

Not less than 3000 mm from ground level at locations where track formation level is above ground surface. (with trenchless method) Not less than 1200 mm (with manual digging) and 3000 mm (with trenchless method) from bottom of laid sleeper at locations where ground & track formation are in same level.

Locations other than New Lines (as approved by Employer)

Not less than 1200 mm (with manual digging) and 3000 mm (with trenchless method from ground level at locations where track formation level is above ground surface.

Other than above As per instructions of the Engineer --do--

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4.6.7 Excavation of Trench

a) To the extent possible, the trenches shall be excavated in straight lines. Wherever a change in line is required, due to site conditions, suitable curvature shall be provided. As far as possible, mechanical means shall be employed for undertaking excavation. Manual excavation method shall be used if adequate working area is not available. The soil shall be stacked on the side of the trench in such a manner that it does not fall back into the trench.

b) Due care shall be taken to avoid damage to any existing cables, pipes or other such installations in the proposed route during execution. While excavating, if route markers, bricks, tiles, bare or protective covers are encountered, further excavation shall not be carried out without the approval of Engineer.

c) In case existing property gets exposed during trenching, the same shall be temporarily

supported or propped adequately as directed by the Engineer. The trenching in such case shall be limited to short lengths. Protective pipes shall be laid for passing the existing cables therein, and the trench shall be refilled, in case there is a danger of collapse, or the trench is endangering existing structure the same shall be sufficiently supported before proceeding with the excavation work. The bottom of the trench shall be level, free from brick bats and gravel etc.

4.6.8 Laying of Cable

Before and after the cable is laid, the individual cores shall be tested for continuity and insulation resistance and ends of cables shall be sealed suitably to avoid ingress of moisture. Surplus length of approx. 3.0 meters shall be left in the shape of a loop at each termination/joint etc. unless otherwise approved by Engineer.

4.6.9 Protection and Sand Cushioning

a) The cable shall be protected to provide warning to future excavators and also for avoiding any accidental mechanical damage by pickaxe blows etc.

b) The cable shall be protected with well-burnt bricks. The bricks on face shall be so provided

that the width of the brick is in the direction of lay of cable. The bricks shall be provided throughout the length of the cable to the satisfaction of Engineer. Wherever more than one cable is laid I n the same trench, the protection cover for cable shall protect at least 50 mm on the side of end cables.

c) Protective covering, sand cushioning of LT/ HT Cable & making good surface at various

locations shall be as indicated here under:

Protection and Sand Cushioning for LT Cable Location Protective Covering Sand cushioning Surface Underground 2nd class Bricks 225 x

100x60 mm (nominal size) width wise on top

Base cushion 80 mm under cable & 100 mm above laid cable

Making good damages and finishing as per original

On platform -do-- -do-- --do-- Under Road Through laid pipe ---do-- --do-- Under Rly Track --do-- --do-- --do-- In wall/floor Plastering --do-- --do-- Other than above As per instructions of the

Engineer As per instructions of the Engineer


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Protection and Sand Cushioning for HT Cable Location Protective Covering Sand cushioning Surface Underground 2nd class Bricks 225x 100x60 mm

(nominal size) width wise on top & length wise on both sides

Base cushion 80 mm under cable & 100 mm above laid cable

Making good damages and finishing as per original

Under Road Through RCC/HDPE/GI pipe ---do-- --do-- Under Rly Track --do-- ---do-- --do-- Other than above As per instructions of the Engineer As per instructions of

the Engineer --do--

4.6.10 Back Filling of Trench

a) After excavation and laying of cables, the trench shall be back filled with the excavated earth, free from stone or other sharp-edge debris and shall be watered if necessary. A 100 mm crown of earth shall be left in the center, tapering towards the sides of the trench to allow for subsidence. The trench shall be inspected at regular intervals particularly during wet weather and any settlement of soil shall be made good by the contractor by further filling, if required.

b) Due to cable laying work, if any disturbance to existing equipments in the area, like roads, pavements and garden takes place, the same shall be made good to original standard /finish after the cable laying work is over.

4.6.11 Cable Route Marker and Joint Indication Marker 4.6.11.1 Route markers shall be provided along straight runs of the cables at locations approved by

the Engineer and generally at intervals not exceeding 50 meters. Wherever the cable route is changing or it is entering a fixed installation, route marker must be provided. Route markers shall be properly grouted in concrete or laid along with the cable securily to avoid theft as per directions of the engineer.

4.6.11.2 Joint indication marker shall also be provided at joints of cable. 4.6.11.3 The word cables, the level of voltage, size of cable, depth shall be inscribed on the route

marker and joints. 4.6.12 Normally no joints are permitted. Under the circumstances, if joints can not be avoided,

specific approval shall be obtained from the Engineer. 4.6.13 Cable Testing

All cable shall be tested jointly at site by the contractor with the engineer, before laying, to ensure that the insulation values of the cable are within limits. The insulation test on the cable shall be conducted with 500 V megger up to and including 1.1 kV grade and with 5000 V megger for cables of higher voltage. The cable cores shall be tested for continuity, insulation resistance etc. All cables shall be again tested after laying and before covering.

4.7 GI Cable trays: GI Trays of size of suitable size as per BOQ may be used for neatly laying cables where it is not feasible to make them underground.

4.7.1 DESIGN REQUIREMENTS:

The hot dip galvanized steel perforated cable trays having rectangular channel section with appropriate depth shall be designed for a uniform load of at least 400N per 1000 mm ladder length tray. The trays shall be fabricated in a length of 2.5 m to 3m. The perforated cable trays shall be manufactured from good commercial, high grade strength sheet steel having minimum thickness of 2mm and shall be hot dip galvanized according to IS-2629 and IS-4759 suitable for indoor/out door use having moderate humidity and air pollution.

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The zinc coating thickness shall works out by applying a 610 gm of zinc per square meter surface with approximate thickness of 80 micron. The zinc coating shall be smooth, clean and uniform thickness and free from defects like ash and dross inclusions, bare patches, black spots, pimples, lumpiness, rust stains, blisters etc. The galvanizing shall not adversely affect the mechanical properties of the coated materials; the quality of the coating will be established by tests as per IS-2633. All manufacturing process including punching, cutting, bending and welding of perforated cable trays shall be completed and burrs shall be removed before the application of galvanization process is applied. Zinc conforming to at least Grade Zn 98 as specified in IS-209-1966 shall be used for the purpose of galvanizing.

The joints of two trays shall be butt construction and shall be made with the help of

coupler plates by nuts and bolts. The coupler plate and nuts and bolts shall also be properly hot dip galvanized, where the bends of the trays are required at site the same shall be supplied by the bidder without any extra cost.

While adopting the modules at site if cutting of any length is required the same shall be cut at site and joined by nuts and bolts with the help of coupler plates.

The perforated cable trays shall be supported on the solid supporting arrangement

made from channel of minimum size 100x50mm and angle iron of size 50x50x6mm thick angle approximately at a distance of 0.1 to 1.2m center to center either from ground/wall or ceiling. However, the supporting system shall be designed by bidder suitable to bear the uniform load of 400N per 1000mm ladder length for 300mm wide tray. The calculations in respect of this design shall be supplied by the successful bidder during design stage. M.S. angle iron brackets shall be further supported/anchored either to wall or ceiling/ground as per the site requirement. The brackets and supporting system shall be painted with two coats of zinc chromate primer followed by two coats of synthetic enamel paint of approved colour conforming to relevant Indian standard.

Bends, tees and cross connections shall also be designed properly as per site

requirement. The free vertical distance between parallel perforated trays/racks/ladder shall be at

least 250mm and the perforated trays shall be 50mm away from the walls. The trays shall be fixed to the brackets with proper nuts and bolts system.

The perforated trays shall be free from sharp edges and burns etc. so that joint

between two trays shall be without any clearance and matched in proper shape. At the bends the curvature in all axis of perforated trays/racks shall be 20R or

maximum size of cable. The supporting brackets/fixing bolts size shall be so calculated that the design load as specified in Design Requirements does not exceed. The perforated trays shall be installed in such a way that as far as possible the cables can be laid directly in place rather than be pulled through.

The current carrying cables as HT cables, LT cables; and DC cables shall be laid in

different tray. The cables shall be fixed in the perforated trays by means of plastic ties or plastic coated wires etc.

The number of perforated tray shall be sufficient in order to accommodate all the power cables indicated in the specification for cables. However, the approximate quantity of different trays have been given under clause 2.21, which can be ensured by the bidder by visiting the site before filling the tender.

4.7.2 EARTHING:

The perforated cable trays along with their supporting arrangements shall be properly earthed by the contractor with nut and bolts from the earthing risers generally in the vicinity of the tray routing. The earthing shall be as per latest I.E. rules and IS/IEC recommendation. The size of

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earth connection shall be such that its conductance should be more than the conductance of 14 sq. mm. Copper conductor.

4.7.3 FABRICATION OF TRAYS All fabrication of trays shall be in accordance with IS: 800 and as per the approved drawings unless otherwise specified.

The trays should have min 2mm thickness with all connected accessories viz. vertical bends, reducers, tees, cross members etc. as required according to the site conditions including painting besides clamping firmly to support the tray with MS angular legs fabricated with 40x40x6mm angular of 1 1/2' length, fixed in CC bed blocks (including casting) for holding the angular, on the RCC / Cover Over Platforms including painting etc. The trays should be fixed with suitable Clamps/ GI angles/ GI flats and with necessary connected hardware to the Trusses or Columns. The running/ arranging of the cables in these trays should be done by duly clamping at regular intervals and undertaking numbering by sticker to the cables for easy identification.

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Tech. Spec. No: RVNL/ Elect/GS/05

HIGH MAST LIGHTING

SYSTEM

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CHAPTER: A-5


HIGH MAST LIGHTING SYSTEM 5.0 Scope

The scope covers supply and erection of the high mast lighting system of specified height including foundation and other civil works. High Mast System includes all components and accessories, foundation bolts with nuts, washers, anchor plates, templates, Metal Halide luminaries (degree of protection IP65), etc. and provision of luminaries on the head frame of high mast with manual/electrical operation arrangements to lower/raise for maintenance purposes.

5.1 Codes and Standards Design, manufacture and performance of the High Mast lighting system shall comply with all currently applicable statutory regulations and safety codes and standards in the locality where the equipment is being installed and generally in accordance with the following standards for the loading of the High Mast. S. No. CODE TITLE 1 IS 875 (Part III) 1987 Code of practice for design loads for structures 2. BSEN 10025/DIN 17100 Grades of MS plates 3. BS5135/AWS Welding 4. BS ISO 1461 Galvanizing 5. TR. No. 7 1996 of ILE UK Specification for masts foundations 6. BS 5135/AWS Longitudinal weld

5.2 Structure

The High mast shall be of continuously tapered, polygonal cross section, presenting an standards to give assured performance and reliable service. The structure shall be suitable for wind loading as per IS 875 Part III of 1987.

5.3 General Constructional Features

The mast shaft shall be made of best steel grade in compliance with BS-EN 10025/DIN 17100 or equivalent, cut and folded to form a polygonal section and shall be telescopically jointed and welded. The welding shall be in accordance with BS 5135/AWS. The top section shall have a flange plate bolted to the head frame. The mast shall be fabricated and butt welded longitudinally to form a tapered section with telescopic friction slip joints. The procedural weld geometry and workmanship shall be exclusively tested on the completed welds. Mast shall be delivered at site in multiple sections. Each section shall be hot dip galvanized (single dip) inside and outside, having uniform coating thickness of 85/65 microns for bottom/top sections respectively. At site the sections shall be jointed together by slip- stressed-fit method. No site welding or bolted joint shall be done on the mast.

5.4 The mast shall have fully penetrated flange, which shall be free from any lamination or incursion. The base plate shall be of single flange and constructed with holes jig- drilled for anchor bolts passage for fixing the high mast on to the concrete foundation. The base flange will be provided with supplementary gussets between the bolt holes to ensure elimination of helical stress concentration of the environmental protection of the mast. The entire fabricated mast shall be hot dip galvanized, internally and externally, having a uniform thickness of 70 microns for the bottom section and 65 microns for the top section.

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5.5 The welded connection of the base plate to the mast section shall fully develop the strength of the section. Ultrasonic testing procedure shall be considered as the minimum permissible testing method. The wall thickness of each section shall be designed to withstand the loads to which the high mast will be subjected but in any case it shall not be less than 3 mm and 4 mm at top and bottom respectively. Shaft section shall not be jointed by circumferential weld or bolting.

5.6 All mast components shall be hot dip galvanized, as per British Standard 729/1971 (1986).

Earthing and earthing terminal shall be provided within the access door area of each high mast. Galvanizing shall be inspected for

(a) Adhesion (b) Mass of zinc coating and (c) Uniformity. 5.7 Mast Design Criteria

(a) The high mast and the lowering system with the required number of flood lights and lamp control gears etc. shall be capable of withstanding a sustained basic wind speed the area as per IS-875.

b) The design shall be such that the high mast with accessories is capable of withstanding external forces exerted by wind pressure and shall have a minimum wind load factor of 1.25 and material factor of 1.15.

5.8 Foundations

The mast shall be erected on suitably designed foundation as per high mast manufacturer’s design with following typical details: Type of foundation as specified by high mast manufacturer. Size of foundation As per high mast manufacturer’s design Load bearing capacity of soil As per soil report of the site at 2 meters depth. Considered wind pressure (Kg per meter sq)

As per IS-875-1987 or latest

Considered wind speed (KMPH As per IS-875-1987 or latest

The rate quoted for the high mast shall include the cost of testing of soil bearing capacityand laying of foundation. The contractor shall get the foundation designed accordingly from OEM/other reputeted firm as decided by the RVNL.

5.9 Lantern carriage 5.9.1 The mobile luminaries’ carriage ring shall be of steel tube construction in two segments. The

unit shall be joined by bolted flanges with stainless steel bolts and nyloc type nuts to enable easy installation or removal from the erected mast. All mobile components of the system shall be located on the mobile part in order to allow visual inspection during each operation. Proper luminary carriage ring support arms shall be provided for supporting the luminaries ring when the latter is lowered for maintenance.

5.9.2 The mobile luminary carriage shall be designed to carry the 9/12 number of luminaries and

control gears as specified in the relevant BOQ item and shall be evenly balanced. Nylon paddle Guide Ring shall be incorporated as a buffer arrangement between mobile luminaries carriage and mast shaft. This is to prevent damage to mast Surface during lowering and raising operation of mobile luminaries’ carriage.

5.10 Winch

(a) For installation and maintenance of luminaries and lamps, it is necessary to lower and raise the luminary carriage by means of suitable winching arrangement at the base of the mast. The speed of raising and lowering of lantern carriage ring shall be at least 3.0 meters per minute.

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(b) The winch must be of robust design and fully sustaining type without the need of brake shoe, springs or clutches. Winching system with the exception of driving unit shall remain permanently inside the mast with pendant switch control. Each mast shall be provided with a double drum winch suitable for raising and lowering the luminaries ring, with gear ratio 53:1 self lubricating type. It can be removed from the mast for maintenance if the need arises in future. The reduction gear of the winch shall be of endless work gear opening in an oil bath and gear shall be made up of High Carbon steel/ phosphor bronze. The minimum safe working limit of the winch shall not be less than 750 kg at 200 RPM. The operating speed of the winch shall be 180 RPM mechanical 0r 1400 RPM electrical motor.

(c) The capacity and the operating speed of the winch shall be clearly marked on each winch on an indelible label together with the recommended specification of the lubricant. A minimum of 6 turns of wire rope shall be on the grooved drum when the mobile luminaries ring is fully lowered to rest on the luminaries supporting arms.

(d) The winch shall be entirely sustaining under all normal circumstances and it is not independent on the brake or restraining device that uncontrolled or dangerous runaway speeds will occur in the event of total failure of this device. Slip test on winch is to be carried out by the manufacturer. All manufacturer’s test certificates and reports shall be submitted by the contractor to the Engineer.

5.11 Head frame

The head frame shall include a pulley system to accommodate three stainless steel hoisting wire ropes at any one time and separate pulleys for the passage of electrical cables. The pulleys shall be of non corrosive material and shall run on self-lubricating bearings with stainless steel axles. The complete head frame chassis shall be hot dip galvanized. The pulley assembly shall be fully protected by a galvanized (both internally and externally) canopy. Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do not get dislodged from their respective positions in the grooves. The head frame shall be provided with guides & stops with PVC buffer for docking the lantern carriage.

Note: Pulleys made of synthetic material such as plastic or PVC shall not be accepted.

5.12 Hoisting and Suspension Wire Ropes 5.12.1 The high mast shall be fitted with 6 mm dia flexible standard stainless steel hoisting wire

ropes of 7/19 construction, with a minimum breaking strength of 2350 kg. The combined lifting capacity of the hoisting wire rope shall have a factor of safety of 7 times the Safe Working Load (SWL) of the winch and shall be entirely suitable for the design application. Center material shall be conforming to DIN 3060.

5.12.2 A transition plate shall be incorporated to:

a) Connect the three suspension wire ropes to the two stainless winching wire ropes. b) Allow fixing of electrical wire cables. c) Ensure even distribution of loads between the two stainless steel winching wires by means

of an equalizer (necessary thimbles and terminals shall be provided for the steel wire ropes). d) Ensure even distribution of loads between the two stainless steel winching wires by means of

an equalizer (necessary thimbles and terminals shall be provided for the steel wire ropes). 5.13 Electrical Cable

a) Electrical cable shall be copper, anti-twisting, round and multi cored. The cable shall be suitable to carry the current of the fittings provided. A suitable terminal Board shall be provided at the base compartment of the high mast for terminating the incoming cable. The electrical connections from the bottom to the top shall be made by a special trailing cable. The cable shall be EPR FR PVC insulated and PCP sheathed to get flexibility and endurance. Size of the copper cable shall not be less than 2.5 sq. mm. At the top there shall be weather proof junction Board to terminate the trailing cable. Connections from the top junction Board to the individual luminaries shall be made by using 3 core 1.5 sq. mm flexible PVC cables of

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reputed make. The system shall have in-built facilities for testing the luminaries while in lowered position.

b) Suitable provision shall be made at the base compartment of the mast to facilitate the operation of internally mounted, electrically operated power tool for raising and lowering of the lantern carriage assembly. The trailing cables of the lantern carriage rings shall be terminated by means of specially designed, metal clad, multi-pin plug and socket provided in the base compartment to enable easy disconnection when required.

5.14 Winch Driving Power Tool

a) A suitable high powered, electrically driven internally mounted power tool, with normal over ride, together with an operating stand, shall be provided for the raising and lowering of the lantern carriage for maintenance purposes. The power tool shall be of single speed to suit the requirements provided with a motor of required rating, so that vibrations associated with high speed operation are avoided.

b) The power tool shall be suitable for lifting of the designed load installed on the lantern carriage and shall also be designed such that it will be not only self supporting, but also align perfectly with respect to the winch spindle during the operation. The power tool shall be supplied complete with push button type remote control switch and six meters of additional power cable, so that the operation can be carried out from a safe distance. In case of failure of electrical supply, provision for manual operation shall exist and shall incorporate a torque limiting device. The power tool shall be reversible. Necessary protection against over load, short circuit, earth fault and single phasing etc. shall be provided.

5.15 Control Panel 5.15.1 Control of raising and lowering operations shall be carried out from the mast base by means

of a portable control panel. The control panel shall be suitable for 3 phases, 415 volts A. C. supply system and shall consists of: a) A power supply and control cable of not less than 5.0 meter length. b) A pendant type control panel equipped with push button for raising and lowering of the

mobile part. The push buttons shall operate on the “ dead man” principle i.e. action shall seize as the button is released.

c) Steel sheet iron control panel of suitable size and built in type, shall be provided and fixed in the high mast at a suitable height.

5.15.2 The panel board shall consist the following:

1 x 63 A TPN MCB switch for incoming. 1 no. of multiple plug socket 16 amps. 3x32 A, SPN MCB for outgoing. Automatic timer switch with contactor of suitable rating for control of 50 % & 100%

lighting OR as approved.

5.16 Torque Limiter a. Model – Electric TD2 b. Lifting Capacity – SWL 750 kg. c. Adjustable/ Non-adjustable - Adjustable. 5.17 Fencing Panel High mast shall be provided with suitable fencing panel of size 2mX2mX1.5m duly painted for

protection of erected high mast as specified in BOQ and as directed by Engineer.

5.18 Earthing: Two pipe electrode earthing shall be provided for each High mast system.

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PRESTRESSED

CEMENT CONCRETE POLES

FOR

MODIFICATION OF POWER LINE

CROSSINGS

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CHAPTER: A-6

Technical Specification No. RVNL/ Elect/GS/06

PRESTRESSED CEMENT CONCRETE POLES FOR

MODIFICATION OF POWER LINE CROSSINGS

6.0 Scope This specification covers pre-stressed concrete cement poles for modification of State Electricity Board’s Power line crossings.

6.1 Application Standards The pre-stressed concrete cement poles and their erection shall comply with the relevant provisions of the following BIS Specifications:

a) IS 1678 of 1998: Specification for pre-stressed concrete poles for overhead power,

traction and telecommunication lines. b) IS 2905 of 1989: Methods for testing of concrete poles for overhead power and

telecommunication lines. c) IS7321 of 1974: Code of Practice for selection, handling and erection of concrete poles

for overhead power and telecommunication lines.

6.2 Earthing : Suitable arrangement for earthing shall be provided.

6.3 Pole Pole shall be pre-stressed, cement concrete (PSCC), 11 meters long, suitable for 330 kg working load, with top section 200 mm x 105 mm and bottom section 410 mm x 140 mm conforming to IS 1678 of 1998.

6.4 Double Pole Structure Pre-stressed, cement concrete (PSCC) double pole structure shall be 11 meters long suitable for 330 kg working load with top section 200 mm x 105 mm and bottom section 410 mm x 140 mm and with 4 nos. of channel cross arms & 2 nos. of cross bracing angles, clamps, bolts, nuts etc. as per SEB’s specifications and site requirement.

6.5 Erection

Erection of pole/double pole structure shall include the excavation of pit 1800 mm deep and making foundation with cement concrete as per approved drawing of SEB/Railway.

6.6 Inspection at Site The contractor shall ensure that the manufacturer numbers the poles for identification. The contractor shall also make arrangements for testing the poles at the manufacturer’s works. The manufacturer’s test report, indicating the pole identification number, shall be furnished by the contractor at the time of supply of poles at site. The poles received at site shall be inspected by the Engineer to ensure that they are free from cracks of breakages of any kind. In case poles are found having cracks/breakages or are not accompanied by test reports, the poles shall not be accepted. The contractor shall replace all the defective poles at his own cost, including transportation charges.

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MODIFICATION OF

POWER LINE CROSSINGS ON

RAILWAY TRACKS

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CHAPTER:A-7

Technical Specification No. RVNL/Elect/GS/07 MODIFICATION OF POWER LINE CROSSINGS

ON RAILWAY TRACKS

7.0 General

a) The scope covers modification of existing power line crossings of Railway track as per the regulations applicable to electrical overhead crossings and/or underground cables crossing the railway tracks operated by the Indian Railways, Railway companies and port commissioner’s railways, including assisted and private sidings on which rolling stock of Indian Railway may work, unless any special section or railway tracks are exempted from these regulations by specific written orders of the Electrical Inspector.

b) Detailed drawing of the proposed modification work of crossing shall be prepared and approval obtained from the Railway and concerned State Electricity Authority.

c) Revised agreement as per the regulations applicable to electrical overhead crossings and/or underground cables crossing the railway tracks shall be got signed from the concerned State Electricity Authority.

7.1 Compliance to Rules: a) All the crossings shall be modified to comply with the latest Regulations for Electrical Crossings

of Railway Track 1987 with up to date amendments issued from time to time thereto. b) Except where otherwise provided for in the regulations, the contents of relevant sections of

the Indian Electricity Act 2003, Indian Railway Act 1890 and the rules made under these and as amended from time to time thereto and the relevant provisions of Indian Railway’s Schedule of Dimensions (IRSOD) for Broad/ Meter / Narrow Gauges together with the latest amendments shall apply to the modified crossings.

7.2 Standard Specifications All materials used in the construction of the crossing shall comply with the relevant latest BIS Specifications.

7.3 Method of crossing – Overhead Line Underground Cables:

All low, medium and high voltages up to and including 11 kV crossings shall normally be by means of underground cables. While for voltages higher than 11 kV, crossing may be through overhead lines or underground cables. The use of underground cable to the extent possible would be advantageous particularly up to and including 33 kV systems.

7.4 Overhead Power Line Crossing 7.4.1 Angle of Crossing

An overhead line crossing shall normally be at right angles to the railway track. In special cases a deviation of up to 30 degree may be permitted. Deviations larger than 30 degree shall have to be specifically authorized by the Electrical Inspector of the Railway.

7.4.2 Structures

a) Steel poles/masts, fabricated steel structures or reinforced/pre-stressed cement concrete poles either of the self supporting type or guyed type conforming in all respects to the Indian electricity Rules, 1956 ( as amended till date) and complying with the latest editions of Codes of Practice, IS: 800-1984 for “Code of Practice for use of Structural steel in General Building Construction, IS: 1678 of 1998: Specification for ‘Pre-stressed Concrete Poles for Overhead Power, Traction and Telecommunication Lines’, shall be used on either side of the track to

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support the crossing span. These structures shall be of the terminal type. For arriving at the crippling load, the wind loads as detailed in the latest edition of IS: 802 ( Part I) – 1995 for “Loads and Permissible Stresses” shall be adopted. The steel structures shall normally be galvanized in accordance with IS:2629-1985 for “Recommended practice for hot-dip galvanizing of iron and steel”

b) The minimum distance of the structures (supporting the crossing span) from the center of the

nearest railway track, including new proposed and considering for future, shall be as per para-11(iv) of IRSOD-2004 and given at para 7.5.2(C)

c) The crossing span shall be restricted to 300 m or to 80% of the normal span for which the

structures are designed, whichever is less. d) Wind pressure

The maximum wind pressure for design of the structure shall be as prescribed in IS: 802/Pt.I/1995 for loads and permissible stresses.

7.4.3 Temperature

The maximum and minimum temperatures for design of the conductors and other wires shall be as prescribed in the latest edition of IS: 802 (pt. 1, Clause-10) with necessary correction for maximum temperature.

7.4.4 Factor of Safety

The factor of safety of all structures, conductors, guards, guys and ground wires used in the crossing shall be as stipulated in the Indian Electricity Rules, 1956 as amended and the relevant code of practice. Ground wires used in the crossing shall be as stipulated in the Indian Electricity Rules, 1956 (as amended till date) and the relevant Codes of Practice.

7.5 Clearance between the Overhead Line and Railway Track An overhead line crossing over electrified railway track shall be located at the middle of overhead equipment span supported by two adjacent traction masts/structures. The distance between any of the crossing conductors and the nearest traction mast or structure under the most adverse conditions shall not be less than 6 m. Note: If, in unavoidable circumstances, the crossing span cannot be so located, the minimum clearance between any of the crossing conductors of the crossing and the nearest traction mast or structure shall not be less than that specified for buildings in Rule 80 of the Indian Electricity Rules, 1956 (as amended till date). Specific permission in this regard shall be obtained from the Employer, prior to execution of work.

7.5.1 No overhead line crossing shall be located over a booster transformer, traction switching station, traction substation or a track cabin in an electrified area.

7.5.2 Clearance for Power Line Crossings including Telephone Line Crossings of Railway

Tracks–Clearances shall be kept as per IRSOD with latest amendment issued from time to time.

7.5.3 Clearance between Power Line & Communication Line:

The minimum clearance to be maintained between a power line and a communication line shall be as prescribed in the “Code of Practice for the Protection of Telecommunication Lines at Crossings with Overhead Power Lines other than Electrical Traction Circuits” (latest edition) issued by Central Electricity Authority (CEA), Telecommunication Directorate, Power and Telecommunication Co-ordination Committee (PTCC Unit), Govt. of India.

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7.6 Insulators

A double set of strain insulator strings shall be used in crossing span in conjunction with a yoke plate where necessary. Each string of such strain insulators shall have one insulator more than the number used in a normal span of the overhead line. The factor of safety of each string of insulators under the worst conditions shall be not less than 2.

7.7 Guarding

a) All overhead power line crossings upto and including 33 kV shall be provided with guarding under the power line. Guarding need not be provided for overhead power line crossings of voltages above 33 kV if the transmission/ distribution line is protected by circuit breakers of modern design with total tripping times of 0.20 seconds for voltage below 220 kV and 0.10 seconds for voltages of 220 kV and above, from the time of occurrence of the fault to its clearance. Wherever, guarding is adopted for the crossing span, cradle guards shall be provided.

b) Minimum height above rail level to the lowest level of cradle guard or guard wires under condition of maximum sag shall not be less than the values specified in the clause 7.3.1.8 above.

c) The minimum height between any guard wire and a live crossing conductor under the most adverse conditions shall not be less than 1.5 meters.

7.8 Anti-climbing Devices and Warning Notices:

Where the voltage exceeds 650 V, the supporting structures (of the overhead line crossing) on railway land shall be provided with anti-climbing devices. Besides, suitable caution/warning notices shall be erected on all such structures, in the regional language and in English, as may be prescribed for the purpose. The anti-climbing devices and the caution/warning notices shall be got approved from the Railway by the Engineer.

7.9 Earthing

(a) Each structure on either side of the crossing span supporting the transmission line conductors shall be earthed effectively by two separate and distinct earths and connections. At least one separate earth electrode shall be provided for each earth connection. Earth resistance of the independent electrode shall be less than 5 ohms.

(b) All guard and stay wires shall be properly clamped to the structures connected to earth so as to maintain proper electrical continuity to earth.

(c) Where struts are provided, they shall also be effectively connected to earth separately as well as to the main structure earths.

(d) Where the earth resistance of the independent tower/structure is higher, the owner shall take necessary steps to improve the earth resistance either by providing multiple earth electrodes or by suitably treating the soil surrounding the earth electrode or by resorting to counterpoise earthing. The method of earthing the transmission/distribution line structures etc., for the crossing span shall be got approved from the Railway by the Engineer.

(e) The cross section of the earth conductor/ connections for the earthing system shall be adequate for the application. They shall not be liable to be damaged or overheated or melted while carrying the short circuit current.

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7.10 Cable Crossing 7.10.1 General

As for as possible, cable crossings shall make use of any existing culverts, sub-ways etc. In case of electrified track(s), the crossing shall be provided at locations at least 5 meters away from any traction substation or switching station or mast or structure erected or proposed to be erected by the railway for the purpose of supply and distribution of power to the traction overhead equipment. The exact locations of such traction substation or switching station or mast or structure in any particular area shall be obtained by the Engineer/ Employer from the Railway.

7.10.2 Cathodic Protection Cathodic protection of the cables shall normally not be adopted, unless specifically required by the Railway or any other organization having assets nearby to which interference is likely to be caused by currents flowing through the crossing.

7.10.3 Method of Laying cable under Railway Track(s)

(a) Cable shall be laid through cast iron or spun concrete pipes/ HDPE pipe etc. as per BOQ item, of suitable diameter and strength. Long lengths of pipe shall be laid with a gradient to facilitate drainage of water. The pipe shall be laid up to the Railway boundary at both ends or up to the point as approved by the Railway/ Engineer. The laying of the cable shall be in accordance with the latest edition of IS: 1255-1983” Code of practice for Installation and Maintenance of Power Cables up to and including 33 kV”

b) The armouring and sheathing of the underground cable laid across or near any electrified railway track shall be earthed by independent earths at the two sealing ends of the cable.

c) No further earthing of the armouring and sheathing of the cable shall be done within 500m of the electrified track. The scheme and method of earthing shall specifically be approved by the Railway.

7.10.4 Termination of cable with structure a) Where the ends of a cable of an underground crossing are terminated on structures for

connection to an overhead line, such structures shall comply with the Regulations in so far as they are applicable to overhead line crossings in respect of structures.

b) The pole on which the cable is terminated shall be provided with strut/stays to take the load of over head mains. The crossing cable shall be inserted in a GI pipe of suitable diameter. The GI pipe shall be supported to the termination pole with proper clamps, bolts and nuts. The clamps shall be provided to support the GI pipe at an interval of not more than 2.0 meter. The supporting GI pipe shall be provided along the structure up to a height of 2 m above the ground level. The open ends of the GI pipe shall be sealed to prevent extraneous matter causing damage to the cable. The exposed portion of the cable above the GI pipe shall be clamped to the pole at an interval of not more than 2 m.

c) The cable end shall be provided with termination kits on either ends of the crossing. Suitable jumper connections shall be provided between the overhead mains and the cable end terminations.

7.10.5 Marking of Crossings

Each cable crossing shall be indicated by at least two cable route markers, one at each end of the crossing within the railway boundaries. The cable route marker shall be fixed at both ends of the underground crossings. The following information shall be clearly displayed on the markers.

Electrical Cable -- kV Number of Cables -- Nos.

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Danger Notice Plate -- In English, Hindi and the Vernacular language of the District

Depth of Cable -- mm below track level. Depth of Cable -- mm below ground level between the toe of bank and

railway fencing

7.11 Coordination with SEBs and standards: The contractor shall coordinate with State Electricity Board authorities for smooth working and

shall arrange required approvals if any. Contractor shall also follow standards and specifications, approved list of concerned SEB for proper energisation.

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Tech. Spec. No. - RVNL/Elect/GS/08

MEDIUM VOLTAGE

SWITCH BOARD

(for Sub Stations)

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CHAPTER: A-8

Technical Specification No. RVNL/Elect/GS/08 MEDIUM VOLTAGE SWITCH BOARD

(for sub stations)

8.1 General (a) Medium voltage switch board shall be cubicle type, floor mounted, free standing type,

dust and vermin proof, totally enclosed & compartmentalized design of uniform height and of multi-tier construction for indoor utilization and suitable for 3 phase, 4 wire, 415 V, 50 Hz AC, solidly earthed neutral, electric supply system complete with accessories, inter connections, continuous GI earth strip, bus bar chamber with copper/aluminium bus bar (as specified I n the relevant BOQ item), ON/OFF & trip indication, all instruments, CT’s energy meters, switchgears etc. (as specified in the relevant BOQ item) in position, duly wired up with copper conductor cable with colour coding, code numbering etc. and other accessories though not mentioned here but necessary to complete the work in all respects.

(b) LT panel shall conform to IS: 8623/Pt-I/1993 (c) The panel manufacturer shall have ISO: 9001 certification with testing arrangement as

per IS: 8623 and power coating facilities in the works.

8.2 Construction 8.2.1 The panels shall be fabricated from 2.0 mm thick CRCA sheet steel. The shroud & partitions

shall be minimum 1.6 mm thick CRCA sheet steel. The panels shall be powder coated in approved shade. The degree of protection shall not be less than IP42 as per IS: 13942/Pt. 1.

8.2.2 Height of panel shall not be more than 2200 mm and operating height of switchgears shall be

between 300 to 1900 mm. Depth of panel shall not be less than 1200 mm. Continuous GI earth bus bar shall be of size not less than 50 x 6 mm.

8.2.3 The following minimum clearances shall be maintained:

i) Between Phases -32 mm ii) Between Phases & Neutral -26mm iii) Between Phases & Earth -26 mm iv) Between Neutral & Earth -26 mm

8.2.4 All functional units shall be arranged in a multi-tier formation & each such unit shall be fully

compartmentalized. Vertical cable alley shall be provided. Cable alley shall have hinged doors & suitable cable clamping arrangement. Vertical bus bars shall be housed in between two feeder compartments in a separate bus chamber. The openings between the bus chambers & feeder compartments shall be covered with Bakelite/hylem sheet of minimum 4.0 mm thickness. All the interconnecting links to the feeders shall be shrouded by means of phenolic barriers to avoid accidental contact. Each compartment shall have its own individual door with concealed hinges & the door shall have interlocking so door can only be opened after switching off the module.

8.3 Bus Bars 8.3.1 The bus bars shall be made of high conductivity aluminium/copper (as specified in BOQ)

conforming to the requirement of IS 5082/1998 for aluminium and IS: 1897/1983 for copper. The bus bars shall have uniform cross section ( basis of bus bar cross section will be maximum of 1000 A/sq. inch for copper and 630A/sq. inch for aluminium). The cross-section of the neutral bus bar shall be same as that of the phase bus bar for bus bars of capacity up to 200 Amp. For higher capacities, the neutral bus bar shall not be less than half (50 %) the cross-section of that of the phase bus bars.

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8.3.2 Bus bars are to be provided in sections as per requirement for feeding essential/non-essential

load and domestic/commercial load as per the approved drawing. 8.3.3 Provision shall be made in the switch board to take in main bus bar trunking from

top for LT panels to be provided with transformers of capacity above 750 KVA. 8.3.4 Bus bars shall be supported on suitable non-hygroscopic, non-combustible, material such as

DMC/SMC. The joints in the bus bars shall be provided with fish plates on either side of the bus bars to provide adequate contact area. Bus supports shall be provided on either side of the joints.

8.3.5 All bus bars shall be insulated with PVC tapes/tubes (heat shrink type) with colour coding

(Red/Yellow/Blue/Black) to withstand the test voltage of 2.5 kV for one minute. 8.4 Molded Case Circuit Breakers (MCCB) 8.4.1 MCCBs shall conform to IS13947/Pt-2/1993 (Ics = 100%Icu) with thermal release setting

70/80%-100% and shall have ON, OFF & TRIP indications with breaking capacity as specified in the relevant BOQ item. MCCBs shall be 3 pole/4 pole (as specified in the relevant BOQ item) and suitable for three phase, 415 Volt, AC supply. MCCB shall overall conform to IS13947/Pt.II/1993.

8.4.2 Tripping unit shall be of thermal-magnetic type provided in each pole and connected by a

common trip bar such that tripping of any one pole operates all the poles to open simultaneously.

8.5 Air Circuit Breaker (ACB)

Air circuit breaker of rating as specified in the relevant BOQ item, ¾ pole ( as specified in the relevant BOQ item), 415V, 3 phase, 50 Hz AC Manual/ Electrical draw out type (as specified in the relevant BOQ item), trip free, front operated, with ON/OFF indications. The breaker shall have Ics – Icw – Icu minimum breaking capacity of 45/50 KA (as specified in the relevant BOQ item). The circuit breaker shall be fitted with CT operated micro-processor based trip unit for over load, short circuit and ground fault trip and shall be independently adjustable. ACB shall overall conform to IS: 13947/Pt. II/1993.

8.6 Fuse Switch/ Switch Fuse Unit

Fuse switch/switch fuse unit shallbe heavy duty, TPN double break of rating as specified in the relevant BOQ item, utilization category AC 23, conforming to IS: 13947/Pt. III/1993 with HRC fuses conforming to relevant IS and one neutral link.

8.7 On load change over Switch 4 pole

On load changeover switch shall be 4 pole, heavy duty of rating (as specified in the relevant BOQ item), utilization category AC 23, conforming to IS:13947/Pt.III/1993.

8.8 ACB Bus Coupler

ACB bus coupler shall be 4 pole (fixed type) of rating as specified in the relevant BOQ item, overall conforming to IS: 13947/Pt. II/1993. The circuit breaker shall have minimum breaking capacity of 45/50 kA (as specified in the relevant BOQ item).

8.9 Indication lights

Clustered LED type indication light shall be provided for ON/OFF indication on each incoming and outgoing module.

8.10 Measurement Instruments for Metering

Measuring instruments shall have accuracy Class I.

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8.11 Current Transformers 8.11.1 Current transformers shall be in conformity with IS: 2705 (Part I, II &III)/1992. Current

transformers shall be rated for 1 kV at rated primary current, rated burden. The rated secondary current shall be 5 A. The acceptable minimum class of various applications shall be as given below:

Measuring : Class 1 Protection : Class 5 to P10

8.11.2 Separate CT shall be provided for measuring instruments and protection. 8.11.3 The current transformers shall be mounted such that they are easily accessible for inspection,

maintenance and replacement. The wiring for CT’s shall be copper conductor, FR insulated wires with proper termination lugs and wiring shall be bunched with cable straps and fixed to the panel structure in neat manner. The VA rating of the CTs shall be 5 VA.

8.12 Miscellaneous

Control switches shall be of the heavy-duty rotary type with plates clearly marked to show the operating position. They shall be semi-flush mounting with only the front plate and operating handle projecting.

8.13 Cable/Bus Trunking Termination 8.13.1 Cable entries shall be provided with metallic glands to prevent damage to the insulation of the

cable and terminals shall be provided in the switchboard to suit the number, type and size of power cables and copper conductor control cables.

8.13.2 Provision shall be made from top for bus trunking terminations/ from bottom for entry of cables through removable gland plates.

8.13.3 Barriers or shrouds shall be provided to permit safe working at the terminals of one module without disturbing of other modules.

8.14 Control Wiring

All control wiring shall be carried out with 1100/660 Volt grade, single core FR PVC insulated cable conforming to IS: 694 having stranded copper conductors of minimum 1.5 sq. mm size for potential circuits and 2.5 sq. mm for current circuits. Wiring shall be neatly bunched, adequately supported and properly routed to allow for easy access and maintenance. Numbering ferrules at each end shall identify wiring. All control fuses shall be mounted in front of the panel and shall be easily accessible.

8.15 Test at Manufacturer’s Works 8.15.1 All routine tests shall be carried out in the presence of the inspecting Engineer. 8.15.2 Original test certificates of all equipments/instruments shall be submitted along with the

supply of panel board after the Inspecting Officer passes the LT panel board. 8.16 Testing and Commissioning

Following tests shall be carried out prior to commissioning of the panel: a) Insulation test: When measured with 500 V megger, the insulation resistance shall not be less than 100 mega ohms.

b) Trip test & protection test.

Note: Each panel shall be displayed with feeder name plate.

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Tech. Spec. No. : RVNL/ Elect/GS/09

MEDIUM VOLTAGE

FEEDER PILLAR &

SWITCH BOARD

(OTHER THAN SUB- STATION WORK)

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CHAPTER: A-9

Tech. Spec. No. RVNL/ Elect/GS/09

MEDIUM VOLTAGE FEEDER PILLAR & SWITCH BOARD (OTHER THAN SUB- STATION WORK)

9.1 Feeder Pillar 9.1.1 General

a) Medium voltage feeder pillar shall be cubicle type, floor mounted, free standing type, dust and vermin proof, totally enclosed, of uniform height and for outdoor utilization and suitable for 3–phase, 4 wire, 415 V, 500 Hz AC, solidly earthed neutral, electric supply system complete with 4 nos. pedestals, accessories, inter-connections, bus bar chamber with copper/aluminium bus bar (as specified in the relevant BOQ item), ON/OFF indication, CTs, switchgears ( as specified in the relevant BOQ item), timer etc. in position duly wired up with copper conductor cable with colour coding, etc. and other accessories though not mentioned here but necessary to complete the equipment in all respects.

b) The manufacturer shall have ISO: 9001 certification with testing arrangement and powder coating facilities in the works.

9.1.2 Digital Time switch (Timer) of suitable rating and contactors (as specified in the relevant

BOQ item) shall be provided in the feeder pillar to operate pump/street lights etc. and this shall be controlled with independent switchgear/s.

9.1.3 Construction 9.1.3.1 The feeder Pillar shall be fabricated from 2.0 mm thick CRCA sheet steel. The shroud &

partitions shall be of minimum 1.6 mm thickness and shall be fabricated from CRCA sheet steel. The feeder pillar shall be powder coated in approved shade by seven tank process. The degree of protection shall not be less than IP 54 as per IS: 13942/Pt.1.

9.1.3.2 Pedestals and base frame shall be of MS angle of 75mm x 75mmx 8 mm (nominal size).

The Feeder Pillar shall have the provision of flush doors on front and back in two equal parts with hinges and concealed lock openable with special key.

9.1.3.3 The following minimum clearances shall be maintained:

i) Between Phases - 32 mm ii) Between Phases & Neutral - 26 mm iii) Between Phases & Earth - 26 mm iv) Between Neutral & Earth - 26 mm

9.1.3.4All functional units shall be arranged in multi-tier formation & each such unit shall be fully compartmentalized. Vertical cable alley shall be provided. Each compartment shall have its own individual door with concealed hinges & the door shall have interlocking so that it can only be opened after switching off the module.

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9.1.4 Bus Bars 9.1.4.1The bus bars shall be made of high conductivity aluminium/copper (as specified in BOQ)

conforming to the requirement of IS 5082/1998 for aluminium and IS: 1897/1983 for copper. The bus bars shall have uniform cross section (basis of bus bar cross section will be maximum of 1000 A/sq. inch for copper and 630A/sq. inch for aluminium). The cross-section of the neutral bus bar shall be same as that of the phase bus bar for bus bars of capacity up to 200 Amp. For higher capacities, the neutral bus bar shall not be less than half (50 %) the cross-section of that of the phase bus bars.

9.1.4.2 Bus bars shall be supported on suitable non-hygroscopic, non- combustible, material such

as DMC/SMC. 9.1.4.3 Bus bars shall be insulated with PVC tapes/ tubes (heat shrink type) with colour coding

(Red/Yellow/Blue/ Black) to withstand the test voltage of 2.5 kV for one minute. 9.1.5 Molded Case Circuit Breakers (MCCB) 9.1.5.1 MCCB shall be TPN of rating as specified in the relevant BOQitem and shall conform to IS-

13947/Pt-2/1993 (Ics = 100%Icuor as specified in relevant BOQ item) with thermal release setting 70/80%-100% or fixed type (as specified in the relevant BOQ item) with breaking capacity of not less than 25 kA for load currents up to 200 amp. & 35 kA for load currents above 200 amp rating. MCCBs shall be suitable for three phase, 415 Volt, AC supply.

9.1.5.2 Tripping unit shall be of thermal – magnetic type provided in each pole and connected by a

common trip bar such that tripping of any one pole operates all the poles and they open simultaneously.

9.1.6 Fuse Switch/ Switch Fuse Unit

Fuse switch/switch fuse unit shall be heavy duty, TPN double break of rating (as specified in the relevant BOQ item), utilization category AC 23, conforming to IS: 13947/Pt. III/1993 with 3 HRC fuses conforming to relevant IS and one neutral link

9.1.7 Current Transformers 9.1.7.1Current transformers shall be in conformity with IS: 2705 (Part I, II & III). Current

transformers shall be rated for 1 kV. Current Transformer shall have rated primary current, rated burden and class of accuracy. The rated secondary current shall be 5 A. The acceptable minimum class of various applications shall be as given below: Measuring : Class 1 Protection : Class 5 P10.

9.1.7.2The VA rating of the CTs shall be not less than 5 VA. 9.1.8 Cable Termination 9.1.8.1 Cable entries shall be provided with metal glands to prevent damage to the insulation of the

cable and terminals shall be provided to suite the number, type and size of aluminium conductor power cables.

9.1.8.2 Provision shall be made for bottom entry of cables through removable gland plates. 9.1.9 Tests at Manufacturers’ Works 9.1.9.1 All routine tests shall be carried out in the presence of the inspecting Engineer. 9.1.9.2 Original test certificates of all equipments/ instrument shall be submitted by the contractor

along with the supply of panel board after the Inspecting Officer passes the feeder pillar.

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9.1.10 Testing and Commissioning at Site

Following tests shall be carried out prior to Commissioning: a) Insulation test b) Trip Tests & Protection Tests

9.1.11 Erection

Brick masonry platform of suitable size with 450 mm height (approximate) shall be constructed in the specified location and cement finish. Feeder pillar shall be erected on this platform by grouting of pedestals as approved by the Engineer.

9.2 SWITCH BOARD 9.2.1 General

a) Medium voltage switch board shall be cubicle type, floor mounted, free standing type, dust and vermin proof, totally enclosed, of uniform height and for indoor utilization and suitable for 3- phase, 4 wire, 415 V, 50 Hz Ac, solidly earthed neutral, electric supply system complete with accessories, inter connections, bus bar chamber with copper/ aluminium bus bar (as specified in the relevant BOQ item), ON/OFF indication, CTs, switchgears (as specified in the relevant BOQ item) timer etc. in position duly wired up with copper conductor cable with colour coding and other accessories though not mentioned here but necessary to complete the equipment in all respects.

b) The switch board manufacturer shall have ISO: 9001 certification with testing and powder coating facilities in the works.

9.2.2 Digital time switch (Timer) of suitable rating and contactors (as specified relevant BOQ item) shall be provided in the panel to operate pump/street lights etc. and shall be controlled with independent switchgear/s.

9.2.3 Construction 9.2.3.1 The panel shall be fabricated fro 2.0 mm thick CRCA sheet steel. The shroud & partitions

shall be minimum 1.6 mm thickness and shall be fabricated from CRCA sheet steel. The panel shall be powder coated in approved shade by seven-tank process. The degree of protection shall not be less than IP 42 as per IS: 13942/Pt.1.

The following minimum clearances shall be maintained: i) Between Phases - 32 mm ii) Between Phases & Neutral - 26 mm iii) Between Phases & Earth - 26 mm iv) Between Neutral & Earth - 26 mm

9.2.3.3 All functional units shall be arranged in multi-tier formation & each such unit shall be fully compartmentalized. Vertical cable alley shall be provided. Each compartment shall have its own individual door with concealed hinges & the door shall have interlocking so that it can only be opened after switching off the module.

9.2.4 Bus Bars 9.2.4.1The bus bars shall be made of high conductivity aluminium/copper (as specified in BOQ)

conforming to the requirement of IS 5082/1998 for aluminium and IS: 1897/1983 for copper. The bus bars shall have uniform cross section ( basis of bus bar cross section will be maximum of 1000 A/sq. inch for copper and 630A/sq. inch for aluminium). The cross-section of the neutral bus bar shall be same as that of the phase bus bar for bus bars of capacity up to 200 Amp. For higher capacities, the neutral bus bar shall not be less than half (50 %) the cross-section of that of the phase bus bars.

9.2.4.2Bus bars shall be supported on suitable non-hygroscopic, non- combustible, material such as

DMC/SMC.

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9.2.4.3 Bus bars shall be insulated with PVC tapes/ tubes (heat shrink type)with colour coding (Red/Yellow/Blue/ Black) to withstand the test voltage of 2.5 kV for one minute.

9.2.5 Molded Case Circuit Breakers (MCCB) 9.2.5.1 MCCB shall be TPN of rating as specified in the relevant BOQitem and shall conform to IS-

13947/Pt-2/1993 (Ics = 100%Icuor as specified in the relevant BOQ item) with thermal release setting 70/80%-100% or fixed type as specified in the relevant BOQ item) with breaking capacity of not less than 25 kA for load currents up to 200 amp. & 35 kA for load currents above 200 amp rating. MCCBs shall be suitable for three phase, 415 Volt, AC supply.

9.2.5.2 Tripping unit shall be of thermal – magnetic type provided in each pole and connected by a

common trip bar such that tripping of any one pole operates all the poles and they open simultaneously.

9.2.6 Fuse Switch/ Switch Fuse Unit

Fuse switch/switch fuse unit shall be heavy duty, TPN double break of rating (as specified in the relevant BOQ item), utilization category AC 23, conforming to IS: 13947/Pt. III/1993 with 3 HRC fuses conforming to relevant IS and one neutral link

9.2.7 Current Transformers 9.2.7.1 Current transformers shall be in conformity with IS: 2705 (Part I, II & III). Current

transformers shall be rated for 1 kV. Current Transformer shall have rated primary current, rated burden and class of accuracy. The rated secondary current shall be 5 A. The acceptable minimum class of various applications shall be as given below: Measuring : Class 1 Protection : Class 5 P10.

9.2.7.2 The VA rating of the CTs shall be not less than 5 VA. 9.2.8 Cable Termination

9.2.8.1 Cable entries shall be provided with metal glands to prevent damage to the insulation of the cable and terminals shall be provided to suite the number, type and size of aluminium conductor power cables.

9.2.8.2 Provision shall be made from bottom for entry of cables through removable gland plates. 9.2.9 Tests at Manufacturers’ Works 9.2.9.1 All routine tests shall be carried out in the presence of the inspecting Engineer. 9.2.9.2 Original test certificates of all equipments/ instrument shall be submitted by the contractor

along with the supply of panel board after the Inspecting Officer passes the feeder pillar.

9.2.10 Testing and Commissioning at Site Following tests shall be carried out prior to Commissioning: a) Insulation test b) Trip Tests & Protection Tests

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Tech. Spec. No- RVNL/ ELECT/GS/10

DISTRIBUTION BOARD

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CHAPTER:A-10


DISTRIBUTION BOARD 10.0 GENERAL

a) Distribution boards for power and light circuit distribution shall be pre-wired, factory built, duty powder coated and complete with copper bus bars, MCB/MCCB/RCBO/RCCB etc. (as specified in the relevant BOQ item) and shall be suitable for 415 V, 3 – phase or 230 V, single-phase supply (as per BOQ item). The distribution boards shall conform to IS: 8623 and IS: 13032 as applicable

b) However, if none of the types readily available from the approved makes meets the requirements, alternative makes may be offered with technical literature and test certificates, for approval of the Engineer.

c) Separate distribution board shall be provided for light and power circuits in quarters of category Type- IV and above & in service buildings, as approved by the Engineer.

10.1 Type

The Distribution Board shall be single/double door type (as specified in the relevant BOQ item) suitable for flush installation. The boards shall be of cabinet design, totally enclosed and shall have a degree of protection not less than IP42 (indoor type) and IP54(outdoor type) as per IS: 13947/Part1/1993.

10.2 Miniature Circuit Breakers (MCB)

10.2.1 Miniature Circuit Breakers for lighting circuits shall be of “B” series and for inductive loads shall be of “C” series. Circuits feeding discharge lamps (HPMV/MH/HPSV) halogen lamps, all power outlet points, equipment/machinery shall be of “C” series (Motor Circuit) type. All miniature circuit breakers shall be of 10 KA rated rupturing capacity unless otherwise specified. MCBs shall generally conform to IS: 8828. They shall be suitable for snap fixing on a standard DIN rail.

10.2.2 Three phase MCBs shall have common trip bar so that all the poles make and break

simultaneously. Miniature circuit breakers shall be quick make & quick break type with trip free mechanism. They shall have thermal & magnetic short circuit protection.

10.3 Residual Current Circuit Breakers (RCCB), Residual Current Circuit Breaker with

Overload, short circuit & earth leakage Protection (RCBO) 10.3.1 RCCB/RCBO shall be used in distribution boards as per BOQ item. The RCCB/ RCBO shall be

rated for 30/100/300 mA fault circuit tripping as specified in the relevant BOQ item or as per site requirement. RCCB and RCBO shall conform to relevant IS.

10.4 Molded Case Circuit Breakers (MCCB)

MCCB shall be TPN and of rating as specified in the relevant BOQ item. It shall conform to IS: 13947/Pt-3/1993(Ics-100% Icu) with thermal release (fixed type) and breaking capacity of not less than 25 KA. MCCBs shall be suitable for 3-phase, 415 V, AC supply.

10.4.1 Tripping unit shall be of thermal-magnetic type provided in each pole and connected by a common trip bar such that tripping of any one pole results in simultaneous operation of all the poles.

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Tech. Spec. No.-RVNL/Elect/GS/11

EARTHING SYSTEM

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CHAPTER-11 Tech. Spec. No.-RVNL/Elect/GS/11

EARTHING SYSTEM

11.0 GENERAL The earth system shall conform to IS: 3043 and as per approved drawing of the Zonal Railway.

Types of earth systems: a) Pipe Earth Electrode: Shall be normally provided for earthing of installations other than

sub-station equipments. b) Plate Earth Electrode : Shall be normally provided for earthing of sub-station equipments. 11.1 Pipe Electrode Earth System 11.1.1 The earth electrode shall be made of G.I. pipe of 50 mm dia, medium class (class B)

conforming to relevant IS. It shall be 3.0 meter long and tapered at the lower end. The pipe shall be drilled with 12 mm dia. holes at intervals of 75 mm from each other, up to 2.0 meter from the bottom end.

11.1.2 The pipe electrode shall be buried in the ground vertically with its top nearly 200 mm below

the top of the enclosure. 11.1.3 A funnel with mesh shall be provided on top of this pipe for watering. Funnel attachment shall

be housed in the masonry enclosure. 11.1.4 The top of pipe electrode shall be housed in a masonry enclosure (finished) of not less than

400mm x 400 mmx300mm (internal size). The covers of the masonry enclosures shall be of concrete with handle for lifting. 11.1.5 Normally an earth electrode shall not be situated less than 1.5m from any building. Care shall

be taken that the excavation for the earth electrode may not affect the column footings or foundations of the building. In such cases, the electrode may be located further away from building. The location of earth shall be such that the soil has reasonable chances of remaining moist. Building entrances, pavements, roads etc. shall be avoided for location of earth electrodes.

11.1.6 Earth resistance shall be reduced by artificial chemical treatment of the soil with sodium

chloride (common salt) mixed with soft coke or charcoal in suitable proportion in layers of 150mm. When this treatment is resorted to, the electrode shall be surrounded by the mixture of charcoal/coke and salt.

11.1.7 The earth lead from earth electrode to equipment/pole/main switch etc. shall be of GI wire of

size (8 SWG or 25mm X 4mm GI strip). The earth lead for LT panel/feeder pillars shall be of GI strip of size (25mm X 4mm GI strip). Earthing of internal wiring (point wiring, power plug wiring, SDB etc) shall be done by means of PVC sheathed copper wire of same size as that of wire used for relevant point wiring.

11.1.8 Earth lead shall be connected to pipe earth electrode by means of galvanized bolts, nuts,

washers & cable sockets.

11.1.9 All materials used for connecting the earth lead with electrode shall be of GI.

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11.1.10 The earth lead shall be securely connected at the other end i.e. main board/pole/structure/equipment/feeder pillar etc. with nuts, bolts, washers etc.

11.1.11 The earth lead from electrode shall be suitably protected from mechanical injury and shall be buried in ground at minimum 300mm depth when located outdoors. The portion within the building shall be recessed in walls/floors at adequate depth.

11.1.12 No earth electrode shall have resistance greater than 5 ohms. In rocky soil, the resistance

may be up to 8 ohms. 11.1.13 Locations having more than one electrode shall be connected in parallel to reduce the

resistance. 11.1.14 In locations where the full length of pipe electrode is not possible to be installed due to

meeting a water table, hard soil or rock, the electrode may be of reduced length, provided the required earth resistance result is achieved with or without additional electrodes, or any alternative method of earthing may be adopted, with the prior approval of the Engineer-in-charge.

11.2 PLATE EARTH ELECTRODE

a) Substation equipments shall be earthed using Plate Earth Electrode. Metallic frame of all equipments such as transformers, HT/LT switchgears/DG sets etc. shall be earthed at two distinct points with GI Plate earth electrodes and neutral points of the transformer/s and DG set/s shall be earthed at two distinct points with copper plate electrodes.

b) Electrodes shall be connected in parallel to minimize resistance.

11.2.1 G.I. Plate Earth Electrode

For earthing HT/LT equipments/DG sets, GI plate earth. Electrode shall be 600mmx 600mmx6mm thick and shall be held vertical in ground with its top not less than 3.0 m below ground level. The earth plate shall be embedded in alternate layers of coke and salt of 150mm thickness so as to avail earth resistance not greater than 1.0 ohm.

11.2.2 A watering pipe of 20mm dia of medium class GI pipe shall be provided and attached to the electrode. A funnel with mesh shall be provided on top of this pipe for watering the earth. The watering funnel attachment shall be housed in masonry enclosure of not less than 40cm x 40 cmx30 cm inner size and shall be provided with hinged MS sheet/CI plate 10 mm thick and having locking arrangement.

11.2.3 One end of GI earth strip of size 40mmx6mm or as specified in the relevant BOQ item shall be securely bolted on the GI earth plate with two bolts, nuts, check nuts and washers, all CADMIUM PLATED. Other end shall be brought above ground level vertically. The portion of this strip that runs in ground shall be buried 500 mm below ground level to guard against mechanical damage. The portion within the building shall be recessed in walls/floors at adequate depth.

11.2.4 The strip shall be connected to the earth terminals of various HT/LT equipments/DG sets etc.

by means of cadmium plated nuts, bolts and washers.

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11.3 Copper Plate Earth Electrode 11.3.1 For earthing of neutral of transformers/DG sets, 600mm x600mmx3mm thick copper plate

earth electrode shall be held vertical in ground with its top not less than 3.0 m below ground level. The earth plate is embedded in alternate layers of coke and salt of 150mm layers each, to avail earth resistance less not greater than 1.0 ohm.

11.3.2 A watering pipe of 20mm dia of medium class GI pipe shall be provided and attached to the electrodes. A funnel with mesh shall be provided on top on this pipe for watering the earth. The watering funnel attachment shall be housed in masonry enclosure of not less than 400 mm x 400mm x300mm inner size and shall be provided with hinged MS sheet/CI plate 10mm thick and having locking arrangement.

11.3.3 One end of copper strip of size 40x5mm or as specified in the relevant BOQ item shall be securely bolted on the copper earth plate by means of two nos. of tinned brass bolts, nuts, check nuts and washers as required. Other end shall be brought above ground level vertically through GI pipe of 50 mm dia. or as specified in the relevant BOQ item. The portion of this strip that runs in the ground shall be taken through medium class GI pipe 50 mm dia or as specified in the relevant BOQ item, buried 500 mm under ground level to guard against mechanical damage. The portion within the building shall be recessed in walls/floors at adequate depth.

11.3.4 The strip shall be connected to the neutral terminals of transformer/DG set by means of tinned brass bolts, nuts and washers, as required. To bring down the earth resistance, every earth electrode shall be surrounded by charcoal and salt.

11.4 Every individual earth electrode shall be allotted a serial number and an earth plate of size

10x22 cm of 14 SWG sheet steel (painted black) fixed in a conspicuous position near the earth. The following information shall be displayed with white or yellow paint on the earth plate.

i) Earth No………………………………. ii) Individual earth resistance…………….ohms. iii) Overall earth resistance…………………ohms. iv) Date of testing……………………………….. 11.5 The following tests shall be carried out before the installation is commissioned. i) Earth resistance test. ii) Earth continuity test.

11.6 Materials and Sizes of Earth Electrodes

Type of Electrode Material Size

Pipe GI medium class 50 mm dia 3.0 m long (without any joint)

Plate (i) GI

(ii) Copper

60 cm x 60 cm x 6 mm thick

60 cm x 60 cm x 3 mm thick Strip (i) GI

(ii) Copper 40X6 mm section

40X5 mm section Conductor 4 mm dia (8 SWG)

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ELECTRICAL DRIVEN

SUBMERSIBLE PUMPS

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CHAPTER:A-12


ELECTRICALLY DRIVEN SUBMERSIBLE PUMPS

12.0 System of Supply The pump shall be, suitable to operate on single phase, 230V or 3-phase, 415 V, (+/- 10%), 50

Hz, AC supply system depending upon rating. 12.1 General Requirements Electrically driven submersible pump set shall be ISI marked and star rated multi-stage,

suitable for operation in the specified diameter of bore well and capable of continuously pumping clear water at specified capacity at the indicated head. Pump set shall be of 2900 rpm (nominal) submersible electrical motor, suitable to operate on 415 V, 3 –phase, 50 Hz, AC supply system equipped with integral non-return valve and all necessary accessories for the application, whether specifically stated or not.

12.2 Pump The Pump shall be of centrifugal type, fitted with multistage impellers, generally conforming to

IS: 8034/2002, suitable for trouble free operation in the bore well when submerged and capable of easy installation in bore hole without damage to bore hole lining.

12.2.1 The pump shall be constructed with casing of high-grade cast iron of sufficient strength and hardness for long lasting. Impellers shall be manufactured from high quality bronze and shall be dynamically balanced. The shaft of the impeller shall be of hardened stainless steel for long life. The impeller guide vanes and diffusers shall be of suitable design with special emphasis to improve the efficiency of the pump.

12.2.2 The material used in all the parts of the pump and casing shall be suitable to withstand corrosive action of the liquid to be handled by the pump and shall be designed for long service.

12.2.3 All bearings/bushes used in the pumps shall be of water lubricating, high loading capacity, synthetic thrust type. The sleeve bearings shall be of special lead bronze having a high bearing load capacity.

12.2.4 The pump shall be complete with a suitable brass strainer at the suction side to prevent any hard material from entering the pump.

12.3 Motor

12.3.1 The motor shall be squirrel cage type induction motor, suitable for operation with the pump, capable of running on 230V, single phase or 415 V, 3 phase, 4 wire, 50 Hz, Ac supply system(as specified). The motor shall be suitably rated to withstand any overload due to higher discharge at a lower head and reduction in head up to 25 % of the specified head without getting over loaded.

12.3.2 The motor shall be of “wet type” according to manufacturer’s standard design and generally conforming to IS: 325.

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12.3.3The casing shall be of stainless steel, tube treated, so as to prevent corrosion and rust during service. The starter winding shall be provided with one-ageing, waterproof, dense synthetic molecular insulation so as to resist the environmental chemical influence and shall have extremely high percussion strength.

12.3.4 The motor shall be assembled on hardened stainless steel shaft and supported on antifriction thrust bearings of synthetic molecular insulation. The sleeve bearings shall be of special bronze make. All the end thrust bearings shall be constructed from such material as to ensured trouble free service and be water lubricated.

12.3.5 The motor shaft shall be fitted with synthetic rubber sealing rings and sand guard to prevent sand and impurities from entering the motor. The motor shall be directly coupled to the pump and shall be provided with a suitable device to prevent uncoupling when the motor is started occasionally in the wrong direction.

12.3.6 The motor shall be equipped with suitable compensative device in order to protect the water inside the motor from getting mixed up with well water which may contain some quantity of sand etc. In the event of slight expansion of water inside the motor, the device shall give a spongy action, to accommodate it and return to normal when the motor is not working.

12.3.7 The electrical cable shall be connected to the motor by means of perfectly watertight sealing gland, to prevent water from entering the motor. The cable shall be protected by a strong cable guard plate. Waterproof cable of suitable size and length shall be supplied.

12.4 Control Panel The control panel shall be wall mounted, cubicle type suitable for outdoor weather proof

application with proper gasketing, complete with incomer TPN MCB 10 KA of suitable capacity, starter, single phase preventer, accessories, internal connections with copper conductor cable etc. and fabricated from 16 SWG CRCA sheet steel duly powder coated. Base plate shall be detachable with cable gland/s. Panel shall be earthed with separate earth suitably.

12.4.1 Starter

The starter for the motor shall be push button operated type with under voltage and over load release for direct on line starting and conforming to IS: 8544.

12.4.2 Indicator lamps for input supply for each phase, output supply

12.4.3 Suitable ammeter and voltmeter for each phase shall be provided.

12.4.4 Suitable electronic/microcontroller based motor protection relay with over/under voltage protection, phase sequence, locked rotor, earth fault, over current protection, dry run protection, single phase preventor, suitable timer control and measurement for running time of pump.

12.5 Accessories

12.5.1 The submersible pump shall be supplied with the following accessories: (a) Non-return valve streamlined for minimum friction and integral in each pump set. The

cone of the valve shall be fully quoted on the periphery valve seating shall be renewable rubber ring type.

(b) Pressure gauge of suitable size and graduated in kg/sq.cm on the delivery side. (c) The pump shall be supplied along with the test certificates and catalogue etc. issued by

manufacturer.

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12.6 Pump and control panel should be suitably provided with two independent earthing system.

12.7 Foundation/Plinth for Centrifugal pumps Centrifugal pumps set with motor shall be fixed on the proper designed plinth as specified by OEM or as per approved drawing.

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Tech. Spec. No. –RVNL/Elect/GS/13

POWER DISTRIBUTION TRANSFORMER

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CHAPTER:A-13

Technical Specification No.–RVNL/Elect/GS/13 POWER DISTRIBUTION TRANSFORMER

13.0 General The transformer shall be suitable for operation in tropical climate and for mixed load and for

continuous operation. It shall be natural cooled, outdoor/indoor type (as specified in the relevant BOQ item) and star rated. The PF at full load shall not be less than 0.8 lagging. It Distribution transformers shall conform to IS: 2026 ( Pt. I to Pt. IV)/1997 for more than 100 KVA rating and IS:1180 upto 100 KVA rating. The efficiency of the transformer shall not be less than 98% at full load. It shall be supplied with first filling of inhibited mineral oil conforming to IS: 12463-1988 capable of withstanding 50 kV (rms) voltage as per IS: 6792/1972.

13.1 Vector Group The vector group shall be DYN 11. 13.2 Tapping An externally operated, off load tap changer with suitable tap indicator and mechanical locking

device shall be provided for giving +/- 5% in steps of 2.5 % each on HT side or as specified in the BOQ. The rated KVA of the transformer shall not be less than the rated capacity of the transformer on extreme tapping positions.

13.3 Parallel Operation The transformers shall be capable of operating in parallel. 13.4 TRANSFORMER CORE: The transformer core shall be built up of cold rolled grain oriented plain strip laminations fully

processed and stress relieved and annealed having low loss and good ageing characteristics. The laminations may be bolted together and the whole core fixed through bolts to the steel frame adequate dimensions or also the construction may be tie rod type but in either case, the design should be such that it prevents undue vibrations and noise in service. Wooden frame for core fixing is not acceptable and contractor offer shall be specific about this.

The transformer shall be suitable for ever fluxing due to the combined effect of voltage and frequency upto 12.5% on any tap without injurious heating. The maximum working flux density at point shall not exceed 19000 lines per square centimeter on the basis M4 and M6 grade.

13.5 WINDINGS: The winding shall be with double copper wound delta connected on primary, star with neutral

brought out for earthing purpose on secondary. The copper wires conforming to IS 7404 (Part 1 and 2)/1974 or the latest version for paper covered conductors shall be used for HV and LV coils. The insulation of the conductors of the HV as well as LV coil shall be double paper coverage (DPC).The vector group unless other wise stated in the appendix 'A', shall be DY 11.

Class of insulation for winding shall be 'A' class. The LV wiring shall be circular and concentric with HV winding on the outside. Vertical duct shall

be provided for both HV and LV windings. The arrangements of the windings must be such that there is no electrical and magnetic balance under conditions of operation. The design shall permit free circulation of oil to ensure absence of hot posts. All similar coils shall be inter-changeable. It is essential that the windings are subjected to a thorough shrinking and seasoning process during manufacture so that no further shrinkage of windings occur during early years of service. Adjustable screws shall be provided for taking up possible shrinkage of

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windings after a number of years of service. The general design and construction of transformer and bracings of the windings shall be such that no mechanical movements of the coils will be possible a dead shot on either sides of the transformer. The short circuit ratings of the transformer shall be as per relevant clause of IS 2026/1977 or latest. The clearance between windings/live parts and nearest earthed parts shall be adequate for sustained voltage of 110% of the rated operating voltage. The clearance between LT bushing internal terminal windings and cord shall be adequate so as to facilitate interposing of protective element if required.

13.6 TERMINAL ARRANGEMENTS:

a) For out door type transformers: Bushing terminals shall be on HV side and cable end box on LV side.

b) For in door type transformers following arrangement shall be provided. HV side: A trifurcating box for three core XLPE Cable suitable size and voltage. LV side: A Cable box of suitable size and voltage to take a four core LT Cable.

13.7 TANK:

The transformer tank shall be rectangular and shall be fabricated with tested MS plates of not less than 5mm thickness at sides top and bottom suitably reinforced and stiffened with ribs etc. All joints of the transformer tank shall be welded both inside and outside in such a way that they are fully hot oil type and such that no bulging occurs during service. The tank plates shall be of such strength that the complete transformer filled with oil can be lifted bodily by means of lifting lugs provided on the tank and the lifting lugs should be of adequate strength to cater for this. This tank design shall be such that core and the windings can be lifted together freely out of the tank with minimum dismantling.

The tank cover shall also be provided with suitable lifting lugs. The tank cover and bushing joints shall be provided with superior quality oil resistant gaskets to render the tank full watertight. In case of outdoor transformers, the cover design shall be such that rain water drains out automatically. The cooling arrangement whether with circular or electrical tubes or with radiators offered for the transformer shall be indicated in Appendix 'B'.

13.8 CONSERVATOR:

Conservator with its oil gauge filling and drain plugs breather shall be fixed to the transformer tank cover. Air release device on the tank cover is necessary unless the conservator is so located has to eliminate the possibility of air being trapped within the main time. Necessary quantity of transformer oil sufficient for the transformers shall be filled along with the transformer.

13.9 FINISH

The exterior of transformer tank and outer ferrous fitting shall be thoroughly cleaned, scrapped and given a primary coat and two finishing coats of durable oil and weather resistance enamel paint. The colour coats shall be dark admiral gray conforming to No.63 of IS 5/1961 for colours for ready mixed paints or its latest version.

13.10 Provision of Additional Fittings

The transformers shall be provided with following additional fittings in addition to those specified in IS-2026: (a) Rollers (b) Explosion vent. (c) Thermometer –dial Type. (d) Inspection covers

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13.11 Tests 13.11.1 Routine Test

Tests as per Clause 16.1.2 of IS: 2026 (Pt.1)/1977 shall be witnessed at manufacturer’s works by the nominated Inspecting Officer.

13.11.2 Type Test Type Test certificates for similar transformer (same voltage class and same rating) as per IS: 2026 (Pt.I)/1997 shall be furnished. A copy of the short circuit test as per Clause 16.11 of IS: 2026 (Pt.I) /1977, successfully carried out on similar transformers (same voltage class and same rating, shall be supplied to the Inspecting Officer.

13.12 Earthing The star point on the low voltage side shall be brought out for solid earthing with copper plate using copper strip of suitable length as per earthing specifications enclosed. Transformer body shall also be provided with independent earthing system other than star point as specified in earthing specification enclosed.

13.13 Installation

Installation of transformers shall be done as per IS 10028 (Pt. II/1981). Suitable concrete work for foundation or mounting arrangements on pole shall be done as directed by engineer for erection of transformer.

13.14 Parameters for acceptance/rejection of transformers shall be as under:

ACCEPTANCE/ REJECTION PARAMETERS

SN IS Clause No. Acceptance Limits Rejection Limits 1 4.3.1/2026 (Pt. I)

(Operation at other than rated voltage)

Limits within +/- 10 % of rated voltage of particular tapping.

Limits exceeding +/- 10 % of rated voltage of particular tapping

2 3.2/2026(Pt.II)(Temperature rise)

Limits as specified in Clause 3.2/IS2026 (Pt II)

Exceeding Limits as specified in Clause 3.2 of IS2026(Pt. II)

3 Table 3.2026 (Pt. I) ( Impedance voltage)

i) 4.5% up to 630 kVA ii) 5% above 630 kVA upto and including 1000 kVA

Exceeding limits i) 4.5% up to 630 kVA ii) 5% above 630 kVA up to and including 1000 kVA

4 8.1.6/2026(Pt.I) (Tap changing equipment)

Limits as specified in Clause 3.2/IS:2026 (Pt. II)

Less than Limits as specified in Clause 3.2/IS:2026 (Pt. II)

5 9.1.3/2026 (Pt. I) (duration of symmetrical short circuit current)

2 seconds Period less than 2 seconds.

6. Table 7/2026(Pt. I) (Tolerances)

As specified in Table-7 Limits exceeding as specified in Table- 7

13.15 Technical Specifications of Transformar Summary:

a Particulars of a specification to Which the transformer should confirm

IS 2026 (Part 'A' to IV 1977or its latest version if any

b No. of transformers required As per BOQ

C Type of transformer Double wound, core type

d Single or polyphase unit Polyphase unit

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e No. of phases in system Three

f Frequency 50 Hz +/- 3%

g Type of insulating and cooling medium Inhibited Mineral oil to IS 12463:1988 with latest amndts.

h Service Outdoor

i Type of cooling Natural, oil cooled (ON) or as specified by purchase/Supply order

j Rated KVA on normal tapping (the figures given are preferred ratings

As per BOQ

k

i

Normal HV supply voltage 11000 volts phase to phase +/- 10%

l

i

No load voltage ratio at normal tap 11000/433 volts

m Tapings required +/- 2 1/2 , 5, 7 1/2 , 10% tapping on HV side

n Type of tapping switch OFF 3/4 load type with locking arrangements

o Method of system earthing Solid earthing of neutral p Material of winding conductors Copper wire IS 7404 (Part I & II) / 1974

q Insulation of winding conductors Double paper covering (DPC)

r Winding connection HV delta LV: Star

s Vector reference DY.11 t Terminal arrangements

i) For indoor type transformers Suitably marked cable boxes with 3 terminals on HV side and 4 on LV side with neutral brought out for earthing

ii) For outdoor type transformers 3 bushings on HV side and 4 bushings on LV side suitably marked

Note: a) Rods, nuts, washers etc. of all HV and LV bushing must be of brass only. b) All bushings shall conform to IS 2099/1973 or its latest version. 13.16 Foundation and Fencing

Suitable foundation, fencing for the transformer shall be provided as specified in the BOQ. The

typical details for foundation and fencing (wherever required) shall be as under:

(i) Foundation M10 type foundation shall be constructed with 20mm coarse aggregate. The size of foundation shall be as per the approved drawing based on Transformer dimensions but shall not be less than 2 x1.5mt Length x breadthX 600mm (height above ground level) duly plastered and finished surface. Curing shall be done as per code applicable. Excavation shall be done complying with Code of Safety as per IS 3764/1992(Latest Version).

(ii) Fencing Fabrication of enclosure for housing transformer shall be made in rectangular formation as required with M.S. angle iron 50x50x8mm spaced at about 2 meters and 12 SWG GI wire. The design of the fencing panel shall be as approved by RVNL. MS strip not less than 15x3mm size shall be provided and welded above the GI wire along the angle frame to hold the GI wire mesh. Height of enclosure shall be 2 meter above ground level. The portion of MS angle to be grouted in foundation shall be 500mm.

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The fencing panels shall be erected on foundation constructed of size 200mmx200mmx500mm deep with cement concrete M10 grade.

(iii) Iron gate: Iron gate shall be fabricated with M.S. angle 50x50x8mm iron frame with iron

grill etc as approved. The size of the gate shall be 2.0 m height X 3.5 m width and fabricated in two parts of aprox size 1.75m each. Gate shall be provided with suitable sliding lock with padlock. Gate shall be fixed on channels of size not less than 100 X 50 mm (weight 7.90 kg/m). Channels shall be erected on foundation constructed of size 300mm X 500mm deep with M10 grade cement concrete.

(iv) Painting: MS portions of enclosure (fencing and gate etc) shall be painted with two coats of red oxide primer and two coats of enamel paint of approved shade.

(vi) Approval of Drawing of Enclosure: Drawing of the enclosure with gate etc shall be got approved from the Engineer prior to start of the work.

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Tech. Spec. No. RVNL/ Elect./ GS/14

WATER COOLED SILENT DIESEL ENGINE DRIVEN ALTERNATOR SET WITH AMF PANEL

(30 KVA AND ABOVE UP TO 500 KVA)

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CHAPTER:A-14

Technical Specification No.RVNL/ Elect./ GS/14

WATER COOLED SILENT DIESEL ENGINE DRIVEN ALTERNATOR SET WITH AMF PANEL

(30 KVA AND ABOVE UP TO 500 KVA) 14 General 14.1 The DG set shall work as a single unit for catering to mixed load comprising electrical power

and for charging battery, average power factor of load being 0.8 (lagging). The set shall be suitable for operation as per specified site conditions.

14.1 (a) Any equipment/accessory not specifically mentioned herein but essentially required for the equipment to meet the site requirement shall be deemed to be included in the DG set.

14.1 (b) All the equipments shall conform to the latest version of BIS Specifications including the following:

Indian Electricity Act 2003 & Rules framed there under. BS5514/IS10000- Internal Combustion Engine. BS2613/IS4722 – Electrical Performance of Rotating Electrical Machines BS1271- Classification of Insulating Materials. IS 13947 – Circuit Breakers.

14.2 Rated Power Output 14.2.1 The Diesel Generating Set shall be capable of delivering continuously (on 24 hours basis)

rated power output at 1500 rpm at site conditions and the engine shall conform to IS:10000/BS5514.

14.2.2 The diesel engine shall be capable for working on 10% over load for one hour in any 12 hours running.

14.3 Oil Engine The diesel engine shall be cold starting, vertical direct injection, 4 stroke cycle, water radiator

cooled, turbo-charged, electric battery start, directly coupled to the alternator, mounted on a combination base plate frame through a flexible coupling. A suitable extension pipe shall be used with exhaust air chest so that the silencer can be mounted.

14.4 A fuel tank for storing the fuel oil with a capacity corresponding to 12 hrs. consumption of the

DG set shall be provided. The fuel piping shall be free from leakage and air locks. The fuel tank shall be supplied with a level gauge to indicate the oil level in the tank and the tank shall be marked to indicate the quantity of diesel oil in the tank.

14.5 Fuel tank shall be in built within an acoustic enclosure OR separately provided at a higher level. 14.6 The engine shall be suitable to run on Diesel Fuel Oil grade ‘ A’ to IS: 1460/2005. 14.7 Governor The engine shall be supplied with an inbuilt electronic governor to maintain the engine speed at

varying loads. The governor shall conform to Class A-1 or G3 as per relevant BS/ IS specification.

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14.8 The engine shall be complete with standard accessories and protective devices including the following:

i) Heavy duty dry type air cleaner. ii) Radiator iii) Fan for Radiator iv) Lubricating Oil Filters. v) Fuel Oil Filters. vi) Fuel injection equipment with governor to control the engine speed up to +3%

under varying load conditions. vii) Engine speed control unit (manually operated). viii) Sump ix) Thermostat x) Safety control against low lubricating oil pressure, high cooling water temperature and

engine over speed. xi) Fly wheel to suite flexible coupling. xii) Exhaust silencer. xiii) Lube oil cooler and water pump. xiv) Fuel tank made of 14 SWG sheet with marking of 50 liter on clear transparent glass

gauge. xv) Corrosion Resistor. xvi) Self starter for electric start system with battery of adequate capacity with battery

charging alternator. (12V or 24V as per original equipment manufacturer recommendations).

xvii) Engine control panel comprising of: a) Oil pressure gauge. b) Water temperature gauge. c) Ammeter d) Hour meter with RPM indicator. e) Push buttons for starter/key switch starter. f) Pilot lamp g) Failure indicator. h) Battery Charging Indication. i) Magnetic pick up fail indication. j) HWT trip indication. k) LLOP trip indication. l) Over speed tripping cum indication.

xviii) Tool kit complete (as supplied by the engine and alternator manufacturers) xix) One set of foundation bolts with nuts. xx) O&M manual of diesel engine xxi) Spare parts catalogue of diesel engine. xxii) Original Test Certificates. 14.9 Silencer Unit

Silencer Unit shall be specially designed, heavy duty, residential type, low noise, meeting the sound pollution norms of Central Pollution Control Board (CBCB). The exhaust pipe shall be wrapped with asbestos/ mineral wool and aluminium cladding and exhaust discharge shall be designed in conformity with extant norms laid down by CPCB and local authority of the area.

14.10 Emission Related Parameters Emission Related Parameters shall be in accordance with extant norms laid down by CPCB and

local authority of the area.

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14.11 Alternator The alternator shall be self exciting, brush less, copper wound, self regulating with screen

protected enclosure, capable of generating 415 V, 3 phases, 4 wires, 50 Hz Ac supply ( with neutral point brought out) at 1500 RPM. The alternator shall conform to BS: 5000/IS: 4722 and the winding shall conform to class F insulation. The alternator shall be provided with Automatic Voltage Regulation (AVR) for regulating the output voltage within +/- 1% of the rated voltage from no load to full load and permissible over load of 10 % for one hour in 12 hours operation.

14.12 Automatic Main Failure Control Panel (AMF Panel) 14.12.1 General

a) Auto main failure unit shall be capable of starting the Diesel Generating set in the event of main power supply failure or low voltage below the specified value and changeover to load from main supply to DG set.

b) The DG set shall start automatically on full load current within 10 seconds of the supply

failure and on restoration of main supply shall stop within 3 minutes after making the changeover from DG set supply to main supply.

14.12.2 Constructional Features

The AMF panel shall be totally enclosed, made of mild steel of at least 14 SWG thick sheets, free standing, floor mounted type and totally enclosed with degree of protection not less than IP54. Front /Rear door of panel shall be hinged and locked. The cubical shall have powder coating of specified colour to give long lasting finish. Wiring circuit diagram of the AMF panel shall be affixed inside the cubical so that it is clearly visible when the front hinged panel is removed. All the switchgears, control devices, push buttons, indication lamps etc. shall be clearly labeled to indicate their operation. The wiring connections in the control panel shall be ferruled.

14.12.3 Protection and Control Equipments

The following control devices and equipments shall be suitably housed in the cubical: a) Multifunction electronic panel meter with display 1 set parameters – current, voltage, power factor, frequency, kW, kWh, maximum demand etc. b) Mode Selector Switch for OFF/ AUTO/ MANUALl/TEST 1 Set c) Push button for start/stop/acknowledge/reset 1 set d) A set of indication lamps for the following indications 1 Set

Load on mains Load on DG Set. Low lube-oil pressure. High coolant temperature.

e) Battery charger consisting of:

Transformer Rectifier DC Voltmeter Charging rate selector switch for trickle/booster charging. Pilot lamps to indicate that charger is working. On/off switch.

f) Main supply air break contactor, four pole, of rating as under and provided with

suitable HRC fuses for short circuit protection- 1 set.

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SN DG set Capacity Contactor Rating 1 82.5 KVA 4 pole contactors 250 amps. 2 160 KVA 4 pole contactors 400 amps 3 250 KVA 4 pole contactors 800 amps

g) Alternator (DG set) Air break contactor of rating as above shall be provided with separate overload relay for overload protection and provided with suitable HRC fuses for short circuit protection – 1 set. h) Main supply voltage monitor – 1 no. i) DG control relays & timer for start/stop/three attempt starting facilities and failure to start and lock. j) Audio alarm hooter in case of low lube-oil pressure, high coolant temperatures, DG set fails to start - 1 no. k) Earth fault relays to cut off the field supply of the alternator. l) Copper Bus bar of rating as under for phases and neutral on the basis of 1000 amp./sq. inch:

SN DG Set Capacity Bus bar for Phases Bus bar for Neutral 1 82.5 KVA 250 amps 200 amps 2 160 KVA 400 amps 200 amps 3 250 KVA 800 amps 400 amps

m) Incoming 4 pole MCCB of 50 kA as under:-

SN DG Set Capacity 4 pole MCCB ( Ics = 100% Icu) with thermal release

setting 70/80%-100% 1 82.5 KVA 160 amps 2 160 KVA 400 amps 3 250 KVA 800 amps

n) Provision shall be made to operate the DG set both on auto and manual mode. o) Size of Cable

SN DG Set Capacity Single core un- armored aluminium conductor cable 1 82.5 KVA 1x 120 sq. mm for phases and neutral 2 160 KVA 1 x300 sq. mm for phase and neutral 3 250 KVA 2x 400 sq. mm for phase and 1x 400 sq. mm for neutral

14.13 Arrangement The engine shall be directly coupled to the alternator through flexible coupling and both the

units including the radiator shall be mounted on a rigid fabricated bed plate. Base plate shall have threaded holes for holding of down bolts for mounting engine and alternator.

14.14 Foundation/Plinth Complete DG set shall be fixed on the proper designed plinth as specified by OEM or as per RVNL approved foundation drawing. 14.15 Tests The generating sets shall be tested at the manufacturer’s works for:

a) Guaranteed fuel –consumption b) Over load Capacity c) Proper operation of protective devices provided for safety of the generating set and AMF

Panel.

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14.16 Acoustic Enclosure The acoustic enclosure shall be conforming to CPCB requirements. In addition, the following requirements shall also be met: a) The acoustic enclosure shall be made of 14 SWG CRCA sheet steel. b) The enclosure shall be of modular construction with the provision toassemble and dismantle easily at site. c) The enclosure shall be powder coated (inside as well outside) with a special pure polyester based powder. All nuts and bolts/ external hardware shall be made from stainless steel. d) The doors shall be provided with high quality EPDN gaskets to prevent leakage of sound. e) Noise Level shall not be more than 75 dBA at 1 meter distance f) Temperature of enclosure shall not exceed the ambient temperature by more than 7 deg. C. g) The door handles shall be lockable type h) Sound proofing of the enclosure shall be done with high quality rock wool/mineral wool conforming to IS8183/1993. The rock wool shall be further covered with fiber glass tissue and perforated sheet i) A special residential silencer shall be provided within the enclosure to reduce exhaust noise. j) Adequate ventilation shall be provided to meet total air requirement. k) There shall be a provision of emergency shutdown from outside the enclosure.

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Tech.Spec.No. RVNL/Elect/GS/15

11 kV VCB HT PANEL

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CHAPTER: A-15 Technical Spec. No. RVNL/Elect/ GS/15

11 kV Vacuum Circuit Breaker HT Panel

15.1 Scope This specification covers manually operated, HT switchgear panels, suitable for 11000 volts, 50

Hz, 3- phase, 3-wire, alternating current, solidly earthed, electric supply system, complete with all accessories. The panel shall be complete with interlocking feature, automatic safety shutters, internal connections for inter-connections of panels, bus bar chamber, ON&OFF indicators, earth sockets, with all the instruments and relays in position and duly wired up with copper conductor cables and any other accessories though not specifically mentioned here but necessary to meet the site requirements in all respects. HT panel shall be fabricated from CRCA steel sheet, 14 SWG, with anti-corrosive coating and powder coated finish of approved colour.

15.2 Particulars of Electric Supply a) Main Supply – 11000 volt 3 phase 50 Hz A. C.

b) Supply for trip circuit – 110 Volt AC from 11000/110 volt potential transformer & indicating circuits through Power Pack.

15.3 Details of Panels

15.3.1 HT switchgear shall be suitable for continuous operation at the specified site conditions. 15.3.2 HT panel shall be flush front, metal clad, horizontal draw out type and fully interlocked.

Each circuit breaker shall be housed in a separate compartment enclosed on all sides. Each withdrawal truck shall have its own circuit breaker. The draw out mechanism shall be so designed and constructed as to permit smooth withdrawal and insertion, free of jerks, easy to operate and position.

15.3.3 Mechanical ON/OFF position indication shall be provided on the front of the circuit breaker. The operating mechanism shall be mounted on the front panel of the truck.

15.3.4 Vacuum circuit breaker shall have an assembly of three vacuum interrupters of proven design. The vacuum interrupters shall be of same make as that of the circuit breaker.

15.3.5 The operating handle and the mechanical trip push button shall be at the front of and integral with the circuit breaker.

15.3.6 The operating mechanism shall provide distinct and separate positions of the circuit breaker on the cradle for:

Service Test Isolated Maintenance

15.3.7 Sheet steel barrier shall be provided between: Instrument panel and potential transformer Instrument panel and current transformer Bus bar chamber and circuit breaker compartment

15.4 Incoming Panel

The panel shall be indoor type, metal clad, extendable on both sides, horizontal draw out type complete with interlocking features, automatic safety shutters, handle for raising and lowering the switchgear and rollers for the rolling in /draw out truck etc. and shall consist of: i) One-triple pole vacuum circuit breaker, 11000 volt, 630 Amp. Rupturing capacity 350 MVA

at 11 kV (Symmetrical). IS

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ii) Three- 630 Amps. Rating, air insulated, high conductivity copper bus-bars of uniform cross-section for electrical purposes, suitably insulated with sleeves and extensible type on the both ends.

iii) One set- ON and OFF (Red & Green) clustered LED type indicating lamps. iv) Six- isolating plug contacts. v) One- IDMT static relay with two current and one earth fault element with over current

setting range 50%-200%, earth fault setting range 10%-40%, short circuit setting range 200%-800% with flag indication and self reset arrangements.

vi) One -110 Volt AC shunt trip release. vii) Three- Double wound resin cast current transformers, burden 15 VA, accuracy class 10 P10

for protection & class 1.0 for metering, ratio 60/30/5A (250 KVA and above up to and including 500 kVA transformers).

viii) One- Digital Ammeter of range suitable for the CT being used. ix) One- Digital Voltmeter of range 0-15 kV to work in conjunction with the PT offered. x) One – 3x 11000/110 Volts, resin cast, potential (voltage) transformer, 100 VA, and

accuracy class 1.0 with protective fuses. The secondary for PT shall have terminals on terminal block from where 110 Volt power supply can be extended to adjoining panels through an extra set of kit kat fuses provided for the purpose.

Xi) One- Electronic Tri-vector meter (with 30 minutes integration ) for maximum demand indicator of suitable range, for unbalanced loads.

Xii) One- cable box complete with accessories suitably mounted on the rear of the panel for incoming cable.

xiii) One digital power factor meter. xiv) Power Pack for tripping system.

Note: The above mentioned tripping and measuring facilities should be provided in a single multi

function numerical relay cum meter to the extent feasible. 15.5 OUTGOING PANEL The outgoing panels shall be of indoor type, metal clad, extendable on both ends, horizontal

draw-out type, complete with inter locking features, automatic safety shutters, handle for raising and lowering the switchgear and rollers for rolling in /draw-out truck etc. and shall consist of: i) One triple pole vacuum circuit breaker- 11000 volt, 630 Amp. Rupturing capacity 350 MVA

at 11 kV (Symmetrical). ii) Three- 630 Amp, air insulated, high conductivity, copper bus bars of uniform cross section

suitable for electrical purposes, suitably insulated with sleeves and extensible type on both ends.

iii) One set – ON and OFF (Red and Green), clustered LED type indicating lamps. iv) Six isolating plug contacts. v) One – IDMT static relay with two over current and one earth fault element over current

setting range 50%-200%, earth fault setting range 10%-40%, short circuit setting range 200 %-800%, with flag indication and self reset arrangements.

vi) One - 110 Volt shunt trip release. vii) Three – Double wound, resin cast current transformers burden 15 VA, accuracy class 10

P10 for protection and indication, ratio 30/15/5A (250 KVA and above up to and including 500 kVA transformers).

viii) One- Digital Ammeter range suitable for the CT being used. ix) One- cable Box complete with accessories suitably mounted on the rear of the panel for out

going cable. x) Power Pack for tripping system.

Note: The abovementioned tripping and measuring facilities should be provided in a single multi

function numerical relay cum meter to the extent feasible

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15.6 Standard Specifications The equipments shall conform to latest version of the following BIS specifications:

1 High voltage AC circuit breaker 11000 volt (VCB) IS:13118/1991 2. AC metal enclosed switchgear and control gear above 1 kV and

up to and including 52 kV (Switchgear Panel) IS: 3427/1997

3. Copper strip for electrical purposes (Bus Bar) IS: 1897/1983 4. Current Transformers IS:2705/1992 5. Relays for Protection IS: 3231/1987 6. Potential (voltage) Transformers IS: 3156/Pt. I to III/1992

15.7 Equipment Specification 15.7.1 Circuit Breaker

The Circuit breaker shall be horizontal draw out type, triple pole, vacuum circuit breaker, for indoor mounting, conforming to IS: 13118/1991. It shall have the following rating and features:

i) Duty - General purpose. ii) Switch voltage - 11 kV iii) Normal current - 630 Amp. iv) Frequency - 50 Hz v) Phases - 3 vi) Symmetrical Breaking Capacity - 350 MVA

vii) Tripping device: It shall be shunt release type on 110 V AC control voltage. It shall trip the circuit breaker automatically in conjunction with the protective relay and also when intended.

viii) Method of operation: Manual drive with auto closing features. ix) The breaker shall be housed in a cubical of sheet steel construction (minimum 2 mm

thick) and totally enclosed. It shall be withdrawn horizontally. The breaker cubical trolley shall be interlocked and of integral design with the main cubical so as to prevent any mal- operation conditions.

15.7.2 11 KV/110 V Potential (Voltage) Transformer (PT) The potential transformer shall be resin cast, draw out type, of accuracy class 1 with

protective fuses. These shall be designed for both protection and metering. Construction shall be matched to suit the switchgear panel. Rated burden of the PT shall be 100 VA. The secondary for PT shall terminate on terminal block, from where 110 V power supply can be extended to adjoining panels through an extra set of kit kat fuses.

15.7.3 Current Transformer (CT) Cast resin, moulded current transformers shall be provided for the panels and shall conform in

all respects to IS2705 (Pt. II & III)/1983. Accuracy shall be of class 1.0 for metering and 10P10 for protective relays. Current transformers shall be double wound and of ratio as per requirement, based on the capacity of transformers to be installed/existing in the sub-station. The construction shall be matched to suit the switchgear panel. Rated burden of CTs shall be 15 VA on the secondary side. The CTs design and construction shall withstand system thermal and dynamic overloads.

15.7.4 Voltmeter Voltmeter shall be digital type of size not less than 96x 96 mm, square, flush mounted and

shall conform in all respects to the relevant BIS specification. The voltmeter shall be suitable for use in conjunction with the 11 kV/ 110 V PTs being offered. All meters shall be tested at 2000 V for one minute.

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15.7.5 Ammeter Ammeter shall be digital type, of size not less than 96x96mm, square, flush mounted and

shall conform in all respects to the relevant BIS specification. The voltmeter shall be suitable for use in conjunction with the CTs being offered.

15.7.6 Over Current And Earth Fault Relays Static type over current& earth fault relays shall conform to the relevant BIS specification

and shall be suitable for the specified CT ratio. The relays shall have inverse time characteristic for over current and operate instantaneously on faults. The relays shall be provided with setting in steps from 50 to 200 % for over current, 200-800% for short circuit setting and 10 to to 40% for earth faults. The relays shall also be provided with flag indication as and reset arrangements.

15.7.7 Electronic Tri-vector Meter The meter is required to be used in conjunction with the PTs and CTs in the main incoming

panel. This meter shall be suitable for recording 3 phase, unbalanced loads. The meter shall be flush mounted and shall conform in all respects to the latest BIS standards. The unbalanced load combination cum maximum demand (with 30 minutes interruption).

15.7.8 Construction of Panels i) The design, construction, enclosures, ventilation, interlocking, earth marking and testing of

HT 11 kV switchgear panels shall be in accordance with IS: 3427/1997. The degree of protection shall not be less than IP42.

ii) The panels are required to be installed indoors. They shall comprise copper HT bus bars,

VCB, auxiliary equipments and HT cable box etc. The panels shall be fabricated from CRCA sheet steel not less than 2 mm thick. The panel shall be of self standing type and fixed to bolts grouted in the foundation.

iii) The cubical shall be finished uniformly with powder coating of specified colour.

iv) All the equipments viz. VCB, bus bars, PTs, CTs, relays, measuring instruments, auxiliary terminals blocks, HT cable in let and outlet, earth points etc. Shall be properly arranged within the cubicles so as to facilitate easy maintenance and replacement. The measuring instruments and operating switches shall be suitably arranged on the front cover of the panel.

v) Suitable interlocking arrangements shall be provided between the front covers and the VCB switches so that the front cover is openable only when the respective VCB is in OFF position.

vi) All the Ht connections shall preferably be arranged at the bottom of the cubicles.

vii) Proper double earth of the non-current carrying parts of all equipments and unit enclosures shall be provided with GI strip of not less than 50 mm x 6mm size.

viii) The drawing of the HT panel shall be got prepared by the manufacturer and got approved from the Engineer, by the contractor.

15.7.9 Space Heaters: The Switchgear Panel shall have thermostatically controlled space heaters in each panel,

with a controlling 12 Amp, 230 V switch socket outlet, to eliminate condensation.

15.7.10 Power Pack Suitable capacity power pack shall be provided for tripping circuits.

15.7.11 Type Test Certificates Copies of type test certificates, successfully carried out on similar type of Vacuum Circuit Breakers, complying with the relevant Indian Standards, from a recognized Test House/ CPRI shall be furnished.

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Tech. Spec. No. RVNL/ Elect/ GS/16

AUTO POWER FACTOR

CORRECTION (APFC) PANEL

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CHAPTER:A-16


AUTO POWER FACTOR CORRECTION (APFC) PANEL 16.0 General The APFC panel shall be totally enclosed, made of mild steel sheet 14 SWG, free standing, floor

mounting, indoor type, with degree of protection not less than IP42. The panel shall be compartmentalized, fixed type, manufactured as per IS 8623 Pt. I & II/1993 & powder coated with specified colour. The panel shall be suitable for operation on 3-phase, 4-wire, 415V, 50 Hz, AC supply system, with automatic or manual switching arrangement for 10 step power factor correction, to achieve power factor near unity. The capacitor bank shall be complete with inter-connections. A continuous GI earth bus bar shall run at the bottom. It shall comprise of the following items: (However, any other item, not specifically listed below, but required for meeting the site requirement, shall also be deemed to be included.)

(1) Incomer shall be double the rating of panel i.e. 250A for 125 kVAR, 50 kA, MCCB 4 pole (Ics

= 100% Icu) conforming to IS 13947/ Part II. (2) Microprocessor based Automatic Power Factor Control Relay of not less than 12 steps with

display of electrical parameters- i.e. power factor, current, voltage, etc. with following specifications: a. 415 V 50 Hz b. Capacity 5 Amps c. Intelligent type d. Built in Automatic and manual control e. Low current cut out relay, f. Relay shall function even at low loads g. It shall have data logging facility and sufficient memory back-up to log the data for 30

days or above.

(3) Indicating Lamp for incoming power supply with suitable back up protection. (4) ON/ OFF indication lights for each set of capacitor (5) Configuration of capacitor output – 10 steps x 12.5 kVAR each with switching ratio 1:2:3:4 (6) Knife type HRC fuses with base of suitable capacity for back up protection of capacitor duty contactor for each capacitor bank. (7) 3- Pole contactor of suitable rating (capacitor duty).

(8) Capacitor shall be low loss, self-healing type for Ac power system having rated voltage 650 V & conforming to IS13340/1993 & IEC 60831.

(9) TPN copper bus bars of 400 amp rating for phase and 200 amp rating for neutral, fitted on insulators and PVC sleeves and duly colour coded. (10) Suitable size cooling fan.

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(11) Inter connection of capacitor duty contactors to bus bars with suitable size PVC copper

conductor cable of 1.1 kV grade, with suitable lugs. Lugs, wherever required, for control wiring of relays, meters, equipments and indicating light etc. Inter connection from MCCB with suitable size copper bus bars, as required.

(12) LT XLPE armoured cable conforming to IS7098/Pt.1/1988 for connection of control panel to

main bus bar of LT switchboard. The cable shall be connected with suitable size of lugs and glands.

(13) LT Current Transformer (CT) conforming to IS2705/Part I to IV, of suitable CTR, for

incoming feeder/s complete with four terminal at input side and two terminal at output side including connection from incoming CTs to summation CT and APFC relay with suitable size copper conductor cable with proper wiring arrangement.

(14) Suitable metering, indication and other accessories, as per site requirement.

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BATTERY CHARGERS

FOR

COACHING APPLICATIONS

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CHAPTER: A-17


BATTERY CHARGERS FOR COACHING APPLICATIONS 17.0 General

The battery charging sets shall be natural air cooled type with full wave bridge connected silicon rectifier stack and chokes for automatic limiting of variation of charging current due to mains voltage fluctuation. The silicon rectifier diodes shall be of capacity such that when 6 diodes are used for 3 phase rectification, the normal capacity of the bridge shall not be less than 175% of rated rectification capacity. The silicon diodes shall be rated for 200 PIV or more. The silicon rectifier equipment shall conform to IS4540/1968 of rating class-B/air cooled. The maximum permissible temperature rise on winding shall not be more than 850 C. Battery charger for following applications shall conform to RDSO specifications listed below: (a) Static Battery charger: RDSO/PE/SPEC/AC/0008(Rev-2)-2010 and STR No.

RDSO/PE/STR/AC/0013-2004 (Rev ‘0’)

(b) Pole mounted battery chargers for train lighting applications- EL/TL/52 (Provisional)

17.1 A maximum of 5% ripple shall be allowed. Surge suppressors and HRC fuses shall be provided for protection of the rectifier diodes. Chokes shall be wound with copper conductors.

17.2 The rating of transformer provided in the battery charging set shall match the rating of

associated rectifier set. The transformer shall be double wound with copper conductor, naturally air cooled, as per IS:2026 with class-F insulation, suitably impregnated to withstand moist tropical climatic conditions. SFU/FSU incorporating HRC fuses and MCCB matching the characteristics of diodes, shall be provided for the control of incoming AC supply. The SFU/FSU & knife switch shall be mounted firmly on a steel frame work below panel sheets. Rewirable fuses shall be provided for pilot lamps and indicating instruments. Two nos. of suitable capacity knife switches shall be incorporated for the control of outgoing DC supply in addition to diode protection type HRC fuses of suitable capacity. (2 nos. of knife switches, each of 200 amp. Capacity, shall be provided for 2 nos. of outgoing cables).

17.3 The silicon rectifier battery charging set shall be capable of giving the rated DC output over the

entire range of 125 to 150 volts. The output voltage shall be capable of adjustment in this range, for which purpose, coarse, medium and fine control, in not less than 4 steps, shall be provided through suitable rotary control switches incorporated on the transformers.

17.4 The arrangement of silicon rectifier stacks, transformers and chokes shall be such that each

item can be dismantled independently, without disturbing the other equipments. 17.5 The battery charging sets are required for indoor use and shall be portable with 4 wheels. The

set shall consist of transformers, chokes, silicon rectifier, control switches, ON/OFF switches. DC Voltmeter, Ammeter of moving coil type, flush pattern, of suitable range and interconnections etc. Cabinet shall be of 14 SWG CRCA sheet steel and powder coated. The bus bars and inter connections shall be of copper conductors.

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17.6 Over Loading 17.6.1 The rectifier transformer unit capacity shall withstand the following over loading: i) 50 % over loading - Continuously. ii) 100% over loading - One hour. 17.6.2 The transformer rectifier unit shall be such that on short circuiting the DC side of the rectifier

bridge, the short circuit current does not exceed 300% of the nominal rating of the rectifier unit.

17.7 Compliance with Specifications All the equipments shall conform to the following BIS specifications:

Mono-crystalline semi-conductor rectifier cells and stack

IS 3895-66

Mono- crystalline semi-conductor rectifier assemblies and equipment

IS4540-68

Direct acting electrical indicating instruments IS1248-68 Heavy duty composite units of air-break switches and fuses for voltage not exceeding 1000 volts.

IS13947-93

MCCB IS 13947-93 Rectifier transformer Clause 5 of IS4540-68 & IS2026

17.8.0 Tests 17.8.1 Type Tests: The manufacturer shall submit type test certificates for tests successfully carried

out on similar type of sets, to the inspecting authority. 17.8.1.1 The following routine tests shall be carried out by the inspecting authority and results

witnessed:

a) Insulation Resistance Test- Insulation resistance shall not be less than 2 ohm before and after the high voltage test. The AC and DC side of rectifier set shall be short circuited while testing.

b) Load Characteristic- The battery charger shall give 200 A at 150V Dc. c) High Voltage Test- 1 kV shall be applied for 60 sec. and rectifier AC/DC side shall be

short circuited before applying the high voltage. d) Load Test-The battery charger shall be connected to variable resistance of water

rheostat and measure the output voltage and current. Check the transformer and temperature after 2 hours run. Check up the core noise or poor lamination or heating.

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Tech. Spec. No.- RVNL/ Elect/GS/18

BATTERY CHARGING

AND

PRE- COOLING POINTS

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CHAPTER: A-18

Tech. Spec. No. RVNL/ Elect/GS/18 BATTERY CHARGING AND PRE- COOLING POINTS

18.1 Battery Charging Points 18.1.1 Battery charging points shall be constructed in two portions in separate enclosures in vertical

formation. One portion (upper) shall contain bus bars, MCB, provision for accommodating incoming cable, outgoing looping cable to/from other point and cable connecting to Emergency Feed Terminal(EFT) etc. and other portion (lower) shall contain EFT terminals for cable connections to feed supply to batteries for charging. Doors shall be provided with locking arrangement and open able with special key.

18.1.2 Battery charging points shall be cubicle type, weather proof, out door type, dust & vermin

proof, conforming to IS-8623 with degree of protection not less than IP54. It shall be suitable for operation on 150V Dc supply system and fabricated with 14 SWG galvanized CRCA sheet with pedestal of MS channel of size 100 x 50 mm (weight 7.914 kg/m), 1200 mm long, 2 nos. aluminum bus bars of size 40x10mm, complete with one no. incoming MCB DP 63 Amps (DC series) 10 KA. Detachable plate shall be provided on bottom for entry of incoming and outgoing cables with suitably sized gland/s. Channel shall be fixed /welded with the enclosure on back side in the centre of the enclosure at a specified distance from the top.

18.1.3 EFT (as per RDSO drawing already in use in Train Lighting system) feeding terminals shall be

of galvanized mild steel, suitably mounted on ebonite/Teflon sheet (approx. 12 mm thick), fixed on the sheet of enclosure.

18.1.4 The feeding terminals shall be marked Red & Black for polarity (“+ve” and “-ve”). Suitable

space shall be provided between terminals. 18.1.5 The incoming connections from bus bars to MCB and from MCB to the feeding terminal (EFT)

shall be done with single core, 10 sq. mm, copper conductor cable, with suitably sized galvanized Ms bolts, nuts and washers.

18.1.6 Enclosure and channel shall be powder coated and of the specified colour. Enclosure shall have

double earth terminals. 18.1.7 Erection

The channel of the battery charging point shall be grouted vertically in ground 300 mm deep with cement concrete as per para 13.0 CH-1A. The clearance between the channel and edge of foundation shall be minimum 200 mm and it shall be duly finished and cured. The muffing shall be 200 mm above ground level.

18.1.8 All equipments and material used shall conform to the following BIS specifications:

S.N. Material/Equipment BIS Specification No. 1 MCB 8828 2. PVC copper conductor cable 694

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18.2 Pre-Cooling Points 18.2.1The pre–cooling points shall be manufactured in two portions, in separate enclosures, in front

and back formation. Bus bar chamber shall be provided on back side of the enclosure and it shall be capable of opening with special type of key. Front portion shall contain switch gears and other items. Detachable plate shall be provided at the bottom for entry of incoming and exit of outgoing cables, with suitably sized cable entry gland/s. Provision for incoming and looping cables from/to other point shall be from bus bar portion. Connections to switch gear shall be done with single core unarmoured aluminium conductor cable of size not less than 120 sq mm. Each enclosure shall have independent hinged flushed doors with sliding type lockable arrangement, as well as concealed lock, open able with special key.

18.2.2 The pre-cooling point shall be manufactured from 3.15 mm CRCA sheet. Pedestals (4 nos. on

corners), shall be of MS angle of size 65x65x8 mm (900 mm long) with base frame of Ms angle of size 40x40x5mm. MS angle pedestals (grouting portion approx. 150mm) shall be bifurcated. The enclosure shall have double earth terminals.

18.2.3 The enclosure and pedestals shall be powder coated with specified shade. 18.2.4 (a) Pre-cooling portion shall be provided with the following, on the front for

utilization/operation without opening the front door: i) One no. 100 A, 4 pole, MCCB 35 kA (Fixed type ) ii) One no. 63A industrial type, iron clad 5 pin (3P +N+E)415 V plug socket with spring

locked cover. iii) One No. 32 A Industrial type iron clad 3 pin (P+N+E) 250 V plug socket with spring

locked cover. iv) Batten Holder fixed on Bakelite sheet base plate with suitable lamp and controlled by 5

A piano type switch. v) 300 A Aluminium bus bar for Phases & 200 A for Neutral, with epoxy coating/ PVC

colour coded sleeves. vi) Cable entry glands of suitable size vi) LED indication lights.

b) The connections from bus bars to MCCB and from MCCB to the feeding terminal (Iron Clad Sockets) shall be done with single core, copper conductor cable of suitable rating with suitably sized galvanized MS bolts, nuts and washers.

18.2.5 All equipments and material used shall conform to the following BIS specifications:

SN Material/Equipment BIS Specification No. 1. MCCB 13947 2 MCB 8828 3 LTXLPE Cable 7098/Pt.1/1985 4 Industrial type plug socket 13947 5 PVC insulated copper conductor cable 694

18.2.6 Erection Pedestals shall be grouted vertically 300 mm deep in ground with cement concrete as per para

13.0 CH-1A. They shall be 200 mm in diameter, duly finished and cured muffing 200 mm above ground level.

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SOLAR HOME & STREET LIGHTING SYSTEM

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Chapter: A-19

Tech. Spec. No.- RVNL/ Elect/GS/19 SOLAR HOME and STREET LIGHTING SYSTEM

(Ref: RDSO spec no. RDSO/PE/SPEC/PS/0093-2008 (Rev. 0) Amnd-3)

19.0 Solar Home Lighting: GENERAL: Solar Home Lighting System shall comprise of lead acid battery, PV module, module

mounting hard-ware, battery box, compact fluorescent lamp complete with luminaries, Fan, control electronics, interconnecting cables/ wires etc.

19.1 Load: Solar home lighting system shall provide solar electricity for operating 2 lights and 1 fan for 24 hours continuously. 19.2 COMPONENT DETAILS:

i) PV MODULE 2 X 37Wp or 1 X 74Wp

ii) Lamp 2 X CFL /LED (11W)

iii) Fan 1 X DC Fan (with wattage less than 20 W)

iv) Battery 1 X 12 V, 75 AH minimum

V) Other Components

Control electronics, module mounting hardware, and battery box of thickness not less than 0.71 mm (made up of MS Sheet), inter-connecting wires/ cables, switches etc.

NOTE: a) All the item shall be as per latest MNES specifications (latest) and shall possess satisfactory

test certificate issued by Solar Energy Centre or any other approved testing centre by MNES.

b) PV Modules manufacturer should be MNES approved. c) The lamps should be housed in an assembly suitable for indoor use, with a reflector on its

back. While fixing the assembly, the lamp should be held in a base up configuration.

19.3 SPECIFICATIONS OF COMPONENTS: 19.3.1 BATTERY:

a) The battery will be of flooded electrolyte type, positive tubular plate, low, maintenance lead acid battery.

b) The battery will have a minimum rating of 12V, 75 Ah at C/10 discharge rate. c) 75% of the rated capacity of the battery should be between fully charged & Load cut off

conditions. d) The Battery shall be of standard makes of Panasonic, Exide, Amaraja, Hitachi, CSB, and

Tata BP 19.3.2 ELECTRONICS & ELECTRONIC PROTECTIONS:

a) The inverter should be of quasi sine or full sine wave type with frequency in the range of 20-35 KHz. Half wave operation is not acceptable.

b) The total electronic efficiency should be at least 80%. c) No backening or reduction in the lumen output by more than 10% should be observed after

1000 ON/OFF cycles (two minutes ON followed by four minutes OFF is one cycle. d) The idle current consumption should not be more than 10 mA.

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e) Electronics should operate at 12 V and should have temperature compensation for proper charging of the battery though out the year.

f) Necessary lengths of wires/cables, switches suitable for DC use and fuses should be provided.

g) Adequate protection is to be incorporated under no load conditions e.g. when the lamps are removed and the system is switched ON.

h) The system should have protection against battery overcharge and deep discharge conditions.

i) Fuses should be provided to protect against short circuit conditions.

19.3.3 PV MODULE(S): a) The PV module(s) shall contain crystalline silicon solar cells. b) The power output of the module(s) under STC should be a minimum of 37W or 74W i.e. two

modules of 37 W each or one module of 74W should be used. c) The operating voltage corresponding to the power output mentioned above d) Should be 16.4 V e) The open circuit voltage of the PV modules under STC should be at least 21.0 Volts.

19.3.4 MECHANICAL COMPONENTS: Metallic frame structure (with corrosion resistance paint) shall be fixed on the roof of the house

to hold the SPV module(s). The frame structure should have provision to adjust its angle of inclination to the horizontal between 0 and 45, so that it can be installed at the specified tilt angle.

19.3.5 INDICATIONS : The system should be provided with 2 LED indicators, a green light to Indicate charging in

progress and a red LED to indicate deep discharge condition of the battery. The green LED should glow only when the battery is actually being charged.

NOTE: Components and parts used in solar home systems should conform to the latest BIS specifications, wherever such specifications are available and applicable. 19.4 Solar LED Street Light system: 19.4.0 Solar Photo Voltaic (SPV) based LED street lighting system shall consists of the following

elements – (a) SPV Module to convert solar radiation directly into electricity. (b) 7 m height GI pole with necessary accessories. (c) Battery bank to store the electrical energy generated by SPV panel during day time. (d) Charge controller to maintain the battery to the highest possible State of Charge (SOC)

while protecting the battery from deep discharge (by the loads) or extended overcharge (by the PV array).

(e) Blocking diode, preferably an Schottky diode, connected in series with solar cells and storage battery to keep the battery from discharging through the cell when there is no output or low output from the solar cell, if such diode is not provided with the module itself.

(f) 15 W LED based luminaire as a light source. (g) Interconnecting wires/cables & hardwares.

The entire system shall be in accordance with RDSO specifications RDSO/PE/SPEC/PS/0093-2008 (Rev. 0) Amnd-3 except pole shall be 7m GI in place of 6m MS given in RDSO specifications. The salient features of the system are listed below:

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19.4.1 GENERAL REQUIREMENTS The system shall be designed to have 4 days autonomy (i.e. system will run for 4 consecutive days without charging from the panel).

19.4.2 Battery Bank:

(a) The storage battery Bank shall have enough capacity to keep the system going on without break down when the weather is not favourable for generation of electricity due to cloudy days and rains.

(b) Battery shall be Tubular Lead Acid, Low Maintenance type with low antimony lead alloy plates and ceramic vent plugs and water topping interval of 6months which are specially designed to be charged & discharged frequently and can handle heavy discharges time after time with minimum charging efficiency of 90%.

(c) The container material shall be PP (d) Battery shall have a design life expectancy of >5 years at 50% DOD at 27°C. (e) The permissible self-discharge rate shall be less than 2% of the rated capacity per month

at 27°C. (f) The charging instructions shall be provided alongwith the batteries. (g) Batteries shall be provided with micro porous vent plugs & acid level indicator. (h) The batteries shall be discharged up to 80% DOD and battery shall be accordingly sized. (i) Suitable Battery Box made of Plastic OR M.S fabricated shall be provided to house the

battery. (j) The minimum capacity of the battery bank shall be 12V/75 Ah @ C10 (k) Alternatively VRLA type battery of proven design for such application may also be

considered provided such battery have been in such application for more than 3 years satisfactory service.

(l) The Battery shall be of standard makes of Panasonic, Exide, Amaraja, Hitachi, CSB, and Tata BP

19.4.3 Cables and Hardware 19.4.3.1 Cable shall meet IS:694 Part 1:1988 & shall be of 650 V/ 1.1 kV. 19.4.3.2 A metallic frame structure (with corrosion resistance paint) to be fixed on the pole to hold the

SPV module(s). The frame structure should have provision to adjust its angle of inclination to the horizontal between 0 and 45 so that the module(s) can be oriented at the specified tilt angle.

19.4.4 POLE GI tubular pole shall be swaged type made from steel of ultimate tensile strength 410 MPa (42 kg/mm2) as per IS: 2713 (Pt. I, II and III) 1980 amended up to date. The pole shall be as per IS designation 410 SP-3. Each pole shall be provided with 16 mm dia GI earth terminals of suitable length for earth connection. Pole shall be suitable to wind pressure of not less than 150 KMPH. Drawing of pole shall be got approved from the RVNL Engineer.

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STANDARD DIMENSIONS OF POLE

Designation

Length of Sections (m)

Outside diameter & thickness of sections (mm)

Base Plate Dimen

sions (LxBxT)

FOUNDATION BOLT Anchor Plate Thickness

(mm)

Foundat

ion in m

m

Bott

om

Mid

dle

Top

Bottom Middle Top Bolt Size (no.xdia) (mm)

Pitch Circle Dia.

(mm)

Bolt Length (mm)

410-SP-3

4.00 1.50 1.50 114.3x 5.4

88.9x 4.85

76.10x 3.25

220X220X12

4X20 205 700 3 500x500x

1250 (depth)

19.4.5 FOUNDATION: Foundation for erection of pole shall be constructed at the approved location. After excavation of pit of suitable size, cement concrete bed of approx.50mm thickness, using cement concrete as per para 13.0 Chapter-1A, shall be first provided at the bottom of the pit. Square foundation shall be made with cement concrete as per para 13.0 Chapter-1A of size as specified in the above table of standard dimensions of pole up to 150mm above ground level. Muffing shall be in level, plastered, finished & also cured. After foundation work, the pit shall be filled with excavated earth. During back filling of earth, ramming and watering shall be done.

19.4.6 ERECTION OF POLE: The pole shall be erected in plumb on constructed foundation at the specified location and bolted on a pre- casted foundation with a set of four bolts. Top of all the poles shall be at the same level to maintain uniformity.

NOTE:

1. Components and part used in the solar street lighting systems should conform to the latest BIS specification. Wherever such specifications are available and applicable.

2. All the item shall be as per latest MNES specification and manufacturer shall possess satisfactory test certificate issued by Solar Energy Centre or any other approved testing centre by MNES and same shall also be furnished at the time of inspection and copies of the same shall be supplied with supply of material/equipment.

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Solar Water Heater

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CHAPTER: A-20 Tech. Spec. No. RVNL/ Elect/GS/20

SOLAR WATER HEATER

(Ref: RDSO spec no. RDSO/PE/SPEC/PS/0094-2008 (Rev-0) AMDT-1) 20.0 SCOPE 20.1 This specification covers the general and technical requirements of solar based water heating

system both flat plate collector (FPC) or Evacuated Tube collector (ETC) type system. Normally FPC type water heater shall be installed unless and otherwise specifically mentioned in BOQ.

20.2 Work includes supply, erection testing and commissioning of solar based water heating system

complete with Solar Collectors, Insulated Tank, Supporting Stand, system piping, instrumentation, electric back up, controls, etc including CONNECTIONS UP TO UTILITY POINTS of the existing arrangement/system as required.

20.3 REFERENCE STANDARDS

IS: 12933:Pt.1/2003 Solar Plate collector – Specifications Part:1 Requirements

IS: 12933:Pt.2/2003 Solar Plate collector – Specifications Part:2 Components

IS:1570-Pt.5/1985 (Reaffirmed 1998)

Schedule of Wrought steels Pt.5 :stainless & heat resisting steel

IS:12931:1990 Solar Energy- Thermal applications-Vocabulary

IS: 1239:1990 Pt.2 (Reaffirmed 2002)

Mild Steel tubes & other wrought steel pipe fittings

20.4 SYSTEM DESCRIPTION

Solar water heating system shall comprise of following:

(a) Solar flat plate/Evacuated Tube collector (FPC/ETC type) (b) Collector stand assembly (c) Stainless steel insulated hot water storage tank (d) Heat transfer medium(i.e. water) (e) Heat Exchanger (where water is hard and more chlorine content)

(f) Inter connecting plumbing (g) An auxiliary heater

20.5 GENERAL

Solar water Heater device shall be operative on Flat Plate Collector/ETC covered by an insulated metallic box with glass sheet on top to receive sun rays and suitable for normal, hard water & pressurized applications for heating capacity per day as specified in BOQ item/s. All systems shall conform to BIS & MNES standards and specifications. System shall be suitable to heat water between the ranges 60-80 degree centigrade. System output temperature shall normally be 60 degree centigrade.

20.6 PIPING & NON RETURN VALVE

Piping from collector to storage tank shall be insulated. Non return valve shall be provided in the piping system.

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20.7 HOT WATER STORAGE TANK

Storage tank shall be double walled. Space between inner and outer walls shall be filled with insulation to prevent heat losses. Inner tank shall be made with stainless steel and outer tank shall be made of galvanized sheet steel/aluminium sheet and powder coated of approved shade. Capacity of tank shall be equal to the capacity of system.

20.8 ELECTRIC BACK UP

Thermostatic controlled, electrical heating element shall be of 2000 watts and shall be connected with the nearby supply point (power plug point) with 3 x4 sq.mm FRLS PVC insulated copper conductor cable.

20. 9 WIRING

All control and sensing wiring shall be housed in MS conduit.

20.10 Technical Requirements

(a) Flat Plate Collectors: ISI mark (2 sq. m. absorber area per100 liter tank capacity system.

(b) Evacuated Tube Collectors/ Heat pipes: Type of tubes 3 layer solar selective (Inner layer of copper coating should be visible).

Detailed specifications of tubes will be as per the guidelines laid down by MNRE for empanelment of anufacturers of ETC based systems.

No. of tubes in a system

To have minimum 1 ½ sq. m. of absorber area per 100 litre tank capacity system. Absorber area will be calculated as follows:

Area in Meter = No. of tubes X Radius in Meter X Length in Meter.

Accordingly, 14 tubes of Dia: 47 mm & length: 1500 mm and 10 tubes of Dia 58 mm & length: 1800 mm will be required for each 100 lpd system.

For higher capacity systems, the no. of tubes calculated as per above could be slightly less. For details, please refer to MNRE Circular no. 25/5/2009-10/ST dated 2nd March, 2010

Procurement From reputed MNRE approved suppliers.

(c) Storage Tanks, Piping, Support structure etc

Inner tank material

SS 304 or 316 grade min/ MS or any other material with anti-corrosive coating for hard water with chlorine contents.

Inner tank thickness

For SS minimum thickness will be 0.5 mm when using argon Arc or metal inert gas for welding & 0.8 mm when using other type of welding. For MS it will be 1.5 mm. No leakage under any kind of negative or positive pressure of water will be ensured.

Inner tank welding

TIG / Seam/ pressurized weld (Open arc weld not permitted).

Storage tank capacity

Not less than system capacity. In case of ETC based system, volume of tubes & manifold not to be included in tank capacity.

Thermal insulation of

Minimum 50 mm thick CFC free PUF having density of

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,

storage tanks 28-32 kg/ cum for domestic systems and 100mm thick Rockwool of 48 kg per cu. m for other systems. For colder regions, it will be 1½ times atleast. In case of higher density insulations, the thickness may reduce proportionately.

Thermal insulation of hot water pipes

Minimum 50 mm thick rock wool or 25 mm thick PUF on GI pipes. For colder regions, it will be 1½ times at least. For higher density insulations, the thickness may reduce proportionately.

Outer cladding & Frames

Al/ FRP or GI powder coated. MS may also be used with Special anti-corrosive protective coatings. Thickness of sheets will be strong enough to avoid any deformation of the cladding.

Valves, cold water tank vent pipe, heat exchanger, make up tank & instruments.

Of ISI mark

Support structure for Collectors, pipng, tanks etc.

Of non corrosive material or have corrosion resistant Protective coating. They will be strong enough to sustain their pressure during the lifetime of system.

20.11 MOUNTING OF SYSTEM System should be mounted on a rigid structure in such location to allow access all the equipments for maintenance, repair and replacement and should be firmly fixed in an approved manner to prevent damage during high winds up to 200 kmph. NOTE: IT SHALL BE ENSURED THAT THE SYSTEM SHALL NOT BE NEAR ELECTRIC POWER LINES.

20.12 At places where water is hard and has larger chlorine content, if FPC based system is proposed

for installation, heat exchanger should be installed alongwith to avoid scale deposition in copper tubes of solar collectors which can block flow of water as well as reduce its thermal performance.

20.13 INSTALLATION

Solar collector array shall be installed at the proper tilt angle, orientation and the elevation above roof and shall have proper exposure to sun throughout the day.

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LIGHTENING ARRESTER

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CHAPTER: A-21


Lightening Arrester

21.0 Lightening arresters shall be provided on the buildings where large public congregates, essential

public services are concerned, lightening strokes are prevalent, or in structures which are very tall, isolated, or are historical or cultural importance. The other buildings may also be provided with lightening arrestors as per risk assessment analysis given in the IEC 62305 chapter-2. The lightening arresters are governed as per IEC 62305 and BIS 2309.

21.1 Generally lightening protection in installation having nuclear or sensitive electronics are provided

with Level1 Lightening protection whereas buildings housing Data Centre and building taller than 20 meter height in isolated location are provided level 2 lightening protection, other buildings having electronics or human occupancy requires level 3 protection and godown having no electronics will require level 4 lightening protection.

21.2 General Description Lightening Protection System shall be in accordance with IEC 62305-3, IS:2309 & IS:3043.

21.3 Principle of Protection

The principle for protection of buildings against lightning is to provide a conducting path between earth and the atmosphere above the building through which the lightning discharge may enter the earth without causing damage to the building. If adequately earthed metal parts of proper proportions are provided and spread properly on and around the building, damage can be largely prevented. The required conditions of protection are generally met by placing all the air terminals, whether in the form of vertical finials or horizontal conductors, on the upper most part of the building or its projections, with lightning conductors connecting the air terminals with each other and to the earth.

21.4 Zone of Protection

The zone of protection of a lightning conductor defines the space within which Air Terminal provides protection against a direct lightning strike with probability of protection as per LPL.

21.5 Protective Angle

This cannot be precisely stated, since it depends upon the severity of the stroke and the presence within the protective zone of conducting objects providing independent paths to the earth. All that can be stated is that the protection afforded by a lightning conductor increases as the assumed protective angle decreases.

(a) However, for the practical purpose of providing an "acceptable degree" of protection for an ordinary structure, the protective angle of any single component part of an air termination network, namely, either one vertical, or one horizontal conductor is considered to be 45 degrees.

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(b) Between three or more vertical conductors, spaced at a distance not exceeding twice their height, the equivalent protective angle may, as an exception, be taken as 60 degrees to the vertical.

(c) Protective angles of zones of protection for some forms of air termination are illustrated in IS 2309 : 1989.

21.5.1 Lightning Protection Level(LPL)

LPL is a number associated with a set of lightning current parameters relevant to the probability that the associated minimum & maximum values do not exceed the normally occurring lightning. LPL can be determined by Risk analysis as explained in IEC 62305-2.

Sr No LPL Lightening Current Peak

Value Min Lightening Current Peak Value Maximum

1.0 LPL Level 1 3 KA 150 KA 2.0 LPL Level 2 5 KA 150 KA 3.0 LPL Level 3 10 KA 100 KA 4.0 LPL Level 4 16 KA 100 KA

Air termination system is to intercept the Lightning current. It consists of vertical air terminal or Mesh conductor or the combination. No drilling or welding is allowed in the terrace for fixing the air terminal.

Values of Rolling sphere radius, Mesh size and protection angle as per Class of LPL/LPS.

Clas of LPL/LPS

Rolling sphere radius (m)

Mesh size (m) Protection angle

Protection angle

1 20 5*5 Refer Graph Below

2 30 10*10

3 45 15*15

4 60 20*20

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80

70

60

50

40

30

20

10

0605040302010

I II IIIIV

Class of LPS

H m

a0

If the structure height is more than 60 meters, top 20% of the height of the structure shall be protected with a lateral air termination system. This is needed because, the probability of flashes to the side is generally more for structures more than 60 meters in height. For structures of height more than 120 meters, ring has to be formed for every 20 meters height of the building above 60 meters height.

21.6 Principal Components The principal components of a lightning protective system are :-

(a) Air terminations, (b) Down conductors, (c) Joint and bonds, (d) Testing joints, (e) Earth terminations, and (f) Earth electrodes.

21.7 Materials

The materials of air terminations, down conductors, earth termination etc. of the protective system shall be reliably resistant to corrosion, or be adequately protected against corrosion. The material shall be one of the following, as specified.

(a) Copper: Solid or flat copper strip of at least 98% conductivity conforming to relevant I.S. Specifications shall be used.

(b) Copper Clad Steel: Copper clad steel with copper covering permanently and effectively welded to the steel core shall be used. The proportion of copper and steel shall be such that the conductance of the material is not less than 30% of conductance of the solid copper of the same total cross-sectional area.

(c) Galvanized Steel: Steel thoroughly protected against corrosion by a zinc coating shall be used.

(d) Aluminium: Aluminium, 99% pure, and with sufficient mechanical strength, and

protected against corrosion shall be used.

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21.7.1 Aluminium should not be used underground, or in direct contact with walls.

21.7.2 All air terminations shall be of GI and all down conductors shall be of GI or aluminium, except where the

atmospheric conditions necessitate the use of copper or copper clad steel for air terminations and down

conductors.

21.7.3 The recommended shape and minimum sizes of conductors for use above and below ground are given in Table-

1 and 2 respectively.

21.8 Layout

The system design and layout shall be done in accordance with IS 2309: 1989 and specified in the tender

documents. 21.8.1 Air Terminations

(i) Air termination networks may consist of vertical or horizontal conductors, or combinations of both. For the

purpose of lightning protection, the vertical and horizontal conductors are considered equivalent and the use

of pointed air terminations, or vertical finial is, therefore, not regarded as essential.

(ii) A vertical air termination, where provided, need not have more than one point, and shall project at least 30 cm,

above the object, salient point or network on which it is fixed.

(iii) For a flat roof, horizontal air termination along the outer perimeter of the roof shall be used. For a roof of

larger area a network of parallel horizontal conductors shall be installed. No part of the roof should be more than

9 m from the nearest horizontal protective conductor.

(iv) Horizontal air terminations should be carried along the contours such as ridges, parapets and edges of flat

roofs, and, where necessary, over flat surfaces, in such a way as to join each air termination to the rest, and

should themselves form a closed network.

(v) All metallic projections including reinforcement, on or above the main surface of the roof which are

connected to the general mass of the earth, should be bonded and form a part of the air termination network.

(vi) If portions of a structure vary considerably in height, any necessary air terminations or air termination network

for the lower portions should be bonded to the down conductors of the taller portions, in addition to their own

down conductors.

21.8.2 Down Conductors

The function of a down conductor is to provide a low impedance path from the air termination to the earth

electrode so that lightning current can be safely conducted to the earth. In practice, depending upon the form

of a building, it is often necessary to have many down conductors in parallel, some or all of which may be a

part of the building structure itself.

In order to reduce the probability of damage to electronic/electrical equipment, the down conductors shall be arranged in such a way that from the point of strike to earth, several parallel current paths should exist & length of the current path should be minimum. Down conductors can be installed separately or more wisely it can be part of natural components of the building Examples are steel reinforcement in RCC columns, metal facades, profile rails, metal doors & windows. Down conductors should be installed at each exposed corner of the structure.

(i) The number and spacing of down conductors shall be as specified, or as directed

by the Engineer-in-charge.

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(ii) Routing

(a) A down conductor should follow the most direct path possible between the air terminal network and the

earth termination network. Where more than one down conductor is used, the conductors should be

arranged as evenly as practicable around the outside walls of the structures.

(b) The walls of light wells may be used for fixing down conductors, but lift shafts should not be used for this

purpose.

(c) Metal pipes leading rainwater from the roof to the ground may be connected to the down conductors, but

cannot replace them, such connections should have disconnecting joints. (d) In deciding on the routing of the down conductor, its accessibility for inspection, testing and maintenance

should be taken into consideration.

(iii) Provision when External Route is Not Available

(e) Where the provision of external routes for down conductors is impracticable, for example, in buildings of cantilever construction from the first floor upwards, down conductors should not follow the outside contours of the building. To do so would create a hazard to persons standing under the over hang. In such cases, the down conductors may be housed in an air space provided by a non-metallic and non-combustible internal duct and taken straight down to the ground.

(f) Any suitable covered recess, not smaller than 76 mm x 13 mm, or any suitable vertical service duct

running the full height of the building may be used for this purpose, provided it does not contain an

unarmoured or a non-metal sheathed cable.

(g) In cases where an unrestricted duct is used, seals at each floor level may be required for fire protection.

As far as possible, access to the interior of the duct should be available.

21.9 Installation 21.9.1 General

(i) The entire lightning protective system should be mechanically strong to withstand the mechanical forces

produced in the event of a lightning strike.

(ii) Conductors shall be securely attached to the building, or other object to be protected by fasteners, which

shall be substantial in construction, not subject to breakage, and shall be of galvanized steel or other suitable

materials, with suitable precautions to avoid corrosion. (iii) The lightning conductors shall be secured not more than 1.2 m apart for horizontal run, and 1 m for vertical run.

21.9.2 Air Terminations

All air terminals shall be effectively secured against overturning either by attachment to the object to be

protected, or by means of substantial bracings and fixings which shall be permanently and rigidly attached to

the building. The method and nature of the fixings should be simple, solid and permanent, due attention being

given to the climatic conditions and possible corrosion. 21.9.3 Air terminal holder

Conductors shall be securely fixed on the terrace by means of air terminal holder which is fixed on the roof by adhesive of good quality taking care of varying weather conditions. Air conductor holder is an insulator & should be of minimum 50 mm height so that even small amount of water logging on terrace is below the level of conductor holder. Air terminal holder shall not be more than 0.5 m apart for a flat conductor & 1m for round conductor of atleast 8mm diameter & 1.0 meter apart for vertical run.

Recommended distance between air terminal holders. Arrangement Recommended distance For ROUND conductors Horizontal conductor on horizontal surface. 1000 mm Horizontal conductor on vertical surface 1000 mm Vertical conductor from Ground to 20m height

1000 mm

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If antenna, air cooler or any other electrical equipment is present above terrace level, the same

have to be protected by using vertical air terminal after calculating the safety or separation distance. The vertical air terminal has to have suitable supports to hold it. Vertical air terminal must be connected to horizontal air terminal by using suitable connectors. At the crossings of the horizontal air terminals, suitable T or Cross connector has to be used for secure connection.

21.9.4 Safety or Separation distance. It is must to calculate safety or separation distance in order to avoid flash over to the electrical equipment when the lightning current is passing through the vertical air terminal. Safety/Separation distance (S) in m = ( ki * kc*L) / km

Coefficient ki depends on class of LPL/LPS.

ki = 0.08 for LPL1,

ki = 0.06 for LPL 2,

ki = 0.04 for LPL3 and 4.

Coefficient kc depends on no of down conductors:

kc = 0.66 for 2 down conductors

kc = 0.44 for 3 or more down conductors

Value of coefficient km = 1

Value of L is the total distance between the equipment to be protected ( for e.g. Antenna) to the equi-potential bonding bar situated just above the ground.

21.9.5 Need for Expansion piece In order to take care the expansion of the metal in summer and contraction of the metal in

winter, expansion piece with suitable connectors have to be used at every 20m distance of horizontal air terminal.

21.9.6 Down Conductors

(i) The down conductor system must, where practicable, be directly routed from the air termination to the earth termination network, and as far as possible, be symmetrically placed around the outside walls of the structure starting from the corners. In all cases consideration to side flashing must always be given.

(ii)(a) Practical reasons may not sometimes allow the most direct route to be followed. While

sharp bends, such as arise at the end of roof are inescapable (and hence permissible), re-entrant loops in a conductor can produce high inductive voltage drops so that the lightning discharge may jump across the open side of a loop. As a rough guide, this risk may arise when the length of the conductor forming the loop exceeds 8 times the width of the open side of the loop.

(b) When large re-entrant loops as defined above cannot be avoided, such as in the case of some cornices or parapets, the conductors should be arranged in such a way that the distance across the open side of a loop complies with the requirement indicated above. Alternatively, such cornices or parapets should be provided with holes through which the conductor can pass freely.

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(iii) Bonding to Prevent Side Flashing Any metal in, or forming a part of the structure, or any building services having metallic parts

which are in contact with the general mass of the earth, should be either isolated from, or bonded to the down conductor. This also applies to all exposed large metal items having any dimension greater than 2 m whether connected to the earth or not.

Material configuration and Min cross sectional area of

air terminal and down conductors Material Type Min cross section

area Remarks

Copper Solid tape 50 sq mm 2mm min thickness

Copper Solid round 50 sq mm 8mm dia

Aluminum Solid tape 70 sq mm 3 mm min thickness

Aluminium Solid round 50 sq mm 8 mm dia

Stainless steel Solid tape 50 sq mm 2 mm min thickness

Value of distance between down conductors as per Class of LPL / LPS.

Class of LPL/LPS Typical distance (m)

1 10 2 10 3 15 4 20

21.9.7 Joints and Bonds

(a) Joints: (i) A lightning protective system should have as few joints as possible. The lightning protective

system shall have as few joints. As far as possible, air terminal & down conductor have to be straight. Where it is not possible, it should NOT be bent at 90 degree (right angles) & should have a curved path of 45 degree.

(ii) Joints should be mechanically and electrically effective, for example, clamped, screwed, bolted, crimped, riveted or welded.

(iii) With overlapping joints, the length of the overlap should not be less than 20 mm for all types of conductors.

(iv) Contact surfaces should first be cleaned, and then inhibited from oxidation with a suitable non-corrosive compound.

(v) Joints of dissimilar metals should be protected against corrosion or erosion from the elements, or the environment and should present an adequate contact area.

(b) Bonds: (i) Bonds have to join a variety of metallic parts of different shapes and composition, and cannot

therefore be of a standard form.

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(ii) There is the constant problem of corrosion and careful attention must be given to the metals involved, i.e. the metal from which the bond is made, and those of the items being bonded.

(iii) The bond must be mechanically and electrically effective, and protected from corrosion in,

and erosion by the operating environment. (iv)External metal on, or forming part of a structure, may have to discharge the full lightning

current, and its bond to the lightning protective system should have a cross-sectional area not less than that employed for the main conductors.

(v) Structures supporting overhead electric supply, telephone and other lines must not be bonded to a lightning protective system without the permission of the appropriate authority.

(vi) Gas pipe in no case shall be bonded to the lightning protective earth termination system.

21.9.8 Test Joints Each down conductor should be provided with a test joint in such a position that, while not inviting unauthorized interference, it is convenient for use when testing.

21.9.9 Earth Termination Network

(i) An earth station comprising one or more earth electrodes as required, should be connected to each down conductor. This shall be specified.

(ii) Each of the earth stations should have a resistance not exceeding the product given by 10 ohms multiplied by the number of earth electrodes to be provided therein. The whole of the lightning protective system, including any ring earth, should have a combined resistance to earth not exceeding 10 ohms without taking account of any bonding [as per 21.9.3(iii)].

(iii) If the value obtained for the whole of the lightning protection system exceeds 10 ohms, a reduction can be achieved by extending or adding to the electrodes, or by interconnecting the individual earth terminations of the down conductors by a conductor installed below ground, sometimes referred to as a ring conductor. Buried ring conductors laid in this manner are considered to be an integral part of the earth termination network, and should be taken into account when assessing the overall value of resistance to earth of the installation.

(iv) A reduction of the resistance to the earth to a value below 10 ohms has the advantage of further reducing the potential gradient around the earth electrode when discharging lightning current. It also further reduces the risk of side flashing to metal in, or of structure.

(v) Earth electrodes should be capable of being isolated and a reference earth point should be

provided for testing purposes. For earth termination system, 2 basic types of earth electrode arrangements are applicable: Type A & Type B arrangement. Earthing system should meet the requirements according to IS 3043, IEC 60364–5–54, IEC 62561–1 to 7, IEC62305 as well as UL 467. Earthing system should offer resistance less than 1 ohms throughout the year. For this purpose, earthing system vendor should do the soil testing and provide the necessary recommendation. In places where Soil resistivity is more, multiple earth electrodes are to be installed to get the required value. In case of multiple earth rods, vendor should provide possible resistance value of each earth pit. This value remains without any change for at least one year. Recommended value should be less than 10 ohms. In places where resistance of each pit is more than 10 ohms, special care needs to be taken. In such cases, Earth Enhancing compound need to be used for the vertical rods as well as horizontal conductors.

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High-grade solid steel rods of SAE 1035 molecular bonded with 99.9% pure electrolytic copper with minimum coating thickness of 250 microns should be used as earth electrode. The rods must be UL listed as well as tested according to IEC62561-2 and comply to the requirements of IEC 60364-5-54. The rods also should withstand short circuit currents as per the chart below. All fasteners used should confirm to the requirements of the above standards. Earth enhancing compound (Soil conductivity improver) should be tested according to IEC62561 – 7 from an National Test House or at any other laboratory approved by the Engineer-in-charge. Exothermic welding material used shall be tested as per IEEE 837

A hole of 100 to 125 mm dia. shall be augured / dug to a depth of about 2.8 meters.

Earth electrode shall be placed into this hole.

It will be penetrated into the soil by gently driving on the top of the rod. Here natural soil is assumed to be available at the bottom of the electrode so that min 150 mm of the electrode shall be inserted in the natural soil.

Earth Enhancing material (min. approx. 30 to 35 KG) shall be filled in to the augured /dug ole in slurry form and allowed to set. After the material gets set, the diameter of the composite structure (earth electrode + Earth Enhancing material) shall be of minimum 100 mm dia. covering entire length of the hole.

Remaining portion of the hole is filled with backfill soil which is taken out during auguring / digging

All the joints to the earth electrode shall be exothermically welded

In places where short-circuit level is more than 10 KA, (eg all panel boards, body) a copper strip of 25 mm * 6 mm with a minimum length of 150 mm need to be exothermically welded to the solid rod. All further connections need to be done to this copper flat.

For interconnection of earth pits, SOLID copper conductors with a size of 25* 3 mm flat or 10 mm copper bonded round steel conductors are to be used for Lightning Protection/ General purpose. In places where short circuit currents of more than 10 KA are expected, copper flats of 25 *6mm or 50 * 6 mm need to be used depending upon the expected short circuit level. In places where short circuit current requirements are more than 10 KA, Exothermic / Aluminothermic welding are only allowed for jointing earth electrode with round / Flat conductor. Connections with nut and bolt need to be completely avoided in applications under ground level, instead exothermic / aluminothermic welding need to be performed.

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21.10 Lightening STRIKE recorder with six digit with min current sensitivity of 0.15 KAmps through to a maximum of 220 KA @ 8/20 Micro Second impulse and operates by means of an inductive pick up loop. With a polycorbonate IP67 protection. The complete system should have earth resistance less than less than 10 ohm.

TABLE-1

Shapes and Minimum Sizes of Conductors for Use Above Ground Sr No Material and Shape Minimum size

1 Round copper wire or copper clad steel wire 6 mm diameter 2 Stranded copper wire 50 sq. mm or (7/3.00 mm dia)

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3 Copper strip 20 mm x 3 mm

4 Galvanized iron strip 20 mm x 3 mm

5 Round aluminium wire 8 mm diameter

6 Aluminium strip 25 mm x 3 mm

TABLE-2

Shapes and Minimum Sizes of Conductors for Use below Ground

Sr No Material and Shape Minimum size

1 Round copper wire or copper clad steel wire 8 mm diameter 2 Copper strip 32 mm x 6 mm

3 Galvanized iron strip 32 mm x 6 mm

4 Round Galvanized iron wire 10mm X 6 mm

5 Aluminium strip 25 mm x 3 mm

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CONTROL SWITCH BOARD FOR A.T.

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Chapter: A-22 Tech. Spec. No.- RVNL/ Elect/GS/22 CONTROL SWITCH BOARD FOR A.T.

22.0 GENERAL

(a) Control switch board shall be cubicle type, mast mounted, dust and vermin proof, totally enclosed & compartmentalized design of uniform height for outdoor utilization and suitable for 1-phase, 2 wire, 415V, 50Hz AC, solidly earthed neutral, electric supply system complete with accessories, inter connections, bus bar chamber with copper bus bar, ON/OFF & trip indication, duly wired up with copper conductor cable with colour coding etc.

(b) Switch board shall conform to IS:8623/Pt.1/1993 (LATEST). (c) The switch board manufacturer shall have ISO: 9001 certification with testing arrangement as

per IS: 8623 and powder coating facilities in the works. (d) Drawing shall be got approved from RVNL’s Engineer.

22.1 CONSTRUCTION

a) The panels shall be fabricated from 1.6 mm thick CRCA sheet steel. The shroud & partitions shall be of minimum 1.6 mm thick CRCA sheet steel. The panels shall be powder coated in approved shade. The degree of protection shall not be less than IP: 65 as per IS: 13942/Pt.1 (LATEST). The bus bar chamber/s and MCCB chamber shall have double doors. It shall be possible to operate the MCCB only after opening of the outer door. The Switch board shall be in vertical formation. Switch board shall be compartmentalized for accommodating bus bars on top & on bottom and MCCB in centre with individual compartment. Each compartment shall have its own door with insulated thumb screw. Each compartment/s shall have provision of concealed lock.

b) Upper side (on top) bus bar compartment shall be for incoming cable from AT to bus bar.

Termination from bus bars to incoming terminals of MCCB shall be with 35 sq.mm copper conductor single core FRLS PVC insulated cable.

c) Lower side (on bottom) bus bar compartment shall be for outgoing cable for feeding supply to

load. Termination from outgoing terminals of MCCB to bus bars shall be with 35/70 sq.mm (for 10 KVA) & 70 sq.mm (for 25 KVA) copper conductor single core FRLS PVC insulated cable.

d) Cable glands with detachable gland plates shall be provided on Lower side (on bottom) bus bar compartment for incoming and outgoing cable entry.

e) Earthing terminal as required shall be provided.

22.3 BUS BAR The bus bars shall be made of high conductivity copper conforming to the requirement of IS: 1897/1983(LATEST) for copper. The bus bars shall have uniform cross section (basis of bus bar cross section will be 1000 A/sq. inch for copper). The cross-section of the neutral bus bar shall be same as phase bus bar. Bus bars shall be supported on suitable non-hygroscopic, non-combustible, material such as DMC/SMC. Bus bars shall be insulated with PVC tapes/tubes (heat shrink type) with colour coding (Red/Yellow/Blue/Black) to withstand the test voltage of 2.5 kV for one minute

22.4 MCCB a) MCCBs (Ics=100%Icu) shall conform to IS: 13947/Pt -2/1993(LATEST).Tripping unit shall be of

thermal-magnetic type provided in each pole and connected by a common trip bar such that tripping of any one pole operates all the poles to open simultaneously.

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22.5 INDICATION LIGHTS a) Clustered LED type Indication light shall be provided for ON/OFF indication on incoming and

outgoing side. b) Cable entries shall be provided with metallic glands to prevent damage to the insulation of the

cable and terminals shall be provided in the switchboard to suit the number, type and size of power cables.

22.6 TESTING AND COMMISSIONING Following tests shall be carried out prior to commissioning of the panel:

a) Insulation test: When measured with 500V meager, the insulation resistance shall not be less than 100 mega ohms.

b) Trip test & protection test.

22.7 ERECTION Control switch board shall be fixed with the mast at suitable height /location and arrangement shall be as approved by the Engineer. Base shall be of Galvanized Mild steel angle of size 50x50x6mm and holding clamps shall be of Galvanized Mild steel flat of size 50x6mm. Nut & bolt shall not be less than 12 mm dia.

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SPECIFICATION FOR LED TYPE LUMINARIES

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Chapter: A-23

Tech. Spec. No.- RVNL/ Elect/GS/23 SPECIFICATION FOR LED TYPE LUMINARIES

23.0 General: This specification covers for the LED fitted luminaries used for outdoor and indoor applications for working at 220+/-10% , 50 Hz +/- 3% , Single phase input system. The luminaries are used at Railway Stations , Circulating Areas, buildings and offices etc. It consist of:

a) Fixture b) LED c) Driver and Electronics

For street light and plateform applications RDSO specification no: RDSO/PE/SPEC/PS/0123(Rev ‘0’)-2009, Amendment ‘2’ shall generally be followed.

23.1 Indoor Applications: The product should be latest state of art and compliant to relevant IEC 60598-1,2,3, IEC 62031 and IEC 62612 or their latest edition depending on the type of luminaries. In addition to the above luminaries shall adhere to relevant BIS standards IS 15885, 16101, 16102, 16103, 16104, 16105, 16106, 16107(Part I & II) as per the application. The product shall be of proven design should possess type test certificate /performance certificate from the accredited laboratory. The product and its major components shall be state of art and of proven design.

It should be capable to work at Maximum ambient air temperature of 65oC (For outdoor product) and 45oC (for indoor product) in atmosphere like coastal, humid, salt laden and corrosive.

Housing, if not used as a heat sink shall be made of 0.5 mm thick CRCA sheet/Extruded Aluminium(2mm) or pressure die cast(PDC-2 mm) confirming to relevant standards, polyester powder coated of at least 40 microns) and high U.V. and corrosion resistance.

Luminaries should be covered with suitable Glass or diffuser with High Transitivity. Outdoor luminaries shall be with clear toughened glass or clear poly carbonate cover.

Lighting fixtures and accessories shall be designed for continuous trouble free operation under diverse atmospheric conditions without deterioration of materials. Degree of protection of enclosure shall be at least IP-65 for outdoor fixtures. However, down lighter and other internal fixture shall be provided with at least IP-55 protection.

To be provided with suitable control optics as per need of application and render glare free to user.

Test papers for various parameters i.e. flux, power, efficacy, chromaticity, temperature, protection etc. Issued by certified agency shall be furnished. Estimation on product’s life and performance shall also be furnished.

(a) Fixture: The fixture should conform to applicable IS 10322/IEC 60598( All parts & amendments) and should have the associated LM-79 report(for Electrical and photometric test methodology for LED lighting) from accredited lab. Test report shall be submitted along with relevant catalogues. The fixture should have a surge protection of 2 KV.

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23.2 LED ( Light Emitting Diode) LED approved makes are Phillips-Lumileds, Osram, Nichia, Cree/Seoul Semiconductor/Approved Equivalent on specific approval of project authority on basis of test reports and specification in comparision of these standard makes. Manufacturer should have IEC (Illuminating Engineering Society) -LM-80 test report and with projected life as per IEC-LM21. Test report shall be submitted along with relevant catalogues. All LED to be solid state embedded as light sources, arrays and modules.

High lumen efficacy LEDs suitable for the application along with following features shall be used:

(i) LED Efficacy at the chip level shall >120 lumen/watt (For High power LED)

(ii) The efficiency of the LED at 85 Degree C junction temperature shall be more than 85%. (iii) The system luminous efficacy of LED luminaire’ shall be as under:

a) Efficacy > 60 lumen/watt for low wattage luminaries (<45W): and b) Efficacy > 80 lumen/watt for a high wattage luminaries (>45W).

(iv) Adequate heat sink with proper thermal management shall be provided. (v) Minimum view angle of the LED shall not be less than 120*. (vi) Power factor of complete fitting shall be more than 0.9 (vii) LED shall be surface mounted type duly soldered to PCB by Reflow system of COB Type.

The Solder used shall be ROHS compatible for environment friendliness. (viii) Colour rendering index CRI >=70 as specified in the item description. (ix) Correlated colour Temperature shall be in the range of 3000 K-6500 K as specified in

item description.

23.3 LED driver. LED driver shall be capable to withstand and work with Input voltage Range from 160V (RMS) to 270 V(RMS) with built in 2KV surge protection. Output voltage of the driver shall be designed to meet the Power requirement of the system. Output voltage ripple should be within 3%. Output over voltage protection should be up to 125 V DC. Full Load Efficiency shall be more than 85%. Total Harmonic Distortion

- For 0-50 W shall be less than 25% - Above 50 W rating shall be less than 15%

Current waveform should meet EN 61000-3-2. LED Driver shall be able to withstand voltage of 350V for 2 hours and restore normal working when normal voltage is applied. The driver should comply to CISPR 15 for limits and methods of measurement of Radio Disturbance characteristics and it should comply to IEC 61547 for EMC immunity requirement. The control gear should be compliant to IEC 61347-2-13, IEC 62031 and IEC 62384.

23.4 General The lumen maintenance of the LED lightings shall not be less than 70% after 50,000 hours i.e. L70 (B50). The supplier shall provide evidence that the LED chipset manufacturer has the patent right to produce the supplied LED chipset to avoid infringement of white LED patent. Free warranty shall commence after delivery and end at 60 months after delivery. The warranty of replaced item shall re-start from date of attending defect/replaced.

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Tech. Spec. No.- RVNL/ Elect/GS/24 VARIABLE REFRIGERANT FLOW (VRF) SYSTEM FOR

BUILDING CENTRALISED AIRCONDITIONING

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Chapter: A-24


SPECIFICATION FOR VARIABLE REFRIGERANT FLOW (VRF) SYSTEM FOR BUILDING CENTRALISED AIRCONDITIONING

24.0 General

Scope of work includes design, fabrication, supply, installation, testing and commissioning of centralized air ventilation with evaporative cooling units. Plant shall be effective to lower the room temperature with respect to ambient temperature with dust free atmosphere. Scope also includes supply of materials, fabrication and fixing of GI ducting suitably sized with supporting MS supporting angles with aluminum powder coated supply air grills with volume control air dampers, MS stand for AHU, sound attenuator, AHU control panel and related civil works. Project is turn-key in nature and the contractor’s scope is to ensure proper functioning and commissioning of the equipment.

24.1 Description

Air conditioning (VRF System): The scope of work includes supply, installation, of all parts mentioned or not in the schedule as per specification and testing, commissioning of complete work as turnkey.

24.1.1 The VRF system shall typically consist of an outdoor unit with multiple digital scroll compressors and different types of indoor units for different zones and electronic control center / microprocessor.

24.1.2 The Variable Refrigerant Flow (VRF) system shall have Digital/ Inverter Scroll Compressor to modulate the refrigerant flow to meet the varying cooling loads and to deliver enormous savings on electricity bills.

24.1.3 The VRF system should be capable of performing cooling during summer / monsoon season to achieve temperatures of 22°C to 28°C in the conditioned rooms as set by the occupant.

24.1.4 The VRF system shall be provided with sophisticated electronic control center to enable zone wise climate control.

24.1.5 The VRF system shall have tropicalized outdoor units, which can operate at ambient temperatures as high as 520C.

24.1.6 The outdoor unit shall have following features: (a) Polyester powder-coated sheet metal housing for longer life. (b) Anti-corrosion blue fins in condenser coil for longer life. (c) Built-in oil separator, accumulator and liquid receiver for oil, liquid and gas balance of

the entire system. (d) Low noise external rotor fan (e) Shall operate at high ambient temperatures as high as 520C.

24.2 Compressor: The compressor(s) shall be combination of highly efficient hermetically sealed fixed scroll and

digital scroll type and should be capable of varying the capacity from 10% to 100% by modulation technology which allows an external control to switch the compressor rapidly between its loaded and unloaded states including crank case/oil heaters complete in all respect.

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24.3 Heat exchanger / Condenser coil: The condenser coil shall be constructed with refrigeration grade soft annealed copper tubes

mechanically bonded to aluminum fins to form a cross fin coils. The aluminum fins shall be given anti-corrosion coating for longer life.

24.4 Refrigeration circuit: The refrigerant circuit shall include liquid and gas shut off globe valves at outdoor end. All

necessary safety devices for controlling the digital scroll compressor shall be provided to ensure the safe and efficient operation of the system.

24.5 Safety devices:

24.5.1 All necessary electrical safety devices including single-phase prevention / phase reversal; overload protection etc to be provided.

24.5.2 All necessary refrigeration safety devices including HP – LP Cut Out Switch etc. to be provided.

24.5.3 The refrigerant used shall be eco-friendly gas R 410A.

24.6 Indoor unit: 24.6.1 This section deals with type and features of indoor units for the duty selected. The

type, capacity and size of indoor units are as specified in “Schedule of Rates / Quantity”.

24.6.2 General: Indoor units shall be as specified in “SOR”. Each unit shall have electronic controller and valve to control the refrigerant flow rate responding to load variations of the room.

24.6.3 The address of the indoor unit shall be set automatically in case of individual and group control.

24.6.4 In case of centralized control, it shall be set by liquid crystal remote controller.

24.6.5 The fan / blower shall be aerodynamically designed turbo, multi blade type, statically and dynamically balanced to ensure low noise and vibration free operation of the system. The fan shall be directly driven type, mounted directly on motor shaft having support from housing except for floor standing ducted type in this case the blower shall be belt driven.

24.6.6 The evaporator coil shall be constructed with refrigeration grade soft annealed copper tubes mechanically bonded to aluminum fins to form a cross fin coils.

24.6.7 Each unit shall be provided with cleanable air filters.

24.6.8 Each indoor unit shall have computerized PID (Program index) control for maintaining design room temperature.

24.6.9 Each unit shall have cordless Remote Controller (RC) as specified in “SOR”. 24.7 Controllers:

24.7.1 Salient Features Cordless Remote Controller: - On / Off control on individual unit - Set temperature - Mode settings -Fan / Cool / Heat / Dry - Air flow direction -Auto swing or fixed angle mode for louvers (applicable only

for Cassette Type) - On / off timer.

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(a) System Controller The system controller can be located in centralized area and has the following

features:

Can control up to 64 indoor units Individual setting for operation Group Stop / Start function Switch On / Off of individual unit. Fan speed settings – Auto / High / Medium / Low Display set temperature Display room temperature Self-diagnostic function for all indoor and outdoor units Air flow direction - Auto swing or fixed angle mode for louvers (applicable

only for Hi Wall and Cassette Type) Long cable connection up to 1000 m between outdoor and indoor units. Compatible with external BMS (Building management system) Modbus or compatible– RTU open protocol

(b) Weekly Timer:Features:

On / Off timing of individual units Programmable for whole week The units can be set to off mode during holidays.

24.8 Type of Indoor Units: 24.8.1 Cassette Type (Ceiling Mounted):

The cassette type units shall have following features: (a) Sleek and low height so as to fit easily into ceiling spaces. (b) Fresh Air Intake Provision so as to draw fresh air and maintain good in door air

quality. (c) Drain Pump with special drain up mechanism (d) No fibrous material to be used on both the panel and the louver. (e) Auto-swing louver to ensure uniform airflow.

24.8.2 Ducted type (Concealed Fan coil):

The ceiling suspended type units shall have following features: (a) Low height, so that it occupies less space above false ceiling / boxing allowing for

more headroom. (b) Fresh Air Intake Provision so as to draw fresh air and maintain good indoor air quality. (c) Shall be acoustically lined for low noise. (d) The fan panel shall be detachable type by loosening wing nuts. Thereby ensuring easy

access for service of motor and coil. (e) The powder coated GI panels shall withstand salt spray test for 1000 hours and shall

be rust proof & maintenance free.

24.9 Refrigerant Piping: (a) Maximum main branch pipe length should not exceed 150 m (b) Maximum elevation difference IDU & ODU < 50 m when ODU is higher than IDU (c) Maximum elevation difference IDU & ODU < 40 m when ODU is lower than IDU (d) Maximum elevation difference between IDUs fed through same ODU, should be less

than 15 m

(e) Main Refrigerant Pipe Line: (i) Refrigerant piping material should be “hard drawn, super clean quality copper,

18 G” for pipe OD 41.28 mm.

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(ii) Refrigerant piping material should be “hard drawn, super clean quality copper, 18 G” for pipe OD 34.93 mm

(iii) Refrigerant piping material should be “hard drawn, super clean quality copper, 19 G” for pipe OD less than 38.10 mm.

(f) End Connection of IDU / ODU: Maximum length of soft pipe for flared connection not to exceed 1.0 m.

(g) Refrigerant piping material should be “soft, super clean quality copper, 18 G” for pipe OD 19.05 & 22.22 mm.

(h) Refrigerant piping material should be “soft, super clean quality copper, 19 G” for pipe OD 15.88 mm

(i) Refrigerant piping material should be “soft, super clean quality copper, 21 G” for pipe OD 6.35, 9.52, 12.7 mm.

(j) The thickness of elbow and socket shall be as per following: - 0.813 mm for pipe OD 6.35, 9.52 & 12.7 mm - 1.000 mm for pipe OD 15.88 mm to 28.58 mm - 1.100 mm for pipe OD 31.75 mm - 1.350 mm for pipe OD 34.93 mm to 41.28mm (k) Bleed nitrogen while brazing the pipes (l) All the pipes should be insulated with 19 mm thick nitrile insulation. The suction line

insulation shall have at least R-0.35 (R-2) insulation, and exposed insulation to be protected by aluminum foil, painted canvas, or plastic cover.

(m) Entire piping work and IDUs to be pressure tested for leakages with 450 psig nitrogen pressure, hold the pressure for 24 hours.

(n) Vacuumise in 2 stages. 2000 micron + Nitrogen 5 psig + 500 micron and hold the vacuum for minimum 06 hours.

(o) Distribution joint kit: Suitable size factory made Y- joint kits / header to be used for suction and liquid line.

(p) All refrigerant piping to be laid on cable tray 150 mm wide.

24.10 Control/ Communication wiring: Supply and erection of communication wires of 2 cores x 0.75 mm2 (shielded wire) in conduit of suitable size as per the direction of site engineer.

24.11 Makes: The acceptable make for VRF system shall be Blue Star, Voltas, Mitsubishi, Toshiba and

Daikin. Minor change in standard design shall be acceptable from approved makes only.

24.12 Air Handling Unit: AHU shall be double skin screw less & sturdy construction for low noise and better thermal

insulation. Double skin panel construction shall allow easy inspection, service and maintenance and reduce the risk of dirt and bacteria accumulation. Pre-filter provided shall be of synthetic non-woven type supported with aluminum and HDPE. Filter efficiency shall be 90% for 10% micron. Control panel shall be provided with powder coated control box to house isolator single phasing preventer and contactors for starting of the motor. Control panel shall be compatible with BMS having open protocol. On-off trip indications and luminous push buttons shall be provided. Provision shall also be made to connect control value, fire dampers, modulating motor and door switch. Fan and motor shall be mounted on aluminum extruded slide rail base frame to adjust belt tension without disturbing motor alignment. Fan section shall be provided with an access door for ease to service, view port shall be provided at fan door panel, which would help monitoring fan and motor status. Door limit switch shall be provided to automatically trip fan with the door is open. Every AHU shall be supplying with a factory fitted GI powder coated volume, control damper to facilitate balancing. All AHU shall be Horizontal/vertical/suspended type so as to occupy lesser floor space. Selection of the type of AHU vertical or ceiling suspended or horizontal shall be based on the rating and the site condition. The fan section shall be provided with an access door for ease serviceability of fan and motor. Aluminum die cast powder coated hinges shall be provided. The unit shall be complete in all respect.

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24.13 Water Circulation System

Cellulose pad on one side of the air cooling system shall be provided for the purpose of water circulation to ensure evaporative cooling effect of the system. The ventilated blower used should be AMCA approved for sound and air. Documentary evidence to this effect shall be made available along with the tender. Bottom tray shall be of size specified in the technical specification made of non-corrosive stainless steel grade SS 304. Suitable humidistat shall be provided to measure humidity level in the room and thereby cutting off pump circulation water. Make up water required due to the loss of water on account of evaporation shall be provided through water-cooling system to enable a inflow at required quantity per hour at 30 Degree Centigrade. Flow of make up water shall be controlled through latest improved mechanism provided in SS tank other than float valve. The system shall be complete in all respect.

24.14 Details for Ducting:

Ducting will include following items- Item No. 1 -This work is mainly consisting of Design, Supply, Installation, Testing and Commissioning of Air cooling system as mentioned in and as per specification enclosed. Foundation, base frame of the drive & nut bolts are in the scope of contractor. Item No. 2 - This work is mainly consisting of Design, Installation of fabricated GI sheet ducting of 18/19/22/24 G along with all material including material required for installation. Item No. 3- This work is mainly consisting of Design, Fabrication and Installation of Aluminum powder coated air grills with G.I volume control dampers along with all material including material required for installation.

Item No. 4 This item work is mainly consisting of Design and Installation of Insulation of latest improved quality CFC free insulating material in coating form. This should be efficient and good looking.

24.15 Evaporative cooling system

Description Specification AHU

Make Voltas, Carrier, Blue Star

Casing Double skin Outer skin 0.6 mm/23G SS 304 sheet Inner skin 0.6 mm/23G SS 203 sheet Air quantity As per schedule item Frame work SS 203 Corner joints Welding by MIG technology Panel thickness 25 mm

Insulation PUF density PUF 55 mm thick / Rock wool 100 mm thick of density 28-32

kg per mt3 PUF material CFC Free, improve quality coating type material. Process Standard process Anti vibration Spring isolators to be provided at fan motor

Pre filter section Type Box type Make Spectrum or equivalent imported Media Non woven synthetic Thickness 48 mm

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Class/efficiency Eurovent class EU3 as per EN-779 standard/ 90% down to 10 micron

Filter area As per suitable for required capacity Humidification section

Casing Double skin Outer skin 0.6 mm/23G SS 304 Inner skin 0.6 mm/23G SS 304 grade Pad Cell deck Pad area As suitable for required capacity Min. pad thickness 8 inches Pad efficiency 90% @ 500 fpm velocity

Sump Material of construction 1.2 mm/18 G stainless steel grade 304 Size and material of float valve

20 mm dia, heavy duty brass

Depth As per suitable for required capacity Pump

Make/model As per standard used by Voltas, Carrier, Blue Star Rating As suitable for required capacity Type Monobloc (IP 65 Protection) Safety against wet run of pump

To be provided with water level switch

Droplet eliminator 4 pass PVC Fan section

Fan make AMCA certified Kruger. Type DIDW, Centrifugal forward curve Model As per standard model used by Voltas, Carrier, Blue Star RPM As per standard rating and capacity Rating As per required capacity Fan efficiency As per relevant IS Fan outlet velocity As per standard rating and capacity

Motor Make ABB, CGL, Hindustan motors Type 4 Pole TEFC Degree of protection IP 65 Insulation Class F Rating As per suitable for required capacity

Supply air damper Type Opposite blade aerofoil aluminum

Note: (1) Minor change in standard design shall be acceptable from approved makes only. (2) Project is turn-key in nature and the contractor’s scope of work is to ensure proper

functioning and commissioning of the complete system. -------------------------------------------------------------------------------------------------------------------------------------------------------------------------

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MACHINE ROOM TYPE ELECTRIC TRACTION PASSENGER LIFT FOR BUILDINGS

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CHAPTER: A-25


MACHINE ROOM TYPE ELECTRIC TRACTION PASSENGER LIFT FOR BUILDINGS

25.0 Scope:

The scope includes design, manufacturing, supply at site, erection, testing, commissioning and handing over in satisfactory working condition of Machine room type motor operated Electric traction passenger lift to the requirements as given in BOQ as per details of Annexure ‘A’, under the operational and environmental conditions encountered during service, complete with all accessories. Specifications and other stipulations are given below. The salient points pertaining to safety shall also be complied by the Supplier/Contractor. All the items mentioned here are general in nature and any item (s) required for proper and safe functioning of the lift shall be supplied with the lift without any extra cost even if not specifically mentioned here.

25.1 General.

The Machine Room type Lift shall be governed by relevant International Standards and International Codes of Practice such as European code of safety EN 81, American National Standard Safety Code for Elevators (ANSI) A117.1, IS: 14665 or latest and IEC 60364 for Electrical Installations of buildings. The traction machine, over speed governor, ropes, brake gear controls and other safety equipment even though corresponding to specification EN 81 and ANSI A117.1 should under all conditions of operations at least match with IS code of specification for passenger Lifts viz. IS: 14665 or latest. This has to be ensured by Lift manufacturers primarily and the manufacturer should have appropriate Quality Assurance accreditation ISO 9000 / ISO 14001. The installations shall be to the highest standard as expected of a fully experienced contractor. The manufacturer shall also comply with the provision of Indian electricity act and rules in vogue and shall be taken over only if and when they fully comply with all their requirements. The lift installation shall also be designed to produce a safe working environment for Engineers and auxiliary workers to work on or around.

Prior APPROVAL OF EMPLOYER shall be obtained for make/detail specifications of the proposed lift before ordering giving all the relevant details and suiting the site conditions.

25.2 Intellectual property rights:

If the Supplier/Contractor intends to use the intellectual property rights of another party in performing the Supplier/Contractor’s obligations under the contract, appropriate licenses shall be obtained from the relevant beneficial owners.

Where any software is provided in the works, the Supplier/Contractor shall submit documents showing that appropriate permission or License have been obtained from relevant beneficial owners of intellectual property rights for the use of the software free of all fees for the whole operating life of the Works. Where O&M manuals and as-built drawings are submitted, the Supplier/Contractor shall obtain appropriate permission or licence from relevant beneficial owners of intellectual property rights to allow the Supervising Officer, the Employer and the subsequent owners or occupiers of the

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Works, and all parties responsible for the operation and maintenance of the Works free from all fees to make additional copies of the manuals and drawings.

25.3 Environmental service conditions: All electrical, electronic and mechanical equipment shall suit the tropical climate for use in service environmental conditions as stated below: - Maximum ambient temperature 55º C Minimum ambient temperature -5º C Maximum Relative humidity 100% Atmosphere Extremely dust and desert weather and desert terrain in

certain areas. The dust contents in air may reach as high values as 1.6 mg/m.cube.

Coastal area The equipment shall be designed to work in corrosive atmosphere.

Maximum Ph value 8.5 Sulphate 7mg/litre Max. concentration of chlorine 6mg/litre Max. conductivity 130 micro siemen/cm Annual Rain fall Ranging between 1750 to 6250 mm with thunder storm. Altitude Not exceeding 1200m

25.4 Specifications:

25.4.1 Geared Machine: The lift machine shall be smooth in operation with minimum noise/vibration and of worm gear reduction type with traction motor, electromechanical brake, worm gearing, driving sheaves and suitable to work on 400/440 Volts AC 3 Phase with neutral at 50 cycles per second supply with VVVF (Variable Voltage Variable Frequency) type of control. The traction motor shall be energy efficient induction type with minimum of BEE’s three-star rating and in accordance to BS 4999 and BS 5000: part 99. The motor shall be designed to operate for an unlimited period according to the expected duty of the lift.

25.4.2 Sheaves: The driving sheave and pulleys should be of hard alloy constructed from fabricated cast steel or S.G iron or suitable wear resistant material and free from cracks, sand holes and other defects with truly machined surface in order to ensure perfect alignment of all bearings and prevent transmission of sound to the building. They shall have machined rope grooves. The traction sheave shall be grooved to produce proper traction and shall be of sufficient dimension to provide for wear in the groove. The deflector sheave shall be grooved so as to provide a smooth bed for the rope. The deflector or secondary sheave assemblies where used shall be mounted in a proper alignment with the traction sheave. Such deflector sheaves shall have grooves larger than the rope diameter as specified in clause 8 of IS:14665 (part-4, Sec.3):2000 or latest. The size of all the sheaves shall be in accordance with clause 8.4 of IS: 14665 (part-4, Sec.3):2001 or latest. Wherever necessary, suitable protective guards may be provided.

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25.4.3 Electric Motor duty cycle:

The driving motor shall be designed specially for heavy duty Lifts to run smoothly under load up to its maximum capacity in either direction with ample power to deal with occasional overloads. It shall be arranged to develop the requisite, torque, enabling the machine to start easily from rest. The motor shall be designed to confirm to S3 duty cycles defined as per IEC duty cycles for non peak and peak periods of operation. The motor and drive system should be designed for not less than 150 starts/hour and stops during the peak periods. The peak periods of lift workings are furnished in Annexure ‘A’.

25.4.4 Brake: A suitable electro magnetic brake, preferably of the direct acting type integrated with motor operating on AC/DC shall be provided, with two brake shoes which are automatically applied by means of a strong compression springs to a brake wheel of large diameter when the circuit is broken and released by means of an electro-magnet. The brake mechanism must incorporate provision to allow for minimum wear of brake lining. It shall also have an emergency quick release device to open the brake without affecting its adjustment so that the car can be lowered or raised manually in the event of electric supply failure. The electric solenoid shall be rated to withstand continuous Lift duty.

25.4.5 Car and car frame: The car enclosure shall be in accordance with clause 4 of IS: 14665 (part-4, Sec.3):2001 or latest, made up of stainless steel 1.5 mm thickness hairline finish. The Lift car shall have stainless steel false ceiling adequately illuminated LED luminaries of flush mounted pattern which shall give illumination of not less than 150 Lux on the lift floor level. The level of illumination in a power failure shall be a minimum of 50 Lux to floor level throughout to be maintained by providing Emergency lights. One axial flow fan of quit running type having a noise level not greater than 30 dBA when measured at a distance of 1 m from the fan and it shall be capable of handling at least 20 air changes per hour of lift car volume, with car doors closed. The effective area of ventilation apertures situated in the upper part of the car shall be at least 1% of the available car area, and the same applies for any apertures in the lower part of the car. The car ventilation fan shall be switched off within a period which shall be adjustable from 5 to 15 minutes after the last registered call is answered. One smoked mirror of half height full width on the rear panel, suitable handrails of 50mm O.D. tubular stainless steel shall be provided at 86mm height from floor level of the car on three sides of the lift car extending to within 150mm of all corners and with a 40mm clearance from car walls to facilitate handicapped passengers. A load plate giving the contract load of the Lift, No. of passenger capacity of the Lift shall be fitted in the Lift car in a conspicuous position. Emergency contact number plate should be provided with front transparent acrylic sheet with flush screw arrangement such that contact numbers can be changed. Suitable slotting arrangement should be done accordingly. The Control logic should be used for controlling lights and fan. The ventilation fan and full lighting shall be switched off by logic and predetermined period if no button is pressed or call registered. The lighting except emergency illumination shall also have connection to motion sensor. The lights and fans supply also should have separate control panel switch to make on/off. The ventilation fan shall also have one switch for operation in addition to motion sensor control. For video remote monitoring security web camera to be installed in the lift car having display with recording arrangement to Control room in addition to self memory of minimum past 72 hours recording.

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Floor to be made of 1.5 mm thickness Stainless Steel with 4mm thick antiskid studded rubber floor to colour and pattern as approved by the employer’s project authority . The switch and control panel buttons to be made with backlit/letter display by LED with dark background and the alpha numeric display in English language and also BRAILLE indents. The control activated voice information of floor level announcement to be provided. The public address system also to be built in for playing emergency announcement/commercial/ entertainment etc. Two number LCD display of size of minimum 32 inch diagonal, motion flow 120 Hz live colours display, HD image on NTSC/PAL/ATSC tuner having VGA/USB/BNC/TV tuner input control to be provided with connection to public address system. The control supply should be brought to control room and VGA, Audio/Video output wiring to be done at Control room of lift/machine room. Safety instructions in international signages pattern to lift users to be provided inside the car as approved by the employer’s project authority. Emergency illumination on LED based luminaries also to be provided in car with adequate SMF battery to support at least 72 hours back up with control switch in lift car itself. The emergency battery back also shall be used for operation of interphone and emergency alarm bell. The roof of the car shall be solid type made of 1.5 mm thickness Stainless Steel capable of supporting a weight of two persons i.e., at least 138 kg as per IS: 14665 (part-4, Sec.3):2001 or latest and shall withstand to a vertical force of 2000N at any position without causing permanent deformation. Lift car, excluding linings, shall be constructed of non-combustible materials. One lighting socket outlet for hand lamp shall be provided on the top of the Lift car for inspection. Suitable hand lamp with appropriate size and length of cable shall be supplied to the maintenance staff by the Supplier/Contractor.

25.4.6 Doors: Landing doors and car door shall be of 2 panel centre opening sliding closed, stainless steel powder coated or hairline stainless steel finish panels as approved by the Employer’s project authority in charge, power operated independent drive with adjustable automatic opening and closing speeds for door. The clear opening should be 900 mm wide x 2000 mm height. The door shall have a fire resistance rating of one hour as per EN 81-58 and ground switch/switches at ground floor level shall be provided on all the lifts to enable the fire service to ground the lifts.

The car doors shall be fitted with a Memco 3D curtain safe edge to detect and open the doors in the event of obstruction/infringement while the doors are closing. The door open time to be made programmable for time delay set in the system. The lift shall be designed to go out of service if the doors are kept open for a long time as programmed. A delay to the start the lift after the doors is closed (say 0.2 to 2.0 seconds) also to be programmable. The landing doors shall be provided with electro-mechanical inter-locks to prevent operation of the Lift unless all the doors are closed and positively locked. The inter-lock shall also prevent the opening of any door until the car has reached the respective landing zone. In the event of failure of Memco 3D curtain suitable mechanical system should be provided to open the doors in the case of obstruction. Any projections on or recesses in the exposed parts of the car doors or landing doors shall be kept to a minimum in order to avoid finger trapping between sliding parts of the door and any fixed part of the car or landing entrance. The clearance between panels or between panels and any fixed part of the car or landing entrance shall not exceed 6 mm. Sliding car and landing doors shall be guided on door tracks and sills for the full travel of the doors. The distance between the car and landing sills shall not exceed 35 mm. The clear height of all entrances on car and landings shall not be less than 2 m. Supplier/Contractor shall provide full door sticker of approved quality and design with adhesive as approved them by employer’s project authority in charge.

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Three good quality digitally printed safety and energy saving tips/instructions as per pictographically international signages pattern of size 2 feet x 3 feet of suitable design to be supplied and fixed on wall at lift on each floor in Hindi/English/Vernacular language (i.e. one each).

25.4.7 Electrical device for proving the car doors closed: Every car door shall be provided with an electrical switch which will prevent the lift car from being started or kept in motion unless all car doors are closed. A mechanical locking device shall also be provided such that the car door cannot be opened from the inside while the car is outside the unlocking zone.

25.4.8 Landing door locking device: Every landing door shall be provided with an effective locking device so that it shall not normally be possible to open the door from the landing side unless the lift car door is in that particular landing zone. It shall not be possible under normal operation to start the lift car or keep it in motion unless all landing doors are in the closed position and locked.

25.4.9 Door locking devices to be inaccessible from landing or car: All door locking devices and door switches, together with any associated actuating rods, levers or contacts, shall be so situated or protected as to be reasonably inaccessible from the landing or the car.

25.5 Car Slinging and Safety Gear: The car body shall be supported in a steel sling so that no strains due to suspensions lifting action of the safety gear are imposed in it. The sling shall be provided with adjustable shoes on each side at the top and bottom to engage accurately with the guides to ensure smooth running. The car and counter weights shall have underneath it an automatic instantaneous type safety gear operated by an over speed governor designed to ensure positive action for excessive speed on the down travel of the car. The safety gear shall be equipped with a contact to cut off power supply/during over load in such event and to bring the car to a stop. Controls and facilities for inspection shall also be provided at top of the car to facilitate inspection and testing as per ISS latest and international standard.

25.6 Governor: The car safety shall be operated by speed governor which shall be in accordance with clause 4 of IS: 14665 (part-4, Sec.3):2001 or latest and shall be adjustable to actuate the safety gears., located overhead and driven by governor rope suitably connected to the car and mounted on its own pulleys. The governor shall be of “V” groove wheel design. The rope shall be maintained in tension by means of weighted or spring loaded tension sheaves located in the pit. The governor rope shall not be less than 10mm in dia and shall be made up of steel and as specified in Clause 25.7 of this Specification.

25.7 Suspension Ropes:

The main suspension ropes shall be in accordance with BS 302 part 4 clause B4.1 and clause 7 of IS: 14665 (part-4, Sec.3):2001 or latest and the requirements for steel wire ropes shall be in accordance with IS: 14665 (part-4, Sec.8):2001 or latest, of the best flexible steel wire construction conforming to IS: 6594/1981 or latest , with a minimum factor of safety of 12 times ,the number of strands and diameter of the ropes shall also comply with the factor of safety requirements of the American National Standard Safety code for Elevators (ANSI)

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A117.1. The supply of steel wire ropes should be three ropes or more and of minimum 10mm dia., from the reputed rope manufacturers and shall be guaranteed for a period of two years. Ends of the ropes shall be properly secured to the car and counter weight hitch plates with adjustable rope shackles having individual tapers babbit sockets or any other suitable arrangement. Each rope shall be fitted with a suitable shackle spring, seat washer, shackle nut & lock and shackle nut split pin.

25.8 Compensation rope: For travels over 30 m and/or rated speed of the lift exceeds 2.5m/s, the Supplier/Contractor shall provide compensation ropes with tensioning pulleys. For speeds of 2.5 m/s or below, quiet operating chains or similar devices may be used as the means of compensation. For speeds above 3.5 m/s, an anti-rebound arrangement of idler tension pulley shall be provided to prevent the counterweight jumping with the application of the car safety gear.

25.9 Diverting Pulleys:

Diverting pulleys necessary for suspension of car on counter weight shall be of cast iron, grooved for wire ropes complete with shaft, bearings and are to be suitably supplied and they shall incorporate devices to avoid:

▪ The suspension ropes, if slack, leaving the grooves.

▪ The introduction of objects between rope & grooves.

25.10 Guide rails: The guide rails shall be in accordance with clause 3 of IS:14665 (part-4, Sec.2):2001 or latest for the car and counterweight and shall be made up of rigid steel ‘T’ sections with machined working surfaces. These guides shall be erected to plumb and shall be complete with suitable fixings at such intervals as to prevent deflection. The strength of the guides, their attachments and joints shall comply with clause 10.1 and 10.2 0f EN 81-1 and BS 5655 : Part 9 Clause B1.2 and be sufficient to withstand the forces imposed due to the operation of the safety gear and deflection due to uneven loading of the car. The section of weights in kg per meter of rails should be furnished by the Supplier/Contractor in Annexure`B’. Guide lubricators of approved design shall be provided.

25.11 Counter Weight: The counter weight shall be in accordance with clause 6 of IS: 14665 (part-4, Sec.3):2001 or latest, shall consists of a structural steel frame with loose cast iron filler weights arranged to balance the full weight of the car plus, approximately 50% of the contract load so as to ensure low power consumption and economical running of the Lift. The factor of safety of steel frame members and the tie rods shall not be less than 5. The guide shoes shall be fitted to the top and bottom of the structural frame on both sides and shall be of replaceable & adjustable type to ensure smooth and quiet running and long life. Counter weights shall be guarded by means of a rigid fixed screen extending from a position of 0.3m above the Lift pit floor to a position at least 2.5m above the Lift pit floor.

25.12 Buffers:

Buffers shall be in accordance with clause 5.15 of IS: 14665 (part-2, Sec.2):2000 or latest. Hydraulic/spring buffers of tested design shall be installed as a means of stopping the car and counter weight at the extreme limits of travel. Buffers in the pit shall be mounted on the steel frame, which shall extend between both the car and counter weight guide rails. Energy accumulation type buffers shall only be used if the rated speed of the lift does not exceed 1 m/s

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and Energy accumulation type buffers with buffered return movement shall only be used if the rated speed of the lift does not exceed 1.6 m/s.

25.13 Operating System:

The Lift operating system shall be of simplex full collective type with provision for operation with or without attendant. It should comprise of a call button at each landing and a set of dispatch buttons together with an emergency stop button in the car. All components shall be well insulated and mounted in a metal case with suitably finished cover.

25.14(a) Control station in car: Each lift car shall have a flush mounted control station comprising:-

1. Call buttons with acceptance signals engraved in Arabic number to correspond with the landing served;

2. An alarm push button with protection from being operated accidentally; the colour of this button shall be yellow;

3. "door open" and "door close" push buttons; 4. Audible and visible signals in connection with the overload device;

5. Light switch, alarm reset switch, fan switch and cleaner's "Stop-switch" keeping the car door open in the form of key switches or housed in a recessed metal box with hinged or sliding lid which will be key-locked.

6. Two-way intercom speaker - the intercom system shall be as specified in Clause 25.17. 7. Any other control as specified in the specification.

All wordings shall be engraved in both English and Hindi characters. The material for the control station shall be stainless steel with a thickness of not less than 2.5 mm. The control station shall be fixed onto the car panel by stainless steel screws of secret-head type.

(b) Additional Control Station: For passenger lifts of 21 persons capacity or larger, two car control station, one on either side of the car doors, shall be provided such that one shall have the above functions 1, 2 and 3 only and one shall have all the functions 1 to 7.

(c) Control station equipped with attendant control: For lifts equipped with attendant control, the control station shall also incorporate:- 1. A non-stop button for the purpose of bypassing landing calls, but the calls shall remain

registered until answered. This button shall be inoperative unless the lift is operated by an attendant.

2. A key-operated attendant control switch to be included in Clause 25.14(a)5. The additional functions specified in this clause shall be provided in the Control Station in

Clause 25.14 (a).

(d) Car direction and position indicator: The direction indicators shall be of illuminated directional indicator with an illuminated area not less than 1125 mm2. The position indicator shall be of digital type display with lamp matrix actuated by solid state circuitry unless otherwise specified. The position indicator shall have a minimum height of 50 mm and easy to read even from a wide angle of view and under an illumination level of 500 lux. LCD display to be provided.

The indicators shall be mounted onto the back of at least 2.5 mm stainless steel faceplates by weld studs and screws flush fit.

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(e) Push /Electronic touch button: All push/electronic touch buttons shall be vandal-resistant design and of flush mounted construction. The push/electronic touch buttons shall have acknowledgement of the call by illumination. The halo shall be formed with flame retarding polycarbonate. Shock loads due to pressing of the pressel must be borne by the body of the unit and not by the contacts.

(f) Lift control buttons: Essential lift controls buttons such as emergency alarm button, intercom button, door opening button, call buttons on landings, floor buttons in the lift car shall not be lower than 900mm or higher than 1200mm above the finished floor level. Braille and tactile markings shall be placed either on or to the left of the control buttons. Such markings shall be minimum 15mm in height and 1 mm raised. All lift control buttons shall have a minimum dimension of 20 mm.

25.15 Fire Emergency return:

When the building’s fire or smoke detectors are activated, all calls should be cancelled automatically and the lift shall travel to the main lobby or a pre-designated floor and park there with the door fully opened. However the Electrical signal that indicates the actuation of the fire sensors must be supplied to the lift controller by others or the fire alarm switch provided on the ground floor is activated. The display to be given in the car with pre-recorded audio message so that passengers do no panic.

25.16 Car lights & Fan automatically shut off: The lift shall be installed with an energy saving feature that automatically switches off the car

internal lighting and ventilation fans when there are no calls registered after a predetermined (Programmable) period of time.

25.17 Interphone: An interphone for the use in case of emergencies shall be installed in the car for direct

communication with the rescue personnel in the control room/machine room or top of the car. The interphone shall be such that it is activated by simply pressing the interphone button on the car operating panel.

25.18 Fault information recording: The lift shall be provided with an automatically fault recording facility. A minimum of 50 last

fault information’s are recorded to check what happened during a break down. 25.19 Arrival chime: An electronic chime to provide an audio signal to inform waiting passengers of the arrival of the

lift car at each floor shall be provided. The chime shall be mounted on the top or bottom of the car. The LED indications for direction of travel and car floor level status to be provided as current.

25.20 Maximum call registration: Limit Maximum car calls to be registered at one time to avoid misuse, improve traffic efficiency

and avoid redundant stopping of the car.

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25.21 Parking floor: To improve efficiency and save time the lift car shall be made programmable to return to a

predetermined floor after remaining idle. The idle time shall also be programmed in consultation with the employer’s project authority.

25.22 Voice anunciator: All kinds of information that include floor, direction and others shall be spoken out to remind

passenger in three languages i.e. Hindi, English and vernacular. 25.23 Handicap: It is special for those people who are handicapped, which include Voice anunciator with hand rails,

back mirror and horizontal push button station with Braille buttons. 25.24 Separate landing display: Big screen dot matrix LCD display shall be provided. 25.25 Duplex indication: In case call request button is pressed by any passenger from any floor or destination request any

user inside the car the corresponding display button to get lit at respective floor and also in the car to avoid redundant operation by passengers.

25.26 Control System and Controller Accessories:

The control system shall be of variable voltage variable frequency (VVVF) microprocessor based simplex full collective. The control system shall include PWM inverter of standard and latest design so as to achieve maximum energy savings and accurate control. The control system will limit the starting current of the motor to the rated full load current under all conditions. The controller shall be enclosed in a suitable sheet steel wall mounted cubicle with front doors for easy accessibility of various equipments either on the top landing or inside the Lift shaft as per standard practice.

(a) Construction: The controller shall be constructed in accordance with IEC 60947 and shall be mounted in a ventilated steel cubicle with hinged front doors and removable hinged rear panels, in which all contactors, solenoids, relays, motor starting equipment etc., shall be fitted. All steel sheets shall be no less than 2.5 mm thick and comply with Clause 25.42 of this Specification.

(b) General requirements: The controller shall comply with the general requirements as stated in EN 81-1, and in particular, the following features shall be included: - 1. Materials used in the construction of the control equipment shall not support combustion. 2. The components shall be designed and mounted in a manner which will facilitate easy

inspection, maintenance, adjustment and replacement. Wirings shall be terminated in such a way that the wires are not damaged. Accessible terminals suitably marked, shall be provided for incoming and outgoing cables.

3. Control circuits at normal mains voltage shall be connected between phase and neutral and shall be supplied through double wound isolating transformer.

4. Where rectifier is used it shall be of the full wave silicon type fed from a transformer. 5. The control circuit shall be protected by suitably rated over-current circuit breakers or HRC

fuses independently. 6. The brake solenoid and any retiring cam shall operate on direct current.

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7. Motors connected to polyphase a.c. power supplies shall incorporate means to prevent the motor from being energised in the event of phase failure.

(c) Solid state controls: Microprocessor-based control shall include the following design features:-

1. The system hardware shall be capable of supporting fully software based supervisory and motor control systems.

2. Interruption of the electrical supply to the lift shall not affect the system memory or software.

3. It shall be possible to change the supervisory control algorithm to meet a change in the use of the building by re-programming the instruction memory.

4. It shall be possible to interrogate, by means of communication access/test points on the controller, the system operating functions by use of a portable unit using diagnostic routines.

5. Visual indicators, e.g. LED'S, shall be provided on the controller to display information on the operational status of the lift.

6. Multiplexing techniques may be employed to reduce the number of trailing cables normally required, if considered cost effective to do so.

(d) Provisions for future remote monitoring of lift:

The Supplier/Contractor shall provide dry contacts of the following output signals for each lift installation in a stainless steel cabinet to serve as the interface unit for future connection by others:

1. Normal/Fault status 2. Duty/Standby status 3. Power Supply Normal/ Fault status 4. Normal/ Essential Power status 5. Passenger trapped alarm

This interface unit shall be located at the management office/caretaker’s room next to the lifts monitoring panel unless otherwise specified on the Drawing or in the Specification.

(e) Energy consumption and Duty Cycle monitoring:

The lifts shall be provided with energy recording devices and duty cycle reporting system. The print out port with RS 232/ USB port to be provided to communicate with PC/Laptop to dawn load energy, duty cycle, fault logs, mode of operation, battery status and other data/information etc. The down loading software to be supplied along with one Laptop PC and printer independent of platform as approved by employer’s project authority. The down loaded data, reports, information shall be platform independent in alpha numeric format in English language and shall have full compatibility and exchange with MS office.

(f) Directional collective control for single lift:

All calls shall be stored in the system and answered in sequence regardless of the order in which they are registered. When the car is travelling in a given direction it shall travel to the further-most call, answering any car call or landing call for the corresponding direction of travel. Landing calls for the direction opposite to that in which the car is travelling shall be by-passed but shall remain stored in the system to be answered when the car returns in the opposite direction. When the car stops for the last call in its direction of travel, preference is given to car

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call(s) for an adjustable period. When all calls have been answered the car remains with doors closed at the floor to which it last travelled.

(g) Energy management of lift system:

For each lift car within a lift has been idling for 2 minutes with the lift doors closed, the lift car’s ventilation shall be shut off automatically until the lift car is activated again by passenger call.

(h) Conduit/Trunking facilities by Supplier/ contractor:

The Supplier/l Contractor or others shall be responsible for the provision of conduit facilities for the alarm buzzers/bells and the supervisory control panel at the landing of designated point of entry between the lift shaft and the position of the panel. The Supplier/Contractor shall furnish sufficient information to the Supervising Officer in good time before the conduit installation work is commenced on site. The Supplier/Contractor shall be liable for all expenses incurred due to his failure to comply with the above requirement.

(i) Supervisory control panel:

Where supervisory control panel is specified in the Particular Specification and/or Drawings, the Supplier/Contractor shall be responsible for the provision of all cablings, visual and audible signal components, and controls for the supervisory control panel from all lifts to the supervisory control panel that is located in the caretaker's office at the landing of designated point of entry unless otherwise specified.

The supervisory control panel shall include at least, but not exclusive, the following basic facilities :-

1. 'In service/Out of service' LED lights for each lift. 2. Floor/position indicators for each lift. 3. Up/Down direction indicator arrows for each lift. 4. System fault alarm buzzer / bell and LED indication lights. 5. Power on indicator. 6. Mute button for alarm buzzer / bell, and alarm reset button. 7. Lamp test button 8. Repeater master unit for intercom system. 9. 'Under Fireman control' LED light for each Fireman's lift.

The conduit/trunking facilities from the lift shaft at the landing of designated point of entry to the position of the supervisory control panel shall be provided by others as in Clause (h) above.

(j) Closed circuit television:

1. a CCTV camera mounted on the ceiling of the lift car; 2. a colour CCTV monitor located at the lift machine room; 3. separate and independent lift travelling audio/video cable(s) for the CCTV system

connecting between the CCTV camera installed in the lift car (with the corresponding power supply MCBs in the MCB boards in the lift machine room) and the CCTV monitor(s) respectively;

4. All the conduit and trunking facilities inside the lift shaft and the machine room (conduit and trunking facilities outside lift shaft and lift machine room will be provided by others unless otherwise specified);

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5. The Supplier/Contractor shall integrate a set of CCTV video signal and emergency alarm signal output connection sockets on the lift supervisory control panel for others to connect the signal output through appropriate plugs to the display monitors of the security control console based on the following conditions: i) the CCTV video signal and emergency alarm signal output connection sockets on the lift supervisory control panel shall be BNC panel sockets.

ii) the Supplier/Contractor shall supply associated connection plugs, which shall suit the BNC panel sockets on the lift supervisory control panel and shall not be less than the sockets in quantity, to the security control console specialist contractor who shall then be responsible for the wiring from the security control console to the plugs.

iii) the BNC connection plugs and sockets shall be of 75 ohm impedance type, service voltage up to 500 V peak and frequencies up to 4000 MHz, and accept common RF cable.

25.27 Controller Accessories: An emergency stop switch shall be provided and fitted on the top of the car for use of persons working thereon. During maintenance suitable limit switch shall be provided for automatically stopping at the required floor. Limit switches shall be provided to cut off the main supply to the driving motor and to cut off DC supply to the brake coil causing immediate application of the brakes in the event of the Lift traveling past the top or bottom terminal limit switches. The limit switches shall be of approved design and make.

25.28 Leveling Accuracy:

The leveling accuracy shall be ±5 mm or lesser for passenger convenience. This leveling accuracy shall be maintained under all conditions of loading.

25.29 Reverse Phase Relay:

A reliable reverse phase prevention arrangements shall be provided on the controller, which shall be designed to protect the Lift equipment against phase reversals and phase failures.

25.30(a) Provision of overload device:

Every lift shall be provided with an overload device which shall operate when the load in the car is 10% or more in excess of the rated load of the lift.The overload device, when in operation, shall:-

1. prevent any movement of the car. 2. prevent the closing of any power operated door whether fitted to the car or to the

landing at which the car is resting , and 3. give audible and visible signals inside the car.

The lift shall resume normal operation automatically on removal of the excessive load. The overload device shall be inoperative while the lift car is in motion.

(b) Full load device:

Every lift other than a service lift shall be provided with a full load device having an adjustable setting range from 80% to 100% of the rated load and when operated, it shall by-pass all landing calls. When the load in the car is reduced, the car shall stop for landing calls as normal.

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25.31 Limit Switches: Terminal limit switches shall be provided to slow down and stop the car automatically at the terminal landing and final limit switches shall be provided to automatically cut off the power and apply the brake should the car travel beyond the terminal landings.

25.32 Top of Car Inspection:

A top of car operating fixture shall be provided on each car, containing continuous pressure buttons for operating the car in both directions and a toggle switch for making the buttons on top of the car operative. This toggle switch when switched to inspection operation shall modify the operation of the car to disconnect it from the normal operation to eliminate all normal operation devices, automatic leveling and power door operation and the car shall run at standard speed for the purpose.

25.33 Automatic Rescue Device:

In the event of power failure or failure of control system where the Lift is in operation the rescue device should take over automatically and bring the Lift to the nearest landing safely. The rescue device should be operated on rechargeable maintenance free batteries. The battery charging system to be supplied such that batteries are kept charged always in situ.

25.34 Alarm Bell and Emergency Light: The alarm bell is to be provided and fitted in an approved position close to the Lift at Ground floors complete with push button inside the car and with necessary SMF rechargeable Battery. Battery operated emergency lamp should also be fitted in the car which shall work automatically in the event of a power failure, providing illumination within the car. The batteries shall be maintenance free and shall be supplied on board with a battery charging system. The battery charge status should be displayed in control room/Machine room.

25.35 Machine room installations: The machine room shall be ventilated such that the motors and equipment as well as electric cables etc, are protected from dust, harmful dust and humidity. The ambient temperature in the machine room shall be maintained between +5ºC and+40ºC. The machine room shall be provided as following-

i. Doors accessing machine room are to be clearly labeled with BS warning signs. ii. Within the machine room an Electric shock Notice shall be installed. iii. Within the machine room adequate Rubber Matting shall be installed. iv. Within the machine room RCD protected 15A socket outlet shall be installed. v. The machine room lighting shall be by twin tube 2x28 W T-5 fittings/ adequate LED

luminaries which shall give illumination of 150 Lux. The level of illumination in a power failure shall be a minimum of 50 Lux to floor level throughout to be maintained by providing Emergency lights. These lights shall be back up at least 72 hours by adequate SMF battery and shall be manually operated by a switch located at a convenient position inside the machine room.

vi. Tool box shall be fitted in the machine room and it shall comprise of the following minimum equipment:

▪ Release Keys ▪ Winding wheel

▪ Log card ▪ Hand Winding instruction

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25.36 Batteries and chargers: The batteries shall be of sealed , high rate maintenance free nickel-metal hydride type, or a type of better functions and performance and approved by the Supervising Officer and shall have a guaranteed life expectancy of at least four (4) years. They shall hot have any memory effect as to affect their usable life or performance. The nickel-metal hydride battery shall comply with EN 61436 and EN 61951-2 where appropriate. The battery charger shall be compatible with the batteries used. The charger shall comply with EN 60335-2-29 and be capable of fully re-charge the batteries in not more than 12 hours.

25.37 Suppression of Radio and Television interference:

The lift installation shall be adequately suppressed against radio and television interference to limits as laid down in BS EN 55014 and BS 613. Interference suppression components shall not be used in any part of the circuit where their failure might cause an unsafe condition.

25.38 Harmonic distortion: The lift installation shall not, by injection of undesirable waveforms into the electricity supply distribution system, adversely affect the power company's system and/or the electricity supply to other users or consumers. The Total Harmonic Distortion (THD) produced by the lift motor drive system measured at the isolator connecting the lift equipment to the feeder circuit of the building is limited to the maximum allowable values specified in Table I. The THD shall be measured at the moment the lift car is moving up with rated load at its rated speed. The Supplier/Contractor shall be responsible for providing all necessary harmonic filter(s) should the THD of the installation exceed the maximum allowable values as specified in Table I.

Table – I Maximum allowable THD for lift motor drive systems.

Circuit Fundamental Current of Motor Drive Maximum THD (%)

400A < I < 800A

80A < I < 400A

I < 80A

15.0

22.5

35.0

25.39 Maximum allowable Electrical power: The running active electrical power of the motor drive of traction lift system carrying a rated load at its rated speed in an upward direction shall be equal to or less than the maximum allowable values specified in Table II.

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Table - II Maximum allowable Electrical power of Traction lifts (Vc < 3)

Rated Load (Kg)

Maximum allowable Electrical power(kW) of Traction lift Systems for various ranges of Rated speed (Vc) in m/s Vc < 1 1 < Vc < 1.5 1.5 < Vc < 2 2 < Vc < 2.5 2.5 < Vc < 3

L< 750 7 10 12 16 18 750 <L < 1000

10 12 17 21 24

1000 <L < 1350

12 17 22 27 32

1350 <L < 1600

15 20 27 32 38

1600 <L < 2000

17 25 32 39 46

2000 <L < 3000

25 37 47 59 70

3000 <L < 4000

33 48 63 78 92

4000 <L < 5000

42 60 78 97 115

L < 5000 0.0083L+ 0.5000

0.0118L+ 1.0000

0.0156L+ 0.5030

0.0190L+ 2.0000

0.0229L+ 0.5000

25.40 Sound reducing:

The whole of the lift/ machinery including the opening and closing of the car and landing doors shall be quiet in operation, and sound reducing rubber pads or other means shall be provided by the Supplier/Contractor where necessary to eliminate vibration and noise transmission.

25.41 Finish:

All metal work supplied by the Supplier/Contractor in out of the way locations such as the lift shaft, lift pit, machine room and on the outside of the lift car shall be properly wire-brushed, cleaned of rust, scale, dirt and grease prior to the application of one coat of rust inhibiting primer, with particular attention paid to the priming of outer surfaces of car doors, inner surfaces of landing doors, metal work associated with door assemblies, the underside and the framework of lift cars. Any part of the equipment, including guide rails, which requires greasing or oiling and any components that are supplied unpainted by the manufacturers due to functional reasons shall not be painted. All normally visible metal surfaces, other than stainless steel and non-ferrous surfaces, shall be finished with one coat of rust inhibiting primer, one under coat/finishing coat and one finishing coat of enamel paint to a colour to be selected by the Supervising Officer.

25.42 Stainless steel:

Unless otherwise specified, stainless steel shall be of EN 10029, EN 10048, EN 10095, EN 10258 and EN 10259Grade 316 or equivalent.

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25.43 Notice Boards: The following stainless steel notice boards engraving conpiciously in both English and Hindi characters shall be provided and rigidly mounted:- 1. "No Smoking", which shall be in each car, 2. "When there is a fire do not use the lift" in each car and on each landing floor.

25.44 Wiring and Earthing: The Employer will arrange single phase and three-phase supply with suitable MCCBs / MCBs for isolation and protection in either on the ground floor or First floor or Second floor as far as possible near the Lift shaft on request by the Supplier/Contractor. All necessary wiring in heavy gauge conduits from the MCB to the driving motor, controller, call push buttons, door locks, limit switches, alarm bell, halfway junction box and wiring inside the car shall be done by the Supplier/Contractor in accordance to IEC 60364 for Electrical Installations of buildings. Necessary traveling cables from the car to the halfway junction box in the shaft shall be provided by the Supplier/Contractor. Equipment earthing required for the machine and in the Lift well should be carried out by the Supplier/Contractor. The main earthing shall be of 4 SWG GI wire and subsidiary earthing by 14 SWG tinned copper wire. All electrical equipments in the Lift including car body shall be provided with two distinct earthing arrangement as per IS standards and connected to the earth pit provided in stations.

25.45 Departure from Specification:

The Supplier/Contractor should supply standard equipment as far as possible but where it does not comply with this specification a list of deviation giving full particulars of deviations from this Specification duly quoting reference to clause No. shall be submitted to the Employer for prior approval.

25.46 Technical Particulars, Drawings etc.:

The approval application shall be accompanied with:- i) Complete technical illustrated literature for the equipments offered. ii) Technical particulars and guaranteed performance of Lifts in the Annexure - `B’.

25.47 Spare parts and tools:

Spares that are considered necessary for continuous satisfactory operation of the equipment for at least two years shall be advised separately, inclusive of rates for reference. Any special tools required for the maintenance of the equipment shall be submitted along with the approval.

25.48 Drawing and manuals:

Complete detailed layout drawings showing the structural requirements in the building and loadings and disposition of various equipments and wiring diagram of various equipments shall be furnished by the Supplier/Contractor before taking up the work. Six copies in English language of the manufacturer’s booklet containing description of various equipments of the Lift shall also be submitted to the employer’s project authority. The operating manual and maintenance schedule shall also be submitted while handing over the installation. The two additional manuals and information shall be supplied in Hindi, English and vernacular language each.

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25.49 Tests and Test Certificates: The Supplier/Contractor shall furnish details of internal tests carried out on all equipment, components and fittings of the Lift at their works. Suitable test certificates should be submitted to Employer to establish: - (a) The satisfactory operation of the Lift includes protective mechanisms, safety devices, brake

gear, etc. with temperature rise of driving motor not exceeding the guaranteed limits. (b) That the floor setting of the car at the landings is correct at all loads from no load to full

load. (c) That the speed of the car is as guaranteed and that the acceleration and retardation are

satisfactory and smooth. (d) That the operation of the contactors, interlocks and time lags are satisfactory and in

correct sequence and the correct functioning of the terminal limit switches.

25.50 General requirements: All dangerous parts shall be effectively guarded. Where applicable, components shall be designed to be inherently safe, obviating the need for external or removable guards. Every lift car body shall be carried in a steel car frame sufficiently rigid to withstand the operation of the safety-gear without permanent deformation of the car frame. The deflection of the members carrying the platform shall not exceed 1/1000 of their span under static conditions with the rated load evenly distributed over the platform. At least four renewable guide shoes, or guide shoes with renewable linings, or sets of guide rollers shall be provided, two at the top and two at the bottom of the car frame.

25.51 Training of Staff: The Supplier/Contractor shall train three staff nominated including one Supervisor nominated by employer’s project authority, during the erection of the Lift at site. They shall also train the staff in the maintenance, operation and trouble shooting of the Lift. However the responsibility of maintenance of Lifts will be with Contractor during the guarantee period.

25.52 Guarantee: The Supplier/Contractor shall guarantee satisfactory performance of the Lift and allied equipments over a period of 24 months in actual service from the date of handing over of the installation to the Railway in normal working conditions. During the guarantee period the Supplier/Contractor shall rectify free of cost of all defects which may develop due to faulty design, material failure and bad workmanship inclusive of free replacement of defective parts. The guarantee will get automatically extended corresponding to the periods during which the equipment is not in use. On every occasion when the equipment goes out of service, the duration between the date of intimation of the failure of equipment to the contractor and the date of handing over of the equipment after repairs in good working condition duly tested and commissioned in the presence of Purchaser’s representative, will be counted for the extension of the guarantee period till the equipment completes actual service for a total period of 24 months. During the guarantee period the parts of the equipments requiring repairs or replacements will be handed over to the contractor at site and the parts after repairs or replacements shall be fitted in the equipment at site by the contractor. All expenses involved in fulfilling the above guarantee obligations shall be borne by the contractor.

25.53 Inspection: The materials will be inspected by purchasers’ nominated representative at manufacturer’s premises or contractors depot as the case may be. The purchaser or his representative shall have the right to be present during all the stages of manufacture and shall be afforded free of charge all reasonable facilities for inspection and testing as well as to examine the stage inspection report of the manufacturer / inspection in addition to the quality audit which the contractor may institute

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as a part of his Programme so as to satisfy himself the materials are in accordance with the specification, approved drawings and designs and purchasers prescribed Quality Assurance Standard.

25.54 Civil Engineering: The contractor should inspect site conditions before ordering. The design of the Lift includes the design of the support system and guidance which includes the support of the traction machine and all its accessories. The Lift shaft is either 230 mm brick / concrete. Contractor should give their design to suit the existing Lift shaft/machine room and well. The design of the Lift should be compatible with the Lift well and Lift shaft/machine room. The contractor should ensure adequate design so as the individual load and their distribution of car, counter weight for both normal and abnormal working (Accident), or with in the structural design limits of Lift well. The anchorage and guidance of car and counter weight will be designed to suit the Lift shaft under all conditions. This is considered as primary responsibility of the contractor.

25.55 Preventive Maintenance and Schedules: The contractor shall service the Lifts thoroughly as per OEM maintenance schedule and attend the breakdown complaints free of charge during the defect liability period of 24 months including all spares, materials and replacable parts free of charge. (a) Important items of Schedule of maintenance during the defect liability period of 24 months is enclosed herewith however OEM recommended schedule of maintenance shall be followed in detail. (b) Maintenance schedule for Electric Lifts: The following maintenance schedule should be carried out during the maintenance of Lifts and a record should be maintained in the office as directed by employer. Any abnormality noticed during the schedule should be attended immediately (within 2 hours) and proper operation ensured. Lifts should be taken up for schedule of maintenance preferably on Holidays or beyond office hours and with mutual agreement with user. I. Monthly Schedule:

Sl. No

Nature of Work

1. Check and attend fittings of Lift (light, fan, emergency light, failure alarm etc.)

2. Check level of the lubricating oil in the gearbox, any unusual sound in the gearbox.

3. Check the operation of all the doors, door locks.

4. Check the brakes and adjust it.

5. Check the operations of the limit switches.

6. Clean machine and associated equipments.

7. Check the main switch contacts and earth connections/continuity.

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8. Check the main switch, fuses etc. (for loose connection, oscillation and ratings etc.).

9. Check the general condition of the motor.

10. Control panel:-

a) Check overhead relays operation

b) Check the interlocks for its proper functioning.

c) Check the relay contacts their operation and chattering.

11. Check the electrical connections

12. Check the foundation bolts of the motor any unusual noise, vibration etc.

13. Check the input voltage & current of the motor and record it.

14. Check leveling switches, arm pivots and limit switch rollers and lubricate.

15. Check the performance of the over speed governors and adjust if necessary.

16. Check the working of the floor selection switch.

17. Check the floor indicators.

18. Check all ropes, hinges, shackles etc.

19. Check the microprocessor control for its proper functioning.

II. Quarterly Shedule of Maintenance:

Sl. No

Nature of Work

1. Lubricate the rope pulley bearings in the Machine Room. 2. Check tightness of the counter weight, fixing clamps, bolts etc. 3. Check the trailing cables for broken / damaged insulation and loose binding. 4. Check the condition of the pit clean the car top and clean the gate. 5. The wire ropes should be cleaned by a stiff brush to remove old lubricant and lubricate it

again by using oil machinery medium or equivalent. 6. Clean the ropes for broken strands and general condition. 7. Check the dia. of the rope and record it. 8. Rope winding drum to be checked for its proper winding in the sheave grooves. 9. Measure the voltage and current at the various test points in the control system including

microprocessor control and record it. 10 Check the foundation bolts of the motor for any vibration.

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III. Yearly Schedule of maintenance:

Sl. No

Nature of Work

1. Overhaul the motor for bearings and alignment. 2. Check car body supports and steel channels. 3. Check the condition and wear in the bearings. 4. Clean and check guide rails. 5. All break gears to be reconditioned. 6. Solenoid coils to be tested. 7. Limit switches to be overhauled and adjusted. 8. All the interlocking arrangements to be overhauled and checked for proper functioning. 9. Gearbox to be overhauled completely. 10 Check the microprocessor units for the proper functioning.

IV. In addition to the above periodical maintenance the firm has to attend the following:- a) The firm has to attend the breakdown failure at any time during the working hours without any

delay. b) They have to supply the required consumables, spares, to keep the Lift in good condition. c) While attending the quarterly schedules the firm has to carry out the monthly schedules also. d) While attending the yearly schedules the firm has to carry out the monthly and quarterly

schedules also. e) Maintenance schedule should be carried out in consultation with f) If the Lift remains OUT OF SERVICE for more than 48 Hours per month, Employer will have

right to impose penalty to the extent of 10% value of the contract.

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ANNEXURE - ‘A’

BRIEF REQUIREMENTS FOR LIFT TO BE SPECIFIED IN BOQ

1. Capacity : ……. Persons. 2. Speed : ……. m/Sec. 3. Car Travel : …. to …. About ….. m (approx.) 4. Stops & Openings : …..stops and …… openings. (All openings on same side.) 5. Control : AC VVVF Variable Frequency with speed encoder 6. Operation : Simplex full collective with/without attendant

7. Controller Microprocessor based Modular control system

8. Communication : Loop type serial communication 9. Power Supply : 3 phase AC 415V ±10% Variation, 50 Hz ±5% Variation.

10. Machine : Geared type induction machine. 11. Hoist way : ….. mm wide x ….. mm deep (Tenderer to Check the

suitability of the same before tendering). 12. Available head room : Tenderer to verify the same at site before tendering. 13. Available Pit Depth : ….. mm (approx.). 14. Position Drive

including Main machine.

: Directly at the top of Lift inside the machine room.

15. Car Enclosure

: Stainless steel car panels of 1.5 mm thickness hairline finish with stainless steel false ceiling adequately illuminated LED luminaries of flush mounted pattern, one axial flow fan with grill of quit running type having a noise level not greater than 30 dBA, one smoked mirror of half height full width on the rear panel, 4mm thick antiskid studded rubber floor of approved color. Suitable handrails of 1-1/4” O.D. round stainless steel provided at 34” height from floor level of the car on three sides with a 1-1/2” clearance from car walls.

16. Car Safety Gear : Over speed governor – operated safety.

17. Landing and Car Doors.

: Landing doors and car door shall be of 2 panel centre opening sliding closed, stainless steel powder coated or hairline stainless steel finish panels, power operated independent drive with adjustable automatic opening and closing speeds for door. The clear opening should be 900 mm wide x 2000 mm with full height Memco 3D curtain safe edge to detect and open the doors in the event of Obstruction /infringement while the doors are closing.

18. Leveling : ±5 mm irrespective of load.

19. Human interface device

a. Hall button with micro stroke push/touch buttons combined with 16 segment digital LED display position indicator.

b. Full height car operating panel with micro stroke push/touch buttons (Located on side panel)

c. Door Open and Door Close button on the Car operating panel. d. 2 Way inter communication system. e. DOT matrix position indicator display integrated with in the Car

operating panel.

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f. Over load indicator i.e. device to sense 80% of rated load and over load. Audio and visual indicator of overload.

g. Battery operated Alarm bell and Emergency Light. h. Fireman’s switch. i. Manual rescue operation. j. Emergency auto rescue device. 20. Peak periods of Lift

workings : Generally between ….. - ….. Hours in morn4mm thick antiskid

studded rubber floor of approved colouring, ….. - ….. Hours in noon and …... - ….. Hours in the evening.

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ANNEXURE - ‘B’

TECHNICAL PARTICULARS AND GUARANTEED PERFORMANCE OF THE LIFT

(TO BE FILLED IN WHILE SEEKING RVNL APPROVAL)

1. Machine:-

a) Main driving motor. :

b) Current in Amps at rated outputs.

:

c) Rated make and type. :

d) Type of enclosure. :

e) Voltage between terminals. :

f) Output in HP. :

g) Weight. :

h) Speed in RPM at rated output. :

i) Class of insulation. :

j) Temperature rise on full load :

2. Brake:-

a) Make. :

b) Type. :

c) Width & diameter of brake wheel. :

d) Method of adjustment. :

e) Provision for manual release. :

3. Car:-

a) Dimension (internal). :

b) Weight (Approx.). :

c) Contract load. :

d) Maximum speed. :

e) Acceleration. :

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f) Retardation. :

g) Method of suspension. :

h) Time for travel between the floors. : 4. Guide Rail:-

(i) For Car:-

a) Size and weight in kg per linear meter in Tee sec.

:

b) No. of Sections. :

c) Spacing of intermediate supports. :

d) Method of lubrication. :

(ii) For Counter weight:-


:

b) No. of Sections.

:

c) Spacing of intermediate supports. : d) Method of lubrication :

5. Control Equipments:-

(i) Control Systems:-

a) System of control and working DC voltage for control.

:

b) Type of VVVF control details. :

c) Potential Energy savings.

:

(ii) Self leveling System:-

a) Type of car leveling device.

:

b) Any special features. :

(iii) Limit Switches:- a) Type.

:


6. Suspension Ropes:- a) No. of ropes. :

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b) Size and no. of strands in each rope.

:

c) Factor of safety.

:

d) Method of attachment to the car.

:

e) Method of attachment to the counter weight.

:

7. Counter weight:- a) No. of sections. : b) Weight of each section. : c) Type of guide shoes. : d) Method of load equalization of ropes. :

8. Wiring:- a) Specification of wires. : b) Method of wiring. :

9. Finishing:- a) Full particulars should be given. :

10. Protection devices, details provided in the Lift:-

11. Special inclusions if any:-

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MACHINE ROOMLESS & GEARLESS VERSION ELECTRIC PASSENGER LIFT

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CHAPTER: A-26

Tech. Spec. No. RVNL/Elect/GS/26 MACHINE ROOMLESS & GEARLESS VERSION ELECTRIC PASSENGER LIFT 26.1.1 Scope:

The scope includes design, manufacturing, supply at site, erection, testing, commissioning and handing over in satisfactory working condition of Machine room less & Gear less machine with permanent magnet motor operated Electric traction passenger lift to the requirements as given in Annexure 'A', under the operational and environmental conditions encountered during service, complete with all accessories. Specifications and other stipulations are given below. The salient points pertaining to safety shall also be complied by the Supplier/Contractor.

26.1.2 General The Machine Room less type Lift shall be governed by relevant International Standards and International Codes of Practice such as European code of safety EN 81,American National Standard Safety Code for Elevators (ANSI) A117 .1 , IS: 14665 or latest and IEC 60364 for Electrical Installations of buildings. The traction machine, over speed governor, ropes, brake gear controls and other safety equipment even though corresponding to specification EN 81 and ANSI A117.1 should under all conditions of operations at least match with IS code of specification for passenger Lifts viz. IS: 14665 or latest. This has to be ensured by Lift manufacturers primarily and the manufacturer should have appropriate Quality Assurance accreditation ISO 9000 I ISO 14001. The installations shall be to the highest standard as expected of a fully experienced contractor. The manufacturer shall also comply with the provision of Indian electricity act and rules in vogue and shall be taken over only if and when they fully comply with all their requirements. The lift installation shall also be designed to produce a safe working environment for Engineers and auxiliary workers to work on or around.

26.1.3 Environmental service conditions: All electrical, electronic and mechanical equipment shall suit the tropical climate for use in service environmental conditions as stated below :-

Maximum ambient temperature 55 deg c

Minimum ambient temperature -5 deg c

Maximum Relative humidity 100%

Atmosphere Extremely dust and desert weather and desert terrain in certain areas. The dust contents in air may reach as high values as 1.6 mg/m.cube

Coastal area The equipment shall be designed to work in corrosive atmosphere.

Maximum Ph value 8.5

Sulphate 7 mg/litre

Max. concentration of chlorine 6 mg/litre Max. conductivity 130 micro siemen/cm

Annual Rain fall Ranging between 1750 to 6250 mm with thunder storm.

Alltitude Not exceeding 1200m

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26.2.0 Specifications: 26.2.1 Gearless Machine:

The lift machine shall be smooth in operation with mm noise/vibration and of single wrap traction type gearless machine with permanent magnet motor operated electromechanical brake suitable to work on 400/440 Volts AC 3 Phase with neutral at 50 cycles per second supply with VVVF (Variable Voltage Variable Frequency) type of control. The traction motor shall be energy efficient induction type with a minimum of BEE's three star rating and in accordance to BS 4999 and BS 5OOO: part 99.The motor shall be designed to operate for an unlimited period according to the expected duty of the lift. The traction machine shall be either induction machine or synchronous machine. The driving sheave should be integrally coupled with the machine and the assembly to be completely mounted on guide rail or on suitable rigid frame fixed to the shaft . The driving sheave should be constructed from fabricated cast steel or S.G iron or suitable wear resistant material with truly machined surface in order to ensure perfect alignment of all bearings and prevent transmission of sound to the building. The motor shall be designed to operate for an unlimited period according to the expected duty of the lift. The Supplier/Contractor shall furnish detailed drawings showing weights to be tackled and the disposition of various loads on the Lifts shaft and Lift well for the approval of employer.

26.2.2 Sheaves: The driving sheave and pulleys should be of hard alloy constructed from fabricated cast steel or S.G iron or suitable wear resistant material and free from cracks, sand holes and other defects with truly machined surface in order to ensure perfect alignment of all bearings and prevent transmission of sound to the building. They shall have machined rope grooves. The traction sheave shall be grooved to produce proper traction and shall be of sufficient dimension to provide for wear in the groove .The deflector sheave shall be grooved so as to provide a smooth bed for the rope . The deflector or secondary sheave assemblies where used shall be mounted in a proper alignment with the traction sheave. Such deflector sheaves shall have grooves larger than the rope diameter as specified in clause 8 of IS:14665 (part-4 ,Sec.3):2000 or latest. The size of all the sheaves shall be in accordance with clause 8.4 of IS: 14665 (part-4, Sec.3):2001 or latest. Wherever necessary, suitable protective guards may be provided.

26.2.3 Electric Motor duty cycle: The driving motor shall be designed specially for heavy duty Lifts to run smoothly under load up to its maximum capacity in either direction with ample power to deal with occasional over loads. It shall be arranged to develop the requisite, torque, enabling the machine to start easily from t he rest. The motor shall be designed to confirm to 53 duty cycles defined as per IEC duty cycles for non peak and peak periods of operation. The motor and drive system should be designed for not less than 150 starts/ hour a nd stops during the peak periods. The peak periods of lift workings are furnished in Annexure 'A'.

26.2.4 Brake: A suitable electro magnetic brake, preferably of the direct acting type integrated with motor operating on AC/DC shall be provided, with two brake shoes which are automatically applied by means of a strong compression springs to a brake wheel of large diameter when the circuit is broken a nd released by means of an electro-magnet. The brake mechanism must incorporate provision to allow for minimum wear of brake lining. It shall also have an emergency quick release device to open the brake without affecting its adjustment so that the car can be lowered or raised manually in the event of electric supply failure. The electric solenoid shall be rated to withstand continuous Lift duty.

26.2.5 Car and car frame: The car enclosure shall be in accordance with clause-4 of IS:14665 (part-4, Sec.3):2001 or latest, made up of stainless steel 1.5 mm thickness hairline finish. The Lift car shall have

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stainless steel false ceiling adequately illuminated LED luminaries of flush mounted pattern which shall give illumination of not less than 150 Lux on the lift floor level. The level of illumination in a power failure shall be a minimum of 50 Lux to floor level throughout to be maintained by providing Emergency lights. One axial flow fan of quit running type having a noise level not greater than 30 dBA when measured at a distance of 1 m from the fan and it shall be capable of handling at least 20 air changes per hour of lift car volume, with car doors closed. The effective area of ventilation apertures situated in the upper part of the car shall be at least 1% of the available car area, and the same applies for any apertures in the lower part of the car. The car ventilation fan shall be switched off within a period which shall be adjustable from 5 to 15 minutes after the last registered call is answered. One smoked mirror of half height full width on the rear panel, suitable handrails of 50 mm O.D. tubular stainless steel shall be provided at 86mm height from floor level of the car on three sides of the lift car extending to within 150mm of all corners and with a 40mm clearance from car walls to facilitate handicapped passengers. A load plate giving the contract load of the Lift, No. of passenger capacity of the Lift shall be fitted in the Lift car in a conspicuous position.

Emergency contact number plate should be provided with front transparent acrylic sheet with flush screw arrangement such that contact numbers can be changed. Suitable slotting arrangement shall be done accordingly. The Control logic shall be used for controlling lights and fans. The ventilation fan and full lighting shall be switched off by logic and predetermined period if no button is pressed or call registered. The lighting except emergency illumination shall also have connection to motion sensor. The lights and fans supply also should have separate control panel switch to make on/off. The ventilation fan shall also have one switch for operation in addition to motion sensor control. For video remote monitoring security web camera to be installed in the lift car having display with recording arrangement to Control room in addition to self memory of minimum past 72 hours recording. Floor shall be made of 1.5 mm thickness Stainless Steel with 4mm thick antiskid studded rubber floor to color and pattern as approved by the employer or engineer in charge. The switch and control panel buttons should be made with backlit/letter display by LED with dark background and the alpha numeric display in English language and also BRAILLE indents. The control activated voice information of floor level announcement to be provided. The public address system a lso to be built in for playing emergency announcement/commercial/ entertainment etc. Two number LCD display of size of minimum 32 inch diagonal, motion flow 120 Hz live colors display, HD image on NTSC/PAL/ATSC tuner having VGA/USB/BNC/TV tuner input control to be provided with connection to public address system. The control supply shall be brought to control room and VGA, Audio/Video output wiring to be done at Control room of lift. Safety instructions in international signage’s pattern to lift users shall be provided inside the car as approved by the employer or engineer in charge. Emergency illumination on LED based luminaries also to be provided in car with adequate SMF battery to support at least 72 hours back up with control switch in lift car itself. The emergency battery back also shall be used for operation of interphone and emergency alarm bell. The roof of the car shall be solid type made of 1.5 mm thickness Stainless Steel capable of supporting a weight of two persons i.e., at least 138 kg as per IS: 14665 (part-4, Sec.3) :2001 or latest ·and shall withstand to a vertical force of 2000N at any position without causing permanent deformation. Lift car, excluding linings, shall be constructed of non- combustible materials. One lighting socket outlet for hand lamp shall be provided on the top of the Lift car for inspection. Suitable hand lamp with appropriate size and length of cable shall be supplied to the maintenance staff by the Supplier/Contractor.

26.3.0 Doors: Landing doors and car door shall be of 2 panel centre opening sliding closed, stainless steel powder coated or hairline stain less steel finish panels as approved by the employer or engineer

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in-charge .power operated independent drive with adjustable automatic opening and closing speeds for door. The clear opening should be 900 mm wide x 2000 mm height. The door shall have a fire resistance rating of one hour as per EN 81-58 and ground switch/switches at ground floor level shall be provided on all the lifts to enable the fire service to ground the lifts. The car doors shall be fitted with a Memco 3D curtain safe edge to detect and open the doors in the event of obstruction/infringement while the doors are closing. The door open time to be made programmable for time delay set in the system. The lift shall be designed to go out of service if the doors are kept open for a long time as programmed. A delay to the start the lift after the doors is closed (say 0.2 to 2.0 seconds) also to be programmable. The landing doors shall be provided with electro-mechanical inter-locks to prevent operation of the Lift unless all the doors are closed and positively locked. The inter-lock shall also prevent the opening of any door until the car has reached the respective landing zone. I n t h e event of failure of Memco 3D curtain suitable mechanical system should be provided to open the doors in the case of obstruction. Any projections on or recesses In the exposed parts of the car doors or landing doors shall be kept to a minimum in order to avoid finger trapping between sliding parts of the door and any fixed part of the car or landing entrance. The clearance between panels or between panels and any fixed part of the car or landing entrance shall not exceed 6 mm. Sliding car and landing doors shall be guided on door tracks and sills for the full travel of the doors. The distance between the car and landing sills shall not exceed 35 mm. The clear height of all entrances on ca r and landings shall not be less than 2 m.

Supplier/Contractor shall provide full door sticker of approved quality and design with adhesive as approved them by employer or engineer in charge.

Three good quality digitally printed safety and energy saving tips/ instructions as per pictographically international signage’s pattern of size 2 feet x 3 feet of suitable design to be supplied and fixed on wall at lift on each floor in Hindi/English/Vernacular language (i.e. one each).

26.3.1 Electrical device for proving the car doors closed: Every car door shall be provided with an electrica l switch which will prevent the lift car from being started or kept in motion unless all car doors are closed. A mechanical locking device shall also be provided such that the car door cannot be opened from the inside while the car is outside the unlocking zone.

26.3.2 Landing door locking device: Every landing door shall be provided with an effective locking device so that it shall not normally be possible to open the door from the landing side unless the lift car door is in that particular landing zone. It shall not be possible under normal operation to start the lift car or keep it in motion unless all landing doors are in the closed position and locked.

26.3.3 Door locking devices to be inaccessible from landing or car: All door locking devices and door switches, together with any associated actuating rods, levers or contacts, shall be so situated or protected as to be reasonably inaccessible from the landing or the car.

26.4.0 Car Slinging and Safety Gear:

The car body shall be supported in a steel sling so that no strains due to suspensions lifting action of the safety gear are imposed in it. The sling shall be provided with adjustable shoes on each side at the top and bottom to engage accurately with the guides to ensure smooth running. The car and counter weights shall have underneath it an automatic instantaneous type safety gear operated by an over speed governor designed to ensure positive action for excessive speed on the down travel of the car. The safety gear shall be equipped with a contact to cut off power supply/dur ing over load in such event and to bring the car to a stop. Controls and facilities for

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inspection shall also be provided at top of the car to facilitate inspection and testing as per ISS latest and international standard.

26.5.0 Governor: The car safety shall be operated by speed governor which shall be in accordance with clause 4 of IS: 14665 (part-4, Sec .3):2001 or latest and shall be adjustable to actuate the safety gears., located overhead and driven by governor rope suitably connected to the car and mounted on its own pulleys. The governor shall be of "V" groove wheel design. The rope shall be maintained in tension by means of weighted or spring loaded tension sheaves located in the pit. The governor rope shall not be less than 10mm in dia. shall be made up of steel and as specified in Clause 26.6.0 of this Specification.

26.6.0 Suspension Ropes : The main suspension ropes shall be in accordance w ith BS 302 part 4 clause B4.1 and clause 7 of IS: 14665 (part-4, Sec.3) :2001 or latest a nd the requirements for steel wire ropes shall be in accordance with IS: 14665 (part- 4, Sec .8):2001 or latest, of the best flexible steel wire construction conforming to IS: 6594/1981 or latest , with a minimum factor of safety of 12 times ,the number of strands and diameter of the ropes shall also comply with the factor of safety requirements of the Ameriican National Standard Safety code for Elevators (ANSI) A117 .1. The supply of steel wire ropes should be three ropes or more and of minimum 10 mm dia., from the reputed rope manufacturers and shall be guaranteed for a period of two yea rs .Ends of the ropes shall be properly secured to the car and counter weight hitch plates with adjustable rope shackles having individual tapers babbit sockets or any other suitable arrangement . Each rope shall be fitted with a suitable shackle spring, seat washer, shackle nut & lock and shack le nut split pin.

26.6.1 Compensation rope: For travels over 30 m and/or rated speed of the lift exceeds 2.5m/s, the Supplier/Contractor shall provide compensation ropes with tensioning pulleys. For speeds of 2.5 m/s or below, quiet operating chains or similar dev ices may be used as the means of compensation. For speeds above 3.5 m/s, an anti-rebound arrangement of idler tension pulley shall be provided to prevent the counterweight ht jumping with the application of the car safety gear.

26.7.1 Diverting Pulleys: Diverting pulleys necessary for suspension of car on counter weight shall be of cast iron, grooved for wire ropes complete with shaft, bearings and are to be suitably supplied and they shall incorporate devices to avoid:

• The suspension ropes, if slack, leaving the grooves. . The introduction of objects between rope & grooves.

26.8.0 Guide rails: The guide rails shall be in accordance with clause 3 of IS:14665 (part-4, Sec.2) :2001 or latest for the car and counterweight and shall be made up of rigid steel 'T' sections with machined working surfaces. These guides shall be erected to plumb and shall be complete with suitable fixings at such intervals as to prevent deflection. The strength of the guides, their attachments and joints shall comply with clause 10.1 and 10.2 of EN 81-1 and BS 5655: Part 9 Clause B1.2 and be sufficient to withstand the forces imposed due to the operation of the safety gear and deflection due to uneven loading of the car. The section of weights in kg per meter of rails should be furnished by the Supplier/Contractor in Annexure 'B'. Guide lubricators of approved design shall be provided.

26.9.0 Counter Weight: The counter weight shall be in accordance with clause 6 of IS: 14665 (part- 4, Sec.3):2001 or latest, shall consists of a structural steel frame with loose cast iron filler weights arranged to

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balance the full weight of the car plus, approximately 50% of the contract load so as to ensure low power consumption and economical running of the Lift. The factor of safety of steel frame members and the tie rods shall not be less than 5. The guide shoes shall be fitted to the top and bottom of the structural frame on both sides and shall be of replaceable & adjustable type to ensure smooth and quiet running and long life. Counter weights shall be guarded by means of a rigid fixed screen extending from a position of 0.3m above the Lift pit floor to a position at least 2.5m above the Lift pit floor.

26.10.0 Buffers: Buffers shall be in accordance with clause 5.15 of IS: 14665 (part-2, Sec.2):2000 or latest. Hydraulic/spring buffers of tested design shall be installed as a means of stopping the car and counter weight at the extreme limits of travel. Buffers in the pit shall be mounted on the steel frame, which shall extend between both the car and counter weight guide rails. Energy accumulation type buffers shall only be used if the rated speed of the lift does not exceed 1 m/s and Energy accumulation type buffers with buffered return movement shall only be used if the rated speed of the lift does not exceed 1.6 m/s.

26.11.1 Operating System: The Lift operating system shall be of simplex full collective type with prov1s1on for operation with or without attendant. It should comprise of a call button at each landing and a set of dispatch buttons together with an emergency stop button in the car. All components shall be well insulated and mounted in a metal case with suitably finished cover.

26.11.2 (a) Control station in car:

Each lift car shall have a flush mounted control station comprising:- 1. Call buttons with acceptance signals engraved in Arabic number to correspond with the

landing served.

2. An alarm push button with protection from being operated accidentally. The color of this button shall be yellow.

3. “door open” and “door close” push button. 4. Audible and visible signals in connection with the overload device. 5. Light switch, alarm reset switch, fan switch and cleaner's "Stop switch" keeping the ca r

door open in the form of key switches or housed in a recessed metal box with hinged or sliding lid which wi ll be key-locked.

6. Two-way intercom speaker - the intercom system shall be as specified in Clause 26.11.4. 7. Any other control as specified in the specification.

All wordings shall be engraved in both English and Hindi characters. The material for the control station shall be stainless steel with a thickness of not less than 2.5 mm. The control station shall be fixed onto the car panel by stainless steel screws of secret -head type.

(b) Additional Control station:

For passenger lifts of 21 persons capacity or larger, to control station, one on either side of the ca r doors, shall be provided such that one shall have the above functions 1, 2 and 3 only and one shall have all the functions 1 to 7.

(c) Control station equipped with attendant control:

For lifts equipped with attendant control, the control station shall also incorporate:-

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1. A non-stop button for the purpose of by passing landing calls, but the calls shall remain registered until answered. This button shall be inoperative unless the lift is operat ed by an attendant.

2. A key-operated attendant control switch to be included in Clause 26.11.2(a)5. The additional functions specified in this clause shall be provided in the Control Station in

Clause 26.11.2(a). (d) Car direction and position indicator:

The direction indicators shall be of illuminated directional indicator with an illuminated area not less than 1125 mm2. The position indicator shall be of digital type display with lamp matrix actuated by solid state circuitry unless otherwise specified. The position indicator shall have a minimum height of 50 mm and easy to read even from a wide angle of view and under an illumination level of 500 lux. LCD display to be provided. The indicators shall be mounted onto the back of at least 2.5 mm stainless steel facep lates by weld studs and screws flush fit.

(e) Push /Electronic touch button:

All push/electronic touch buttons shall be vandal-resistant design and of flush mounted construction. The push/electronic touch buttons shall have acknowledgement of the call by illumination. The halo shall be formed with flame retarding polycarbonate. Shock loads due to pressing of the pressel must be borne by the body of the unit and not by the contacts.

(f) Lift control buttons: Essential lift controls buttons such as emergency alarm button, intercom button, door (opening button, call buttons on landings, floor buttons in the lift car shall not be lower than 900mm or higher than 1200mm above the finished floor level. Braille and tactile markings shall be placed either on or to the left of the control buttons. Such markings shall be minimum 15mm in height and 1 mm raised. All lift control buttons shall have a minimum dimension of 20 mm.

26.11.2 Fire Emergency return: When the building's fire or smoke detectors are activated, all calls should be cancelled automatically and the lift shall travel to the main lobby or a pre- designated floor and park there with the door fully opened. However the Electrical signal that indicates the actuation of the fire sensors must be supplied to the lift controller by others or the fire a larm switch provided on the ground floor is activated. The display to be given in the car with pre-recorded audio message so that passeng ers do not panic.

26.11.3 Car lights & Fan automatically shut off: The lift shall be installed with an energy saving feature that automatically switches off the car internal lighting and ventilation fans when there are no calls registered after a predetermined (Programmable) period of time.

26.11.4 Interphone: An interphone for the use in case of emergencies shall be installed in the car for direct communication with the rescue personnel in the control room or top of the car. The interphone shall be such that it is activated by simply pressing the interphone button on the car operating panel.

26.11.5 Fault information recording: The lift shall be provided with an automatically fault recording facility. A minimum of 50 last fault information's are reco rded to check what happened during a break down.

26.11.6. Arrival chime: An electronic chime to provide an audio signal to inform waiting passengers of the arrival of the lift car at each floor shall be provided. The chime shall be mounted on the top or bottom of

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the car. The LED indications for direction of travel and car floor level status to be provided as current.

26.11.7 Maximum call registration: Limit Maximum car calls to be registered at one time to avoid misuse, improve traffic efficiency and avoid redundant stopping of the car.

26.11.8 Parking floor: To improve efficiency and save· time the lift car sha l be made programmable to return to a predetermined floor after remaining idle. The idle time shall also be programmed in consultation with the employer or engineer in charge.

26.11.9 Voice anunciator: All kinds of information that include floor, direct ion a nd others shall be spoken out to remind passenger in three languages i.e. Hindi, English and vernacular.

26.11.10 Handicap: It is special for those people who are handicapped, which include Voice enunciator with hand rails, back mirror and horizontal push button station with Braille buttons.

26.11.11 Separate landing display: Big screen dot matrix LCD display shall be provided.

26.11.12 Duplex indication: In case call request button is pressed by any passenger from any floor or destination request any user inside the car the corresponding display button to get lit at respective floor and also in the car to avoid redundant operation by passengers.

26.12.0 Control System and Controller Accessories:

The control system shall be of variable vo ltage variable frequency (VVVF) microprocessor based simplex full collective. The control system shall include PWM inverter of standard and latest design so as to achieve maximum energy savings a nd accurate control. The control system will limit the starting current of the motor to the rated full load current under all conditions. The controller shall be enclosed in a suitable sheet steel wall mounted cubicle with front doors for easy accessibility of various equipments either on the top landing or inside the Lift shaft as per standard practice.

(a) Construction: The controller shall be constructed in accordance with IEC 60947 and shall be mounted in a ventilated steel cubicle with hinged front doors and removable hinged rear panels, in which all contactors, solenoids, relays, motor starting equipment etc., shall be fitted. All steel sheets shall be not less than 2.5 mm thick and comply with Clause 20.0 of this Specification. (b) General requirements:

The controller shall comply with the general requirements as stated in EN 81-1, and in particular, the following features shall be included:

1. Materials used in the construction of the control equipment shall not support combustion. 2. The components shall be designed and mounted in a manner which will facilitate easy

inspection, maintenance, adjustment and replacement. Wirings shall be terminated in such a way that the wires are not damaged. Accessible terminals suitably marked, shall be provided for incoming and outgoing cables.

3. Control circuits at normal mains voltage shall be connected between phase and neutral and shall be supplied through double wound isolating transformer.

4. Where rectifier is used it shall be of the full wave silicon type fed from a transformer.

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5. The control circuit shall be protected by suitably rated over-current circuit breakers or HRC fuses independently.

6. The brake solenoid and any retiring cam shall operate on direct current. 7. Motors connected to polyphase a.c. power supplies shall incorporate means to prevent the

motor from being energised in the event of phase failure. (c) Solid state controls:

Microprocessor-based control shall include the following design features:-

1. The system hardware shall be capable of supporting fully software based supervisory and motor control systems.

2. Interruption of the electrical supply to the lift shall not affect the system memory or software. 3. It shall be possible to change the supervisory control algorithm to meet a change in the use

of the building by re-programming the instruction memory. 4. It shall be possible to interrogate, by means of communication access/test points on the

controller, the system operating functions by use of a portable unit using diagnostic routines.

5. Visual indicators, e.g. LED'S, shall be provided on the controller to display information on the operational status of the lift.

6. Multiplexing technique s may be employed to reduce the number of trailing cables normally required, if considered cost effective to do so.

(d) Provisions for future remote monitoring of lift: The Supplier/Contractor shall provide dry contacts of the following output signals for each lift installation in a stainless steel cabinet to serve as the interface unit for future connection by others:

1. Normal/Fault status 2. Duty/Standby status 3. Power Supply Norma l/ Fault status 4. Normal/ Essential Power status 5. Passe nger trapped alarm

This interface unit shall be located at the management office/caretaker's room next to the lifts monitoring panel unless otherwise specified on the Drawing or in the Specification.

(e) Energy consumption and Duty Cycle monitoring:

The lifts shall be provided with energy recording devices and duty cycle reporting system. The print out port with RS 232/ USB port to be provided to communicate with PC/Laptop to dawn load energy, duty cycle, fault logs, mode of operation, battery status and other data/information etc. The down loading software to be supplied along with one Laptop PC and printer independent of platform as approved by employer or engineer in charge. The down loaded data, reports, information shall be platform independent in alpha numeric format in English language and shall have full compatibility and exchange with MS office .

(f) Directiona l collective control for single lift:

All calls shall be stored in the system and answered in sequence regardless of the order in which they are registered. When the car is traveling in a given direction it shall travel to the further-most call, answering any car ca ll or landing call for the corresponding direction of travel. Landing calls for the direction opposite to that in which the car is traveling shall be by- passed but shall remain stored in the system to be answered when the car returns in the opposite direction. When the car stops for the last call in its direction of travel, preference is given to car call(s) for an adjustable period. When all calls have been answered the car remains with doors closed at the floor to which it last traveled.

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(g) Energy management of lift system:

For each lift car within a lift has been idling for 2 minutes with the lift doors closed, the lift car's ventilation shall be shut off automatically until the lift car is activated again by passenger call.

(h) Conduit/Trunking facilities by Supplier/ contractor:

The Supplier/I Contractor or others shall be responsible for the prov1s1on of conduit facilities for the alarm buzzers/bells and the supervisory control panel at the landing of designated point of entry between the lift shaft and the position of the panel. The Supplier/Contractor shall furnish sufficie nt information to the Supervising Officer in good time before the conduit installation work is commenced on site. The Supplier/Contractor shall be liable for all expenses incurred due to his failure to comply with the above requirement.

(i) Supervisory control panel:

Where supervisory control panel is spec ified in the Particular Specification and/or Drawings, the Supplier/Contractor shall be responsible for the provision of all cablings, visual and audible signal components, and controls for the supervisory control panel from all lifts to the supervisory control panel that is located in the caretaker's office at the landing of designated point of entry unless otherwise specified.

The supervisory control panel shall include at least, but not exclusive, the following basic facilities :-

1. 'In service/Out of service LED lights for each lift. 2. Floor/position indicators for each lift. 3. Up/Down direction indicator arrows for each lift. 4. System fault alarm buzzer I bell and LED indication lights. 5. Power on indicator 6. Mute button for alarm buzzer I bell, and alarm reset button. 7. Lamp test button. 8. Repeater master unit for intercom system. 9. 'Under Fireman control' LED light for each Fireman's lift.

The conduit/trunking facilities from the lift shaft at the landing of designated point of entry to the position of the supervisory control panel shall be provided by others as in Clause 26.12.0(h).

(j) Closed circuit television: 1. a CCTV camera mounted on the ceiling of the lift car; 2. a color CCTV monitor located at the lift control room; 3. separate and independent lift travelling audio/video cable(s) for the CCTV system

connecting between the CCTV camera installed in the lift car (with the corresponding power supply MCBs in the MCB boards in the lift control room) and the CCTV monitor(s) respectively;

4. All the conduit and trunking facilities inside the lift shaft and the control room (conduit and trunking facilities outside lift shaft and lift control room will be provided by others unless otherwise specified) ;

5. The Supplier/Contractor shall integrate a set of CCTV video signal and emergency alarm signal output connection sockets on the lift supervisory control panel for others to connect the signal output through appropriate plugs to the display monitors of the security control console based on the following conditions : i) the CCTV video signal and emergency alarm signal output connection sockets on the lift

supervisory control panel shall be BNC panel sockets. ii) the Supplier/Contractor shall supply associated connection plugs, which shall suit the BNC

panel sockets on the lift supervisory control panel and shall not be less than the sockets in quantity, to the security control console specialist contractor who shall then be responsible for the wiring from the security control console to the plugs.

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iii) the BNC connection plugs and sockets shall be of 75 ohm impedance type, service voltage up to 500 V peak and frequencies up to 4000 MHz, and accept common RF cable.

26.12.1 Controller Accessories:

An emergency stop switch shall be provided and fitted on the top of the car for use of persons working thereon. During maintenance suitable limit switch shall be provided for automatically stopping at the required floor. Limit switches shall be provided to cut off the main supply to the driving motor and to cut off DC supply to the brake coil causing immediate application of the brakes in the event of the lift travelling past the top or bottom terminal limit switches. The limit itches shall be of approved designing and make.

26.12.2 Levelling Accuracy:

The leveling accuracy shall be ±5 mm or lesser for passenger convenience. This leveling accuracy shall be maintained under all conditions of loading.

26.12.3 Reverse Phase Relay:

A reliable reverse phase prevention arrangements shall be provided on the controller, which shall be designed to protect the Lift equipment against phase reversals and phase failures.

26.12.4(a) Provision of overload device: Every lift shall be provided with an overload dev ice whic h sha ll operate when the load in the car is 10% or more in excess of the rated load of the lift. The overload device, when in operation, shall:- 1. prevent any movement of the car. 2. prevent the closing of any power operated door whether fitted to the car or to the landing

at which the car is resting, and 3. give audible and visible signals inside the car.

The lift shall resume normal operation automatically on removal of the excessive load. The overload device shall be inoperative while the lift car is in motion.

(b) Full load device: Every lift other than a service lift shall be provided with a full load dev ice having an adjustable setting range from 80% to 100% of the rated load and when operated, it shall by-pass all landing calls. When the load in the car is reduced, the car shall stop for landing calls as normal.

26.12.5 Limit Switches:

Terminal limit switches shall be provided to slow down and stop the car automatically at the terminal landing and final limit switches shall be provided to a utomatically cut off the power and apply the brake should the car travel beyond the terminal landings.

26.12.6 Top of Car Inspection:

A top of car operating fixture shall be provided on each car, containing continuous pressure buttons for operating the car in both directions and a toggle switch for making the buttons on top of the car operative. This toggle switch when switched to inspection operation shall modify the operation of the car to disconnect it from the normal operation to eliminate all normal operation devices, automatic leveling and power door operation and the car shall run at standard speed for the purpose.

26.12.7 Automatic Rescue Device:

In the event of power failure or failure of control system w here the Lift is in operation the rescue device should take over automatically and bring the Lift to the nearest landing safely. The rescue device should be operated on rechargeable maintenance of free batteries. The battery charging system to be supplied such that batteries are kept charged always in situ.

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26.13 Alarm Bell and Emergency Light: The alarm bell is to be provided and fitted in an approved position close to the Lift at Ground floors complete with push button inside the car and with necessary SMF rechargeable Battery. Battery operated emergency lamp should also be fitted in the car which shall work automatically in the event of a power failure, providing illumination within the car. The batteries shall be maintenance free and shall be supplied on board with a battery charging system. The battery charge status to be displayed in control room.

26.14 Batteries and chargers: The batteries shall be of sealed, high rate maintenance free nickel-metal hydride type, or a type of better functions and performance and approved by the Supervising Officer and shall have a guaranteed life expectancy of at least four (4) years. They shall hot have any memory effect as to affect their usable life or performance. The nickel-metal hydride battery shall comply with EN 61436 a nd EN 61951-2 where ap propriate. The battery cha rger shall be compatible with the batteries used. The charger shall comply with EN 60335-2-29 and be capable of fully re-charge the batteries in not more than 12 hours.

26.15 Suppression of Radio and Television interference: The lift installation shall be adequately suppressed aga inst radio and television interfere nce to limits as laid down in BS EN 55014 and BS 613. Interference suppression components shall not be used in any part of the circuit where their failure might cause an unsafe condition.

26.16 Harmonic distortion: The lift installation shall not, by injection of undesirable waveforms into the electricity supply distribution system, adversely affect the power company's system and/or the electricity supply to other users or consumers. The Total Harmonic Distortion (THO) produced by the lift motor drive system measured at the isolator connect ing the lift equipment to the feeder circuit of the building is limited to the maximum allowable values specified in Table I. The THO shall be measured at the moment the lift car is moving up with rated load at its rated speed.

The Supplier/Contractor shall be responsible for providing all necessary harmonic filter(s) should the THO of the installation exceed the maximum allowable values as specified in Table I.

Table-I max allowable thd for lift Motor Drive Systems

Circuit fundamental current of Motor Drive.

Maximum THD (%)

400A ≤ I< 800A

80A ≤ I<400A

I<80A

15.0

22.5

35.0

26.17 Maximum allowable Electrical power:

The running active electrical l power of the motor drive of traction lift system carrying a rated load at its rated speed in an upward direction shall be equal to or less than the maximum allowable values specified in Table II.

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Table - II Maximum allowable Electrical power of Traction lifts (Vc < 3 )

Rated Load {Kg)

Maximum allowable Electrical power{kW) of Traction life Systems for various ranges of Rated speed {Vc) in m/s

Vc ≤ 1 1< Vc ≤ 1.5

1.5 < Vc < ≤ 2

2 < Vc < ≤ 2 .5

2.5 < Vc < ≤ 3

L< 750 7 10 12 16 18

750 <L ≤ 1000

10 12 17 21 24

1000 <L ≤ 1350

12 17 22 27 32

1350 <L ≤ 1600

15 20 27 32 38

1600 <L ≤ 2000

17 25 32 39 46

2000 <L ≤ 3000

25 37 47 59 70

3000<L ≤ 4000

33 48 63 78 92

4000 <L ≤ 5000

42 60 78 97 115

L < 5000 0.0083L+ 0.5000

0.0118L+ 1.0000

0.0156L+ 0.5030

0.0190L+ 2.0000

0.0229L+ 0.5000

26.18 Sound reducing:

The whole of the lift/ machinery including the opening and closing of the car and landing doors shall be quiet in operation, and sound reducing rubber pads or other means shall be provided by the Supplier/Contractor where necessary to eliminate vibration and noise transmission.

26.19 Finish:

All metal work supplied by the Supplier/Contractor in out of the way locations such as the lift shaft, lift pit and on the outside of the lift car shall be properly wire -brushed, cleaned of rust, scale, dirt and grease prior to the application of one coat of rust inhibiting primer, with particular attention paid to the priming of outer surfaces of car doors, inner surfaces of landing doors, metal work associated with door assemblies, the underside and the framework of lift cars. Any part of the equipment, including guide rails, which requires greasing or oiling and any components that are supplied unpainted by the manufacturers due to functional reasons shall not be painted. All normally visible metal surfaces, other than stainless steel and non-ferrous surfaces, shall be finished with one coat of rust inhibiting primer, one under coat/finishing coat and one finishing coat of enamel paint to a colour to be selected by the Supervising Officer.

26.20 Stainless steel:

Unless otherwise specified, stainless steel shell be of EN 10029, EN 10048, EN 10095, EN 10258 and EN 10259Grade 316 or equivalent.

26.21 Notice Boards: The following stainless steel notice boards engraving conspicuously in both English and Hindi characters shall be provided and rigidly mounted: -

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1. "No Smoking", which shall be in each car, 2. "When there is a fire do not use the lift" in each car and on each landing

floor.

26.22 Wiring and Earthing:

The employer will provide single phase and three-phase supply with suitable MCCBs I MCBs for isolation and protection in either on the ground floor or First floor or Second floor as far as possible near .the Lift shaft on request by the Supplier/Contractor. All necessary wiring in heavy gauge conduits from the MCB to the driving motor, controller, call push buttons, door locks, limit switches, alarm bell, halfway junction box and wiring inside the car shall be done by the Supplier/Contractor in accordance to IEC 60364 for Electrical Installations of buildings. Necessary travelling cables from the car to the halfway junction box in the shaft shall be provided by the Supplier/Contractor. Equipment earthing required for the machine and in the Lift well should be carried out by the Supplier/Contractor. The main earthing shall be of 4 SWG GI wire and subsidiary earthing by 14 SWG tinned copper wire. All electrical equipments in the Lift including car body shall be provided with two distinct earthing arrangement as per IS standards and connected to the earth pit provided in stations.

26.23 Departure from Specifications:

The Supplier/Contractor should supply standard equipment as far as possible but where it does not comply with this specification a list of deviation giving full particulars of deviations from this Specification duly quoting reference to clause No. shall be submitted to the Employer for prior approval.

26.24 Technical Particulars, Drawings etc.:

The approval applicationr shall be accompanied with:- i) Complete technical illustrated literature for the equipments offered. ii) Technical particulars and guaranteed performance of Lifts in the Annexure- 'B'.

26.25 Spare parts and tools:

Spares that are considered necessary for continuous satisfactory operation of the equipment for at least two years shall be advised separately, inclusive of rates for reference. Any special tools required for the maintenance of the equipment shall be submitted along with the tender.

26.26 Drawing and manuals: Complete detailed layout drawings showing the structural requirements in the building and loadings and disposition of various equipments and wiring diagram of various equipments shall be furnished by the Supplier/Contractor within a month of acceptance of the tender. Six copies in English language of the manufacturer's booklet containing description of various equipments of the Lift shall also be submitted to the Engineer in charge nominated by employer The operating manual and maintenance schedule shall also be submitted while handing over the installation to the Railways. The two additional manuals and information shall be supplied in Hindi, English and vernacular language each

26.27 Tests and Test Certificates:

The Supplier/Contractor shall furnish details of internal tests carried out on all equipment, components and fittings of the Lift at their works. Suitable test certificates should be submitted to employer and to engineer establish: - (a) The satisfactory operation of the Lift includes protective mechanisms, safety devices,

brake gear, etc. with temperature rise of driving motor not exceeding the guaranteed limits.

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(b) That the floor setting of the car at the landings is correct at all loads from no load to full load.

(c) That the speed of the ca r is as guaranteed and that the acceleration and retardation are satisfactory and smooth.

(d) That the operation of the contactors, interlocks and time lags are satisfactory and in correct sequence and the correct functioning of the terminal limit switches.

26.28 General requirements:

All dangerous parts shall be effectively guarded. W here applicable, components shall be designed to be inherently safe, obviating the need for external or removable guards. Every lift car body shall be carried in a steel car frame sufficiently rigid to withstand the operation of the safety-gear without permanent deformation of the car frame. The deflection of the members carrying the platform shall not exceed 1/1000 of their span under static conditions w ith the rated load evenly distributed over the platform. At least four renewable guide shoes, or guide shoes with renewable linings, or sets of guide rollers shall be provided, two at the top a nd two at the bottom of the car frame.

26.29 Training of Staff: The Supplier/Contractor shall train five staff including two Supervisors nominated by client or employer in charge, during the erection of the Lift at site. OEM place They shall also train the staff in the maintenance, operation and trouble shooting of the Lift. However the responsibility of maintenance of Lifts will be with Contractor during the guarantee period.

26.30 Guarantee:

The Supplier/Contractor shall guarantee satisfactory performance of the Lift and allied equipments over a period of 24 months in actual service from the date of handing over of the installation to the Railway in normal working conditions. During the guarantee period the Supplier/Contractor shall rectify free of cost of all defects which may develop due to any reason including faulty design, material failure and bad workmanship inclusive of free replacement of defective parts. The guarantee will get automatically extended corresponding to the periods during which the equipment is not in use. On every occasion when the equipment goes out of service, the duration between the date of intimation of the failure of equipment to the contractor and the date of handing over of the equipment after repairs in good working condition duly tested and commissioned in the presence of Railway's representative, will be counted for the extension of the guarantee period till the equipment completes actual service for a total period of 24 months. During the guarantee period the parts of the equipments requiring repairs or replacements will be handed over to the contractor at site and the parts after repairs or replacements shall be fitted in the equipment at site by the contractor. All expenses involved in fulfilling the above guarantee obligations shall be borne by the contractor.

26.31 Inspection:

The materials will be inspected by purchasers' nominated representative at manufacturer's premises or contractors depot as the case may be. The purchaser or his representative shall have the right to be present during all the stages of manufacture and shall be afforded free of charge all reasonable facilities for inspection and testing as well as to examine the stage inspection report of the manufacturer/ inspection in addition to the quality audit which the contractor may institute as a part of his Programme so as to satisfy himself the materials are in accordance with the specification, approved drawings and designs and purchasers prescribed Quality Assurance Standard.

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26.32 Civil Engineering:

The contractor should inspect site conditions before quoting the tender. The design of the Lift includes the design of the support system and guidance which includes the support of the traction machine and all its accessories. The Lift shaft is either 230 mm brick I concrete. Successful contractor should give their design to suit the existing Lift shaft/control room and well. The design of the Lift should be compatible with the Lift well and Lift shaft/machine room. The contractor should ensure adequate design so as the individual load and their distribution of car, counter weight for both normal and abnormal working (Accident), or within the structural design limits of Lift well. The anchorage and guidance of car and counter weight will be designed to suit the Lift shaft under all conditions. This is considered as primary responsibility of the contractor.

26.33 Preventive Maintenance and Schedules: The contractor shall service the Lifts thoroughly as per OEM maintenance schedule and attend the breakdown complaints free of charge during the defedt liability period of 24 months including all spares, materials and replacable parts free of charge.

(a). Important items of Schedule of maintenance during the defect liability period of 24 months is enclosed herewith however OEM recommended schedule of maintenance shall be followed in detail.

(b). Maintenance schedule for Electric Lifts: The following maintenance schedule should be carried out during the maintenance of Lifts and a record should be maintained in the office as directed by employer. Any abnormality noticed during the schedule should be attended immediately (within 2 hours) and proper operation ensured. Lifts should be taken up for schedule of maintenance preferably on Holidays or beyond office hours and in mutual agreement with the user.

I . Monthly Schedule of maintenance:

S No.

Nature of Work

1. Check and attend fittings of Lift (light, fan, emergency light, failure alarm etc.)

2. Check level of the lubricating oil in the gea rbox, any unusual sound in the gearbox.

3. Check the operation of all the doors, door locks.

4. Check the brakes and adjust it.

5. Check the operations of the limit switches.

6. Clean machine and associated equipments.

7. Check the main switch contacts and earth connections/ continuity.

8. Check the main switch, fuses etc. (for loose connection, oscillation and ratings etc.).

9. Check the general condition of the motor. RVNL



10. Control panel:-

a) Check overhead relays operation

b) Check the interlocks for its proper functioning.

c) Check the relay contacts their operation and chattering. 11. Check the electrical connections

12. Check the foundation bolts of the motor any unusual noise, vibration etc.

13. Check the input voltage & current of the motor and record it.

14. Check leveling switches, arm pivots and limit switch roll rs and lubricate. 15. Check the performance of the over speed governors and adjust if necessary.

16. Check the working of the floor selection switch.

17. Check the floor indicators. 18. Check all ropes, hinges, shackles etc.

19. Check the microprocessor control for its proper functioning.

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II.Quarterly Schedule of maintenance

III. Yearly Schedule of maintenance:

Sr No.

Nature of work.

1 Overhaul the motor for bearing and alignment.

2 Check car of body supported and steel channels.

3 Check the condition and wear in the bearings. 4 Clean and check guide rails. 5 All break gears to be reconditioned. 6 Solenoid coils to be tested.

7 Limit switches to be overhauled and adjusted. 8 All the interlocking arrangements to be overhauled and checked for proper functioning. 9 Gearbox to be overhauled completely.

10 Check the microprocessor units for the proper functioning.

Sl. No Nature of Work

1. Lubricate the rope pulley bearings.

2. Check tightness of the counter weight, fixing clamps, bolts etc.

3. Check the trailing cables for broken I damaged insulation and loose bindinq.

4. Check the condition of the pit clean the car top and clean the gate.

5. The wire ropes should be cleaned by a stiff brush to remove old lubricant and lubricate it again by using oil machinery medium or equivalent.

6. Clean the ropes for broken strands and general condition. 7. Check the dia. of the rope and record it. 8. Rope winding drum to be checked for its proper wind ing in the sheave grooves.

9. Measure the voltage and current at the various test points in the control system including microprocessor control and record it.

10 Check the fixing bolts of the motor for any vibration.

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IV. In addition to the above periodical maintenance the firm has to attend the following:-

a) The firm has to attend the breakdown failure at any time during the working hours without any delay.

b) They have to supply the required consumables, spares, to keep the Lift in good condition.

c) While attending the quarterly schedules the firm has to carry out the monthly schedules also.

d) While attending the yearly schedules the firm has to carry out the monthly and quarterly schedules also.

e) Maintenance schedule should be carried out in consultation with user mostly on Holidays or beyond office hours.

f ) If the Lift remains OUT OF SERVICE for more than 48 Hours per month, Railways will have right to impose penalty to the extent of 10% value of the contract .

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ANNEXURE”A“

BRIEF REQUIREMENTS FOR LIFT

1 Capacity : …..persons.

2 Speed : ….m/sec.

3 Car Travel : .... to .... About ..... m (approx.)

4. Stop and opening. : ….stop and …..opening……(all openings on same side)

s. Control : AC VVVF Variable Frequency with speed encoder 6. Operation : Simplex full collective with/w ithout attendant

7. Controller : Microprocessor based Modular control system

8. Communication : Loop type serial communication

9. Power Supply : 3 phase AC 415V ±10% Variation, 50 Hz ±5% Variation.

10. Machine : Gearless type induction/synchronous machine withpermanent magnet motor operated.

11. Hoist way : ..... mm wide x ..... mm deep (Tender to Check the suitability of the same before tendering).

12. Available head room : Renderer to verify the same at site before tendering.

13. Available Pit Depth : ..... mm (approx.).

14. Position Drive including Main machine.

: Directly at the top of Lift inside the shaft.

15. Car Enclosure : Stainless steel car panels of 1.5 mm thickness hairline finish with stainless steel false ceiling adequately illuminated LED luminaries of flush mounted pattern, one axial flow fan with grill of quit running type having a noise level not greater than 30 dBA, one smoked mirror of half height full width on the rear panel, 4mm thick antiskid studded rubber floor of approved color ,suitable handrails of 50mm O.D. tubular stainless steel shall be provided at 86mm height from floor level of the car on three sides of the lift car extending to within 150mm of all corners and with a 40mm clearance from car walls to facilitate handicapped passengers.

16. Car Safety Gear : Over speed governor- operated safety. RVNL



17. Landing and Car Doors.

: Landing doors and car door shall be of 2 panel centre opening sliding closed, stainless steel powder coated or hairline stainless steel finish panels, power operated independent drive with adjustable automatic opening and closing speeds for door. The clear opening should be 900 mm wide x 2000 mm with full height Memco 3D curtain safe edge to detect and open the doors in the event of Obstruc- tion I infringement w hile the doors are closing 18. Leveling : ±5 mm irrespective of load.

19. Human interface device

a. Hall button with micro stroke push/touch buttons combined with 16 segment digital LED display positio n indicator.

b. Full height car operating panel with micro stroke push/touch buttons (Located on side panel)_

c. Door Open and Door Close button on the Car operatinq panel.

d. 2 Way inter communication system.

e. DOT matrix position indicator display integrated with in the Car operating panel.

f. Over load indicator i.e. device to sense 80% of rated load and over load. Audio and visu l indicator of overload.

g. Battery operated Alarm bell and Emergency Light.

h. Fireman's switch.

i. Manual rescue operation.

j Emergency auto rescue device.

20 Peak periods of Lift work ings

: Generally between..... - ..... Hours in morning, ..... - ..... Hours in noon and ...... - ..... Hours in the eveninq.

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ANNEXURE - 'B'

TECHNICAL PARTICULARS AND GUARANTEED PERFORMANCE OF THE LIFT

(TO BE FILLED IN AND RETURNED ALONG WITH THE TENDER)

1. Machine:-

a) Main driving motor. :

b) Current in Amps at rated output. :

c) Make and type. :

d) Type of enclosure. :

e) Voltage between terminals. :

f) Output in HP. :

g) Weight. :

h) Speed in RPM at rated output. :

i) Class of insulation. :

j) Temperature rise on full load :

2. Brake:-

a) Make. :

b) Type. :

c) W idth & diameter of brake wheel. :

d) Method of adjustment. :

e) Provision for manual release. :

3. Car:-

a) Dimension (internal) . :

b) Weight (Approx.). : c) Contract load. :

d) Maximum speed. :

e) Acceleration. :

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f) Retardation. :

g) Method of suspension. :

h) Time for travel between the floors. :

4. Guide Rail:-

(i) For Car:-

a) Size and weight in kg per linear meter in Tee sec . :


c) Spacing of intermediate supports. :

d) Method of lubrication . :

(ii) For Counter weight:-


:


c) Spacing of intermediate supports.

:

d) Method of lubrication :

5. Control Equipments:- :

(i) Control Systems:- :

a) System of control and working DC voltage for control.

:

b) Type of VVV F control details. :

c) Potential Energy savings. :

(ii) Self leveling System:- :

a) Type of car leveling device. :


(iii) Limit Switches:- :

a) Type. :


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6. Suspension Ropes:- :

a) No. of ropes. :

b) Size and no. of strands in each rope. :

c) Factor of safety. :

d) Method of attachment to the car. :

e) Method of attachment to thecounter weight. :

7. Counter weight:- :

a) No. of sections. :

b) Weight of ea ch section. :

c) Type of guide shoes. :

d) Method of load equalization of ropes. :

8. Wiring:- :

a) Specification of wires. :

b) Method of wiring.

:

9 FINISHING. :

a) Full particulars should be given. :

10. Protection devices, details provided in the lift:- :

11. Special inclusions if any:- : RVNL




MISCELLANEOUS SPECIFICATIONS

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CHAPTER : A-27


MISCELLANEOUS SPECIFICATIONS

27.1 RDSO SPECIFICATIONS: RDSO has issued specifications for items which are listed below. These items should be procured as per RDSO specifications:

SR No.

Item RDSO Specification No. & Dt

1. CENTRALIZED AIR VENTILATION WITH AIR COOLERS OF WAITING ROOM AND DEPARTURE LOUNGE AT THE STATIONS

RDSO/2009/EM/SPEC/0001, (Rev.‘0’)Amdt.1

2. ENERGY SAVER CUM INTELLIGENT MOTOR CONTROLLER SPECIFICATION FOR AC INDUCTION MOTORS

RDSO/PE/SPEC/PS/0098(REV ‘0’)-2008, Amdt. ‘1’

3. STAND-ALONE WIND + SOLAR PHOTOVOLTAIC HYBRID POWER GENERATING SYSTEM FOR LEVEL CROSSING GATES

RDSO/PE/SPEC/PS/0124-2009 (Rev. 0) Amendment ‘1’

4. Manufacture & Supply of Solar Cooker RDSO/2009/EM/SPEC/0003, Rev. ‘0’ Amdt. 1

5. INTEGRATED RENEWABLE ENERGY BASEDPOWER SUPPLY ARRANGEMENT

RDSO/2009/EM/SPEC/0004 (Rev. ‘1’) – 2012

7. TECHNICAL SPECIFICATION FOR FAULT TOLERANT UNINTERRUPTED POWER SUPPLY (UPS) SYSTEM FOR PRS, EDP CENTERS AND OTHER SIMILAR REQUIREMENTS OF ONLINE UPS SYSTEM

RDSO/PE/SPEC/PS/0023– 2001 (Rev-0) Amdt No. 3

8. INTEGRATED SOLAR PHOTO VOLTAIC BASED POWER SUPPLY SYSTEM LIGHTING LOADS FOR ELECTRIC LOCO SHEDS & WORKSHOPS

RDSO/2009/EM/SPEC/0005 Rev. ‘0’, Amdt. ,1,

9. LED SIGNAGE SYSTEM for stations and circulating areas

RDSO/PE/SPEC/PS/0086-2009 (Rev.‘ 0’), Amdt-1

10. GRID CONNECT SOLAR GENERATING SYSTEM OF CAPACITY 10 KWp to 100 KWp

RDSO/PE/SPEC/PS/0092-2008 (Rev. ‘0’), Amdt -4

11 STAND-ALONE SOLAR PHOTOVOLTAIC LED BASED STREET LIGHTING SYSTEM

RDSO/PE/SPEC/PS/0093-2008 (Rev. 0) Amnd. 3

12 Solar based water Heating System RDSO/PE/SPEC/PS/0094-2008 (Rev-0) AMDT-1 (Withdrawn)

13 PASSENGER ESCALATORS TO BE INSTALLED AT VARIOUS RAILWAY STATIONS OF INDIAN RAILWAYS

RDSO/PE/SPEC/TL/0095 (REV ‘1’) -2012

14 DOUBLE-CAPPED TUBULAR T5 FLUORESCENT LAMPS, T5 LUMINAIRE & ELECTRONIC BALLAST

RDSO/PE/SPEC/PS/ 0100 (REV. ‘1’)-2011

15 MAINTENANCE FREE EARTH FOR ELECTRICAL INSTALLATION

RDSO/PE/SPEC/PS/0109(REV.0)-2008, Amendment ‘1’

16 ENERGY EFFICIENT LED BASED LUMINAIRE UNIT FOR STREET LIGHT AND PLATFORM LIGHTING

RDSO/PE/SPEC/PS/0123(Rev ‘0’)-2009, Amendment ‘2’

17 POWER SAVER IN LIGHTING SYSTEM DSO/PE/SPEC/PS/0083(REV ‘0’)-2008 Amendment 1

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18 PASSENGER ELEVATOR FOR INDIAN RAILWAYS RDSO/2013/EM/SPEC/0016 (Rev ’0’) 19 Control and distribution panel for CLS supply in 25

KV AC traction system TI/SPC/PSI/CLS/0020 (12/02) with A&C slip No. 1 to 4 or latest

20 Manufacture and supply of single/multi core 11/33 KV grade XLPE insulated and PVC sheathed armoured/ Unarmoured power cables for electric supply purpose

RDSO/2009/EM/SPEC/0002, REV-1

21 Static battery chargers RDSO/PE/SPEC/AC/0008 (Rev-2) 22 POLE MOUNTED TYPE BATTERY CHARGERS FOR 11V

SG COACHES EL/TL/52 (Prov)

27.2 Tripping Characteristics of MCBs:

Based on the tripping Characteristics, MCBs are available in B” and ‘C’ Curve to Suit different types of applications.

‘B” Curve: For Protection of electric circuits with equipment that does not cause surge current (lighting and socket outlet circuits). Short circuit release is set to 3-5 In

‘C” Curve : For Protection of electric circuits with equipment that cause surge current (inductive and motor circuits). Short circuit release is set to 5-10 In

‘D” Curve : For Protection of electric circuits which cause high in rush current when they are switched ON. Typically 15 times the normal running current (Transformers, Heavy Start Motors, 2 Pole Motors). Short circuit release is set to 10-20 In.

27.3 Class of Insulation (For Electric Motors):

Type Max. Operating Temp.

Materials Used

Y 90°C Cotton, silk, paper, and similar organic material and combination of such material which are not (impregnated) nor immersed in oil.

A 105°C Above materials impregnated with Varnish or enamel or oil immersed.

E B

120°C 130°C

Comprise inorganic materials such as mica, glass fibre asbestos or combination of these materials in built up form with binding cement.

F 155°C Class B materials when built up with suitable cement or binder.

H 180°C Consists of materials or combination of materials such as mica, glass fibre Silicon lastomer with suitable winding, impregnating or coating substances as silicon resins.

C Above 180°C Materials such as mica Porcelain, glass quartz and asbestos with or without inorganic binder.

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27.4 Degrees of Protection as per DIN 40 050 and to IEC 144:

The degree of protection is specified in accordance with DIN 40 050 and with Publications of the International Electro technical commission (IEC) by means of the letters IP (International Protection) and two characteristic numerals.

The first numeral indicates the degree of protection against contact with live parts and the ingress of foreign bodies; the second numeral indicates the degree of protection against water.

First characteristic numeral. Degree of protection against contact with live parts and the ingress of foreign bodies

Second characteristic numeral. Degree of protection against water.

First characteristic Numeral

Degree of Protection. Second characteristic numeral

Degree of Protection.

0 No protection of persons against contact with live or moving parts inside the enclosure. No protection of equipment against increase of solid foreign bodies.

0 No protection.

1 Protection against accidental or inadvertent contact with live or moving parts inside the enclosure body large surface of the human body as, for example, a hand, but no protection against deliberate access to such parts. Protection against ingress of large solid foreign bodies of diameters greater than 50mm.

1 Protection against drops of condensate. Drops of condensate falling vertically on the enclosure shall have no harmful effect.

2 Protection against contact with live or moving parts inside the enclosure by figures. Protection against ingress of medium size solid foreign bodies of diameters greater than 12mm.

2 Protection against drops of other liquids. Drops of falling liquid shall have no harmful effect when the enclosure is tilted any angle up to 15 from the vertical.

3 Protection against contact with live or moving parts inside the enclosure by tools, wires or such objects of thickness greater than 2.5 mm. Protection against ingress of small solid foreign bodies of diameter greater than 2.5 mm.

3 Protection against rain. Water falling as rain at an angle equal to or less than 60 with respect to the vertical shall have no harmful effect.

4 Protection against contact with live or moving parts inside the enclosure by tools , wires or such objects of thickness greater than 1 mm.Protection against ingress of small solid foreign bodies of diameter greater than 1 mm.

4 Protection against splashing liquid: Liquid splashed from any direction shall have no harmful effect.

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5 Complete Protection against contact with live or moving parts inside the enclosure. Protection against harmful deposits of dust. The ingress of dust is not totally prevented, but dust cannot enter in an amount sufficient to interfere with the satisfactory operation of the equipment enclosed.

5 Protection against water –jets: Water projected by a nozzle from any direction under slated conditions shall have no harmful effect.

6 Complete Protection against contact with live or moving parts inside the enclosure. Protection against increase of dust.

6 Protection against conditions on ships decks(deck water light equipment):Water due to heavy seas shall not enter the enclosures under prescribed conditions’.

7 Protection against immersion in water. It must not be possible for water to enter the enclosure understated conditions or pressure and time’.

8 Protection against indefinite immersion in water under specified pressure. It must not be possible for water to enter the enclosurse’

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RVNL



APPROVED MAKES

OF

EQUIPMENTS & MATERIALS

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RVNL



CHAPTER: A-28

APPROVED MAKES OF EQUIPMENTS & MATERIALS

1. All Equipments & Materials should conform to latest version of BIS or other indicated specification as per RVNL Policy guidelines. All energy consuming equipments should have minimum 3 star rating given by BEE, wherever applicable.

SN Equipment/ Material BIS Specification

No. Name of Manufacturer/Brand Name

1. PVC Conduit

9537/Pt.3/1983 AKG

Poly cab Precision

Finolex , CROWN

Presto Plast ,AKU, SUDHAKAR , NANDI 2. 1.1 kV PVC Insulated,

multi strand Copper conductor Cable for wiring (ISI Marked)

694/1990 The National Insulated Cable Co. Grandlay Electricals ( India)Delhi

Cable Corporation of India Ltd. Fort Gloster Industries Ltd.,

Universal Cable Co.

Asian Cables

Vijay Cables Industrials New Delhi

Sunhome Cables Industries New Delhi

ICL Cable, Rajpura

Incab

Torrent

Skytone

Poly Cab Arun Manufacturing Delhi

Vishal Brandh of Desmesh Cables

Finolex

Uniflex , PRIMECAB

RPG

Unistar

Indian Cable Co. Kolkata

Havell’s

Frexton Cables(I)

Ajanta cables

Indrani Cables Fixolite Wires & Cables

Cab com

RVNL



Galaxy power cables

Victor cables Tara Cables Deco Industries

Maxwell New Delhi

Oriental Power cable Pee Kay Industries

Cab cond, New Delhi Ajanta Electric Industries.

Insucon cables & cond. KEI industries Ltd., Mid Light Electrical Pvt. Ltd. Bharat Cab brand of Vardman cables

Anchor, PLAZA, RR CABLES, LEADER, UNI STAR

3. Metal Box (enclosure for accessories)

14772/2000 Anchor , HAVELLS Cona , GM , C&S ,MDS ,

Legrand , INDOASIAN ,TOYOMA

4(i) Electrical Accessories for wiring (ISI Marked)

Relevant Anchor , GM Cona

SSK(top Line) Precision ( Prime) Vinay ( Clair 30)

Leader Legrand, Havell’s, HPL, C&S, Ryder, ABB, Hensel.

4(ii) Electrical Accessories for wiring (Modular switches& Sockets) (ISI Marked) (NEW ITEM)

Relevant Anchor- Roma Woods

Indo Asian- Hussman

Havell’s- Crab Tree , GM , MARU , LEADER , LEGRAND ,TOYOMA

5 Phenolic Laminated Sheets(ISI Marked)

2036/1995 Bakelite Hylum Ltd. Calcutta Formica India Ltd. Motia Khan New Delhi, Super Hylan, Pvt Ltd.New Delhi, Surendra composites Pvt.Ltd. Bhopal

6 Industrial Type Iron Clad Socket

13947 Havell’s

Crompton Control & Switchgear

BCH

Standard Electricals HPL India Ltd.

RVNL



GE

Siemens

L&T

Indo Asian 7 i) MCB

ii) RCBO iii) RCCB

i) 8828/1996 ii)IEC:61009 iii) IEC: 61008

Havell’s

Crompton

Control & Switchgear

Legrand GEC

Jyoti

L&T MDS Siemens GEC

Andrew Yule Indo Asian Schneider Standard Electricals Merlin Gerin ABB Moeller HPL India BCH

8 Call Bell ( NEW ITEM) Relevant Anchor

Cona , GM

MAX. Leader SSK

9 MCB Distribution Boards 8623/1993, 13032/1991

Havell’s

Crompton

Control & Switchgears

GE , GM Standard

HPL India

L&T , LEGRAND Siemens

Indo Asian , C&S BCH

10 Electronic Regulator (ISI Marked)

Relevant Anchor

Usha

ERIK

RIDER

CGL , GM

Jay Engg.

RVNL



Matchwell Elect Roma Cona Plaza

11 Ceiling Fan/Air Circulating Fan( ISI Marked

374/1979 Khaitan

Crompton

Usha

Orient

Bajaj

Havell’s

Kedia Polar GEC Almonard

Phillips Anchor

12(i) Exhaust Fan (ISI Marked)

2312/1967 Crompton

GEC, Almonard

Usha

Bajaj Khaitan

Polar Orient Phillips

12(ii) Exhaust Fan/ Fresh Air fan with fibre body

Relevant Usha Bajaj Khaitan Polar , HAVELLS

13 AC Units ( Window & Split type)* , Cassette AC, Tower AC , Packaged AC , Battery Operated AC

Relevant 1391/Pt.1/1992

VOLTAS

Carier Air con

Blue Star

Amtrex Appliances

Sidwal Refrigeration

Frick India Ltd.

LG , TROPYCOOL Samsung , O General Godrej , PANASONIC

Fedders Lloyd

Hitachi

Shri Ram

Onida Videocon

Daikan

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14 Water Cooler SS Body 1475/Pt.1/2001 Voltas

Blue Star

Sidwal Refrigeration

USHA Fedders Lloyd

Kelvinator Shriram, Eureka Forbes

15 Auto Voltage Corrector Relevant As recommended by the OEM of Ac Unit/Water Cooler

16 Geyser 2082/1993 Racold

Bajaj Electricals Crompton

Venus

Johnson

Superhot

USHA SPHEREHOT, Havells.

17 Power Distribution Transformer

2026 Crompton Greaves NGEF

AREVA T&D India Ltd., New Delhi

Kirloskar Electric Co. Ltd., New Delhi

Andrew Yule and Co., New Delhi

Bharat Bijlee Ltd., New Delhi

Bharat Heavy Electricals Ltd., Kanohar Electrical Ltd., Meerut, (UP)

Mirzapur Electrical Industries Ltd., Mirzapur, (U.P)

ABB

Siemens Voltas

Volt Amp. ,

Kerala Electric and Allied Engg. Co. Ltd.,

Rama Krishna Transformers, Hyderabad

ECE Industries

Radhika Electricals

Tesla , SHAKTI GEC TELK

RVNL



Hint Transformers EMCO

Mahindra Transformers Ghaziabad

Vijay Electricals Indo Tech. Transformers Ltd.,

PN Engg.

Power Master Electricals, Kolkata

Automatic Electrogear, Kolkata Alfa Transformers, Bhubaneshwar

Orissa Transformers, Pvt. Ltd., Bhubaneshwar

United Machinery Corporation, Kolkata, Star Delta Transformers Pvt. Ltd.Bhopal.

18. 11 kV Vacuum Cricuit Breaker Panel

13118/1991 & 3427/1997

AREVA T&D India Ltd.,

ABB

Crompton Siemens India BHEL Jyoti

Andrew Yule Kill Burn Voltas Biecco Lawrie

ECE Industries Schneider electric India GEC L&T , Denson Yamuna Power

19 HT 11 kV and 33 kV XLPE (E) Cable (ISI Marked)

7098/Pt.2/1985 ISI APPROVED SUPPLIERS

20(i) HT Protection Relays ( Over current, Earth Fault and other protective relays for transformers & Panels (Introduction/Static/Numberical type) ( NEW ITEM)

3231 AREVA T&D IndiaLtd. L&T

ABB Easun Rey Rolle Alind BHEL Jyoti

GE BCH Minilac Enercon

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20(ii) LT Protection Relays (NEW ITEM)

3231 AREVA T&D IndiaLtd. L&T

ABB Easun Rey Rolle Alind BHEL Jyoti

GE BCH Minilac Enercon VXL

21 D.G. Set ( NEW ITEM) Engine 10000/1980, Alternator: 4722/2001

Engine: Kirlosker

Cummins

Ashok Leyland

Greaves Ltd.

Caterpillar

PentaVolvo Alternator

Kirlosker Electric Co. Hubli Jyoti Crompton

Stamford

Kerala

Leroy Somer

Kirlosker Green 22 Cable Jointing/

Terminating Kit for 11 kV to 33 kV HT cables

13573/1992 Yamuna Gases and Chemicals Ltd., New Delhi

Mohindra Engg.& Chemical Product, New Delhi

Raychem RPG Ltd.,New Delhi

Hari Consolidated Pvt. Ltd.,New Delhi

XICON Safe Systems Shrink Fit

REPL DENSON Yamuna Super Seal Birla 3M

RVNL



23(i) Measuring & recording Instruments( Electrical)

Relevant Auto Electric Havell’s Meco Instruments Motwani L&T National Instruments

Shanti Toshniwal

Siemens Sivananda Electronics

JMP CIE Electric & Electronic devices. IMP Industrial Meters Rishab

Moeller (HPL) 23(ii) Electric Energy Meter 13779/1999 Cl.1.0 Havell’s

L&T HPL Baroda Electric Meters

VXL India Ltd. Jaipur Metal Works

Capital Power System ECE

Meters & Instruments Industrial Meters Anchor Indo Asian

Max Well

IMP Swecure Meters ABB

Enercon, BENLO RVNL



24 L.T. XLPE armoured Aluminium Conductor Cable (ISI Marked)

7098/Pt. 1/1985 ISI APPROVED SUPPLIERS

25(i) APFC Panel (NEW ITEM)

Relevant L&T Siemens ABB, Neptune

25(ii) Capacitor 13340/93 Siemens

ABB

L&T

BHEL Indian Capacitors

Khatau Junker Shreem

Unistar Junkar W.S. Insulators

Hind Rectifier Voltas

Schneider Indian Condensers EPCOS Universal Cables, Neptune

26 CLS control Panel for AT supply ( NEW ITEM)

RDSO Tech. Spec. No. TI/SPC/PSI/CLS/0020 (12/02) with A&C slip No. 1 to 4 or latest

JAPS

S&S

Suntron & Matrix & Other RDSO’s approved makes

27 ACB & ACB Bus coupler 13947/Pt.1&3/1993 Siemens

Control & Switch Gear ALSTOM

L&T

Crompton

Jyoti

Mysore Electric Industries GEC(AREVA) Scheneider Electric India JSL Industries Ltd.,New Delhi BCH

RVNL



MEI ABB English Electric Havell’s , Enercon NGEF

Legrand

Standard BHEL Power Boss N.N. Planner Minilac Andrew Yule , Indo Asian

28 MCCB 13947/Pt.1&3/1993 Siemens Control & Switch Gear ALSTOM L&T Crompton

Jyoti Mysore Electric Industries GEC(AREVA)

Scheneider Electric India

JSL Industries Ltd.,New Delhi

BCH ABB HAVELLS Legrand Standard,Electricals

BHEL

Merlin Gerin Indo Asian

29 Time switch ( timer) Solid State

Relevant General Industrial Control Pvt. Ltd.,

MDS Legrand Havell’s Jyoti BHEL

BCH GE ABB, Indo Asian L&T

Siemens Minilac Legrand

RVNL



30 Fuse Switch Unit/ Switch Fuse Unit, COS & HRC fuses

13947/Pt.1&3/1993 L&T

Siemens Control & Switchgears Hevell’s

GE Indo Asian

Crompton

NGEF ABB Jyoti Mysore Electric HPL

Standard BCH Indo Asian Kenbar GEC ( Areva) SHNEIDER Electric Legrand Andrewyule Moeller

Merlin Gerin

31 Cable Jointing/ Terminating Kit for LT cables

Relevant DENSON Yamuna

Mohindra Engg. & Chemicals Products, New Delhi

Raychem RPG Ltd.,New Delhi

Hari Consolidated Pvt. Ltd.,New Delhi

Yaswant Industrial Works (P) Ltd Make: Super Seal

32 Current Transformers 2705/1992 Havell’s

AE

CGL, Risabh

C&S MECO Kappa Siemens

L&T Schneider

JSL Ind.

RVNL



33 Ferrules, Thimbles/ Lugs

Relevant Dowells

G.J.Metal Works Usha Martin Universal Machines Kamlesh Industries KSE Electrical UML Engg ASCON

34 Flood Light and street light Luminaries

10322/Pt.5/sec.3/1987& 10322/Pt.5/sec.5/1987

Philips Bajaj Crompton

GE Wipro

Osram Genlec Surya Sylvania , Asian Illumination enterprises New light industries ECE Industries Ltd.

Keselec Schreder Havell’s

35. Energy Efficient Luminary & Lamps

10322/pt.5/1987 Asian Bajaj Philips Crompton Wipro

GE

Osram AREVA Havells

36 CFL Luminaries 10322 Keselec

Crompton Philips Bajaj GE

Wipro , Asian

Mysore lamps

Shinkolite Pvt. Ltd. Twinkle Industries

Tilok Chand & Sons

Surya Roshini

Havell’s Osram

RVNL



37 Metal Halide lamps Relevant IEC Philips Bajaj Crompton GE Osram

Arklite

Surya Sylvania

Wipro Venture

38 CFL IEC 901 Phillips

General Electric

Bajaj Crompton

Osram Surya Wipro Havell’s

Sylvania 39 High Mast Lighting

Tower Relevant Bajaj

Phillips Crompton General electric

BPP UTKARSH

40 Tubular Pole

Reputed make with the approval of the Employer

41 GI Pipe (ISI Marked) 2713/Pt.1 to 3/1980 1239/Pt.1/2004

TATA Jindal Utkarkash PRAKASH-SURYA Surya TT Swastik

42 Porcelain Insulators LT-1445/1977 HT-731/1971 & fitting IS 486/Pt.2/1989

Bengal Potteries Ltd.

BHEL W.S. Insulators Seshasayee Industries Ltd., Venkateshwara Ceramics Jaya Shree Insulators

Insulators and Electricals Company.

Mahalaxmi, RASTRIYA,

43 ACSR Conductor (ISI Marked)

398/Pt.II/1996 Reputed make ISI mark with the approval of the Engineer.

RVNL



44 RCC Hume /HDPE pipe/DWC Pipe

Relevant Reputed make ISI mark with the approval of the Engineer

45 Battery Charger for Train Lighting

2026 & 3895 Hind Rectifier Usha Rectifier

Suresh Electricals Pyramid

Automatic Electric

Delta Electric Universal Industrial products

Trinity Electric Venus Engg. R.S. Power

Engineering Services Equipment control

46 i) H.S. Pump

1520/1980

Maxflow Pumps India Ltd., Gurgaon

Geeta Flow Pumps India Pvt. Ltd.

Kirloskar

Worthington Pumps India Pvt. Ltd., Ghaziabad

Beacon Weir Ltd.,Chennai

Mather & Platt Ltd., Pune Jyoti Ltd., New Delhi

Luxmi Pumps

KSB Suguna

ii) Control Panel for Pump

Relevant Original as supplied with pump by OEM

RVNL



47. i) Submersible Pump

8034/2002

KSB Pumps Ltd. Calama

Mody Industries (FC) Pvt. Ltd., New Delhi

India Electrical & Engg. Co. Ahemdabad

Jyoti Ltd., New Delhi

Crompton Kirloskar

KK Pumps Lix,o Hydraulics Shroff Engg.

Waterman

SB Pumps Flow Tech

Suguna

TEXMO SABER

ii) Control Panel Relevant Original as supplied with pump by OEM

48 11 kV Air break Gang operating Switch with Drop Out fuse 200 A & 400 A (NEW ITEM)

IS:9921/1993 ABB

ALIND

Crompton Greaves Jyoti

Mysore Electric

NGEF

Siemens

Trans Electricals

IE Power Gears Pvt. Ltd.,Hyderabad

S&S Power Switch Gears LTd.,

Kiron

Alliance Engg. Pvt. Ltd. ECE Industries

49 33 kV Air break Gang Operating Switch with Drop Out Fuse 200 A to 1750 A

IS: 9921/1982 ECE Industries

ABB

IE Power Gears Pvt. Ltd., Hyderabad

S&S Power Switch Gears Ltd.

Alliance Engg. Pvt. Ltd. HLM

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50 Rotary Switch & Selector Switch

Relevant Kay Cee L&T ,

Slazer GE ABB

C&S Siemens HPL Moeller

51 Contactors 13947 L&T

Jyoti GEC C&S Siemens Crompton MEI , Indo Asian NGEF Legrand

BCH Standard BHEL Minilac Enercon

Andrew Yule NN Planner Power Boss Scheinder

Mysore Electric

52 L.T. Panel 8623 Firm s having ISO:9001 certification & testing facilities in works as per IS: 8623

53 Solar lighting system for Crossing Gate

IS – 12834, 12763, 12761 Part - 1

TATA BP, BEL, TITAN, SSPL, ANDROMEDA, SUNWATT, JAIN SOLAR SYSTEM, CIRA, Nano Bright

54 Induction Lamp Relevant Bajaj, Philips, LVD Raes, Halonix, Fortune Art.

55 Remote Energy Monitoring , Control and Data Aquisition System of Power, AMRs ( New Item)

Relevant AMI , Analogic , J&J ,VisionTech

56 Elevator , Escalator, Travelator and lifts(New Item)

Relevant Thyssen Krupp , Jhonson , Schindler , OTIS , Kone ,

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57 LED Lamps Relevant Phillips-Lumileds, Osram, Nichia, Cree/Seoul Semiconductor

58 Solar Water Heater Relevant Tata-BP Solar, Racold thermo ltd, Kotak Urja, Anu solar, Jain Irrigation OR other MNRE approved sources with prior approval of RVNL

59 GI Octogonal Poles Relevant PHILIPS, BAJAJ, SURYA AND OTHER REPUTED MAKES WITH PRIOR APPROVAL OF RVNL

60 Battery for solar systems

PANASONIC, EXIDE, AMARRAJA, HITACHI, TATA BP

61 Street light controller energy pack

BAJAJ, PHILIPS, CROMPTON GREAVES, HAVELLS

62 Air Curtains CROMPTON GREAVES, HAVELLS, POLAR

63 Cable Fault Locator APLAP Thane, MRPC Hyderabad, ELECTROCON SYSTEM Bengaluru, AISHWARYA TELECOM LTD

64 Cable Route Tracer APLAP Thane, MRPC Hyderabad, ELECTROCON SYSTEM Bengaluru, AISHWARYA TELECOM LTD

65 Digital Meggar MOTWANI, KUSUM, MECO, METRAVI, RISHAB, MEGGER

66 Digital Earth Tester Meggar

MOTWANI, KUSUM, MECO, METRAVI, RISHAB, MEGGER

67 Cable Tray (GI) Firms having ISO:9001 certification & testing facilities in works

NOTE: 1. If any item/ equipments are not included in the above list, good quality material/equipment shall

be procured, in accordance RVNL policy as stipulated. 2. If any work requires coordination and acceptance of other department of Central/State

government, the contractor shall follow approved vendor list and standards, specifications of that department and take their approval before ordering the material/equipment.

------------------------------------------------------------------------------------------------------------------------------------------ RVNL



RVNL



IMPORTANT INDIAN STANDARDS

(IS)

RVNL



RVNL



CHAPTER: A-29

IMPORTANT INDIAN STANDARDS Note: The following IS codes (issued by Bureau of Indian Standards) shall be referred with their latest amendments for supply, erection, testing and commissioning of the equipments and materials. S.No IS Number Standard Title 1 IS/10000/Part

1/1980 Method of tests for internal combustion engines: Part I Glossary of terms relating to Test methods.

2. IS10000/Part10/1980

Methods of test for internal combustion engines: Part 10 Tests for Smoke Levels, Limits and Corrections for Smoke Levels for Variable Speed Compression Ignition Engines.

3 IS10000/Part 11/1980

Methods of tests for internal combustion engines: Part 11 Information to be supplied by the purchaser to the manufacturer and information to be supplied by the manufacturer along with the engine

4 IS10000/Part 13/1980

Methods of tests for internal combustion engines- Part 13: Recommendations on Nature of Tests Required for Functional changes in Critical Components

5 IS10000/Part2/1980

Methods of tests for internal combustion engines: Part 2 Standard reference conditions

6 IS10000/Part3/1980

Methods of tests for internal combustion engines: Part 3 Measurements for testing –units and limits fo accuracy

7 IS10000/Part5/1980

Methods of tests for internal combustion engines: Part 5 preparation for tests and measurements for wear

8 IS10000/Part6/1980

Methods of tests for internal combustion engines: Part 6 Recording of test results

9 IS10000/Part7/1980

Methods of tests for internal combustion engines: Part 7 Governing tests for constant speed engines and selection of engines for use with electrical generators

10 IS10000/Part8/1980

Methods of tests for internal combustion engines: Part 8 Performance tests

11 IS10000/Part9/1980

Methods of tests for internal combustion engines: Part 9 Endurance tests

12 IS10000/Part IV/1980

Methods of tests for internal combustion Engines Part IV: Declaration of Power, Efficiency, Fuel Consumption and Lubricating Oil Consumption

13 IS10000/PartXII/1980

Methods of tests for internal combustion Engines- Part XII: Specimen Test Certificates

14 IS10001/1981 Specification for performance requirements for constant speed compression ignition (diesel ) engines for general purposes( up to 20 kW)

15 IS 10027/2000 Composite units of Air-break Switches and Rewritable Type Fuses for Voltages Not Exceeding 650 V Ac- Specification

16 IS 10118/Part 2/1982

Code of practice for selection, installation and maintenance of Switchgear and control gear: Part 2 Selection

17 IS10118/Part 3/1982

Code of practice for selection installation and maintenance of Switchgear and control gear: Part 3 Installation.

18 IS10118/Part 4/1982

Code of practice for selection installation and maintenance of Switchgear and control gear: Part 4 Maintenance

19 IS 10118/Part I/1982

Code of practice for selection installation and maintenance of Switchgear and control gear: Part I : General

20 IS 10322/Part1/ 1982

Luminaries: Part 1 General requirements

21 IS10322/Part 2/1982

Specification for Luminaries- Part 2: Constructional Requirements

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22 IS 10322/Part 3/1984

Specification for Luminaries- Part 3: Screw and Screw less Terminals

23 IS 10322/Part4/ 1984

Specification for Luminaries – Part 4: Methods of Tests

24 IS10322/Part5/Sec1/1985

Luminaries: Part 5 Particular requirements, sec 1 General purpose luminaries

25 IS 10322/Part 5/Sec2/1985

Specification for Luminaries – Part 5: Particular Requirements- Section 2: Recessed Luminaries

26 IS10322/Part5/Sec 3/1987

Luminaries: Part 5 Particular requirements, Section 3 Luminaries for road and street lighting ( superseding IS: 2149)

27 IS 10322/Part 5 / Sec 4/1987

Luminaries: Part 5 Particular requirements, Section 4 portable general purpose luminaries.

28 IS 10322/Part 5/Sec5/1987

Luminaries: Part 5 particular requirements, Section 5 Flood light (superseding IS: 1947)

28A IS:15111 T-5 Fluorescent tubelight 29 IS 10617/Part 1/

1983 Specific for Hermetic Compressors- Part 1: High Temperature Application Group

30 IS/10617/Part 2/1983

Specification for Hermetic Compressors – Part 2: Medium Temperature Application group

31 IS 10617/Part 3/1983

Specification for Hermetic Compressors- Part 3: Low Temperature Application group

32 IS 11037/1984 Electronic type fan regulators 33 IS 11338/1985 Specification for Thermostats for Use in Refrigerators, Air Conditioners,

Water Coolers and Beverage Coolers 34 IS 12021/1987 Specification for Control Transformers for Switchgear and Control gear for

Voltages not exceeding 1000V ac. 35 IS12155/1987 General and safety requirements for fans and regulators for household

and similar purposes 36 IS1239/Part

1/2004 Steel tubes, tubular and other wrought steel fittings- specification-part 1: Steel Tubes

37 IS 1239/Part 2/1992

Mild steel tubes, tubular and other wrought steel fittings, part 2 mild steel tubular and other wrought steel pipe fittings

38 IS 1248/Part 1/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories- specification – part:1 Definitions and General Requirements.

39 IS 1248/Part 2/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories-Part 2: Special Requirements for Ammeters and Voltmeters

40 IS 1248/Part 3/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories- Part 3: Special Requirements for Watt meters and Varmeters

41 IS 1248/Part 4/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories- Part4: Special Requirements for Frequency Meters

42 IS 1248/Part 5/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories- Pat 5: Special Requirements for Phase Meters, Power Factors Meters and Synchroscopes

43 IS 1248/Part 6/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories- Part6: Special Requirements for Ohmmeters ( Impedance Meters) and Conductance Meters

44 IS 1248/Part 7/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories- Part 7: Special Requirements for Multi- Function instruments

45 IS 1248/Part 8/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories- Part 8: Special Requirements for Accessories

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46 IS 1248/Part 9/2003

Direct Acting indicating analogue electrical measuring instruments and their accessories- Part 9: Test Methods

47 IS 1255/1983 Code of practice for installation and maintenance of power cables up to and including 33 kV rating

48 IS 1258/2005 Bayonet Lamp holders 49 IS12640/Part

1/2000 Residual Current Operated Circuit- Breaking for Household and Similar Uses- Part 1 Circuit- Breakers with Integral Over current Protection (RCCBs)

50 IS 12640/Part 2/2001

Residual Current Operated Circuit- Breaking for Household and Similar Uses- Part 2 Circuit- Breakers with Integral Over current Protection (RCVOs)

51 IS 1271/1985 Thermal evaluation and classification of electrical insulation 52 IS 1293/2005 Plugs and Socket- Outlets of Rated Voltage Up to and including 250 Volt

and Rated Current Up to and including 16 Amperes- Specification 53 IS 13010/2002 AC Watt Hour Meters, Class 0.5, 1 and 2 – Specification 54 IS 13032/2002 Ac Miniature Circuit- Breaker Boards for Voltages not exceeding 1000V-

Specification 55 IS 13118/1991 Specification for High – Voltage Alternating – Current Circuit-Breakers 56 IS 13340/1993 Power Capacitors of self-healing Type for Ac Power Systems having Rated

Voltage up to 650 V – Specification. 57 IS 13779/1999 AC Static Watt- hour Meters, Class 1 and 2- Specification 58 IS13925/Part1/19

98 Shunt capacitors for Ac power systems having a rated voltage above 1000 V Part 1 : General performance, testing and rating safety requirements- Guide for installation and operation

59 IS 13925/Part 2/2002

Shunt Capacitors for Ac Power Systems Having a Rated Voltage Above 1000 V – Part 2: Endurance Testing

60 IS 13925/Part 3/2002

Shunt Capacitors for Ac Power Systems Having a Rated Voltage Above 1000 V- Part 3: Protection of Shunt Capacitors and Shunt Capacitor Banks

61 IS 13947/Part 1/1993

Specification for Low Voltage Switchgear and Control gear- Part 1: General Rules

62 IS 13947/Part 2/1993

Specification for Low- Voltage Switchgear and Control gear- part 2: Circuit Breakers

63 IS 13947/ Part 3/1993

Specification for Low Voltage Switchgear and Control gear-Part 3: Switches, Disconnectors, Switch Disconnectors and Fuse Combination Units.

64 IS 13947/Part 4/Sec 1/1993

Specification for Low-Voltage Switchgear and Control gear- Part 4: Contractors and Motor-starters- Section 1: Electromechanical Contractors and Motor Starters

65 IS 13947/ Part Part 5/Sec 1/2004

Low Voltage Switchgear and Control gear- specification- Part 5: Control Circuit Devices and Switching Elements- Section 1: Electromechanical Control Circuit Devices

66 IS 13947/Part 5/Sec 2/2004

Low Voltage Switchgear and Control gear- specification- Part 5: Control Circuit Devices and Switching Elements- Section 2: Proximity Switches.

67 IS 1445/1977 Porcelain insulators for overhead power lines with a nominal voltage upto and including 1000 V

68 IS 1460/2005 Automotive Diesel Fuels- Specification 69 IS 14697/1999 AC Static Transformer Operated Watt-hour and VAR Hour Meters, class

0.2 and 0.5 S- Specification 70 IS 1475/1978 Specification for Self-contained Drinking Water Coolers 71 IS 1475/Part

1/2001 Self-Contained Drinking Water Coolers- Specification – Part 1: Energy Consumption and Performance

72 IS 1897/1983 Copper Strip for electrical purposes 73 IS 14772/2000 General Requirements for Enclosures for Accessories for Household and

Similar Fixed Electrical Installations- Specification

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74 IS 14930/Part 1/2001

Conduit Systems for Electrical Installations- Part 1: General Requirements

75 IS 14930/Part 2/2001

Conduit Systems for Electrical Installations- Part 2: Particular Requirements- Conduit Systems Buried Underground

76 IS 15111/part 1/2002

Self Ballasted Lamps for General Lighting Services- Part1: Safety Requirements

77 IS 15111/Part 2/2002

Self Ballasted Lamps for General Lighting Services- Part 2: Performance Requirements

78 IS 1678/1998 Specification for prestressed concrete poles for overhead power, traction and telecommunication lines

79 IS 1777/1978 Industrial luminaries with metal reflectors 80 IS 1897/1983 Copper strip for electrical purposes 81 IS 1944/Part

5/1981 Code of practice for lighting of public thoroughfare: Part 5 Lighting for grade separated junctions, bridges and elevated roads (Group D)

82 IS 1944/Part 6/1981

Code of practice for lighting of public thoroughfare: Part 6 Lighting for towns and city centres and areas of civic importance (Group E)

83 IS 1944/Part 7 /1981

Code of practice for lighting of public thoroughfare Part 7 lighting for roads with special requirement (Group F)

84 IS 1944/Parts I and II /1970

Code of practice for Lighting of public Throughfares

85 IS 2026/Part 1/1977

Power transformers: Part 1 General

86 IS 2026/Part 2/1977

Power transformers: Part 2 Temperature-rise

87 IS 2026/Part 3/1981

Power transformers: Part 3 Insulation level and dielectric tests

88 IS 2026/Part 4/1977

Power transformers: Part 4 Terminal marking, tappings and connections

89 IS 2026/Part 5/1994

Power Transformer: Part 5 Transformer/Reactor bushings minimum external clearance in air specification

90 IS 2036/1995 Phenolic Laminated Sheets- Specification 91 IS 2082/1993 Stationary storage type electric water heaters 92 IS 2086/1993 Carriers and bases used in rewirable type electric fuses for voltages up to

650 V 93 IS2121/Part

1/1981 Conductors and earth wire accessories for overhead power lines: Part 1 Armour rods, binding wires and tapes for conductors

94 IS 2121/Part 2/1981

Conductors and earth wire accessories for overhead power lines: Part 2 Mid span joints and repair sleeves for conductors

95 IS 2121/Part3/ 1992

Conductors and earthwire accessories for overhead power lines: part 3 Accessories for earthwire

96 IS 2121/Part 4/1991

Conductors and earth wire accessories for overhead power lines: part 4 non tension joints

97 IS 2141/2000 Hot Dip Galvanized Stay Strand- Specification 98 IS 2206/Part

2/1976 Flameproof electric lighting fittings: Part 1 Well-glass and bulkhead types

99 IS 2206/Part 3/1976

Flameproof electric lighting fittings: Part 2 Fittings using glass tubes

100 IS 2206/Part 3/1989

Flameproof electric lighting fittings: Part 3 Fittings Using Fluorescent Lamps and Plastic Covers

101 IS 2206/Part 4/1987

Specification for Flameproof Electric Lighting Fittings- Part 4: Portable Flame-proof Hand lamps and Approved Flexible Cables.

102 IS 2268/1994 Electric call bells and buzzers for indoor use 103 IS 2312/1967 Propeller type ac ventilating fans 104 IS2418/Part Specification for Tubular Fluorescent Lamps for General Lighting Service-

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I/1977 Part I: Requirements and Tests 105 IS2448/Part

1/1963 Adhesive insulating tapes for electrical purposes: Part 1 Tapes with cotton textile substrates

106 IS2516/Part 1/Sec 1/1985

Circuit breakers: Part 1 &2 Requirements and tests: sec 1 Voltages not exceeding 1000 V AC or 1200 V DC (Withdrawn)

107 IS2516/Part 1/Sec 2/1980

Circuit-breakers: Part 1 General and definitions, sec 2 For voltages above 1000 V AC (Withdrawn)

108 IS 2516/Part 1/Sec 3/1972

Circuit breakers: Part 1 General and definitions, section3 Voltages above 11 kV (Withdrawn)

109 IS2516/Part 2/Sec 2/1980

Circuit Breakers: Part 2 rating, sec 2 for voltages above 1000 V AC (Withdrawn)

110 IS2516/Part 3/Sec 2/1980

Circuit breakers: Part 3 Design and construction, sec 2 for Voltages above 1000 V AC (Withdrawn)

111 IS2516/Part 4/Sec 2/1980

Circuit Breakers: Part 4 Type Tests and Routine Tests: sec 2 For Voltages above 1000 V AC (Withdrawn)

112 IS2516/Part 5/Sec 2/1980

Circuit Breakers: Part 5 Information to be given with enquiries Tenders and Orders and Rules of Transport Erection and Maintenance : sec 2 for Voltages above 1000 V AC (Withdrawn)

113 IS 2551/1982 Danger Notice plates 114 IS 2629/1985 Recommended Practice for Hot-Dip Galvanizing of Iron and Steel 115 IS 2667/1988 Fittings for rigid steel conduits for electrical wiring 116 IS 2675/1983 Enclosed distribution fuse boards and cutouts for voltages not exceeding

1000 V Ac and 1200 V DC 117 IS 269/1989 Specification for 33 grade ordinary Portland cement 118 IS 2705/Part

1/1992 Current transformers: Part 1 General requirements

119 IS 2705/Part 2/1992

Current transformers: Part 2 Measuring current transformers

120 IS 2705/Part 3/1992

Current transformers: Part 3 Protective current transformers

121 IS 2705/Part 4/1992

Current transformers: Part 4 Protective current transformers for special purpose applications

122 IS 2713/Parts 1 to 3/1980

Specification for Tubular Steel Poles for Overhead Power Lines

123 IS 278/1978 Specification for Galvanized Steel Barbed Wire for Fencing 124 IS 2905/1989 Methods of test for concrete poles for overhead power and

telecommunication lines 125 IS 2997 /1964 Air circulator type electric fans and regulators 126 IS 302/Part

1/1979 General and Safety Requirements for Household and Similar Electrical Appliances

127 IS 302/Part 2/sec 201/1992

Safety of household and similar electrical appliances: Part 2 Particular requirements, Section 201 Electric immersion water heater

128 IS 302/Part 2/sec 203/1994

Safety of Household and similar Electrical Appliances- Part 2: Particular Requirements- Section 203 Electric Call Bells and Buzzers for Indoor Use

129 IS 302/Part 2/sec 204/1994

Safety of household and similar electrical appliances: Part 2 Particular requirements: Section 204 Electric water boilers

130 IS 302/Part 2/sec 21/1992

Safety of household and similar electrical appliances Part 2 Particular requirements, Section 21 Stationary storage type electric water heater

131 IS 302/Part 2/sec 35/1993

Safety of Household and Similar Electrical Appliances – Part 2: Particular Requirements- Section 35: Electric Instantaneous Water Heaters

132 IS 302/Part 2 sec 59/1999

Safety of Household and Similar Electrical Appliances- Part 2: Particular Requirements- Section 59: Insect Killers

133 IS 302/Part 2/sec 80/2003

Safety of Household and Similar Electrical Appliances- Part 2 Particular Requirements- Section: 80 Fans

134 IS 304/1981 Specification for High Tensile Brass ingots and Castings

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135 IS 3043/1987 Code of Practice for earthing 136 IS 3156/Part

1/1992 Voltage transformers: Part 1 General General requirements

137 IS 3156/Part 2/1992

Voltage transformers: Part 2 Measuring voltage transformers

138 IS 3156/Part 3/1992

Voltage transformers: part 3 Protective voltage transformers

139 IS 3156/Part 4/1992

Voltage Transformers: Part 4 Capacitor voltage transformers

140 IS 3231/Part 0/1986

Electrical relays for power systems protection: Part 0 General introduction and list of parts

141 IS 3231/Part 1/Sec 1/1986

Specification for Electrical Relays for Power System Protection part 1 : General Requirements Section 1: Contact Performance

142 IS 3231/Part 1/Sec 2/1986

Electrical relays for power system protection: Part 1 General requirements, section 2 Insulation tests

143 IS 3231/Part 1/Sec 3/1986

Electrical relays for power system protection: Part 1 General requirements, section 3 High frequency disturbance test for static relays

144 IS 3231/Part 2/Sec 1/1987

Specification for Electrical Relays for Power System Protection- Part 2 : Requirements for Principal Families- Section 1 : All –or- Nothing Relays

145 IS 3231/Part 2/Sec 2/1987

Specification for Electrical Relays for Power System Protection- Part 2: Requirements for Principal Families- Section 2: General Requirements for Measuring Relays

146 IS 3231/Part 2/Sec 3/1987

Electrical relays for power system protection: Part 2 requirements for principal families, section 3 General requirements for thermal relays

147 IS 3231/Part 3/Sec 1/1987

Specification for Electrical Relays for Power System Protection- Part 3: Requirements for Particular Group of Relays- Section 1: Non-specified Time or Independent Specified Time Measuring Relays.

148 IS 3231/Part 3/Sec 2/1987

Specification for Electrical Relays for Power System Protection- Part 3: Requirements for Particular Group of Relays- Section 2: dependent Specified Time Measuring Relays.

149 IS 3231/Part 2/Sec 3/1987

Specification for Electrical Relays for Power System Protection- Part 3: Requirements for Particular Group of Relays- Section 3: Biased (percentage) Differential Relays.

150 IS 3231/Part 3/Sec 4/1987

Specification for Electrical Relays for Power System Protection- Part 3: Requirements for Particular Group of Relays- Section 4: Directional Relays and Power Relays.

151 IS 3231/Part 3/Sec 5/1987

Electrical relays for power system Protection: Part 3 Requirements for particular group of relays, section 5 Impedance measuring relays

152 IS 325/1996 Three phase induction motors 153 IS 12463/ 1998 New insulating oils 154 IS 3412/1994 Electric water boilers 155 IS 3419/1988 Fittings for rigid non-metallic conduits 156 IS 3427/1997 AC Metal Enclosed Switchgear and Control gear for Rated Voltages Above

1 kV and Up to and including 52 kV 157 IS 3528/1966 Waterproof electric lighting fittings 158 IS 3553/1966 Specification for Watertight Electric Lighting Fittings 159 IS 371/1999 Ceiling Roses- Specification 160 IS 374/1979 Electric Ceiling type fans and regulators 161 IS 3764/1992 Code of safety for excavation work 162 IS 3842/Part

12/1976 Application guide for electrical relays for Ac systems: Part 12 Differential relays for transformers

163 IS 3842/Part IV/1966

Application Guide for Electrical Relays for AC Systems- Part IV: Thermal Relays

164 IS 3854/1997 Switches for domestic and similar purposes 165 IS 3895/1966 Mono crystalline semi-conductor rectifier cells and stacks

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166 IS 398/Part 1/1996

Aluminium conductors for overhead transmission purposes: Part 1 Aluminium stranded conductors

167 IS 398/Part 2/1996

Aluminium conductors for overhead transmission purposes: Part 2 Aluminium conductors, galvanized steel reinforced.

168 IS 398/Part 3/1976

Aluminium conductors for overhead transmission purposes: Part 3 Aluminium conductors, aluminized steel reinforced.

169 IS 398/Part 4/1994

Aluminium conductors for overhead transmission purposes: Part 4 Aluminium alloy stranded conductors (aluminium magnesium silicon type).

170 IS 398/Part 5/1992

Aluminium conductors for overhead transmission purposes: Part 5 Aluminium conductors, galvanized steel reinforced for extra high voltage ( 400 kV and above).

171 IS4064/Part 1/1978

Air break switches, air-break disconnectors, air break switch disconnectors and fuse-combination units for voltages not exceeding 1000 V ac or 1200 V dc: Part 1 General requirements

172 IS 4064/Part 2/1978

Air break switches, air-break disconnectors, air break switch disconnectors and fuse-combination units for voltages not exceeding 1000 V AC or 1200 V dc: Part 2 Specific requirements for the direct switching of individual motors

173 IS 4160/2005 Interlocking Switch Socket Outlets- Specification 174 IS 418/2004 Tungesten Filament Lamp for Domestic and Similar General Lighting

Purposes 175 IS 4289/Part

1/1984 Specification for Flexible Cables for Lifts and Other Flexible Connections- Part 1: Elastomer Insulated Cables

176 IS 4289/Part / 2/2000

Flexible Cables for Lifts and Other Flexible Connections- Specification- Part 2: PVC Insulated Circular Cables

177 IS 4347/1967 Code of practice for hospital lighting 178 IS 4540/1968 Monocrystalline semiconductor rectifier assemblies and equipment 179 IS 4615/1968 Switch socket outlets (non-interlocking type) 180 IS 4648/1968 Guide for Electrical Layout in Residential Buildings 183 IS 4722/2001 Rotating Electrical Machines- specification 181 IS 4770/1991 Rubber Gloves- electrical Purposes- Specification 182 IS 4794/Part

1/1968 Push button switches: Part 1 General requirements and tests

183 IS 4794/Part 2/1986

Push buttons switches: Part 2 push button switches, type 1

184 IS 4984/1995 Specification for high density polyethylene pipes for potable water supplies

185 IS 5039/1983 Distribution pillars for voltages not exceeding 1000 V Ac and 1200 V DC 186 IS 5082/1998 Wrought aluminium and aluminium alloy bars, rods, tubes and sections

for electrical purposes 187 IS 5216/Part

I/1982 Recommendations on safety procedures and practices in Electrical Work- Part I: General

188 IS 5216/Part II/1982

Recommendation on Safety procedures and practices in Electrical Work- Part II: Life Saving Techniques

189 IS 5300/1969 Specification for Porcelain Guy Strain Insulators 190 IS 5578/1984 Guide for marking of insulated conductors 191 IS 5613/Part

1/Sec 1/1985 Code of practice for Design, installation and Maintenance of Overhead power Lines- Part 1: Lines Up to and Including 11 kV- section 1: Design

192 IS 5613/Part 1/Sec 2/1985

Code of practice for Design, installation and Maintenance of Overhead power Lines- Part 1: Lines Up to and Including 11 kV- section 2: Installation and Maintenance

193 IS 5613/Part 2/Sec 1/1985

Code of practice for Design, installation and Maintenance of Overhead power Lines- Part 2: Lines above 11 kV Up to and Including 220 kV- section 1: Design

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194 IS 5613/Part 2/Sec 2/1985

Code of practice for Design, installation and Maintenance of Overhead power Lines- Part 2: Lines above 11 kV and Up to and Including 220 k V, - section 2: Installation and maintenance.

195 IS 5613/Part 3/Sec 1/1989

Code of practice for Design, installation and Maintenance of Overhead power Lines- Part 3: 400 kV Lines section 1: Design

196 IS 5613/Part 3/Sec 2/1989

Code of practice for Design, installation and Maintenance of Overhead power Lines- Part 3:400 kV Lines –Section 2 Installation and Maintenance

197 IS 6236/1971 Direct Recording electrical measuring instruments 198 IS 694/1990 PVC insulated cables for working voltages up to and including 1100 V 199 IS 6949/1973 Summation current transformers 200 IS 6792/1992 Method for Determination of Electric Strength of Insulating Oils 201 IS 7098/Part

1/1988 Cross linked polyethylene insulated PVC sheathed cables: Part 1 For working voltage up to and including 1 100 V

202 IS 7098/Part 2/1985

Cross linked polyethylene insulated PVC sheathed cables: Part 2 for working voltages from 3.3 kV up to and including 33 kV

203 IS 7098/Part 3/1993

Cross –linked polythelene insulated thermoplastic sheathed cables: part 3 for Working voltages from 66 kV upto and including 220 kV

204 IS 731/1971 Porcelain insulators for overhead powerlines with a nominal voltage greater than 1000 V

205 IS 732/1989 Code of Practice for Electrical Wiring Installations. 206 IS 7321/1974 Code of practice for selection, handling and erection of concrete poles for

overhead power and telecommunication lines 207 IS 7935/1975 Insulator fittings for overhead power lines with a nominal voltage up to

and including 1000 V 208 IS 800/1984 Code of practice for general construction in steel 209 IS 802/Part 1 Sec

1/1995 Code of practice for use of structural steel in overhead transmission line towers, Part 1 Materials and Loads and permissible stresses Section 1 Materials and Loads

210 IS 802/Part 1 /Sec 2/1992

Code of practice for use of structural steel in overhead transmission line towers part 1: Material, loads and permissible stress section 2 Permissible stress.

211 IS 802/Part 2/1978

Code of Practice for use of structural steel in overhead transmission line towers- Part II: Fabrication, Galvanizing, Inspection and Packing

212 IS 802/Part 3/1978

Code of practice for use of structural steel in overhead transmission line towers, part 3 Testing

213 IS 8034/2002 Submersible Pumpsets-specification 214 IS 8041 /1990 Specification for rapid hardening Portland cement 215 IS 8061 /1976 Code of practice for design, installation and maintenance of service lines

upto and including 650 V 216 IS8183 /1993 Bonded mineral wool 217 IS 8530/1977 Maximum demand indicators (class 1) 218 IS 8623 Part

1/1993 Specification for Low- Voltage Switchgear and Controlgear Assemblies- Part 1: Requirements for Type-Tested and partially type- Tested Assemblies

219 IS 8623/Part 2/1993

Specification for Low- Voltage Switchgear and Controlgear Assemblies- Part 2: Particular Requirements for Busbar Trunking Systems ( Busway)

220 IS 8623/Part 3/1993

Specification for Low- Voltage Switchgear and Controlgear Assemblies- Part 3: Particular Requirements for Equipment where unskilled persons have Access for their use.

221 IS 875/Part 1/1987

Code of practice for design loads (other than earthquake ) for buildings and structures Part 1 Dead loads- Unit weights of building material and stored materials ( Incorporating IS1911:1967)

222 IS 875/Part 2/1987

Code of practice for design loads (other than earthquake ) for buildings and structures Part 2: imposed loads

223 IS 875/Part 3 Code of practice for design loads (other than earthquake ) for buildings

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1987 and structures Part 3: Wind loads 224 IS 875/Part

4/1987 Code of practice for design loads (other than earthquake ) for buildings and structures Part 4 Snow loads

225 IS 875/Part 5/1987

Code of practice for design loads (other than earthquake ) for buildings and structures Part 5 Special loads and load combinations

226 IS 8828/1996 Electrical Accessories- Circuit Breakers for Over Current Protection for Household and Similar Installations

227 IS 8884/1978 Code of practice for the installation of electric bells and call system 228 IS 9224/Part

1/1979 Low voltage fuses: Part 1 General requirements (Withdrawn)

229 IS 9224/Part 2/1979

Low voltage fuses: Part 2 Supplementary requirements for fuses for industrial applications (Withdrawn)

230 IS 9224/Part 4/1980

Low voltage fuses: Part 4 Supplementary requirements for fuse-links for the protection of semiconductor devices (Withdrawn)

231 IS 9537/Part 1/1980

Conduits for electrical installations: Part 1 General requirements

232 IS 9537 /Part 2/1981

Conduits for electrical installations: Part 2 Rigid steel conduits (superseding IS: 1653)

233 IS 9537/Part 3/1983

Conduits for electrical installations: Part 3 Rigid plain conduits of insulating materials (superseding IS: 2509)

234 IS 9537/Part 4/1983

Specification for Conduits for Electrical Installations – Part 4: Pliable Self- recovering Conduits of Insulating Materials

235 IS 9537/Part 5/2000

Conduits for Electrical Installations- Part 5: Pliable conduits of Insulating Material

236 IS 9537/Part 6/2000

Conduits for Electrical Installations- Specification- Part 6: Pliable Conduits of Metal or Composite Materials.

237 IS 9537/Part 8/2003

Conduits for Electrical Installations- Specification- Part 8: Rigid Non- Threadable Conduits of Aluminium Alloy

238 IS 9583/1981 Emergency lighting units 239 IS 9900/Part

1/1981 High pressure mercury vapour lamps: Part 1 Requirements and test

240 IS 9974/Part 1/1981

High pressure sodium vapour lamps: Part 1 General requirements and tests

241 IS 13573: 1992 Joints and Terminations of Polymeric Cables for Working Voltages from 6.6 kV up to and including 33 kV – Performance Requirements and Type Tests

242 IS: 1391 Pt.II/1992(Amdnt.I

Split type Air Conditioner.

243 IS:1391 Pt.I/1992( Amendment 1&2

Window type Air Conditioner

244 IS 456:2000 PLAIN AND REINFORCED CONCRETE CODE OF PRACTICE

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PART-B

RAILWAY ELECTRIFICATION WORKS

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CHAPTER: B-1 GENERAL REQUIREMENTS FOR 25 kV AC OHE 1.1 INTRODUCTION: This part contains general, technical and other specifications for design and erection of complete 25 kV AC 50 Hz single phase traction overhead equipment, switching stations, booster transformer stations, LT supply transformer stations complete with foundations, structures, return conductors and 25 kV feeders if any. This part also gives reference to technical specifications of materials and components, procedure for submission of designs and drawings of basic arrangements, components and fittings designs and other typical designs relating to overhead equipment, switching stations and booster transformer stations. A list of the standard drawings is included in the annexure to these Technical Specifications. The design and erection of OHE shall conform to standards and specifications, guidelines laid down in A.C. Traction Manual, IR Schedule of Dimension-2004, RDSO and Railway Board issued from time to time with their latest amendments. The details covered here are for 25 KV conventional OHE. For high rise OHE, CHAPTER: B-18 may be referred for relevant details and specifications of RDSO. The specifications issued here are meant for guidelines and does not supersede any of the rules/regulations/codes/instructions issued by Railway Board/RDSO/CORE etc from time to time and they shall be followed accordingly. 1.2 SYSTEM PARTICULARS: The nominal voltage of the overhead equipment will be 25 kV AC 50 Hz, single phase. The supply voltage may, however, rise upto 27.5 kV. One terminal of the 25 kV system will be solidly earthed at the traction sub-station and also connected to the running rails. The other terminal will be connected to the overhead equipment through switchgear provided at the traction sub-station and at the feeding station. 1.3 ROLLING STOCK: (a) LOCOMOTIVES The electric locomotives will generally be equipped with DC motors fed through rectifiers/AC Motors installed on the locomotives. (b) OVERSIZE CONSIGNMENTS The specific requirement in regard to movement of steam locomotives and over size consignments for each section, if necessary, are indicated in the Particular Requirements.

1.4 POWER SUPPLY: (a)SUB-STATIONS Electric Power will be supplied at 25 kV AC 50 Hz. Single phase from traction sub-stations located along the track. (b)SWITCHING STATIONS Power supply will be controlled to the different sections of traction overhead equipment by switching stations. At these stations the switching will be effected by means of “Interrupters” which are single pole, non-automatic circuit breakers capable of repeatedly interrupting normal full load current. There are three types of switching stations:

(1) Feeding stations (2) Sectioning stations (3) Sub-sectioning stations.

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(C) FEEDING STATIONS Supply will be effected to the overhead equipment through switchgear installed at feeding stations. All feeding stations will be located normally near the track.

(d) SECTIONING STATIONS The sub-stations cannot, as a rule be paralleled and consequently a neutral section of overhead equipment with insulated overlaps on either side will be provided approximately midway between two consecutive feeding stations. Neutral sections may also be provided at feeding stations. Facilities to bridge the neutral section between feeding stations will be provided at sectioning stations.

(e) SUB-SECTIONING STATIONS In order to facilitate maintenance of overhead equipment and to permit isolation of faulty sections and expeditious restoration of power supply in healthy sections, sub-sectioning stations with insulated overlaps will be provided between the feeding stations and the sectioning stations.

(f) RETURN CONDUCTORS In order to reduce interference to telecommunication circuits arising from A.C. 50 Hz. Single phase traction current in the overhead equipment, a return conductor may be provided for each main running track. These return conductors, if provided, shall be connected at intervals to booster transformers and to the rails. (g) BOOSTER STATIONS Booster transformer stations are provided in conjunction with return conductors to reduce inductive interference to telecommunication circuits arising from single phase 25 KVAC traction. The Booster stations are located along the track. 1.5 SAFETY INSTRUCTIONS (a) EARTHING Earthing shall be provided as per Indian Electricity(IE) Rules with latest amendments and as

per the railway specifications and site requirements. (b) INDIAN ELECTRICITY RULES 1956 While the Indian Electricity Rules 1956, as amended up to date, are to be followed in their

entirety, particular attention is drawn to the various clauses indicated in Annexure’I’. Any installation or portion of installation, which does not comply with these rules, should be got rectified immediately.

The detailed instructions on safety procedures given in I.S.S. and Indian Electricity Rules, respective State Electricity Board’s regulation with up to date amendment shall be applicable.

(c) ELECTRICAL LICENCE AND COMPETENCY CERTIFICATE The Electrical Contractor/Sub-Contractor shall hold a valid Electrical Contractor’s License for

HT/EHT of voltage equal to or more than 25 kV issued by the Statutory Authority of any state. All work on electrical installations shall be done under the direct supervision of persons holding valid certificates of competency issued by the appropriate authority.

1.6 APPROVED SUPPLIERS All equipment, components and fittings shall be procured from RDSO/CORE approved

suppliers/sources with prior approval of RVNL. 1.7 Safety Rules for working on OHE

While working on OHE all the safety rules as per ACTM 20332 to 20348 should be followed strictly. Salient features of the rules are as under:

(a) Permit to Work

Before commencing work on any part of the dead OHE or within 2m of live OHE, a permit-to-work shall be obtained from TPC or other authorized person as detailed in Chapter VI.

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(b) Earthing before Commencement of Work 1. All metallic parts within reach (either directly or through tools etc.) shall be earthed, after

they are made dead. 2. Each working party shall be protected by at least two independent earths, one on each

side of a working party. 3. If the distance between the working parties exceeds 100m intermediate earths shall be

provided in such a manner as to ensure that the distance between earths does not exceed 100m.

4. Even when earthing is provided by isolator switches with earthing heels, additional temporary earths as above shall also be provided.

(c) Use of safety belts, protective helmets etc.

At the work site staff is advised to wear helmets and use safety belts to protect themselves against injury. Official incharge of work shall observe relavent provision of G & SR for protection of trains before and whole time the work is in progress on OHE. Measure laid down shall be observed by all concerned to prevent accidental energization of the section under power block on account of electric train movements.

(d) Provision of Special Caution Boards on Vehicles: Railway board vide their letter No. 2009/RE/161/4 FTS-748 dtd.26-08-14 have advised to provide a special caution board on all departmental vehicles, track machines, platform shelters. The compliance of the same should be ensured.

1.8 Compliance to Various Rules and Regulations The present Book of specification containing part-I (Electrical General specification) and part-II (TRD Specification) contains only list of important details of specifications. The contractor shall however follow all the rules, regulations and instructions applicable for the work such as:

1. AC Traction Manual 1994. 2 . IR Schdule of Dimension 2004. 3 . Standrads, drawings laid down by RDSO/CORE. 4 . Instructions issued by Railway Board/RDSO/CORE/Zonal Railway/RVNL as applicable for the

project. 5 . Indian Electricity Rules 1956. 6 . Indian Electricity Act 2003. 7 . BIS Specifications 8 . Any other rules/standards/instructions etc relevant for the work framed/laid down from time

to time. Only the latest version of rules/standards/drawings/instructions shall be applicable

unless specifically stated otherwise. In case of any conflict between various instructions, decision of the Employer shall be final. In case of any conflict/discrepancy between specifications contained in this book and specifications as per above mentioned authorities, later shall prevail.

Notwithstanding any approval of drawing or work by RVNL, the contractor shall be finally responsible for following correct instructions and drawings as per latest amended details. In case any mistake is found in the work/drawing later on which is not carried out/prepared in accordance with laid down standards, rules and regulations, the Employer shall be free to reject it at any stage of the work. The contractor shall be liable to dismantle/modify/redo the rejected work without any extra cost as per directions of the Employer. The decision of the Employer shall be final in this regard. In this technical specification, the latest standards/drawings/ instructions /letter/ Code of Practice etc means latest up to the date 28 days prior to the deadline for submission of bids.

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CHAPTER : B-2

OVERHEAD EQUIPMENT 2.1 TRACK

(a) GAUGE AND TRACK CENTRES The track gauge is 1676 mm (5’-6”). In multiple track zones, the normal distance between

track centres varies between 4720mm and 5500 mm. (b) SPEED The overhead equipment which shall be of the simple polygonal type and pre-sag should be

designed for a maximum speed of 160 kmph (approx. 100 miles/h) if unregulated, unless otherwise specified in any particular section.

(c) CURVES The minimum radius permissible is 175m (573 ft.) i.e. a 10 deg. Curve. Inside station limits,

the curvature at a 1 in 8.5 turnout is 8 degree i.e. of radius 219m (716 ft.). (d) SUPER ELEVATION The maximum super elevation is 165 (6.5”). On curves the minimum setting of structures

shall be decided on the basis of maximum super elevation (see para 4.10). For purposes of design and erection of overhead equipment, the actual super elevation as existing at site or as indicated to the contractor shall be adopted.

(e) LOW JOINTS For low or loosely packed rail joints a difference of 25mm (1”) in the level of opposite rails

may be taken as the basis for estimating the displacement of the pantograph with respect to its normal position.

(f) FORMATION

Generally sections with more than one track have common formation. In certain lengths, however the formation for different tracks may be separate (see relevant drawing listed in the Annexure to these Technical Specifications).

(g) DISPLACEMENT The general design of overhead equipment shall permit a displacement of +/- 100 mm of

tracks without difficulty and any adjustment of the overhead equipment on this account shall be of such a nature as could be done conveniently without changing any component of the overhead equipment.

2.2 SECTIONING (a) INSULATED OVERLAPS Insulated overlaps are provided for facility of isolation. Some of the overlaps may be provided

with manually operated isolator switches. In addition, for connecting the overhead equipment to booster transformers, insulated overlaps are to be indicated in the sectioning diagrams.

(b) YARD SUPPLY The sectioning diagram/s also indicate the track in stations yards and siding whose

equipments is electrically independent from those of other tracks. The overhead equipment in yards and sidings may be fed through isolator switch or

interrupter in accordance with arrangement indicated in the sectioning diagram/s.

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(c) SECTION INSULATORS Section insulators shall be provided as indicated in the sectioning diagrams, on cross-overs

between main tracks and to isolate sections of overhead equipment in yards and sidings. Section insulators may also be used to form neutral sections at special locations as indicated in the approved drawings. Section insulator should be so located that the following conditions are fulfilled:

i) At location of section insulator, the axial distance between the catenary and contact wire shall not be less than 450 mm in the case of sigle-wire section insulator and 600 mm in the case of double wire section insulator without increasing the encumbrance at the supports beyond 1.40m.

ii) The section insulator is to be located beyond the point where the centre distance between the two tracks is equal to or more than 1.65 meter. If the section insulator is erected with the free ends of the runners away from the centre of the turn outs this distance may be reduced to 1.45 metre.

iii) The stagger of contact wire at the location of the section insulator should normally be zero, but in no case should it exceed +/- 100 mm.

iv) As far as possible, on loops the section insulator shall be located close to the first support of the overhead equipment for the loop.

v) The preferred location of section insulator on main running track is 2 to 10 m from the support in the direction of the traffic, though its provision on the main line should be avoided.

vi) In double line section the runner should be in the trailing direction.

(d) PROTECTION OF ISOLATED SECTIONS:

PROTECTION BY SIGNAL OF THE ISOLATED SECTIONS Normally a stop signal is provided before the insulated overlap, with an isolator so that approaching train is stopped from entering the isolated section. Although the distance between the stop signal and the sectioning points has not been specified in the rules it is desirable to provide 120 m between the stop signal and centre line of the insulated overlap of the section insulators i.e. the sectioning point.(Para 30.2 ACTM vol-ii)

(e) FEEDERS & RETURN FEEDERS OF 25 KV ALONG TRACK 25 kV along track feeders may connect sections of overhead equipment to a switching station

or an isolator switch or gantry. Such feeders will be run usually on traction structures and sometimes on independent masts. A single ‘SPIDER’ conductor shall be used for such feeders.

(f) RETURN CONDUCTOR Return conductor may be run on traction structures or masts. A single ‘ SPIDER’ conductor

shall be used for such return conductors. (g) SCHEMATIC ARRANGEMENTS The different arrangements of feeders, return feeders, 25 kV along track feeders and return

conductors are shown in the drawing listed in the Annexure to these Technical Specifications. (h) SHORT NEUTRAL SECTION OF PTFE TYPE Neutral section shall be located away from stop signals, level crossings and shall be on

tangent track and on level to the possible extent. (i) If neutral section is provided after a stop signal, the distance * between signal and neutral

section shall be such that after stopping, the train shall be able to pick up enough speed to coast the neutral section without any risk of stalling.

(ii) If neutral section is provided before a stop signal, the distance* between neutral section and signal shall be such that the train shall not cross the signals in an effort to cost the neutral section.

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* NOTE: The distance should preferably be 1600 metre away on section with gradient up to 1 in 300 and 2500 metre away in case of higher gradient upto 1in 200, if unavoidable.

(iii) The PTFE type short neutral section shall be located on level tangent track at least 400 m after the stop signal and 200m before the stop signal. Where, however, modification require to comply with these guide lines are difficult or entail heavy investment, the Chief Electrical Engineer of the Railway may direct any other arrangement to be followed consistent with safety and reliability. For location on graded section guidelines of para2.2 h (i),(ii) shall be followed.

(iv) PTFE type short neutral section assembly shall be procured as per RDSO specification NO.

TI/SPC/OHE/SNS/0000(01/00) or latest. 2.3 PANTOGRAPHS: (a) The outline of the pantograph, its dimensions and its current collecting area are shown in a

drawing listed in the Annexure to these Technical Specifications. (b) NUMBER AND PRESSURE Each locomotive will be equipped with two pantographs, but any one pantograph generally the

trailing one will be in use at a time. The working pressure of the pantograph on the contact wire may vary between 5 and 15 kg.

(c) SPACING IN MULTIPLE HEADED TRAINS The distance between adjacent running pantographs in the case of multiple heading would

normally be 20 metre. This distance may, however, be reduced to 7.9metre between two pantographs in very exceptional cases.

(d) INSULATION CLEARANCE The electrical clearances for the pantograph on tangent tracks and on curves for design and

erection of overhead equipment shall be based on the IR schedule of Dimensions 1676mm. Gauge, 2004 and any other amendments/orders that may be issued by the Railway Board from time to time.

2.4 OVERHEAD EQUIPMENT:

(a) BRIEF DESCRIPTION Essentially the traction overhead equipment shall consist of a standard catenary wire from

which a grooved contact wire is suitably suspended by means of droppers. In order to cater for a speed of 160 kmph the contact wire is given a pre-sag of about 100 mm or 72m span and reduced suitably for other spans.

(b) CATENARY The catenary wire shall be of cadmium copper 19/2.10 mm, 65 mm sq. (c) CONTACT WIRE The contact wire shall be grooved and made of hard drawn copper 107/150sq. mm cross

section. 65/150 sq mm OHE with 1200/1200 kgf tension shall be adopted for new electrification in terms of RDSO L.No. TI/OHE/GA/2013 DT 30th April,2013.

(d)DROPPERS

Droppers shall be made of hard drawn round copper wire, approximately 5 mm dia. Droppers shall be spaced not more than 9 m apart.

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(e) ENCUMBRANCE As a general rule, the nominal “encumbrance” i.e. the centre distance between the catenary

and the contact wire at the support shall be 1.40m. Deviation from this figure will be permitted in special cases (e.g. spans near over-bridges, structures with more than one cantilever etc.).

(f) Jumpers:

All jumpers connected to OHE conductors shall be of copper only. The in –span jumpers potential equalizer jumpers at insulated overlaps and neutral section shall be of 50 mm sq. nominal 19/1.8 mm size. Flexible jumper of nominal section 105 mm sq., 19/7/1.06mm size shall be used at overlaps turnouts, crossings, etc. Provision of long cross type G-jumper on parallel run side instead of cross-over/turn out side as per RDSO drawing No ETI/OHE/G/02141 Rev ‘C’ or latest.

(g) BRIDDLE WIRE Bridle wire for supporting contact wire for regulated tramway equipment shall be of cadmium

copper 7/2. 10 mm in size.

(h) ANTI THEFT JUMPER Anti theft jumper of 50 mm sq. nominal, 19/1.8 mm in size shall be used in out of run wire of

conventional OHE and copper cadmium anti-creep wire as an anti-theft measure. The jumper connecting the Aluminium Conductors to any other conductors terminal or clamp

shall be made with the aid of suitable bi-metalic clamps. All aluminium jumpers of size 19/7/1.4 mm bare ¾ hard shall be used to connect other aluminium conductors such as return conductor. The tail ends of feeder wires from the strain clamps at the termination of a feeder, return feeder or return conductor may be connected directly to a terminal or clamp where feasible to avoid the use of a separate jumper wire.

(i) OHE FITTINGS/COMPONENTS OHE fittings/ components shall be forged/ compression type instead of malleable cast iron

type wherever these type of fittings are available as per RDSO approved list.

2.5 TYPE OF EQUIPMENT: The overhead equipment used shall normally be either of the regulated or unregulated type.

Unregulated tramway type equipment (contact wire only) may be adopted where specially indicated by the Engineer.

(a) REGULATED In the regulated type of overhead equipment, the tension of both the catenary and the

contact wires shall be maintained at a constant value at all temperatures by means of automatic tensioning devices desired to take up the variation in the length of overhead equipment due to temperature variation.

An anti creep shall be provided at a point approximately midway between two tensioning

devices and not more than 750 metres from any one of them. The general arrangement of an anti-creep is shown in a drawing listed in the Annexure to these Technical Specifications. The arrangement shall generally consist of the galvanized steel wire anchored on the masts adjacent to the anti creep central mast in accordance with the relevant drawing listed the Annexure to these Technical Specifications. Alternatively, the arrangement may consist of anchoring the catenary on either side of the boom of a portal with the contact wire running through and providing a jumper connection as per general arrangement shown in typical drawing listed in the Annexure to these technical specifications. The engineer shall indicate the type of anti-creeps to be adopted in the pegging plans. RDSO drawing No. TI/DRG/OHE/GENL/RDSO/00001/12/0 REV ‘0’ or latest, Ref.ETI/OHE/G/02111 Rev-A

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dt.23.10.2012 or latest is to be followed for use of catenary wire in place of GI wire at ACC locations in polluted area.

(b) UNREGULATED The unregulated type of overhead equipment has no provision for automatic regulation of tension of either the catenary or the contact wire.

(c) TRAMWAY TYPE EQUIPMENT REGULATED CONTACT WIRE ONLY In tramway type equipment regulated, only a contact wire is provided without a continuous catenary or droppers. The tension in the contact wire is regulated. At support, bridle wire is used for supporting the contact wire.

2.6 PLANE OF CONTACT:

(a) REGULATED The regulated overhead equipment shall be so erected that the contact wire has the designed sag.

(b) UNREGULATED In the case of unregulated equipment, the contact wire shall have no sag at an ambient temperature of 35 deg. C.

(c) TRAMWAY TYPE In tramway type equipment, the contact wire will have its own natural sag when erected.

(d) DROPPER Dropper charts to be used for standard span of regulated and unregulated overhead equipment would be supplied by the Engineer. Droppers for non-standard spans, span with section insulators and special locations shall be calculated by the Contractor in accordance with the method indicated by the Engineer and submitted to the Engineer for approval.

Dropper schedule of OHE having presage of 0.8mm/meter shall be used as below- i. For 1000/1000 KgF Tension - RDSO drgs TI/DRG/OHE/DROP/00001/10/1,

TI/DRG/OHE/DROP/00002/10/1, TI/DRG/OHE/DROP/00003/ 10/1 should be used [RDSO letter No: TI/OHE/SHS/2014 dt 29/9/2014].

ii. For 1100/1100 KgF Tension - RDSO drgs TI/DRG/OHE/DROP/00001/17/0, TI/DRG/OHE/DROP/00002/17/0, TI/DRG/OHE/DROP/00003/17/0 should be used [RDSO letter No: TI/OHE/GA/2017 dt 17/10/2017].

2.7 TENSIONS:

(a) REGULATED In regulated equipment the tension in the catenary and contact wire shall be 1,100 kgf in

each conductor.

(b) UNREGULATED In unregulated equipment the tension in the catenary and in the contact wire at 35 degree C

without wind shall be, 1,100 kgf in each conductor.

(C) TRAMWAY TYPE In regulated type tramway equipment, the tension shall be 1,250 kgf.

2.8 CLEARANCE: (a) GENERAL The distance between live parts and parts at earth potential (for parts likely to be earthed) shall

be as large as possible. In all cases the values given in the latest version of the Schedule of

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Dimensions shall be observed along with any other supplementary rules, that may be issued by the Railway Board.

(b) OVER BRIDGES & TUNNELS The clearances which are to be made available at over bridges, signal, gantries and other

overline structures shall be based on the above rules. (c) PLATFORM SHEDS AND OTHER STRUCTURES In the course of checking the overhead equipment pegging plans, the Contractor shall prepare

a list of platform sheds and other structures in the vicinity of track to be wired. The clearances to these structures shall be in accordance with those shown in the relevant drawings listed in the Annexure to these Technical Specifications. If these clearances are not available, the Contractor shall advise the Engineer in time to enable the latter to take up the necessary modifications.

(d) The electrical clearances to be maintained under the worst conditions of

temperature, wind etc. are as follows: (A&C 14 to ACTM Vol II Pt II) Minimum vertical/lateral distance between any live part of overhead equipment or pantographs and parts of any fixed structures (earthed or otherwise or moving loads): a) Long duration 250 mm b) Short duration 200mm Note: i) Long Duration means when the conductor is at rest and short Duration means

when the conductor is not at rest. ii) A minimum vertical distance of 270 mm shall normally be provided between rolling stock and contact wire to allow for a 20 mm temporary raising of the track during maintenance. Wherever the allowance required for track maintenance exceeds 20 mm, the vertical distance between rolling stock and contact wire shall correspondingly be increased. iii) Where adoption of above clearances is either not feasible or involves abnormally high cost, Permanent Bench Mark shall be provided to indicate the level of track to be maintained.

(e) Working Clearance:

Minimum clearance between live conductor/equipments and such earthed structure/live parts of different elementary sections where men are required to work shall be 2 m. Where the clearance is not obtained the structure shall be protected by earthed metallic screens or prescribed warning boards.

(f) The clearance between any part live at 3 kV and any part at earth potential (or part likely to be earthed) shall be not less than 150 mm under static condition and 70 mm under dynamic conditions.

2.9 HEIGHT AND GRADIENT OF CONTACT WIRE Minimum height from rail level to the underside of the contact wire shall be:

(i) Under Bridges and in Tunnels : 4.80 m (ii) In the Open : 5.50 m (iii) At Level Crossings : 5.50 m (iv) In Running and Carriage Sheds : 5.80 m (a) STANDARD HEIGHT:

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Normally the height of contact wire (under side surface) above the track plane shall not be less than 5.50m at any point in the span under the worst temperature conditions. To ensure this, the normal height at the suspension point shall be as under: Type of OHE Normal Height of contact wire at the support point i) Regulated:

OHE Normal Height of contact wire at the support point - 5.60 m. All new OHE line shall be carried out with the pre- sag of 50 mm for max span. (As per Rly Bd letter no. 2001/Elect. (G)/170/1 dt 22.11.2016)

ii) Unregulated

- Unregulated OHE designed 5.75 m For areas with temp. range of 4 deg.C to 65 deg. C

- Unregulated OHE designed for 5.65 m Areas with a temp. range of 15 deg. C to 65 deg. C

(b) The height may be reduced under overline structures after a clearance study. The minimum height shall be 4.92 m for the broad gauge and 4.02 m for the metre gauge to permit movement of “C” class ODC without physical lifting of wires. In case” C” class ODC movement is not required, the height could be reduced to 4.80m (BG). Height may be further reduced to 4.65 if rolling stock higher than 4.265 m are not allowed on such lines.

(c) At electric locomotive sheds and loco inspection pits, the minimum height shall be 5.80m

for the BG and 5.50m for the MG. (d) All level crossings, the minimum height shall be 5.50m for both broad and metre gauges.

(e) Erection tolerance: [Para 7.3 of ACTM] A tolerance of +/- 20mm is permissible on the height of contact wire as measured at a

point of support except on either side of an over bridge where tolerance of +/- 10 mm will be allowed. But the difference between the heights of contact wire at two adjacent supports shall not exceed 20mm. In spans with gradient of contact wire, this difference of 20 mm is measured over and above the approved gradient.

(f) GRADIENT OF CONTACT WIRE Any change in the height of the contact wire shall be made gradually and the maximum

slope shall not normally exceed 2 mm per metre on main lines and 10 mm per metre on sidings. In no case shall the relative gradient of the contact wire in two adjacent spans be greater than 1 mm/m on main lines and 3 mm/m on sidings.

(As per Rly Bd letter no. 2001/Elect. (G)/170/1 dt 22.11.2016)

2.10 STAGGER:

To ensure uniform wear of contact strips of pantographs, the contact wire shall normally be staggered in a manner given below.

a) Tangent Track On tangent track the contact wire is normally given a stagger of 200 mm at each support

alternately on either side of the centre of the track. This is relaxed in special cases for ensuring

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requisite clearances in difficult locations such as in the vicinity of signals. Subject to stagger at midspan not exceeding the permissible values given in Drg. No. ETI/OHE/G/ 00202.

b) On tangent track, the catenary stagger is zero for masts supporting a single equipment. The catenary is fixed vertically over the contact wire at all supports at which more than one equipment is supported, at flexible head spans and at supports with reduced encumbrance, on tangent as well as curved tracks.

c) Curved Track On curves, the stagger of the contact wire at supports should not exceed 300mm. The stagger

of the catenary on curved track shall be determined with reference to Drg. No. ETI/OHE/G/00202. The standard values adopted are 0, +200 and -200.

d) Turnouts and Diamond Crossing At turnouts, the stagger of the contact wire on the main running line shall be in accordance

with Drg. No.ETI/OHE/G/00202. The stagger of contact wire of the branching line shall not exceed 300 mm at any point in the span. This is achieved by selecting a suitable location for the mast near the centre of the turnout in the case of overlap type equipment, or by suitably adjusting the point of crossing of the two contact wires in the case of crossing type equipment.

e) Uninsulated overlap At uninsulated overlaps, the stagger should conform to drawing No. RE/33/G/0 2121 Sh. 1. On

non uniform curves or at other locations where staggers different from those indicated in these drawings are adopted, the following points should be observed.

i) The stagger of the in running contact wire does not exceed to 100 mm on tangent track

and 300 mm curved track at any support, at which only one contact wire is in running. ii) In any span of the centre of which only one of the contact wires is in running ( as in a

4-span overlap), the mid-span stagger of the in-running contact wire does not exceed the values given in Drg. No. ETI/OHE/G/00202.

iii) The two contact wires run parallel to each other between the intermediate supports at a distance of 200 mm from each other.

f) Insulated Overlap At insulated overlaps, stagger should conform to Drg. No. ETI/OHE/G/02131 Sh. 1. On non –

uniform curves and other locations where stagger different from those shown in this drawing are adopted. The points mentioned against un-insulated overlap spans also apply, with the difference that between intermediate masts the two contact wires run parallel at a distance of 500 mm from each other.

g) Neutral Section: The stagger at overlap type neutral sections should conform to Drg. No. ETI/OHE/G/02161, Sheet No. 1.

i) The stagger at section insulator type neutral section should be so adopted that the stagger at the section insulator assembly is within the limit of +/- 100 mm. ii) PTFE type neutral section shall be erected on tangent track only. The stagger shall be zero at support.

2.11 SPAN: Standard spans shall be determined in accordance with following RDSO drawings: Sr No Location RDSO Dwg Ref

1 Conventional OHE ETI/OHE/G/00202 2 Regulated Tramway OHE ETI/OHE/G/00201 3 Insulated overlaps ETI/OHE/G/02131/Sheet1

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4 Un-Insulated overlaps RE/33/G/02121 5 Neutral Section ETI/OHE/G/02161/Sheet1

The spans should be as large as practicable. The maximum span of the OHE in tangent track is 67.5 m. Spans may be reduced in interval of 4.5m based on curvature, signal locations etc keeping in view stagger limits, signal visibility. Maximum span of OHE is also limited based on the wind zones of the section in the country as per IS-875 (Part-3)-1987, which is re-affirmed in 1997. Typical max permissible spans have been circulated by Rly Bd vide letter No: 2001/Elect. (G)/170/1 dt 22.11.2016 which is as under:

Sr No

Basic wind speed (m/sec)

Designed wind pressure (kg/ m2)

Revised Max

permissible span (m) *

1 33 73 67.5 2 39 105 63 3 44 136 54 4 47 155 49.5 5 50 178 40.5 6 55 216 36

* Ref: Rly Bd letter no. 2013/RE/161/3 (FTS-69861) dtd 22.02.2013 with 5% reduction]

Note: (a) On main tracks, the lengths of two consecutive spans shall not normally differ by more than

18m. (b) The spans in case of unequal encumbrances shall be such that the axial distance between the

catenary and contact wire at the min dropper is not less than 150mm. (c) With crossed type OHE at facing turnouts, the anchor spans shall be restricted to 54m. (d) Where earth wire is provided, the max span over level crossings should be 58.5m. (e) Spans should be restricted when loaded with section insulators.

2.11 TERMINATION

(a) GENERAL Traction overhead lines shall be terminated using components as specified in RDSO Drg. The

termination may be carried forward by one or two spans if anchoring facilities so require. (b) Terminating wires shall be electrically connected to the conductors with which they

are likely to approach closely or come into contact under normal conditions. (c) SUPPLEMENTARY INSULATION If a terminating wire passes a live conductor to which it should not be connected, i.e. in a

different elementary section, the portion of the terminating wire close to the live conductor shall be separated by means of insulators. The insulators shall be located in such a manner as to clear the zone of the pantograph under the worst conditions and as far away as is possible from live conductors.

(d) Following important points should be kept in mind:

(i) Back to back anchoring of OHE may be done only for fixed type OHE (without counter weight).

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(ii) No live anchor or equipment shall be provided near or over any hut or building. In such cases cut in insulator should be provided and OHE earthed.

(iii) Masts with counter weights should be avoided on plateforms [para 18.7 ACTM].

2.13 TYPES OF STRUCTURES: (a) The overhead equipment of main tracks in case of multiple track section shall be electrically

and mechanically independent of one another by provision of independent cantilever masts to the maximum extent possible (see the Annexure to these Technical Specifications).

(b) HEAD SPANS Head span construction may be adopted with unregulated overhead equipment. A single head

span shall not normally cover more than six tracks (See the Annexure to this technical specification for general arrangement drawings of head-span carrying complete overhead equipment).

(c) PORTALS In cases where the tracks in a multiple track section do not permit location of independent masts

and where automatic tensioning of overhead equipment is required, rigid portals may be used. Also in the vicinity of points and crossings, portals may be used, provided it is not possible to have prescribed setting with independent cantilever masts. These structures shall be equipped with standard bracket assemblies for supporting individual equipment of different tracks. The use of such structures is to be avoided as far as possible and for this purpose, the Engineer will arrange to slew the tracks, if practicable. A single portal shall normally not cover more than five tracks (See also 4.7). Portal structures shall also be employed at anti-creep central locations and such portals will have necessary guy arrangement.

(d) FOUNDATIONS

Foundations for all structures shall be designed in an economical manner by following the methods of design indicated by the Engineer and observing the schedule furnished by him.

2.14 CANTILEVER ASSEMBLY: The bracket assembly carrying overhead equipment shall be swivel type. The assembly shall be

such that the tubes adopted will permit easy adjustment of the whole equipment after erection to cater for displacement of the track during maintenance up to the extent of 100 mm on either side except as otherwise relaxed by the Engineer (see Para 2.1 g). In special locations, pull –off arrangements may be used with the approval of the Engineer.

In sections where High speed trains with 150 kmph or higher speed are likely to be run, drop bracket assembly as per drg No ETI/OHE/P/2360 alongwith steady arm drg ET/OHE/P/2390 should be used to give 100mm push up. [RB letter 2001/RE/170/1 dt 13/3/2007 & 2001/Elect(G)/170/1 Pt 30/6/2009].

2.15 OVERLAPS:

Overlaps shall be provided at suitable intervals such that neither the tension length exceeds 1500 m nor the fixed anchor to balance weight anchor exceeds 750m.

(a) GENERAL

The two contact wires at the overlapping zone shall be parallel to each other in a plane parallel to the track and run separated from each other.

(b) INSULATED In the case of insulated overlaps, the separation between the two contact and the two catenary wires shall be 0.5m (see the Annexure to these Technical Specifications for general arrangement drawings).

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2.16 POINTS & CROSSINGS: Arrangements of overhead equipment of different types e.g. regulated, unregulated or tramway at points and crossings shall be in accordance with the standard drawings.

2.17 ISOLATORS

Manually operated isolators single or double pole type, with or without earth contact assembly may be required to bridge certain section insulators or insulated overlaps (see para 2.1.11). In certain large yards, isolators controlling different lines may be grouped together on a gantry (see the Annexure to these Technical Specifications).

2.18 RETURN CONDUCTORS

At all Booster stations, the return conductor shall be provided with cut-in-insulators. At point mid way between two booster stations, the return conductor shall be connected to the rail through suitable terminal lugs which will provide a means of isolation, when required. The drawings showing the general arrangement of connections to the return conductor are listed in the Annexure to these Technical Specifications. The connection from the isolating arrangement to the rail shall be by means of 2 MS. Flats, each of minimum size 40mm x 6 mm and at feeding stations 4 M.S. flats each of minimum size 40 mm x 6 mm. The flats shall be given two coats of red oxide zinc chromate primer to IS: 2074:1992 or latest CNSL based and finished with two coats of Bitumen 85/25 blown grade. Return conductors may be taken under ground in special locations such as under overline structures with the approval of the Engineer. The return conductor shall also be connected with buried rail on either side of the overlap before the feeding post. The cut-in-insulator should be provided on the return conductor before the feeding post within the overlap limits and two independent rail connection links from the mast on either side on the cut-in-insulator. The same practice is to be adopted for the return conductor, on all sub-sectioning and sectioning posts.

2.19 BRIDGES AND TUNNELS: (a) OVERBRIDGES The complete overhead equipment (i.e. both the catenary and the contact wires) shall

normally pass under over-line structures. Additional intermediate suspension points shall be provided, if necessary, to ensure the specified minimum height of contact wire being maintained. In special cases catenary may be anchored on either side of the overline structure and the contact wire carried underneath using insulated catenary.

Under all over bridges, insulated piece of catenary wire shall be provided as per RDSO’s specification No. TI/SPC/OHE/INSCAT/0000 (04/00) with A&C No. 2 (9/16) or latest to avoid cutting of strands.

(b) TUNNELS AND CUTTINGS

The arrangements proposed for the equipment in tunnels and cuttings shall take into account the special features of each location and shall be in accordance with general design specified in part- II.

(b) SAFETY SCREENS On over-bridges, metallic protective screens shall be provided on both sides of the complete bridge covering all the tracks in order to prevent any person from coming into contact with the live overhead equipment. Such screens shall be properly earthed.

2.20 HEIGHT GAUGES AT LEVEL CROSSINGS Height gauges will be provided at all level crossings in accordance with the following standard plan drawings:

1. At National Highway having Class-I road or TVU > 1 lakh) Standard plan- Height

Gauge for level crossing (For Clear span above 7.3 m Upto 12.2 M) details of structure & foundations Drg. No. TI/DRG//CIV/HGAUGE/RDSO/00002/05/0.

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2. At State Highway having Class-I road or TVU > 1 lakh) Standard plan – Height for level crossing (For clear span upto 7.3m) details of structure & foundations Drg. No. TI/DRG/CIV/HGAUGE/RDSO/00001/05/0

3. At Other roads (Class-II to IV) height gauges at level crossings upto 7.30 m span Drg. No. RE/CIVIL/S/138-04 (Mod. -R1).

4. At Other roads (Class-II to IV) and TVU < 1 lakh Standard plan details of height

gauge for span 7.30m to 10.00m with Rail type for Location where TVU less than 1,00,000 Drg No. RE/CIVIL/S-148/2011 (Mod-R1) with ISMB-225.

In case of non availability of ISMB-225, RDSO dwg with ISMB-250 TI/DRG/CIV/H.GAUG/RDSO/00001/14/0 DT 25/9/2014 may be used.

2.21 BONDING AND EARTHING:

(a) Bonding and earthing shall be done in accordance with the code of practice for bonding and earthing for power supply installations as per RDSO specification No. ETI/PSI/120(2/91) with A&C Slip No. 1 (10/93).

(b) LONGITUDINAL AND TRANSVERSE BONDING Longitudinal and transverse bonding of tracks, bonding of structures including traction

structures to rails and associated earths shall be provided in accordance with the above code.

(c) TRACTION STRUCTURE BONDING Every traction mast or structure shall be bonded to a non-track circuited rail unless it is

provided with a continuous earth wire or it is individually earthed by means of an earth station. For general arrangement drawings, see the Annexure to these Technical Specifications.

(d) DOUBLE RAIL TRACK CIRCUIT Where track circuits are provided on both rails, traction masts/structures shall not be bonded to

rails but shall be provided with an earth wire made of steel reinforced aluminium conductor consisting of 6 strands of aluminium and one strand of steel each of 4.09 mm dia. (RACCOON) (conforming to IS:398 Pt. II/1976 or latest). The earth wire shall be run on traction masts or structures. They shall be divided into different electrical sections not exceeding 1000m length. The earth wire in each such section shall be connected at two traction structures, situated at a distance not exceeding 250 m on either side of the mid-point of the section to two 10 Ohm, earth stations which will be provided by the Contractor.

(e) STRUCTURE BOND IN AUDIO FREQUENCY TRACK CIRCUIT (AFTC) AREAS

(i) The structure bonds shall continue to be provided. However, earth wire is not required to be provided. (ii) The structure bonds shall be painted with ‘high build epoxy paint’ to RDSO Specification No. M&C/PCN/111/2006.

2.22 LIGHTENING ARRESTORS: No lightening arrestors will be provided on the traction overhead equipment.

2.23 PTFE TYPE SHORT NEUTRAL SECTION ASSEMBLY:

PTFE type short neutral section assembly shall consist of resin bonded fiber glass or equivalent) insulators covered with either Teflon (or equivalent) with PTFE spacers (or similar) adequately dimensioned and rated for the application. The insulators shall have suitable end fitting for connections to the contact wire through end fitting. For smooth passage of pantograph without any shock from contact wire to insulator and vice-versa, suitable runners preferably of stainless steel shall be provided. The central position of the assembly along with arc trap shall be solidly earthed as the latter with earth clamp is provided to trap any arc current caused by break of

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contact between pantograph and live contact wire when it passes from contact wire to insulator. The distance between arc trap and nearest line position shall be adjustable up to a maximum of 320mm. Suitable means of suspension of the components of the assembly from the catenary conductor shall be provided. The complete assembly shall be as light as possible and so constructed that adjustments of components can easily be made during erection and maintenance for ensuring smooth passage of pantograph. In the catenary conductor, resin bonded fiber glass insulators with suitable covering shall be provided. The insulators shall have suitable end fittings for connections to catenary wire through end fittings. The central portion shall be solidly earthed.

The neutral section assembly shall be suitable for erection symmetrically on either side of the cantilever bracket support with regulated or unregulated conventional/composite OHE where one point each for suspension of catenary conductor and contact wire is available as also shown in GA drawing under the Annexure to these Technical Specifications.

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CHAPTER: B-3

FOUNDATIONS

3.0 SCOPE: This chapter deals with the design of foundations and anchor blocks for traction structures carrying overhead equipment (including those on bridges), structures at switching stations and booster stations and other concrete work. It also deals with the specifications for concrete.

3.1 Conformity with IRSOD-2004

While designing and casting the foundation special care should be taken for adhering to all the latest provisions laid down in IRSOD. Some of the important provisions are as under: Below and above Rail Level: Miniumum horizontal distance from centre of track to any structre for Existing works and for New works or alteration to existing works as per IRSOD with latest amendment issued from time to time.

In case any infringement is detected at any stage of the project execution, such foundations are liable to be rejected by RVNL not with standing any approval given or supervision done by RVNL. Final responsibility for the work done lies with the contractor and he shall replace and re-cast all the rejected foundation and re-erect OHE (if required) free of cost.

3.2 DESIGN OF FOUNDATION:

(a) SOIL PRESSURE

For design of foundations for traction structures carrying overhead equipment, the Contractor shall determine the type and allowable bearing pressure of soil at suitable intervals and adopt the type and size of foundations, suitable for particular locations with the help of the approved employment schedules. In cases of particularly weak soil, the bearing pressure may have to be determined for each location where so advised by the Engineer. Soil bearing pressure, using SPT (falling weight equipment) should be determined generally for every 5 kilometer interval or less wherever change of soil is encountered. In general, IS code of practice (IS 6403:1981 or latest) should be followed. In addition, at every 250 m the soil bearing pressure should be determined by dial gauge type penetrometers. Dial gauge type penetrometers shall also be made available by the Contractor at each foundation site so as to facilitate cross check at each individual location. For design of foundations for masts and gantries at switching stations and booster stations, the Contractor shall determine the type and allowable bearing pressure of soil at the locations of such stations and shall prepare designs for the foundations suitable for each location to suite the bearing pressure of the soil in consultation with the Engineer.

(b) GUIDING INFORMATION

Subject to para 3.2 (a) above, the following allowable bearing pressures may generally be expected for various kinds of soil. The information is given for general guidance only. (i) Average good soil in banks and cutting 11,000kg/sq.m. (ii) Moorum soil in cutting 22,000kg/sqm (iii) New banks & bad soils in banks and cutting 5,500kg/sqm (iv) Poor soil 8000 kg/sqm (v) Black cotton soil-pure gravity foundation shall normally be adopted. However, under

reamed pile foundations may be adopted at the option of the Engineer in limited locations for trial purpose. In the case of dry black cotton soil, the soil should be subjected to a bearing pressure as close as possible but not exceeding 16,500 kg/sqm the depth of the foundation block being not less than 2.8m. In case of wet black cotton soil, the soil should be subjected to a bearing pressure as close as possible but not exceeding 8,000 kg/sqm.

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In the case of hard rock, a hole should be blasted in the rock, or by means of any other drilling and pneumatic method and the mast sealed into it with concrete.

(c) STRUCTURES CARRYING OVER-HEAD EQUIPMENT

Foundations for traction structures carrying overhead equipment shall be either of the side bearing, side gravity or new pure gravity type according to their location, formation of the sub-grade and bearing pressure of the sol. In new filled up soil or cinder formation, pure gravity sand-filled core foundations, or foundations with cast-in-site reinforced concrete piles, or cantilever types foundation with counter-weights or guyed foundations may be adopted.

(d) SUPPORT FOR OHE IN TUNNELS: In the lined tunnels, stubs for supporting OHE cantilever assembly should be provided on

boyh sides of the tunnel opposite each other. This would facilitate restoration of OHE in the event of damage to stubs on one side. [para18.15 ACTM]

(e) ON BRIDGE PIERS

Complete design of foundations for traction structure on bridges to suit different locations and local conditions will be furnished by the Contractor. Core holes for erecting masts on bridges should be provided as per RDSO/RE standard drawing on both sides of all the piers. Holes on the piers which are not used for foundation should be filled with dry sand covered with concrete slab [para 18.16 ACTM].

(f) TYPICAL DESIGN

Typical design and drawings of side bearing and new pure gravity and side gravity type foundations are included in the drawings listed in the Annexure to these Technical Specifications. Employment schedules for standard foundations for traction structures for various locations and types are also included in the drawings listed in the Annexure to these Technical Specifications.

(g) SPECIAL FOUNDATIONS

In the case of foundations at locations not covered by the employment schedules furnished by the Engineer, the Contractor shall prepare special designs and furnish full design calculations justifying the choice of the type of foundations for such locations. In black cotton soil especially pile foundations of under reamed type as per RDSO’s standard designs (Reference RDSO’S Drawings No. ETI/C/0062 MOD. “B”) or any other approved design may have to be cast at limited locations for trial purpose. The Contractor may furnish the technical details of alternative design, construction methods proposed to be adopted and their previous background/experience if any. The decision of the Engineer with regard to feasibility and suitability of adoption of the alternative design for each type of foundation will be final.

(h) MASTS & FABRICATED STRUCTURES AT SWITCHING STATIONS

Foundations for the masts of gantries at switching stations shall be of the pure gravity type, the base of which shall rest on consolidated soil.

(i) FENCING POSTS Foundation for fencing posts shall rest on consolidated soil if the depth of unconsolidated soil is

less than 1.5 m below the datum level and shall be rectangular parallel piped in shape. If the depth of unconsolidated soil is more than 1.5 m the foundation block shall rest on reinforced concrete piles cast-in-site or reinforced concrete foundation may be adopted as desired by the Engineer.

(j) EQUIPMENT PEDESTALS

Pedestals for interrupters and LT supply transformers where required, shall be of mass concrete with the base resting on consolidated soil.

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(k) CABLE TRENCHES

The cable trench shall rest on original ground if the depth of unconsolidated soil is less than 0.5 m. If the depth of the unconsolidated soil is more than 0.5m, the cable trench shall be made of reinforced cement concrete of approved design supported at suitable intervals on concrete pillars.

3.3 CONCRETE: (a) Concrete for foundations shall be nominal mix of following grade: Foundation

concrete grade Grouting and Muff concrete grade

1 In normal soil- where concrete is

(a) in contact or buried under non-aggressive soil/ground water

M-10 M-15

2 (b) exposed to coastal environment M-15 M-20

3 Soft rock with bearing capacity 45000 kg per sqm and Hard rock with bearing capacity 90000 kg per sqm where concrete is

(a) buried under non aggressive soil/ground water

M-15 M-20

4 (b) exposed to coastal environment M-20 M-20

(c) For cable trenches at switching stations/TSS, M-15 grade concrete shall be used.

Main Provisions of IS:456-2000 or Latest

TABLE -9: PROPORTIONS FOR NOMINAL MIX CONCRETE (CLAUSE 9.3 AND 9.3.1)

Grade of water concrete

Total Quantity of dry aggregate by mass per 50 kg. of cement, to be taken as the sum of the individual masses of the fine and coarse aggregates kg max.

Proportion of fine/coarse aggregate (by mass)

Quantity of water per 50 kg. of cement max.

1 2 3 4

Kg Generally 1:2 but subject to an upper limit of 1:1.5 and a lower limit of 1:2.5

Litres M5 800 60 M7.5 625 45 M10 480 34 M15 330 32 M20 250 30

NOTE: The proportions of the fine to coarse aggregate should be adjusted from upper limit to lower limit progressively as the grading of the fine aggregates becomes finer and the maximum size of coarse aggregate becomes larger. Graded coarse aggregate shall be used.

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Example: For an average grading of the fine aggregate (that is zone II of Table 4 of IS: 383-1970* or latest) the proportions shall be 1:1.5, 1:2 and 1:2.5 for maximum size of aggregate 10mm, 20mm and 40 mm respectively.

* Specification for coarse and fine aggregates from natural sources for concrete (second revision). “Volume Batching may be allowed only where weight batching is not practicable and provided accurate bulk densities of materials to be actually used in concrete have earlier been established. The quantities of fine and coarse aggregate (not cement) may be determined by volume. If the fine aggregate is moist and volume batching is adopted. Allowance shall be made for bulking in accordance with IS: 2386 (Part-III-1963 or latest) the mass volume relationship should be checked as frequently as necessary, the frequency for the given job being determined by Engineer to ensure that the grading is maintained”. In judging the acceptability of the materials, quality of concrete and the method of work, the Engineer will generally observe the provisions of the “Indian Standard Code of Practice for Plain and Reinforced Concrete, IS: 456-2000 or latest. The crushing strength of concrete shall not be less than the limits given below (as per IS456-2000 or latest Table-2 Grade of Concrete):

Specified Characteristic Compressive Strength of 15 cm Cubes at 28 days

Grade of Concrete At 28 days age (a) M10 (b) M15 (c) M20

10 N/mm2 15 N/mm2 20 N/mm2

NOTE: (a) Test specimen of works tests shall be taken at the site of work from mixture

of concrete ready for pouring into the foundation hole. All tests shall be carried out in accordance with IS: 516-1959 or its latest version. The sample of concrete from which test specimens are made shall be representative of the entire batch.

(b) Age is reckoned from the day of casting.

Specified Characteristic Compressive Strength of 15 cm Cubes at 28 days

The indicative Compressive Strength of 15 cm Cubes at 7 days shall normally be 67% of same value at 28 days.

3.5 SIZE AND GRADING OF AGGREGATES

The graded coarse aggregate 40 mm nominal size (table 2 of IS: 383-1970) shall be used for foundation. A coarse aggregate for grouting, muffs, cable trenches and embedding shall be of 20mm graded nominal size as per table of IS: 383-1970 (specification for coarse and fine aggregate from natural sources for concrete).

Fine aggregate shall be graded from 10 mm downwards. The maximum size of aggregate for under reamed pile foundation shall be 20 mm graded nominal size. In case river sand is not available easily and nearby, quarry dust of appropriate grading may be used without affecting strength of the concrete and with prior approval of competent authority.

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3.6 SAND CORED FOUNDATIONS:

After erection of masts in sand-cored foundations, the core hole of the foundation blocks shall be filled with dried sand and covered with a layer of bitumen of 80 mm thickness below 30 mm from top level of the block. A hemispherical shaped muff shall be provided on such foundations in lieu of standard type.

3.7 SINKING OF CONCRETE SHELLS:

Where the water-level is high, one or more sections of reinforced concrete shells may have to be sunk before casting concrete. The size of each of shell shall be 1200 mm outside dia x 50 mm thick x 600 mm high reinforced with 6mm (1/4”) dia rods spaced 150 mm apart, both longitudinally and circumferentially, the concrete shall be of grade M10 as per provisions of para 3.3.

3.8 CEMENT: The cement to be used in the construction of foundations, RCC structures shall be ordinary Portland cement of 43 grade (conforming to IS-8112) or 53 grade (conforming to IS-12269) as approved by RVNL based on requirement and availability.

3.9 SELECTION OF FOUNDATIONS (Ref. ACTMVol-II Part-II para 6.5.3 to 6.5.7) Side bearing foundations are used for masts where the soil bearing capacity is 11000 or 21500 kgf/m sq and 300 mm wide shoulder is available on the banks. However, for overlap iner masts and masts on the inside of curves, 550 mm wide shoulder is necessary (Typical Drg No. ETI/C/0023).

(a) New pure gravity foundations may be used for masts where soil bearing capacity is 5500, 8000 and 11000 kgf/m sq. or where adequate shoulder width as mentioned in above para is not available. In such cases, it should be ensured that foundation is not exposed. (b) Side gravity foundations may be used for masts where soil bearing capacity is 8000 and 11000 kgf/m sq or adequate shoulder width is not available. No portion of foundation should be exposed. (c) Foundations in black Cotton soil (i) The foundation of the black cotton should be done preferably in dry season i.e. from November to May. Excavations should be avoided as far as possible in case of unexpected rains in dry season also. (ii) In black cotton soils, WBC and NBC type of foundations are used. Primarily WBC foundations are to be adopted where swelling/ shrinkage is not expected to take place at the foundation level and NBC foundations have to be provided where swelling/ shrinkage is expected to occur. (iii) The safe bearing capacity should be determined in accordance with IS: 6403 latest. (iv) When in doubt regarding classification BC soil as to dry or wet, it is preferable to make NBC type foundation. 3.10 Where foundations are constructed on the slope of banks, the foundations should be so located that generally no part of it is exposed. The top of foundations may then be brought to the desired levels (rail level -500 mm) by providing a super block of length and breadth equal to the top dimension of foundation. The increase in bending moment due to increased setting

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distance should be calculated and the designation of foundation to allow for this BM should be selected. 3.11 The top of foundation should be 50-100 mm above the surrounding ground level. The length of mast below rail level should be minimum 1850 mm for regulated OHE and 1750 mm for un-regulated OHE. A 1350 mm embedment of mast in concrete is necessary. Concrete cushion of 150 mm below the bottom of mast is also necessary. Where necessary, these may be achieved by providing a supper block of length and width equal to the top dimension of foundation. However, portion of existing pure gravity foundations corresponding to a depth of 500 mm of embankment having slope of 1:2 may be exposed. (As per ACTM para no 6.5.9 vol-II part-II). Giving due consideration to the above, the most economical type of foundation should be adopted. 3.12 VOLUME CHARTS: The foundation bending moment codes (FBM) for each location are obtained from the mast employment schedules or by actual calculations. Bearing capacity of the soil is determined at the outer toe of the bottom of foundation at a representative number of locations. Where foundations are placed on the slope of banks due to increase in setting distance, the bearing capacity of the soil should be determined on the slope. Bearing capacity of the soil should be determined thus would be considerably less than those determined on the top of foundation. Selection of the type and size of foundation is done from volume chart based on shoulder width and the extent of projection above ground level as detailed below. 3.13 Type of foundations The following types of foundations are used for OHE mast and portals: 1. For Masts: (i) a) Side bearing ( Type B) b) Side gravity ( Type:BG) c)Pure gravity for black cotton soil

(type: WBC) (ii) New pure gravity(Type:NG) (iii) NBC type foundation for dry black

cotton soil (16500 &11000 kgf/m sq) 3.0 m depth

iv) New pure gravity for different soil and site conditions( 500 mm exposed ) (type: NG or SPL)

v) New pure gravity for black cotton soil (for 8000 kgf/m sq soil pressure, 2.5 m depth (Type : NBC)

vi) Foundations in soft rock ( bearing capacity 45000 kgf/m sq)

vii) Foundations in hard rock (bearingcapacity 90,000 kgf/m sq.)

2. For Portals: (i) In ordinary soil (ii) In dry black cotton soil

Drg. No. TI/DRG/CIV/FND /RDSO/ 00001/04/0 Sheet 1 Mod. B for 2.8 implantation or TI/DRG/CIV/FND/RDSO/00001/12 /0 for sheet 1 for 2.9 m implantation -do- sheet 2 -do- sheet 3 -do- sheet 4 -do- sheet 5 Drg. No. ETI/C/0059 Mod C Drg. No. ETI/C/0060 Mod D Drg. No. ETI/C/0005/68 Drg. No. ETI/C/0063

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Note: (i) In the cases of OHE foundations in deep rock cutting, the foundation should be below the

drain. (ii) For all future construction of pure gravity foundations drawing No. Drg No.

TI/DRG/CIV/FND/RDSO/00001/04/0 Mod. B or TI/DRG/CIV/FND/RDSO/00001 /12/0 for 2.9 m implantation only shall be followed.

3.14 LAYING OF FOUNDATIONS: (a) The Contractor shall carry out soil pressure tests in accordance with methods approved by the

Engineer to determine permissible bearing pressure of various representative types of soils in the presence of the Engineer during site pegging. He shall adopt only those values that are accepted by the Engineer for the design of foundations.

(b) LOCATION The location of each foundation or anchor block shall be set out correctly in accordance with

the approved structure/cross-section drawings or foundation layout drawings, as the case may be, in the presence of the Engineer.

(c) METHOD OF INSTALLATION The contractor shall adopt mechanized method (concrete mixer) for installation of foundation

normally. In exceptional circumstances such as mechanical breakdown of mixer, work in difficult approaches etc, the contractor may adopt manual method of mixing with the approval of the Engineer subject to adding 10% extra cement in terms of CPWD specifications for concrete work. When manual mixing is adopted, it shall be carried out on water tight plateform. The contractor may erect traction masts or structures in the same operation as casting of foundations or erect them subsequently in core holes left in foundation blocks and grout them separately. In any case, the method of casting of foundation blocks and erection of masts or structures shall be subject to the approval of the Engineer.

(d) EXCAVATION Normally, excavation of soil for foundations or anchor blocks along side the tracks may be

done up to the length of 1 to 1.2 m and depth of 0.8 to 1m without shoring, provided the excavated hole is concreted immediately and not left overnight. Shoring shall otherwise be done unless the hole is re-villed with soil and tamped. In case the length of excavation is 1 to 1.2 m and depth of excavation for foundations and anchor blocks alongside the tracks is more than 0.8 to 1m, the excavation may be undertaken only after certification by the Engineer to be safe and concrete is cast on the same day. Shoring shall be done to the satisfaction of the Engineer, if the excavated hole is left overnight. All water logged locations will come under the purview of this para. In poor soil or ash banks, no excavation shall be done without adequate shoring and piling, for large foundations and water logged locations shoring shall be done in accordance with drawings submitted by the Contractor and approved by the Engineer. Shoring /shuttering of the pits should be provided effectively to the satisfaction of the Engineer. Core hole covers should be provided promptly on casting of foundation (within 48 hours) and their edges cemented to the foundation blocks. Prior to doing so, water should be filled in the core hole so as to assist in curing. The date of casting should be inscribed on the foundation block. In case of platform areas and Level crossings, the core holes should be filled with sand before provision of core hole covers. So as to prevent any injury to rail users If the core hole cover gets damaged or is displaced. The track ballast should be restored to its original form promptly after casting of the foundation block. The excavated earth should be removed well clear of the area so as to avoid any mixing up with the track ballast or any obstruction to the track drains. In case of cuttings, the earth should be thrown well away from the shoulders so that there is no risk of its flowing back to the drain during the rains.

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(e) CONCRETING All concreting or grouting shall be done in accordance with para 3.3 with coarse aggregate

grade for the purpose specified in para 3.5. The concrete shall be poured and compacted properly with Vibrator in general. However, in rare cases, manual tamping may be adopted with approval of the Engineer. The contractor shall arrange to provide concrete testing samples for tests at specified intervals or as and when required by the Engineer, to determine crushing strength after 7 days and 28 days curing as required. Testing shall be arranged by the contractor at his own cost. Spare vibrator shall always be kept at site of casting of foundation for use in emergency.

(f) MUFFS All anchor blocks and foundations of structures carrying overhead equipment shall be provided

with concrete muffs. The top of these muffs shall be above the level of ground the track formation and of adequate height of not less than 15 cm to afford reasonable protection during rainy weather. Muffs may be installed at the same time masts are grouted or after the mast/ structure is loaded with equipment. The foundations of structures for switching stations need not, however, be provided with muffs. The top of such foundations shall be given a slope of 1 in 50 towards the edge to ensure that water does not collect at the base of the structure of the frame work of the equipment.

(g) Suitable grooves or niches shall be provided in the foundation blocks, wherever required, at

the time of casting, to enable embedment of earth strips etc. to avoid the necessity of chipping of concrete.

(h) Conduits for cables should be embedded in the foundation blocks, wherever required, to avoid

subsequent chipping off and breaking of the foundation blocks. (i) Shuttering Suitable iron shuttering of proper dimensions as per type of foundation shall be used while

casting the foundations in the exposed portions or any where required as per the site conditions so as to get proper shape and finish.

3.15 MOIST CURING

Exposed surfaces of concrete shall be kept continuously in damp or wet condition by ponding or by covering with a layer of sacking, canvas, hessian or similar material and kept constantly wet for atleast seven days from the date of placing concrete in case of ordinary Portland cement.

3.16 SAMPLING AND TESTING OF CONCRETE:

Sampling and Testing of concrete shall be done generally as per CORE letter No: EL/CORE/Policy/system Improvement/0272/003 dated 26/2/2003. The provisions are summarized as under:

(a) GRADING OF AGGREGATES:

Graded course aggregate should be used in all type of foundation work. Normal size of graded aggregate 40mm should be used for foundation and 20mm for muffing grouting etc conforming to the requirements as per table-2 of IS :383-1970 which is reproduced below: -

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GRADED COARSE AGGREGATE

IS Sieve Designation % passing for graded aggregate nominal size 40mm 20mm

80 mm 100 -

40 mm 95 to 100 100

20 mm 30 to 70 95 to 100

16 mm - -

10 mm 10 to 35 25 to 55

(b) SAMPLING & TESTING PROCEDURE OF AGGREGATES: Sieve analysis of representative sample of ballast selected randomly from different parts of stock

e.g. slope, top & inside be done. The sample for sieving shall be prepared from larger sample either by quartering or by means of a sample divider. The weight of the sample shall be not less than 50 Kg for 40mm or 20mm size aggregate (Table No. II of IS -2386(Pt. I) - 1963). The air dry sample shall be weighted and sieved successively on the appropriate sieves starting with the largest. Care should be taken to ensure that the sieves are clean before use. A material passing register should be maintained for the aggregates and necessary test results should be recorded in that in the Performa given under items 3.0 & 4.0 below.

(c) MECHANICAL TESTING OF COARSE AGGREGATES The coarse aggregate should be tested for its mechanical properties as per procedures laid down in IS:2386 Pt.IV, from each source and after getting satisfactory test results only , the source should be approved by an officers for regular supply of the aggregate. The test results should conform to IS: 2386 Pt IV. The test record should be maintained in the material passing register as per the Performa given below: The record for Mechanical Testing of Coarse aggregate: three samples from every supply source:

Sample

No.

Source of

Supply.

Crushing

Strength

Date of

Testing

Result Tested

By

Initial of Super-Visor.

Counter

Signature of officer.

(d) SIEVE ANALYSIS Sample as detailed vide Para 2.0 above should be drawn from every supply lot sieve analysis should be done and recorded as per the format given below. It satisfies the parameters given under Para 1.0 above, then only the same may be allowed for use. The test results should be maintained in the material passing register.

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Record for Sieve Testing of Coarse aggregate: three samples from every supply lot:

Date of Receipt.

Source of Supply.

Sample Location.

Date of Testing Result Tested By

Initial of Supervisor

Counter Signature of officer.

(e) Testing of Compresssive Strength (Cube Testing) One sample of three cubes should be cast in every two track kilometers or 50 cu meter of concrete (whichever is early) and they should be subjected to compressive strength test after a curing period of 7 days and 28 days as approved by the officer. The test should be carried out in accordance with IS 516-1959 or latest and test results should conform to IS 456-1978 (Table-2 for 28 days). The test results should be maintained in the profarma given below:

(f) ACCEPTANCE CRITERIA Acceptance criteria for test sample shall be as per clause 16 of IS: 456:2000 or latest. In case test results of cube testing do not conform to IS-456 as detailed above, detailed investigation of foundations including tests like rebound hammer and core cutting shall be done as deemed fit by RVNL for final acceptance or rejection of the foundations. After detail investigations, foundations which are finally rejected by the Employer, the contractor shall re-cast all the rejected foundations free of cost as per directions of the Employer. The core of the rejected foundations shall be filled with the soil so as to level the surrounding ground properly. OHE masts if erected shall be retrieved free of cost by the contractor and used elsewhere. 3.17 SUPERVISION: Constant and strict supervision of all the items of the construction is necessary during the progress of the work, including the proportioning and mixing of the concrete. Supervision is also of extreme importance to check the reinforcement and its placing before being covered. Before any important operation, such as concrete or stripping of the form work is started, adequate notice shall be given to the construction supervisor.

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Test cube No.

Sample Location

Date of Casting

Date of Testing

Test Result Tested by

Initial of

Sup

Counter Sig of officer Sample1 Samp 2 Samp 3 Remarks

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CHAPTER: B-4

OHE STRUCTURES 4.1 SCOPE: This chapter deals with the design of steel structures and steel work for overhead equipment,

switching stations, booster transformer stations and LT supply transformer stations and the specification for steel and pre-stressed concrete trial mast.

4.2 TYPES: Structures and gantries may consist of any or more of the following types: (i) Broad flange beams (ii) Rolled steel joists (I section). (iii) Fabricated steel Structures (Welded/bolted). Structure/ uprights shall generally be embedded in concrete foundation blocks in special cases

Structures may be secured by means of holding down bolts. 4.3 DESIGN: (a) STEEL STRUCTURES Designs for steel structures shall, except where otherwise provided, comply with the

Indian standard code of practice for use of structural steel in General Building Construction- IS: 800-1984. The thickness of smallest steel sections used shall be 5 mm for galvanized members.

(b) All the steel structures and small part steel for carrying overhead equipment are to be

fully galvanized after drilling and fabrication as per specification No. ETI/OHE/13 (4/84) with A&C Slip No. 1 to 3.

4.4 CANTILEVER MASTS: (a) LOAD For purposes of design the worst possible combination of all loads that may occur shall be

considered. The load shall include the following (weights to be assumed for design of structures are shown against important items).

(i) Weight of overhead equipment (1.60 kg/ meter for each conventional and 1.32 kg/metre fore ach composite OHE).

(ii) Weight of bracket supporting the overhead equipment (60 kg/ normal bracket) (iii) Weight of a man (60 kg) (iv) Weight of an earth wire (0.32 kg/metre). (v) Weight of feeder, return conductor or other special equipment wherever they occur. (vi) The effect of eccentricity of vertical and horizontal loads on the bracket due to

variation in temperature. (vii) Wind loads perpendicular and parallel to the track. The wind pressure adopted shall

be as specified in the Bidding Document. (viii) Radial forces on the mast, due to stagger, curvature, anchorage etc. (ix) Weight of the mast itself. (x) Any other load or loads that may occur due to special location of the structure.

(b) REVERSE DEFLECTION Notwithstanding the provisions contained in IS: 800-1984 or latest referred to in para 4.3

above regarding permissible deflection, the following shall apply.

(i) The deflection at the top of the mast due to permanent loads shall not exceed 8 cm and the mast shall be so erected that it stays reasonably vertical after application of permanent loads.

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(ii) The additional deflection under maximum wind pressure shall not exceed 8 cm at the level

of the contact wire.

(iii) All traction masts and structures shall be erected with the correct reverse deflection so that they become reasonably vertical after they are loaded.

(c) TORSION The torsional rotation of the mast due to permanent loads shall not exceed 0.1 radian. (d) TYPICAL DESIGN The typical design of a traction mast is included in the set of standard drawings listed in the

Annexure to these Technical Specifications. Employment schedules for standard masts for various locations and types are included in the standard drawings listed in the Annexure to these Technical Specifications to enable selection of suitable type for different locations and local conditions.

4.5 ANCHOR MASTS: (a) Masts at which overhead equipment will be anchored will be anchored shall also normally be of

the same type as those in other locations. Anchor masts shall normally be provided with suitable guys but struts may be permitted in special cases.

(b) DWARF MASTS At certain locations where due to local conditions it is not feasible to anchor the guy rod on a

foundation block in the ground, a dwarf mast shll be used in accordance with approved designs. 4.6 HEAD SPANS (See paras 2.13 and 5.16) (a) LOAD

The loads to be considered shall be as detailed in para 4.4 (a) as far as applicable and at their worst combination.

(b) SAG FOR HEAD SPAN WIRE The sag of the head span wire shall be approx. on-tenth (1/10) of the span.

(c) MINIMUM TENSION IN CROSS SPAN & STEADY SPAN WIRES For purpose of design, a minimum tension of 200 kg, shall be ensured in the span wires for

worst combination of temperature and wind load. (d) DEFLECTION OF MAST Deflection at the top of the mast or structure shall be limited to one eightieth (1/80th) of its

height above foundation. (e) TYPICAL DESIGN Typical design for head span mast carrying overhead equipment for 4 tracks will be furnished

by the contractor.

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4.7 PORTALS: (SEE 2.13) (a) GENERAL Portals shall be of fabricated steel of standard types of Engineer’s designs. The most

important designs are covered by Drawings listed in the Annexure to these Technical Specifications.

(b) LOAD The load shall be as detailed in para 4.4 (a) as applicable. 4.8 STRUCTURES ON BRIDGES:

a) The structure may be either cantilever masts or portals (hinged or fixed at base) depending on the type and condition of bridge pier capping. As far as possible cantilever masts grouted in foundations blocks on pier will be used. Where this is not possible cantilever masts with holding down bolts or suitable portals (hinged or fixed at the base) may be adopted.

b) Designs of Structures on bridges to suit different locations and local conditions will be

furnished by the contractor to the Engineer.

4.9 SPECIAL STRUCTURES: In the case of structures at locations not covered by the employment schedules, the

contractor shall furnish complete design calculations justifying the choice of the type of structures for such locations.

4.10 SETTING OF STRUCTURES: a) The setting is the distance from the centre line of the track, on straight or curved track to the

face of the mast/ structure. b) On straight track and outside of curve, the standard setting shall be as per the relevant

drawing included in the Annexure to these Technical Specifications. Minimum setting of structures shall be 2.9 m plus curve allowance as required. Whenever this distance can not be provided, specific approval of Engineer shall be obtained before erection. The setting of portal upright, overlap/turn-out structures, anchoring structures and other masts carrying more than one OHE will be 3.0 m wherever possible.

c) EXTRA CLEARANCE ON CURVES The minimum setting of structures on curves shall be determined by adding to the above

minimum figures an extra clearance indicated in the table included in the set of standard drawings listed in the Annexure to these Technical Specifications.

d) STRUCTURES WITH COUNTER WIEIGHTS In case of structures carrying counter-weight assemblies, the term “ setting” shall refer to the

minimum distance of the counter-weight from the track center under the worst conditions of wind.

e) STRUCTURES ON PLATFORM The setting of structures on platform shall be not less than 4.75 m. f) STRUCTURES NEAR SIGNALS In the vicinity of signals, structures shall be located in a manner which shall ensure good

visibility where necessary, the setting shall be increased as per the relevant drawing included in the Annexure to these Technical Specifications.

g) STRUCTURES NEAR PLATFORM The setting of structures on platform shall be not less than 4.75m.

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h) PAINTING OF SETTING DISTANCE OF STRUCTURES The value of setting of masts/ structures shall be painted on each mast/ structure. The figure

shall be 25 mm in size in black on yellow background. In addition, the track level shall also be marked on the mast/structure by a horizontal red painted stroke.

4.11 NUMBERING OF STRUCTURES CARRYING OF STRUCTURES CARRYING OVERHEAD

EQUIPMENT: All structures shall be numbered in accordance with the numbering given in the approved overhead equipment layout plans. Retro reflective type number plate shall be provided on each mast or structure as per approved designs. (In terms of Rly Bd letter no. 2001/Elect. (G)/170/1 dt 22.11.2016)

(a) SIGMA BOARDS FOR EASY IDENTIFICATION OF STOP SIGNALS DURING FOGGY WEATHER Sigma Boards for easy identification of stop signals during foggy weather shall be provided as per RDSO specification No. TI/OHE/ 33A (Rev-8) and Drg. No. TI/DRG/ OHE/ PLTBRD/RDSO/00036/12/0 circulated vide Railway Board letter No. 2017/Elect.(TRS)/11/4 Pt. dated 20.12.2017.

(b) Warning Boards, Danger Boards and other Signages: All the equipments like isolators, masts, DJ boards, EMU/MEMU boards and panto raise/lower boards etc shall be numbered and provided as per RDSO standard with enamelled/retro reflective plates. Similarly separate boards for MEMU shall be provided as per prescribed standard.

Danger boards at all LC gates, stations, cabins, TSS, switching posts shall be provided at prominent places cautioning the public. Similarly first aid chart shall also be displayed as per standard at these places.

4.12 STEEL WORK FOR SWITCHING STATIONS AND GANTRIES:

(a) HORIZONTAL MEMBERS OF GANTRY The horizontal member of the main as well as the auxiliary gantry carrying isolator switches,

insulators, potential transformers etc. shall be made from steel sections viz. channels, angles and small joists, single or fabricated. They shall preferably be attached to masts by means of clamps to avoid drilling of masts sections.

(b) For purpose of design all possible loads which may occur in the worst combination shall be

considered. The loads shall include the followings: -

(i) Weight of insulators, instrument transformers, isolator switches, bus- bars, and their accessories.

(ii) Loads caused by feeders, along and across tracks, return feeders etc. (iii) Loads caused by anchorage due to guying of anchored masts (where

applicable). (iv) Pull or push on the structures due to anchorage and radial tension (where

applicable). (v) Wind load on the different structures, conductors and equipment.

(vi) Weight of men working on the structures. (vii) Weight of structure itself. (viii) Erection loads. (ix) Any other load or loads which may occur due to special equipment wherever

they occur.

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(c) TENSION OF CONDUCTORS For purpose of designs the maximum tension of different conductors, without wind load, shall

normally be as under: - (i) Maximum tension in the cross feeders at switching stations under worst conditions: -

(1) For spans less than 18m……….100 kgf (2) For spans more than 18m…....200 kgf.

(ii) Maximum tension in longitudinal feeders running parallel to the track at the switching stations under worst conditions 150 kgf.

(iii) Tension in anchored overhead equipment in case of sectioning and paralleling stations-2000 kgf.

(d) DEFLECTION OF GANTRY MASTS

Deflection under the permanent loads (at an average temperature of 35 deg. C without wind) at the top of the fabricated structures of mast shall be limited to one eightieth (1/80) of its height above foundation.

(e) Masts of the gantry at which feeder or overhead equipment will be anchored at the switching

stations shall normally be provided with suitable guys, but struts shall not be permitted.

(f) CHAIRS AND BRACKENTS Chairs, brackets and supporting steel work carrying potential transformers, lightning arrestors, insulators, etc. shall be made of fabricated steel and shall be mounted on the main auxiliary gantry preferably by means of clamps to avoid drilling of mast sections.

(g) UPRIGHTS AND FENCING

Uprights carrying operating handles of isolators and fencing posts shall be made from steel sections, viz. channels, angles or small joists, either single or fabricated.

(h) STEEL Steel conforming to IS:2062-1992 or latest shall be used for all fabricated steel work.

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CHAPTER: B-5

EQUIPMENTS, COMPONENTS AND MATERIALS

-OHE & SWITCHING STATIONS

5.1 GENERAL: This chapter deals with the details and specifications of the equipment, components and

materials to be used for traction overhead equipment, switching stations, booster transformer stations and LT supply transformer stations.

5.2 COMPLIANCE WITH STANDARD SPECIFICATION:

In the technical specifications of equipments, components and materials, references are made to the following standard specifications:

(i) International Electro Technical Commission (abbreviated as IEC) publications. (ii) British Standards (abbreviated as BS) (iii) Bureau of Indian Standards (abbreviated as IS) 5.3 QUALITY ASSURANCE: The provisions of quality assurance will apply, including facilities to be provided by the

manufacturer. 5.4 INTER CHANGEABILITY:

All equipments, components and fittings shall be inter-changeable and supplies shall be in accordance with the Engineer’s designs unless otherwise specifically approved by him. Components such as fuses, indication lamps etc. should be replaceable with substitutes available indigenously, as far as possible.

5.5 TECHNICAL SPECIFICATIONS:

The technical specifications included in Annexure-2 to these specifications will govern the supply and testing of important materials, components and equipments.

5.6 NOMENCLATURE AND MARKING:

(a) All components and fittings shall bear the respective identification number and a mark to identify the source of supply except in the case of galvanized tubes, bolts and nuts and /or any other fittings as may be agreed to by the Engineer.

(b) In case of insulators, galvanized steel tubes, stainless steel wire rope and conductors, name of

manufacturer shall be specified in “ As Erected” drawings for identification. 5.7 STEEL WORK AND PROTECTION AGAINST RUST:

(a) GALVANISING

All ferrous materials and fittings shall be hot dip galvanized according to the specification ETI/OHE/13(4/84) with A&C slip No. 1 to 3

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(b) PAINTING Some components or parts may, with the approval of the Engineer, be protected only by paint and parts so protected shall be given two coats of composite Aluminium primer and two coats of Aluminium paint. The second coat of Aluminium paint shall be applied after erection.

(c) RECTIFICATION AT SITE

In case of modifications which would damage the protective coat, repairs to such damage would be allowed only in exceptional circumstances. The part damaged shall be protected in accordance with the method indicated in specification ETI/OHE/13(4/84) with A&C slip No. 1 to 3 or any other method approved by the Engineer. The Contractor shall in such cases obtain prior permission from the Engineer before carrying out repairs.

5.8 BRACKET ASSEMBLY COMPONENTS: ( See para 2.14)

(a) ARRANGEMENT FOR NORMAL OHE The arrangement of the different fittings and structural components of bracket assemblies are shown in drawings listed in the Annexure to these Technical Specifications. The employment schedule of bracket will be furnished by the Contractor.

(b) BRACKET

The bracket tubes shall be of seamless cold drawn or electric resistance weld steel complying with ETI/OHE/11 (5/89) with an insulator near the support. The length of the tubes shall be such that there is a free length of about 200 mm beyond the catenary suspension bracket to facilitate adjustment during track maintenance (see para 7.9 (b). Ensure projection of RT at pull off i. e. –ve stagger location to be beyond the vertical plane of the contact wire as per RDSO drawing No. ETI/OHE/G/02106 Rev ‘C’. The Raised Register Arm Clamp conforming to RDSO drawings ETI/OHE/P/1370-1, Revision-‘F’ or latest shall only be used. Gap between mast fitting for hook insulators & top of the mast should be as per drawing no. RE/33/G/0001.

(c) TUBULAR STAY ARM Steel tubes with adjustable steel rods shall be used for tubular stay arm of all bracket

assemblies. (d) REGISTER ARM

The register arm shall be electrical resistance weld or cold drawn steel tubes of proper dimensions and duly formed. It shall be suspended by a dropper from the catenary suspension clamp/bracket tube. A hook and eye arrangement shall be used at the bracket end to permit free movement in every direction.

(e) STEADY ARM

The steady arm shall normally be fitted in all assemblies for overhead equipment in running. The steady arm shall be of light alloy BFB section arranged to work always in tension in accordance with ETI/OHE/21(9/74). Steady arms of secondary tracks may be of solid galvanized steel rodding. The contact wire shall be fixed by a simple swivel clip without threaded parts. Steady arms shall normally be 1.0m long but for special locations such as turnouts, diamond crossing etc, the steady arms shall be longer as indicated in the relevant drawings listed in the Annexure to these Technical specifications.

Bent steady arms of aluminium alloy tube conforming to Spec. ETI/OHE/21 (9/74) shall be used for neutral section overlap and in the central mast of a 4 span insulated overlap.

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(f) BRACKET FOR UNREGULATED TRAMWAY TYPE EQUIPMENT

Brackets provided on cantilever masts for tramway type unregulated equipment shall normally span two tracks and the contact wires carried on V-type clamps suspended from a san wire. The span wire shall be provided with a turn buckle at only one end.

5.9 Use of Forged OHE Fittings: Wherever applicable, forged fittings shall be used as per RDSO guidelines vide letter No:

TI/OHE/FTGFE/12 dated 03/09/2012, 13/7/2012 including subsequent letters. As on date the list of these fittings is: Register arm hook top, Register arm hook bottom, Large Register arm hook top, Large Register arm hook bottom, 25mm drop bracket part, Steady arm hook(BFB), tubular Stay Sleeve, Register Arm Eye piece 25 mm, Steady Arm Clamp 25 mm, Mast fittings for Hook Insulators, 9 T eye Turn Buckle, 9 T eye bolt left, 9 T eye bolt right, 9 T Clevis bolt left, 9 T Clevis bolt right, 18 mm Single Clevis assembly, Clevis and Eye etc. The list may be enlarged/decreased as per RDSO instructions.

5.10 DROPPERS: (SEE PARA 2.4 and 2.6) (a) GENERAL DESIGNS

The droppers shall generally be designed as shown in standard drawings and made of copper wire about 5 mm diameter conforming to IS: 282:1982 or latest and shall be attached to the catenary wire by a copper dropper clip. The contact wire shall be held by a clip of aluminium bronze as shown in the standard drawings. The distribution of dropper shall be in accordance with standard designs.

(b) LOADING The droppers shall be able to withstand a vertical load of 200 kg at the point of attachment to the contact wire and the clip shall not slide under a horizontal load of 120kgf.

(c) The permissible tolerance in the overall length of a dropper will be +/- 5mm. 5.11 INSULATORS:

(a) All insulators except those on return conductors and earth wires shall be of the solid core type. Disc insulators shall be used on return conductors and earth wires or other locations as desired by the Engineer. All solid core insulators shall conform to TI/SPC/INS/0070(04/07).

(b) Use of Insulators:

Normally porcelain insulators with creepage distance of 1050mm shall be used. Composite/Hybrid insulators shall be used only in polluted, stone pelting areas in terms of RB policy circular No RB/Elect/TRD/04-12 dt 04/07/2012 with approval of CEE of concerned zonal Railway. Testing of 25 KV porcelain and composite insulators before installation is to be ensured as per RDSO guidelines TI/MI/0042 (12/2008) Rev 0.

(c) INTER-CHANGEABILITY

For free inter-changeability only the following types of insulators shall be used. While the shapes of the insulators may vary slightly from those shown in the drawings, the essential dimension of the galvanized malleable cast iron caps as given in standard drawings shall be adopted.

(i) Stay arm Insulators: These insulators will be used in conjunction with the tubular

stay arm of all bracket assemblies. (ii) Bracket Insulators: These will be used at the base of each bracket assembly in

conjunction with bracket tubes. (iii) 9- tone Insulators: These will be used at all places for cut-in and terminal insulation

including those in return conductors, but excluding those in earth wire.

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(iv) Solid core post insulators: These will be used at all places for supporting isolator mechanism, bus-bars, jumpers etc. of 25 kV.

(v) Disc insulators 255 mm: Clevis type 255 mm disc insulators will be used for return conductor suspension and for earth wire cut-in insulator.

(vi) 11 kV Post insulators: These will be used at all places for supporting bus-bars, jumpers etc. in conjunction with return conductor/return feeders.

5.12 ENDING FITTINGS AND SPLICES: (a) GENERAL DESIGNS

Terminating or ending fittings and splices on copper conductor shall be of cone type clamping on both the inner and outer strands of conductor except for contact wire ending clamps which may be of wedge type. The arrangement shall be easy to install and also be such as would apply the clamping pressure gradually without shock (see ETI/OHE/49(9/95) with AC slip No. 1 of (3/97), No. 2 of (4/2000)-core-1, 3 of (8/2001), core 2&4 of (3/2002) core-3&5. For aluminium Alloy/ conductor, the end fittings shall be either cone type, strain clamp type or any other type as approved by the Engineer.

(b) LOADING

All the parts shall be capable of withstanding without damage, a load greater than the ultimate strength of the wires to which they are fitted. In case of threads, no damage shall occur when they are subjected to a load equal to two third of the ultimate strength of the wires.

(c) RESTRICTED USE OF SPLICES

The use of splices shall generally be avoided and their use shall be restricted to the minimum necessary. Over main line tracks, there shall usually be no splice in the contact wire on first erection. Elsewhere, not more than one splice be used over any tension length (i.e. anchor to anchor) for which prior approval shall be taken from the Engineer. Additional splices may, however, be provided on mainline track in station area/yards for introduction/shifting of overlaps and crossovers for yard modification. Splices may also be permitted for repair of damage due to thefts or Railway accidents.

(d) SRENGTH OF ASSEMBLED FITTINGS

The strength of fittings assembled with appropriate conductors or wires shall be not less than that of the conductor or wire itself.

(e) ADDITIONAL TERMINATING WIRES

Cadmium copper stranded wire of 65 sq. mm nominal section or 37/2.1 mm ( as used in head span construction ) may be used as additional terminating wires for extending single and double conductors respectively, if termination at the nearest structure is not feasible.

(e) PG Clamps:

The Parallel grooved Clamps conforming to following RDSO drawings (or as amended) shall only be used: (i) Parallel Clamp (90/50) – RDSO drawing no. ETI/OHE/P/1040-3, Revision ‘B’ or latest

(ii) Contact Wire Parallel Clamp (Part Small) – RDSO drawing no. ETI/OHE/P/1041-2, Revision ‘D’ or latest

(iii) Parallel Clamp (150/160) – RDSO drawing no. ETI/OHE/P/1050-3, Revision ‘A’ (iv) Parallel Clamp Part (150 / 105 - 150) – RDSO drawing no. ETI/OHE/P/1051-2, Revision

‘C’. (v) Parallel clamp (105/240)-RDSO drawing No. ETI /OHE/P/1530-1 Revision” C’

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5.13 ELECTRICAL CONNECTIONS FOR OHE: (a) GENERAL DESIGNS

All electrical connections between conductors shall be made by parallel clamps. The general arrangements of connections are shown in the standard drawings, listed in the Annexure to these Technical Specifications.

(b) JUMPERS Copper jumpers shall be of any of the followings:

(i) Large jumpers of annealed copper in accordance with specification ETI/OHE/3(2/94) with A&C slip No. 1 of 4/95.

(ii) Small jumpers of annealed copper in accordance with the specification IS: 9968 (PT.2) -1981.

(c) BUS BARS

Bus-bars or rigid jumpers of copper where used shall be of 18 mm dia copper rod in accordance with RE/30/OHE/5 (11/60). Aluminium bus-bars wherever used shall be of 36/28 mm tubing (see 5.19). Aluminium tubular bus-bars shall be made of Al. alloy grade 63401 (WP condition) to IS: 5082-1981. The tolerance on diameter and thickness shall be as per Class I, IS: 2673-1979.

(d) FEEDERS

Feeders shall be of all Aluminium conductor 19/3.99 mm (SPIDER). (e) RETURN CONDUCTOR

The return conductor shall be of all Aluminium conductor 19/3.99 mm (SPIDER). The arrangement of return conductor carried on traction structures is shown in drawings listed in the Annexure to these Technical Specifications.

(f) The general characteristics of all wires and conductors shall be as per RDSO/CORE drawings.

(f) Earth wire shall be of steel reinforced Aluminium conductor 7/4.09 mm (RACCOON) conforming to IS: 398-(Part-II) 1976.

5.14 TERMINAL CONNECTORS FOR EQUIPMENTS:

Interruptor, Booster Transformer and LT supply Transformer shall be supplied along with the terminal connectors suitable for taking jumper/bus-bar as required. However, ALCU strips shall be provided for bi-metallic connections wherever required.

5.15 REGULATING EQUIPMENT: (a) GENERAL

This follows the Specification no. TI/SPC/OHE /ATD/0060 Rev. 1. A general arrangement is shown in the standard drawings of CORE/RDSO. The regulating equipment should have a minimum adjustment range of 950mm. Stainless steel wire rope in accordance with TI/SPC/OHE/WR/1060 with A&C slip no. 1 & 2 shall be used in these equipments and these shall be sufficiently flexible for the purpose. Fixing arrangement for mast anchor fitting for anti falling device for 3- Pulley modified ATD should be as per RDSO drg. no TI/DRG/OHE/ATD/RDSO/00009/05/0 or latest and provision of double eye distant rod as per RDSO MI no TI/MI/0008 Rev 0 (or latest). The anchor height, X-Y adjustment chart and guide tube will be as per RDSO drawing No. TI/DRG/OHE/GUYHR/RDSO/00001/14/0(Sheet-1 to 4), TI/DRG/OHE/ATD/RDSO/00003/99/3 - Three Pulley ATD and drawing No.ETI/OHE/G/01505 respectively.

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Anti slipping device assembly (SPACER ANGLES) shall be provided as per RDSO DRAWING NO. TI/DRG/OHE/ATD/RDSO/00009

(b) COUNTERWEIGHT

Counter weights and arrangements used shall be such that these could be accommodated within 330 mm (13 inches) measured transverse to the track under the worst wind conditions. The vertical upward movement shall be limited with a fixed top.

(c) REDUCTION RATIO

Reduction ratio in the arrangement used shall be five for winch type, three in case of three pulley type and five in case of five pulley type.

5.16 HEADSPAN CONSTRUCTION: (see para 2.13 and 4.6) (a) SIZE AND FACTOR OF SAFETY

All span wires used in head-span construction shall be of stranded cadmium copper conductor 65 sq. mm or 130 sq. mm cross section. All the wires shall be designed with a factor of safety of not less than 4 under the most unfavourable conditions.

(b) TURN BUCKLES

Each span wire shall be equipped with a turn buckle at each end of the span. (c) ADDITIONAL INSULATORS

Additional insulators shall be provided as necessary in head span, cross span and steady span, wires to ensure electrical independence between the equipment in different elementary electrical sections.

5.17 ISOLATORS:

25 kV isolator switches shall comply with specifications as indicated in para 5.5. 5.18 INSULATION LEVEL:

Interruptors, potential Transformers line indication type, 42 kV Lightning Arrestors and other equipments shall be suitable for insulation levels indicated in the relevant specifications.

5.19 BUSBARS: (a) No splicing will normally be allowed in the tubular bus-bars unless the length of the bus-bar

exceeds 6m.

(b) GENERAL The bus-bar shall be clean, smooth, mechanically sound and free from surface and other

defects. Provision shall be made where necessary to allow for expansion and contraction of bus-bars caused by temperature variation. The open ends of bus-bars shall be covered by suitable tube caps, wherever the tubular bus-bars are required to be bent, the radius of the bend shall be not less than 200 mm.

(c) JOINTS

(i) The joints in bus-bars shall be mechanically and electrically sound so that the temperature rise under normal working condition does not exceed 40 deg. C for an ambient temperature of 65 deg. C.

(ii) All aluminium joints shall be thoroughly cleaned and smeared with suitable. Oxidation inhibiting joint compound before and after assembling the joint. Similar procedure shall be followed for connecting the equipment terminals to the Aluminium bus-bars with bi-metallic connectors.

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5.20 CABLING:

(a) FOR LT SUPPLY 240-volt AC supply from LT supply transformer at switching stations shall be brought and

terminated on the LTAC distribution board in the remote control cubicles at the switching stations by 1100 Volt, aluminium conductor, XLPE insulated, PVC sheathed and steel armoured heavy duty cable conforming to IS7098/Pt. I/1988 of following sizes:

i) 5kVA AT - Cable size 2x25 sq.mm ii) 10 kVA AT - Cable size 2x 70 sq.mm iii) 25 kVA AT - Cable size 2x 185 sq. mm iv) 50 KVA AT - Cable size 2 x 300 sq. mm (b) CONTROL AND INDICATION CIRCUITS All other cables for control and indication at switching stations shall be 1100 –V grade PVC

insulated and sheathed un-armoured (heavy duty) complying with IS: 1554 (Part-I)-1988. The cables shall be provided as indicated in the Table below:

PURPOSE RUN CIRCUIT

VOLTAGE COPRE SIZE AND MATERIAL

NO. OF CORES

Control and indication of interrupters

From each interruptor to terminal board

110 V DC 2.5 sq. mm copper

7

Catenary indication

From line indication type PT to terminal board

100 V AC 2.5 sq. mm copper

2

Heater supply for interruptor control mechanism,

(i) From interruptor to interruptor ii) From each interruptor to fuse box iii) From fuse box to distribution board

240V AC 4 sq. mm Al 2

Battery supply

i) 110 V Battery charger to battery ii) 110 V battery to 15 Amp Dc fuse box iii) 15 A DC fuse vox to terminal board.

110 V DC 4.0 sq. mm copper

2

Note: (i) In case of feeding stations which are located within the traction sub-station premises, the

cables shall be run from individual equipment and terminated inside the sub-station control room.

(ii) Notwithstanding the sizes of cables given above, the Bidder shall assure himself that various cables would suit the ratings of equipments offered by him.

(c) SPECIFICATION

The cables shall be resistant to decay, abrasion, acids, alkalies and other corrosive materials.

All indoor wiring on walls shall be clamped neatly on heavy PVC rigid conduit of nominal thickness 2 mm fixed to the wall by means of PVC plug rolls. The cable run layout at a typical switching stations is shown in the relevant drawing already included in the Annexure to these Technical Specifications.

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5.21 LITERATURE FOR EQUIPMENT:

The contractor shall within one month of issue of letter of Acceptance, supply 25 copies of detailed schedule, catalogues and drawings of all parts of the equipment.

5.22 INSPECTION AND TESTING: The inspection of all fittings/equipments will be done by RITES or person nominated by the

Employer. ------------------------------------------------------------------------------------------------------------------------------------------

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CHAPTER: B-6

DESIGNS AND DRAWINGS

for OHE and switching station

6.1 GENERAL: (a) This chapter deals with the procedure for approval of designs and drawings.

(b) The type designs shall be as few as possible to cover the largest field of application consistent with economic consideration.

(c) In all drawings as far as possible, only internationally accepted symbols shall be used. 6.2 CONTRACTOR’S DRAWINGS: (a) The Contractor shall submit to the Engineer for approval, except where otherwise specified, all

detailed designs and drawings which are necessary to ensure correct supply of equipments, components and materials and to enable correct and complete erection of overhead equipment, switching stations, booster transformer stations, LT supply transformer stations and other associated systems, in an expeditious and economic manner.

(b) RESPONSIBILITY

It is to be clearly understood that all original designs and drawings shall be based on a thorough study of the project site. General designs and dimensions shall be such that the Contractor is satisfied about the suitability of the designs for the purpose. The Engineer’s approval will be based on these considerations and notwithstanding the Engineer’s acceptance, the ultimate responsibility for the correct design and execution of the work shall rest with the Contractor.

6.3 STANDARDS FOR DRAWINGS:

All designs, legends notes on drawings and schedules of materials shall be in English and shall be prepared in the metric system. All designs and drawings shall conform to the specification RE/OHE/25(3/66) & ETI/PSI/31(5/76).

6.4 BASIC DESIGNS: (a) STANDARDS DESIGNS

Where the Contractor adopts designs and drawings conforming to the standard designs, drawings, and specifications of the Research Designs and Standards Organisation, Manak Nagar, Lucknow 226011 (RDSO) for basic arrangements, equipments, components and fittings of traction overhead equipment, switching stations booster transformer stations and LT supply transformer stations and adopts employment schedules furnished by the Engineer, he shall verify such designs, drawings and employment schedules and satisfy himself before use that these are correct. Within two months of the issue of letter of acceptance, the contractor shall indicate to the Engineer, the list of standard basic arrangements, components and fittings, drawings and employment schedules, which he will adopted for the purpose of the work. The proper procedure shall be followed for approval of basic designs. The contractor for his use and reference shall obtain reproducible transparent film (50 microns) each of such standard basic arrangement, component and fittings drawings and employment schedules from Chief Electrical Engineer, Railway Electrification, Allahabad -211001, on payment as per the prescribed rates.

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(b) DEVIATIONS

Normally, deviations from the standard drawings shall not be made by the Contractor. However, in exceptional cases where the contractor desires to suggest improvements as a result of his experience, site requirements or any other reasons, he shall justify his proposals with supporting explanatory notes.

6.5 SPECIAL DESIGNS: (a) In cases where standard designs, drawings or employment schedules do not cover

requirement of special locations or site conditions, the Contractor shall submit his own designs or drawings along with supporting calculations and notes for scrutiny and approval of the Engineer.

(b) Such special designs shall generally be in conformity with the basic designs furnished by the

Contractor and in accordance with the specifications. If the Contractor wishes to adopt special designs which do not conform to the general basic designs of the CORE/RDSO, he shall submit alternative designs and drawings justifying his proposals.

6.6 PARTICULAR DESIGNS & WORKING DRAWINGS FOR OHE: (a) PEGGING PLANS

The pegging plans for sections to be electrified, indicating the type of overhead equipment, locations of masts and other general particulars will be prepared on the basis of the latest survey by the Contractor, if not supplied by the Engineer.

(b) CONTRACTOR’S PEGGING PLANS Deleted (c) PRINCIPLES OF LAYOUT

The contractor shall in all cases ensure that the final pegging plans are in conformity with the latest ‘ Principles of preparation and checking of OHE layout plans and sectioning diagram’ issued by RDSO.

(d) PROVISIONAL LAYOUT PLANS

The Contractor shall prepare and submit overhead equipment layout plans incorporating the following information:-

(i) The run of wires in different thickness or colour in special cases and termination. (ii) The run of wires for future wiring indicated to the Contractor in dotted lines. (iii) Exact position of all cut-in-insulators, including section insulators. (iv) Direction and value of stagger at each traction structure location. (v) Clearance of live conductors to structures in the vicinity including bridges, signals

gantries etc. (vi) Layout of feeders. (vii) Jumper connections and connections to switches and switching stations. (viii) List of infringements. (ix) Kilometer numbers and type of Structures. (x) Location and numbers of switches. (xi) Schematic sectioning diagram drawn to convenient scale showing section insulator,

number of switches, elementary sections and connections to switches and switching stations.

(xii) Table giving references of approved profile drawings, feeder layout plans and other relevant drawings.

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(e) OHE PROFILE DRAWINGS

After completion of the overhead equipment layout plans, the Contractor shall prepare overhead equipment profile drawings showing the actual height of the contact wire under each over line structure, the gradient and height of the contact wire under each over line structure, the gradient and height of the contact wire on either side of the structure and the encumbrances at structures, until normal height of contact wire and encumbrances are restored.

(f) CROSS SECTION DRAWINGS While the layout plans are being finalized, the Contractor shall submit for approval, in –so-far as yards between outer most points and crossings are concerned, cross-section drawings for each structure showing guy rods, if any, indicating the cross-section of the formation, height and nature of soil, type of foundation block, structure proposed, reverse deflection of the structure and all necessary particulars for erection of the foundation and the structures. In the preparation of drawings, care shall be taken to show all obstructions such as signal wires, points rods and their correct location in references to track/tracks as well as underground obstructions like pipes cables, etc. after collecting such information from the site.

In open line sections, cross-sections shall be submitted in the following performa, separately for each Railway line for special foundation drawings with all necessary details shall be submitted to the Engineer. In case of side bearing foundation with extra depth, formation details at such location and necessary details of anchor foundation will be submitted.

CROSS-SECTION FOR THE OPEN ROUTE SECTION…………….KM…… ……………………………to………………………..

SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 LOCATION No. CHAINAGE DETAILS

SETTING DISTANCE IN ‘m’ STEP DISTANCE IN ‘m’ B.M. CODE SOIL TYPE & PRESSURE FOUNDATION TYPE AND SIZE MAST SIZE & LENGTH IN ‘m’ MAST EMBEDDED LENGTH ‘m’ REVERSE DEFLECTION in cm SUPER MAST LENGTH (m) CROSS ARM LENGTH (m) ANY OBSTRUCTION

(g) FINAL LAYOUT PLANS

After all the cross section drawings in a section covered by the layout plan are finalized and foundations are cast, the Contractor shall revise the layout plans to take into account any modifications to the locations of structures during the process of casting of foundations and submit the final layout drawings as ’as erected’ drawings.

(h) STRUCTURE ERECTION DRAWINGS The contractors shall then submit Structure erection drawings for each structure incorporating

all the details included in the cross section drawing for the structure and as erected at site and the details or the bracket assembly, mast extensions, isolator mounting frame and anchorage of overhead equipment, feeder or return conductors proposed for each structure together with all particulars necessary for the correct erection of overhead equipment at the structure. For structures with isolators, the details of electrical connections shall also be incorporated. In open line sections, the Contractor shall submit structure erection particulars in the typical

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proforma as given below separately for each main line track in addition to particular details as indicated in the proforma for cross section drawings. Any modification to this proforma, if found necessary, will be finalized at time of preparation of structure erection drawings with the approval of the Engineer.

SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 LOCATION No. CHAINAGE 1. ENCUMBRANCE 2. CONTACT WIRE HEIGHT 3. STAGGER (i) CATENARY ii) CONTACT

4. STAY ARM i) (a) M ii) CODE

5. BRACKET i) (b) M ii) CODE

6.REGISTER: i) C/D (M) ii) CODE

7. STD/BENT CODE 8. IDENTIFICATION MARK (SEE PARA (6.11) OTHER REFERENCES/CODES FOR MISCELLANEOUS ITEMS LIKE STEEL WORK FOR STAY/BRACKET ATTACHEMNT, MISC. SINGLE/DOUBLE CAT. ETC. WILL BE INDICATED. NOTE: The proforma for SED at individual locations shall be as per standard proforma already

circulated and shall be adopted in consultation with the Engineer. 6.7 PARTICULAR DESIGNS & WORKING DRAWINGS FOR SWITCHING STATIONS (a) CONTRACTORS LOCATION PLANS ETC. The location plans and schematic diagrams of connections for all the switching

stations, booster transformer stations and LT supply transformer stations will be furnished by the Contractor. These will indicate the following as applicable.

i) Overhead equipment layout in the vicinity of switching or other stations.

ii) Location of main masts. iii) Arrangement of cross feeders and longitudinal feeders to be anchored on the gantry if

any, including jumper connections to the overhead equipment. iv) Scheme of connections of interrupters.

v) Position of the remote control cubicle with respect to the switching stations. vi) Fencing outline at the switching stations. The Engineer shall satisfy himself about the correctness and applicability of the location plans

given by the Contractor before adopting them for detailed designs. (b) DETAILED DRAWINGS The Contractor shall submit for approval of the Engineer the following drawings: -

(i) Cross-section drawings for each switching station indicating the cross section of the formation transverse to the track at each location of main mast and longitudinal

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section parallel to the track along the centre line of the interrupters. These drawings shall be prepared after an accurate survey at site and shall indicate the nature of the soil, its bearing capacity, compactness and in case of loose soil, transverse section of the parent soil. In the preparation of the drawings care shall be taken to show all obstructions to be removed, such as signal wires, rods and their correct location with reference to the track/s as well as under-ground constructions like pipes, cables etc. after collection of such information from the site.

(ii) GENERAL ARRANGEMENT DRAWINGS

General arrangement drawings shall be prepared for switching stations indicating the general arrangement of all equipments run of bus bars, position of pedestal insulators, steel frame work and fencing. The drawings shall also include the schematic connection/diagram and an isometric view of bus bars and connections. The drawings shall include an elevation view of the switching stations from behind a transverse cross section and plan sectional views at the level of feeder anchors, insulator beams, potential transformer beams and ground. Each drawing shall have a schedule of all equipments required at the switching station along with drawing references of details of these equipments.

iii) STRUCTURAL DRAWINGS

Structural assembly drawings shall be prepared for switching stations indicating the steel frame work assembly. The drawings shall include one elevation view of the steel frame work assembly from behind, a transverse cross section and plan views at various levels such as at the level of feeder anchors, insulator beams/and ground. In the assembly, each component member shall be marked with its reference number. The drawing shall also have a schedule of component members along with drawing reference number. The weight of the component members shall be indicated in a separate weight schedule. The drawings shall be prepared for the various structural components. An individual drawing shall be made for each component and this shall include all fixing bolts, nuts and washers whose sizes will be mentioned on the drawings. Unit isolator beams, potential transformer beams weight of the component shall also be given in the drawings.

iv) FOUNDATION LAYOUT AND CROSS-SECTION DRAWINGS

Foundation layout & cross-section drawings for each switching station indicating layout of all foundations in plan, transverse cross-section of various foundations through center line of main masts, interrupters, fencing uprights and LT supply transformers, if any, and longitudinal sections parallel to track through the center line of the cable trench. All foundations shall be marked serially on the drawing and listed in a schedule on the drawing indicating the volume of concrete for each foundation block.

(v) FENCING LAYOUT DRAWINGS

Fencing layout drawings shall be prepared for each switching station indicating the layout of the entire fencing and anti-climbing device in plan. Each upright, fencing panel and fixture on the upright shall be indicated on the drawing by its reference number. A schedule of components viz. uprights, panel fixer, and barbed wire shall be included in the drawings indicating the drawing references of components. An individual drawing shall be made for each type of panel, fencing post and fixture for mounting the anti-climbing device. The drawing of each fencing post shall indicate the unit weight of the fencing post.

vi) EARTHING LAYOUT DRAWINGS

Earthing layout drawing shall be prepared for each switching station indicating the layout of full earthing system in plan. The drawing shall show the location of earth electrodes and mark the runs of earthing strips and connections to each equipment,

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mast, fencing post and fencing panel. All components shall be marked with their reference numbers, for further details of the run of conductors and connections, separate drawings which may be common to all switching stations may be made and references to these drawings marked on the layout. A schedule of components shall be made out in the drawing giving drawing references of components.

(vii) CABLE RUN LAYOUT.

Cable run layout shall be prepared for each switching station indicating inter-connection between various equipments, indoor and outdoor, along with schematic arrangements and physical disposition of equipments, colour coding or code number and the index scheme adopted for terminals. The drawings shall also indicate the cable size and grade s of insulation. The quantity of various cables required shall be indicated on the drawings.

(viii) EQUIPMENT DRAWINGS

Equipment drawings shall be prepared for all switching stations. Drawings should be dimensioned and should indicate: -

1. Fixing or mounting hole dimensions and arrangement; 2. Net weight of the equipment; 3. Characteristic and rating of equipment; 4. Circuit diagrams; 5. Overall dimensions and other important dimensions;

6. Height and vertical and horizontal dimensions of all exposed live parts; and 7. Notes explaining the operation of the equipment

(ix) MISCELLANEOUS DRAWINGS This covers miscellaneous drawings applicable to all switching stations. These drawings shall include drawings or sketches made for study of clearances, isolator alignment details, scheme of interlocks, number plates of various equipments and “U” bolts for cable mounting, caution or instruction boards, outriggers for bus bar supports and non-standard bus bar connectors.

(x) EMPLOYMENT SCHEDULES AND CHARTS

This covers Employment Schedules and charts applicable to all switching stations. These will include:

1. Employment schedule for pure gravity type of foundations for main masts for

various direct loads and bending moments; 2. Employment schedule for all other foundations for various depths of parent

soil from the datum level. 3. Sag tension charts for cross feeders for various spans and tensions.

6.8 BOOSTER & L.T. SUPPLY TRANSFORMER STATION DRAWINGS: The Contractor shall submit for approval to the Engineer drawings for booster transformer

stations and LT supply transformer stations, similar to those detailed for switching stations in 6.7 (b). The following drawings may, however, be combined together:

(i) Cross-section and foundation layout drawings; (ii) General arrangement, structural and earthing layout drawings.

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6.9 SCHEDULE OF QUANTITIES: (a) Within one month of issue of Letter of Acceptance, the Contractor shall assess the quantities

of various items of work including various components and fittings as covered in the Bill of Quantities and also those required to satisfactorily commission the works, and submit the same for the approval of the Engineer as Assessment 1. Such an assessment can be revised at suitable intervals after the first assessment is approved and till the work is completed. Such reassessments shall be denominated as Assessment 2, Assessment 3 etc., and shall also be submitted for approval of the Engineer.

On receipt of approval of each final layout plan from the Engineer, the followings Schedules of

quantities relating to each layout plan shall be submitted within a fortnight:

i) Schedules of number of masts, types, weight of different masts and total weight of masts;

ii) Schedules of number of foundations, types, volume of different foundations and total volume;

iii) Schedule of quantities of various items of work other than masts and foundation under various Schedules

iv) Schedule of net tension lengths of contact, catenary and feeder wire lengths required to be ordered;

v) Schedule of lengths of other wires and conductors required to be ordered and vi) Schedules of small parts steel work to be supplied by the Contractor.

(b) SWITCHING/BOOSTER STATIONS Within a fortnight of receipt of approval of relevant drawings for each switching booster

station, the following schedules of quantities shall be submitted:

i) Schedule of number of foundations, types, volume of different foundations and total volume. Overlapping foundations will be treated as one foundation;

ii) Schedule of number of masts, types, weight of different masts, and the total weight of masts of each gantry;

iii) Schedule of steel work, types, weight of each member and total weight and iv) Schedule of quantities of various items of work not included under (i), (ii), and (iii)

above. 6.10 SUBMISSION OF DRAWINGS & SCHEDULES: (a) The submission of designs and drawings for approval shall be done in the proper manner. In

case, the Contractor wishes to deviate from the standard drawings he should submit to the Engineer, the revised drawings, with full details of deviation sought explaining the necessity of deviation, calculations and other supporting documents. The Engineer, if satisfied about the necessity and adequacy of deviations, shall refer the matter to RDSO for necessary approval. In case of deviations on working drawings, decision shall be communicated by the Engineer to the Contractor. The number of copies of drawings which shall be submitted are indicated in the following sub-paras. The Engineer will return one copy of the drawings either with approval subject to modification where necessary or with comments. The engineer shall endeavour to return this copy within a period of fifteen days from the date of receipt and shall normally return the copy within a month. Where drawings are returned with comments or approval subject to modifications, the Contractor shall submit to the Engineer within fifteen days of receipt of such advice, the revised drawings for approval taking into account the comments or modifications. Also the contractor shall as far as possible avoid correspondence on such comments and shall endeavor to settle any difference of opinion on the comments by discussion with the Engineer. No drawings shall be resubmitted without

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incorporating the modifications required by the comments of the Engineer, unless the Engineer has agreed to the deletion of such comments.

(b) DEVIATION FROM STANDARD DESIGN In case of deviation from standard designs and drawings, copies of correspondence and

drawings shall be sent in duplicate to the Engineer. In the particular case of deviations in the design of fittings, the drawings submitted by the Contractor shall be actual manufacturing drawings complete with tolerances and full specifications of the materials used. In addition, four samples of the modified fittings shall also be submitted, after the drawings are approved.

(C) SPECIAL DESIGNS Special designs to meet the requirement of particular locations and local conditions shall be

submitted in due time in duplicate for approval. (d) PEGGING PLANS Two copies of the Engineer’s pegging plans shall be sent back after verification if found

correct. If modifications are required, fresh pegging plans incorporating the modifications shall be submitted in two copies for approval (see para6.6).

(e) CONTRACTOR’S PEGGING PLANS: ------DELETED--- (f) CROSS-SECTION DRAWINGS Cross-section drawings shall be submitted for approval in two copies for a convenient section

at a time separately for sections within station limits and section outside station limits. Such drawings shall be submitted progressively and as far as possible without gaps (see para 6.6).

(g) OHE LAYOUT PLANS AND PROFILE DRAWINGS Overhead equipment layout plans, provisional and final and profile drawings shall be

submitted for approval in three copies (see para 6.6). (h) STRUCTURE ERECTION DRAWINGS Structure erection drawings shall be submitted for approval in two copies for a section at a

time separately for sections within station limits and sections outside station limits, progressively and without gaps.

(i) SCHEDULE OF QUANTITIES

Schedules of quantities for each approved layout plan/switching station shall be submitted for approval in two copies.

(j) SUB-SECTION FEEDER DRAWINGS – Deleted. (k) SWITCHING/BT/LT SUPPLY TRANSFORMER STATIONS All drawings for sw3itching stations, booster transformer stations and LT supply transformer

stations shall be submitted for approval in three copies. (l) DISTRIBUTION COPIES On receipt of Engineer’s unqualified approval to the Contractor’s drawings and Schedule of

Quantities, the Contractor shall submit original tracings of those drawings and schedules for the signature of the Engineer in token of approval within seven days of the receipt of approval and the Engineer shall as far as possible return the same to the Contractor within 7 working days thereafter. On receipt of these tracings from the Engineer, the Contractor shall submit copies for distribution to field officers and other departments as indicated below within 7 days of receipt of approved tracings:

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i Standard designs including fittings drawing as per para 6.10(b) 6 copies ii Special designs 6 copies iii Final pegging plan 2 copies iv Structure Cross- section drawings 6 copies v OHE layout plans 6 copies vi OHE profile drawings 6 copies vii Structure erection drawings 6 copies viii Schedule of quantities 6 copies ix Drawings for switching stations, booster transformer stations &

LT transformer stations 6 copies

One soft copy of each drawing (on Autocad) will also be supplied on CD. 6.11 COMPLETION DRAWINGS & SCHEDULES: After completion of works, all drawings and designs submitted by the contractor and approved

by the Engineer shall be made up to date by incorporating actual supply and erection particulars, including the name and make of insulators, galvanized steel tubes, stainless steel wire rope etc. The mark of conductors shall be specified in the “As erected” OHE layout plans, SEDs and other relevant drawings for identification. Such drawings and schedules shall then be verified and corrected, if necessary, by the contractor jointly with the Engineer. The verified and corrected drawings shall be supplied in six sets, one of which shall be transparencies of linen or film reproduction or any other durable material approved by the Engineer. One soft copy (on Autocad) will also be supplied on CD.

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CHAPTER: B-7

ERECTION AND INSTALLATION OF EQUIPMENT-OHE

PART-1: PRINCIPLES 7.1 SCOPE This chapter deals with the methods of erection and installation of traction equipment,

including casting of foundations and erection of structures. 7.2 METHODS OF ERECTION: All work shall be done in accordance with methods of erection and installation of equipment

approved by the Engineer. In the case of switching stations, booster transformer stations, LT supply transformer stations, standard methods adopted for erection and installation of electrical equipment shall be adopted.

7.3 SECTIONING: The entire equipment shall be erected in accordance with the finally adopted sectioning

diagram and in such a way so as to facilitate sectioning which may be required in future and which will be indicated by the Engineer.

7.4 INSPECTION: All erection and installation work shall be subject to inspection by the Engineer to ensure that

the work is done in accordance with the specification, approved designs and drawings, is in line with the best industry practices and of best quality.

7.5 MEASUREMENTS: All measurements for location of structures and foundations shall be made with the aid of

steel tapes. On curves, these measurements shall be taken on the outer rail of the middle track in the case of odd number of tracks and on the inner rail of the first outer track from the centre of the formation in the case of even number of tracks. Structures on curves shall be located in the radial offset of the location as determined.

7.6 BOLTS, NUTS ETC.: All bolts, nuts, locknuts, screws, locking plates & split cotter pins etc. shall be properly

tightened and secured and the contractor shall carry out systematic inspection of this aspect of work after all adjustments to overhead equipment are completed and prior to offering completed sections to the Engineer for inspection and testing.

7.7 DAMAGE TO GALVANISING/PAINTING: In loading transport and erection, all galvanized/painted materials shall be handled with care

to avoid damage to galvanized/painting. If galvanizing/painting is damaged in spite of all care taken, the damaged part of component shall be put up for inspection, to obtain permission from the Engineer to carry out repairs as per para 5.7 (c).

7.8 MASTS AND STRUCTURES: (a) ERECTION In case traction masts or structures are erected in cored foundations, till such time they are

grouted, they shall be properly wedged to prevent them leaning towards the track and endanger safety of moving vehicles. In case traction masts or structures are erected simultaneously with the casting of the foundations, the Contractor shall provide suitable temporary supports approved by the Engineer. The masts shall be embedded in the foundation blocks for the correct length specified in approved drawings.

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NOTE: Mast/uprights should be grouted on the same day they are dropped in the

foundations. (b) INFRINGEMENT TO STANDARD DIMENSIONS In erection, care shall be taken to ensure that no part of the traction mast, structure or any

fitting located on such mast or structure infringes the latest version of the Schedule of Dimensions for 1676 gauge.

(c) ALIGNMENT OF MAST AT GANTRIES

The main masts of gantries shall be carefully aligned to enable easy and good assembly of fabricated steel work.

7.9 OVERHEAD EQUIPMENT:

(a) A suggested method for erection of traction overhead equipment which would ensure good speed and quality erection, is included in CH-7 part-2-wiring procedure of this chapter. The Contractor may, however, follow other methods which they consider would speed up and ensure good quality work, subject to the approval of the Engineer. Any wiring method should take into consideration appreciable stretch of the catenary and contact wires in the initial days after they are strung and put under tension.

(b) BRACKET TUBES In the erection of bracket assemblies, it shall be ensured that the free length of the bracket

tube beyond the catenary suspension bracket is at least 200 mm to facilitate adjustment during maintenance.

(c) STAY ARMS The choice of stay arms shall be such that their adjuster are capable of adjustments of

minimum of 90 mm in either direction except as otherwise relaxed. (d) INSULATORS Before insulators are used in bracket assemblies or dispatched from the Contractor’s Depot to

work site for erection, they shall be tested as specified for routine mechanical test. NO chipped or cracked insulators shall be installed. All insulators shall be cleaned before offering complete wired sections for inspection and testing.

(e) STRINGING CATENARY Care shall be taken to avoid kinking or bird caging of the catenary wire in stringing and

subsequent operations. While stringing, the wire shall be suspended from pulley blocks hung from the suspension clamp eye of bracket assemblies. The pulleys shall be fitted with ball bearing and shall be of swivel type to permit free movement in all directions to prevent damage to the strands of the wire. The design shall also be such that it will prevent slipping off of the wire during stringing operations. The designs of the pulley shall be submitted to the Engineer for approval. After initial stringing of the catenary, it shall be maintained at the ‘no load tension’ (see section 2 of this chapter) for a minimum duration of 48 hours before the pulley blocks are removed and the catenary is clamped to suspension clamps of bracket assemblies. Shorter periods may, however, be allowed by the Engineer.

(f) STRINGING CONTACT WIRE Care shall be taken to avoid formation of kinks, twists and damage to contact wire in stringing

and subsequent operations. While stringing the contact wire, it shall be suspended from pulleys hung from droppers and fitted to the catenary in its final position. In curves, the contact wire shall be run in pulleys located at traction masts or supports, corresponding to the approximate final position of the wire.

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(g) LOCATION OF DROPPERS Droppers shall be correctly positioned in each span to ensure correct level of contact wire as

per dropper chart applicable to the particular span. (h) CLIPPING DROPPERS The dropper shall be clipped on the contact wire only after a minimum duration of 48 hours

from the time the automatic tensioning device is brought into action. Shorter periods may, however, be allowed by the Engineer.

(i) - NIL- (j) AUTO TENSIONING DEVICE The auto-tensioning device shall be erected with the correct height of the counter-weight

above rail level with corresponding distance between the pulleys of the device for a temperature of 35 deg. C before it is connected to the overhead equipment and put into action. The installation of the device shall be such as to permit free, easy and unobstructed movement of counter-weight.

(k) CUT-IN-INSULATORS All insulators in and out of run shall be so positioned that they are away from the zone swept

by the pantograph and will not foul with it. The live parts of these insulators shall also be so located that they are at least 2 m away from the structures, other than those supporting traction overhead equipment.

(l) SECTION INSULATORS All section insulators shall be so located that they are beyond the zone swept by the

pantograph running on adjacent tracks and there is no unusual sag due to the same. Where section insulators are installed, the contact plane of the runners of the insulators as well as those of overhead equipment connected to it shall be parallel to the track plane.

(m) ANTI-WIND CLAMP Anti-wind clamp shall be provided as shown in the relevant drawing (refer Annexure to these

Technical Specifications). (n) CONNECTIONS All jumper connections including anti-theft jumpers shall be made properly with parallel

clamps and finished neatly without any loose wire or cables. The length of flexible jumpers shall be adequate to avoid any disturbance to overhead equipment or restraint in the relative movement of conductors, but the jumpers should not be excessively long. The ends of jumpers shall be tinned including the portion inside the first parallel clamp.

(o) SEPARATION BETWEEN OHE In erection, the physical separation required between overhead equipments and brackets

assemblies on the same structure at insulated overlaps shall be ensured. (p) GRADIENT OF CONTACT WIRE. The gradient of the contact wire on either side of over line structures with restricted

clearances shall be correctly adjusted and adequate clearance maintained between the over line structure and the live equipment. Details as per para 2.9(g) shall be followed.

(q) ADJUSTMENT AT TURNOUTS ETC Careful adjustment of equipment shall be made on equipments at turnouts, crossovers,

diamond crossings, overlaps and special locations, for position of bracket assemblies, stay arms and height of contact wire to ensure that pantographs of electric rolling stock will not foul with any parts of the bracket assemblies and change over of the contact wire is effected smoothly.

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(r) For wiring in large yards, the Contractor shall, prior to the execution of works, submit to the

Engineer for approval, the sequence of stringing of catenary and contact wires to arrange for proper crossing of wires. Endeavour will be made by the Engineer to arrange for traffic blocks to suit approved sequence of wiring.

7.10 ISOLATORS:

Isolator switches shall normally be so mounted that when the switches are being operated, the operator faces the oncoming direction of train. The operating handles and contact blades shall be correctly aligned for easy operation.

7.11 BUS BARS AND CONNECTIONS:

Bus bars and connections shall be neatly shaped and bent to give an aesthetic appearance.

7.12 EARTHING: The copper earth strips or MS flats used for earth shall be bent and shaped neatly before

connection to the structure or frame work of equipment. The connection of MS flats to steel work shall be made at a height not exceeding 15 cm from the datum level of the switching station. Before making earth connections, the ends shall be cleaned thoroughly and tinned for copper strips. All junctions shall be properly secured to avoid loose contact. Portions of copper earth strips which remain visible above the ground level should be painted with suitable paint to make them inconspicuous.

7.13 TOLERANCES: The permissible tolerance in dimensions for erections from those included in the appropriate

drawings or schedules for different items are given below:

(a) MEASUREMENTS The span length shall not vary more than +/- 50 mm as measured along the appropriate rail

(see para 7.5). The cumulative error of measurement of all spans in a kilometer shall be not more than 1000mm.

(b) SETTING OF STRUCTURES

The setting of structures shall not be less than that included in the appropriate cross section drawings, specially those with the minimum setting of 2.90m. A tolerance of +/- 20 mm will be permitted subject to minimum specified value, if the structure is not located in between tracks.

(c) HEIGHT OF CONTACT WIRE +/- 20 mm will be permitted on the height of contact wire at points of supports as shown in the

relevant structure erection drawings, except under overline structures where no tolerance will be permitted.

(d) Limits and Tolerances in Structure Erection Drawings/Tower wagon Checking: Following tolerances are recommended hereby for adoption in RE works at field level as per

RDSO letter no: TI/OHE/GA/2013 DT 14th May, 2013:

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Sl No Item Limits/Tolerances 1 Register Arm tube projection - 150-200 mm in case of push off locations.

- For pull off locations, it shall project over contact wire plane.

2 Bracket tube projection 150-200 mm 3 Dip between Register Arm Tube

& Steady Arm - 200-250 mm on tangent track (BFB Steady arm). - 250-320 mm on curves (BFB Steady arm and bend Tubular Steady arm)

4 Encumbrance +50 mm 5 Length of 'A' dropper (1st

dropper from support) + 5 mm 6 Spacing of 'A' dropper (1st

dropper from support) + 30 mm 7 Length of other droppers + 5 mm 8 Spacing of other droppers + 50 mm 9 Stagger of Catenary wire + 30 mm 10 Height of Catenary wire + 50 mm 11 Stagger of Contact wire + 10 mm 12 Position of compensation plate It shall be in vertical plane. 13 Difference in height between

mainline contact wire and the crossover contact wire at support

50 mm (minimum)

7.14 SUPPLEMENTARY INSTRUCTIONS: Further working instructions will be issued if considered necessary by the Engineer. These

should be considered to imply that the standard of work of the Contractor requires to be improved.

7.15 Tree Trimming:

Trimming/cutting of trees in the (to be) electrified section shall be ensured as per RB lr No: 2008/Elect.(G)/1/161/8 pt dt 05/09/2012.

7.16 In pure RE works, wiring train/crane/UTV shall be provided by RVNL but in combined works, the contractor shall have to make their own arrangement for mast and OHE erection.

In all the works, for final checking adjustment and inspection of OHE, Tower wagon will be provided free of cost by RVNL. Diesel, lubricant, watering and security of Tower wagon shall be provided by contractor.

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CHAPTER: B-7(b)

ERECTION AND INSTALLATION OF EQUIPMENT-OHE PART-2: WIRING PROCEDURE-OHE

7.20 WIRING PROCEDURE: This sections deals with wiring procedure which may be adopted for erections of normal

overhead equipment. The following procedure for erection of overhead equipment has been formulated with a view to ensure that:

(i) Bracket assemblies (brackets) and regulating are correctly installed in their final position. (ii) The conductors are correctly tensioned and (iii) The need for final adjustments of overhead equipment immediately before energisation

and commissioning is virtually eliminated. 7.21 GENERAL

In the case of regulated overhead equipment when the regulating equipments are in action, the tension in the conductors should remain constant, irrespective of variations in the ambient temperature. As the regulating equipments are brought into action a few days after the stringing of conductors the equipment is unregulated in the intervening period. Any of the following two procedures may be followed for tensioning and clamping of conductors of regulated overhead equipment during stringing operations i.e. before the regulating equipments are brought into action:

(i) The catenary is tensioned to 1100kgf, the stipulated tension at the mean temperature of

35 deg. C, whatever may be the ambient temperature during the stringing operations. In this case, at the time of clamping the catenary to the bracket, the brackets should be placed at angular positions corresponding to temperature at the time of clamping, and proportionate to their distance from the anti-creep.

(ii) The catenary is strained to a stringing tension corresponding to the ambient temperature

for the equipment span of the tension length. In this case, the brackets are placed in the mean position i.e. at right angles to the track, when the catenary is clamped or the regulating equipment commissioned.

The advantage of the second method is that once the catenary is strung at the proper

tension, there would be no necessity to adjust each bracket separately at the time of clamping the catenary or commissioning the regulating equipment. The erection work is, thus considerably simplified and the possibility of errors greatly reduced. This is also applicable to erection of unregulated overhead equipment.

7.22 ERECTION OF BRACKETS: After the brackets are fabricated correctly in the Contractor’s Depot, in accordance with the

approved structure erection drawings, and provided with indelible labels and /or painted marking indicating the intended locations for each bracket, they are removed to the site of work and erected on traction masts or supports. The brackets are swiveled to a position at right angles to the track and secured in that position by means of steel wires tied to similar brackets located on the opposite side of the track or other suitable means.

7.23 ANTICREEP:

The anti-creep of the tension length is then installed in its final positions.

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7.24 LOCKING THE REGULATING EQUIPMENT:

In the case of regulated overhead equipment, the regulating equipments are erected on the terminal masts or structures and their movement locked by suitable means in the middle position, with the distance between the pulleys of the regulating equipment corresponding to 35deg. C.

7.25 TEMPORARY ARRANGEMENT: A pulley of approximately 30 cm. in dia. is attached to the overhead equipment and the

regulating equipment by means of temporary accommodation fittings at both ends of the tension length to be wired. Over this pulley a flexible stranded wire is passed over. At each end of the wire two ending clamps, one for catenary and one contact wire, are attached. The wire is also clipped in the middle by’ U’- clamps. The length of this temporary arrangement from the regulating equipment to the extremities of the stranded wire passing over the temporary pulley shall be a little longer than the distance between the regulating equipment and the ends of the catenary and contact wires in their final position, to permit easy clamping of terminal fittings during the final termination of the wire.

7.26 STRINGING OF CATENARY: The catenary is initially terminated in the ending clamp of the temporary arrangement at one

end of the tension length. The catenary is then paid out from the reel of the wiring train and run on pulley blocks hung from the suspension clamp eyes of brackets until the terminating point at the other end of the tension length in reached.

7.27 TENSIONING OF CATENARY: The catenary is strained up to the stringing tension’ corresponding to the equivalent span of the

tension length and the ambient temperature at the time of stringing with the aid of a dynamometer, and terminated at the tension. For this purpose, the ambient temperature shall be deemed to be the temperature registered by a thermometer tied to a length of catenary wire 3 to 4 meters long, laid flat on the top platform, on one of the wagons of the wiring train. Subsequently, the tension in the wire is checked by measurement of sag with the help of leveling the attached to suspension points and to the catenary at mid span by a ladder working party. The sag shall be measured in two spans, each preferably greater than 54 metres, and situated on either side of anti-creep approximately midway between the anti-creep and the termination points. The value of sag measured by this method should be within +/-5% of the theoretical value for the corresponding stringing tension, and the temperature at the time of this measurement. In case the discrepancy is more, the tension should be adjusted again and sag re-checked as above (see note 1 below). After the sag is checked and the catenary is terminated at the end fitting of the temporary arrangement at the terminating point.

In order to restrict the duration of traffic blocks to the minimum, in the first block, a catenary is strained to the stringing tension with the aid of dynamometers and terminated. In the subsequent block, the sag is checked and the tension readjusted with ladders, if necessary.

7.28 CLAMPING THE CATENARY: The catenary is clamped on the brackets placed at right angles to the track (see note 2 below). 7.29 DROPPERING: Droppers are fitted to the catenary at the correct locations. At the contact wire ends these

droppers may be provided with small pulleys or hooks to act as temporary supports when the contact wire is strung.

Hooks made of scrap contact wire, suspended from the catenary wire, may also be used as

temporary supports.

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7.30 STRINGING OF CONTACT WIRE: The contact wire is initially terminated in the contact wire ending clamp of the temporary

arrangement at one end of the tension length. The wire is then paid out from the reel wagon of the wiring train and supported on the pulleys hung from droppers or on hooks until the terminating point at the other end of the tension length is reached (see note 3 below). In curves, the contact wire shall be registered on pulleys located at traction masts or supports corresponding to the approximate final position of the wire. The axes of these pulleys should be more or less vertical.

7.31 TENSIONING OF CONTACT WIRE: The contact wire is strained to a tension of approximately 1.2 times the tension corresponding

to the ambient temperature and terminated in the ending clamp of the temporary arrangement. 7.32 REGULATING EQUIPMENT IN ACTION: The regulating equipment is put into action with the counter weight at the correct height above

rail level and with distance between pulleys or the regulating equipment corresponding to a temperature of 35 deg. C. The regulating equipment is then released and brought into action. The ‘U’ clamp connecting the flexible stranded wire passing round the temporary pulley is also removed.

7.33 FINAL ADJUSTMENT: The entire installation is left in this condition as long as it is possible, preferably for a period not

less than 15 days (see note 4). The temporary pulleys are removed and the conductors terminated in the permanent end fittings, compensating plates, insulators and turn buckles (see note 5 below). The equalizer plate is kept vertical or at a slightly inclined position (the contact wire being shorter than the catenary by 2 or 3 cm) and the position of the regulating equipment is checked in relation to the temperature at the time. The contact wire is clipped on to the droppers (in the vertical position) and on the steady arms. Contact wire height at the bracket is adjusted as also the stagger and register arm clearance.

7.34 CONCLUDING REMARKS: If the above method is followed with care no further adjustment may be needed.

NOTE: (1) It should be ensured that sagging is done carefully and accurately. The adjustment of

tension in the catenary after checking of sag, if required, would be easy if a temporary turn buckle is inserted in the temporary termination.

The use of leveling lathes is recommended for the following reasons:

(i) The accuracy of adjustment is greater than that with a dynamometer. (ii) No traffic block is required for this operation. (iii) It obviates the necessity of initial tensioning of the catenary accurately thus

permitting a deduction in the period of traffic block required for the wiring train.

(2) If feasible without offering any hindrance to progress of works, the catenary may be maintained at stringing tension for a period of 48 hours before checking sag and clamping it to the brackets. This would ensure equalization of tension in the different spans. Before clamping the catenary to the brackets, the sag should however, be checked in two spans as indicated in para 7.27.

(3) If it is difficult to obtain a separate traffic block for stringing contact wire, the wire may be

paid out at the same time as the catenary, with the following precautions:

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(i) The contact wire is run and suspended from independent pulleys hooked on to the brackets, separately from the catenary pulleys, to avoid twisting together of the two conductors.

(ii) The contact wire should not be suspended from the catenary until the latter is clamped on to the brackets.

(iii) The tension in the contact wire before termination should be about 1500 kgf. This will ensure that sag is not excessive.

(iv) The adjustment of tension and checking of sag of the catenary wire is carried out as if the contact wire had not been strung. Only after adjustment of tension and checking of sag is completed, the contact wire is transferred to the pulleys attached to the droppers or to hooks suspended from the catenary and the tension is adjusted as indicated in para 7.31.

(4) When the contact wire is under tension, creep takes place which results in an increase in

the length of wire and, consequently, the droppers and the equalizer plates would become oblique.

Though creep may continue for a long time, may be about a year, the bulk of it would occur during the days following stringing. If sufficient period of time is allowed, the contact wire may be clipped to the droppers and the equalizer plates, all in the vertical position, and the necessity for any further adjustments before energisation and commissioning of the OHE may be reduced to a great extent. If this precaution is not taken, at the time of energisation of the OHE, the droppers may not all be vertical and staff would have to be detailed for shifting the dropper clips which is attendant with risk of damage to the contact wire.

(5) Before the temporary arrangement is removed, a reference mark should be made on each

conductor. After final termination of the conductors, it should be ensured that two marks are in the same relative longitudinal position as they were before the removal of the temporary arrangement.

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CHAPTER: B-8

INSPECTION AND TESTING-OHE & Switching Station 8.1 SCOPE: This chapter deals with the inspection and testing of completely erected overhead equipment,

switching stations, booster transformer stations and LT supply transformer stations. 8.2 OVERALL PERFORMANCE: The overall performance of the overhead equipment should be such as would permit collection

of current by electric rolling stock with full load at speeds up to and including the maximum specified for the design of overhead equipment, smoothly, without mechanical shocks or prejudicial sparks (see para 2.10) and without undue heating in the case of other equipments.

8.3 RESPONSIBILITY: The general tests of overall performance stipulated below are only supplementary to other tests

on structures, foundations, equipment, components and fittings as specified. Any testing and acceptance by the Engineer of overall performance shall be subject to the general terms of guarantee.

(a)INSPECTION AND TESTING CHARGES:

All inspection and testing charges shall be borne by the Contractor unless otherwise astated. 8.4 TESTS OF OHE:

(a) GENERAL As soon as a section is ready for inspection and testing, the Contractor shall advise the

Engineer in writing. Tests to be carried out by the Engineer will be done in the presence of the Contractor’s representative and shall include the following apart from other reasonable tests that the Engineer may like to conduct with a view to ensure himself of the soundness of the equipments and their erection in strict compliance with the specifications.

(b) INSULATION The strength of the insulation and the dielectric strength of the entire equipment as installed

shall be tested with a 2500 V megger. (C) CONTINUITY

The electrical continuity of the line and the existence of bad contact, if any, will be tested with a megger. (d) ELECTRICAL INDEPENDENCE

The electrical independence of individual elementary sections in relation to one another shall also be tested with a Megger. (e) SWITCHES

All isolators shall be tested for smooth and trouble free operation. (f) TENSION DEVICES

All automatic tensioning devices shall be tested for sensitive functioning and adjustment. (g)STAGGER AND HEIGHT

The stagger and height of contact wire over the entire section of completed overhead equipment and the clearances available shall be measured and the measurement shall be checked against approved drawings. These measurements shall be carried out at low speed with a vehicle or device to be arranged by the Purchaser, the movement of which will follow the track levels as closely as possible. Tolerance that will be permitted on the dimensions shall be as per para 7.13 of this specification.

The actual position of the two contact wires, relative to each other, at overlaps and turnouts, shall also be checked. Special attention shall be paid to smooth movement of pantographs over section insulators, particularly those which are likely to be frequently traversed.

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(h)MECHANICAL BEHAVIOUR The mechanical behavior of the entire equipment shall be tested at various speeds under

normal pantograph pressure without energizing the overhead equipment. (i) ENERGISING

If the overhead equipment, after being subjected to the above tests in an un-energised condition, is found to be satisfactory, it will be energized with the normal 25 kV Ac supply.

(j)Tests shall then be conducted to check if the power collection performance of the overhead equipment is satisfactory after ensuring that the contact wire is adequately clean. For this purpose, an observation car shall be attached next to the electric locomotive. The behavior of the overhead equipment will be watched at various speeds. Power collection shall be considered unsatisfactory if a long blue flash is observed, indicating that the contact between the contact wire and the pantograph is not continuous.

8.5 INSPECTION AND TESTING OF SWITCHING STATIONS ETC:

(a)GENERAL As soon as a switching station, booster transformer station or LT supply transformer station is

ready for inspection and testing, the Contractor shall advise the Engineer in writing. Testing will be carried out by the contractor at his cost jointly with the Engineer. These shall include the tests which the Engineer may like to conduct with a view to assure himself of the soundness of the equipments and their erection in compliance with these specification However, testing equipments such as those indicated below and staff required for the tests shall be provided by the Contractor free of charge:

(i) Oil testing equipment. (ii) 2500 V & 500 V meggers. (iii) Earth megger and accessories. (iv) Continuity tests apparatus. (v) Avometer; The Contractor shall take full responsibility for these tests inter-alia his other responsibilities.

(b)VISUAL INSPECTION Visual inspection which shall include check for satisfactory workmanship shall cover all

connections, painting, plastering, cleanliness of insulators etc. and compliance with Indian Electricity Rules.

(c) OPERATIONS TEST

This tests will be conducted on every individual item of equipment such as interrupters, isolators, relays etc. to ensure that the equipment as a whole is functioning properly and is mechanically sound i.e. in the particular case of isolators the fixed contact and knife blade have been correctly aligned and operations does not cause undue strain on the equipment. The operation tests will be carried out with the high tension installation disconnected from the supply, but by actuating power devices where such are provided. Continuity tests of high tension connections after setting such interrupter and isolator in their respective positions shall also be conducted as part of the operation test.

(d) INSULATION

The strength of insulation of the various items of equipment and of the entire installation as a whole shall be tested with a 2500 V/500 V megger, as required.

(e) DIELECTRIC STRENGTH OF OIL The dielectric strength of the oil of the Booster transformer & LT supply transformer, at each

station, shall be tested before commissioning in accordance with IS 12463-1988 or latest. Should this not be found correct, the Contractor shall arrange at his own expense, to have it rectified.

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(g) ISOLATORS

All isolators will be tested for smooth and trouble free operation.

(h) INTERRUPTERS Operation of trip and close coils for interrupters, shall be tested for satisfactory performance

with the respective equipments de-energised. 8.6 EARTHING:

(a)Earth wires will be checked for continuity and electrical isolation after every 1000mapprox. (b)Clearances between earth wires and out-of –run wires of overhead equipment and signals shall be checked.

(c)Earth resistance shall be measured separately for each earth electrode. In the case of interconnected earth electrodes, the net resistance of the Inter-connected electrodes shall also be measured.

8.7 DETAILED PROCEDURE FOR TESTS: The detailed procedure for inspection and testing will be furnished to the contractor. The

contractor shall submit the results of tests in the proforma which will be furnished by the Engineer, in quadruplicate.

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CHAPTER: B-9

SWITCHING STATION BUILDING

9.1 GENERAL: This chapter deals with details and specifications for design and construction of switching

station buildings and associated electrical works. 9.2 EARTH WORK:

(a)Earth work in cutting or embankment in the premises of switching station buildings is included in the scope of construction of building. The buildings will be adequately leveled with earth duly consolidated in the premises or as directed by the Engineer.

(b) Mechanical Compaction: As far as possible, mechanical compaction shall be done for full or part height of embankment,

as decided by the Engineer. If this is not possible, the suitable method for compaction will be decided by the Engineer.

(c) Excavation:

All cuttings shall be taken down carefully to the precise level and section as shown in the drawings or as decided by the Engineer. In case the bottom of the cutting is taken down deeper than is necessary by oversight or neglect of the contractor, the hollow must be filled up to true depth with selected material and rammed, as approved by Engineer. Cuttings with the formation in rock will be excavated to 15 cm below the true formation and filled up to true level with cutting spoil to ensure that no lumps of solid rock project above formation level.

(d) Drainage of cuttings:

In excavating cuttings, special precautions are to be taken to ensure that the excavations drain themselves automatically. To ensure this, the central block of earth or gullet is to be excavated first. This will be done in such a manner that the bottom of the excavation shall where possible, slop downwards from the center of the cutting towards the ends. It will be made in such cuts or steps as may from time to time, be directed. Generally, in deep cuttings the first cut or step will approximately follow the surface of the ground where this will secure the necessary slope for drainage, and will be excavated to a depth not exceeding 3 m or as decided by the Engineer, with perpendicular sides, leaving pathways for workmen along the sides of the cut parallel to the central line after about every 15 m. In shallow cuttings, not exceeding 2m in the deepest part, the gullet may be cut at once to formation level.

(e)Catch Water drains:

Where required, catch water drains shall be constructed on the up hill side leaving a berm of one metre from the boundary of the railway land. The cross sectional area of the catch water drain shall normally not exceed 0.75 sq. m. The spoil from the catch water drain will be thrown up on the side towards the cutting.

(f) Berms and Spoil banks:

No spoil shall be deposited within a distance of 6 m from the top edge of the slop-e of any cutting.

(g) The spoil heap shall be roughly but neatly dressed off to a slope of 1-1/2:1 and shall form a

continuous bund along the top of the cutting. In country where there is any cross fall sufficient spoil shall be thrown on the uphill side of the cutting to supplement the catch water drains and assist in keeping drainage out. This work must be done first.

(h) All material excavated from cutting suitable for pitching, ballast, masonry or any other purpose

whatever, shall be the property of the Railway, and shall be stacked, as also disposed of, as directed by the Engineer.

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(i) Springs or inflow:

Should springs or inflow of water appear in cuttings, or should they be flooded the contractor must arrange for bailing, pumping or drainage of water, without obstruction to adjacent works.

(j) Blasting: If any blasting operations are necessary, they shall be carried out by the contractor with all

safety precaution as per purchase directives. 9.3 FOUNDATIONS:

(a) Foundations shall be designed by the contractor in accordance with the tender specification. The contractor shall get the relevant drawings approved by the Engineer. The foundation work may involve wet excavation also, for which all due precautions by way of pumping and other operations, preventing blowing are to be adopted.

(b) Plinth filling: Plinth filling shall be done with earth in 15 cm layers, duly consolidated, watered & rammed

unless otherwise specified. In black cotton soil, the soil shall be removed for a depth of 60 cm and top 30 cm filling shall be done with sand.

(c) Wherever it is necessary in case of deep trenches, shoring or timbering for such trenches shall

have to be provided to avoid collapsing of earth. (d) Apron: For protection of plinth, an apron as specified in drawing No. RE/Civil/BS -11/95 shall be

provided. 9.4 REINFORCED CEMENT CONCRETE WORK:

(a) RCC of the switching station shall be cast on the controlled concrete technology for M-15 grade conforming to IS: 456-2000 or latest. The design of all RCC work shall be prepared by the contractor and got approved from Engineer well in time.

Test concrete specimen shall be cast at the site of work and tested in accordance with the relevant specification.

(b) If unavoidable due to site conditions, concrete may have to be laid in water as per laid down procedure.

(c) All RCC works shall be finished smooth.

9.5 SUPER STRUCTURES: (a) Brick work: Besides following relevant specification, well burnt bricks shall only be used. The

brick work shall be laid in ENGLISH BOND. The brick work below plinth shall be done in Cement mortal of ratio 1:4(1 cement, 4 sand). The brick work above plinth shall be done in cement mortal or ratio 1:6. Curing of the brick work shall be done for a minimum period of fourteen days.

(b) Plastering: Plastering on inside and outside surfaces shall be done with cement mortar of ratio

1:3 and shall have a thickness of 10mm. (c)Finishing: All external surfaces shall be treated with snowmen over two coats of cement primer

of approved quality and all internal surfaces of wall and ceiling shall be white washed with three coats.

9.6 FLOORING: (a)Following pattern of the flooring shall be adopted:

(i)Base concrete- 100 mm thick cement concrete of ratio 1:4:8 with under layer of 100 mm thick sand filling over well compacted earth.

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(ii)Top layer- 40 mm thick cement concrete of ratio 1:2:4, laid in panels with glass dividing strips of 25 mm x 3mm. Top surface of the flooring shall be finished smooth.

(b) Suitable anti termite treatment, pre and post treatment as approved by the Engineer, shall be provided.

9.7 ROOFING: RCC roof, complete in all respects in accordance with RDSO drawing No ETI/C/0067 Mod.-B

shall be provided. Water proofing of roof shall be carried out by the contractor. The type of water proofing treatment, will be got approved from the Engineer. The contractor shall ensure at the time of hanging over of the building that roofs are leak proof and water tight. The contractor shall also provide CI rain water pipes of specified size.

9.8 DOORS, WINDOWS, VENTILATORS: Pressed steel doors, windows, ventilators and grills etc. shall be provided in accordance with

drawing no. RE/Civil/S-129-2001 Rev-II. All steel work shall be painted with two coats of ready mixed paint of approved quality and shade with Red Oxide primer coat.

9.9 BUILDING MATERIALS:

Building materials not already specified above, shall be used in accordance with approved drawing by RVNL or as specified by the Engineer.

9.10 WIRING: Wiring of the substation shall be done as per RVNL standard specifications given in

Part-A. Electrical fittings, plug points and appliances as indicated in following table shall be provided in a switching station. The contractor shall get the locations of the electrical fittings/appliances approved from purchaser.

TABLE

SN DESCRIPTION OF ITEM QUANTITY 1 Wiring of Light (3 nos), Fan (1 No.) Ex. Fan (1 No.) &

light plug points (1 No) 6 Nos.

2 Wiring of power plug points (16 Amp.) 2 Nos. 3 1x28 watt Surface type T-5, Energy Efficient Luminary

with Tube 2 Nos. (inside the building)

4 1x150 watt Street light Metal Halide (MH) Luminary with Lamp 150 watt

1 No. (outside the building)

5 230Volt Ac, 450mm, 900 RPM exhaust fan. 1 No. (battery room)

6 AC ceiling fan 1400 mm sweep complete with stepped type electronic regulator

1 No.

7 Double Door MCB Distribution Board complete with Incoming MCB DP-32 Amp with RCCB 100 mA and O/G---6-16 amps. MCB SP-3 Nos. & 20 amps. MCB SP-3 Nos.

1 Nos. (Main)

9.11 TESTING AND COMMISSIONING: On completion, all works including wiring, electrical fittings and appliances shall be tested

jointly with the representative of the Engineer in accordance with IS: 732/1989 or latest and commissioned.

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CHAPTER: B-10

TRACTION SUB-STATIONS/FEEDING POSTS

GENERAL REQUIREMENTS 10.1 INTRODUCTION

This part deals with general information and criteria for design, manufacture, supply, erection and testing of equipment at 132/25 kV (or any other rating depending on input voltage availability from grid with output always being 25 kV AC) traction sub-stations, feeding stations and 25 kV Shunt Capacitor Bank. These traction sub-stations are also referred to as “SUB-STATIONS” in these technical specifications.

10.2 DEFINITIONS The following definitions shall apply for the purpose of this specification, in addition to

definitions applicable to standard equipments. (a) ”Grid Sub-station” means the sub-station of a power supply authority which is connected to the

grid network in the area and from which 132 kV (or any other level ) power is supplied to the Railway for electric traction.

(b) ”Interrupter” means a single pole single phase non-automatic circuit breaker capable of

interrupting normal full load current. (c) “Return Feeder” means the conductor of the feeder line from a traction sub-station to the

corresponding feeding station which is connected to the earth terminal of the traction transformer secondary winding.

(d) “Traction overhead equipment” means the overhead conductors and other associated

equipment and structures erected over the track to supply power to the electric locomotives. (e) “Traction sub-station” means a sub-station that converts the grid supply voltage to 25 kV AC to

supply power to traction overhead equipment installed on the railway track, in accordance with this specification.

(f) “25 kV Feeder” means the conductor or feeder line from the traction sub-station to the

corresponding feeding station and which is connected to the unearthed terminal of the traction transformer secondary winding.

(g) ”Feeding station” means the 25 kV interrupters and other associated equipment as also

structures erected near the track, within or outside the sub-station boundary, for feeding different sections of the traction overhead equipment.

(h) ”Shunt Capacitor Bank” means shunt capacitor equipment, along with control gear, protective

relays, series reactor and accessories erected on 25 kV side of a traction sub-station for the purpose of maintaining unity power factor and reduction of maximum demand.

10.3 FUNCTIONS The traction sub-stations covered by this specification will be installed to supply power for

electric traction at 25 kV Ac 50 cycles single phase through the traction overhead equipment.

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10.4 LOCATION The locations of the traction sub-stations are given in the Bidding Documents. 10.5 CLIMATIC DATA

The climatic data pertaining to the area in which the sub-stations will be located are given in the Bidding Documents.

10.6 WIND PRESSURE Structures and foundations for the sub-stations shall be designed for a wind pressure as per

wind zone of the area indicated in the IS-875 Part-3 unless otherwise indicated in the Bidding Documents.

10.7 SYSTEM PARTICULARS (a) Power will be received at 132 kV ( or any other voltage available in the region) single phase,

50 cycles at the traction sub-stations and stepped down to 25 kV by means of single phase traction transformer. On the primary side the traction transformers will be connected across two phases of the 132 kV, 3 phase system, On the secondary side one terminal of the transformer will be solidly earthed and also connected to the traction rails, the other terminal will be connected to the traction overhead equipment through 25 kV switchgear.

(a) Adjacent sub-stations will normally be connected across different phases to reduce the

unbalance on the three phase power supply system. In order to keep the supply from two adjacent sub-stations separate, a neutral section is provided on the traction overhead equipment approximately midway between them. The neutral section is normally kept dead. Electric locomotives coast through the neutral section with power off.

(b) The traction sub-stations, will normally be unattended and all switching operations will be

carried out by remote control from a Remote Control Center.

(c) FEEDERS & RETURN FEEDERS 25 KV ALONG TRACK FEEDERS 25 kV along track feeders may connect sections of overhead equipment to a switching station

or an isolator switch or gantry. Such feeders will be run usually on traction structures and sometimes on independent masts. A single ‘ SPIDER’ conductor shall be used for such feeders.

(e) SCHEMATIC ARRANGEMENTS

The different arrangements of feeders, return feeders, 25 kV along track feeders and return conductors can be seen from the drawings listed in the Annexure.

(f) JUMPERS

All jumpers connected to OHE conductors shall be of copper only. The in –span jumpers, potential equalizer jumpers at insulated overlaps and neutral section, shall be of 50 sq mm nominal section, 19/1.8mm size. Flexible jumpers of nominal section 105 sq mm, 19/7/1.06 mm size shall be used at overlaps, turnouts, crossings etc.

The jumper connecting the Aluminium conductors to any other conductors, terminals or clamps shall be made with the aid of suitable bi-metallic clamps. All aluminium jumpers of size 19/7/1.4 mm bare ¾ hard shall be used to connect other Aluminium conductors such as return conductor. The tail ends of feeder wires from the strain clamps at the termination of a feeder, return feeder or return conductor may be connected directly to a terminal or clamp where feasible to avoid the use of a separate jumper wire.

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(g) Capacitor Bank for FP A capacitor bank may be provided at feeding posts, for power factor correction. This shall be of outdoor type, mounted on steel racks for connection to the 25 kV bus through single pole isolator and circuit breaker. The capacitor bank shall consist of groups of individual capacitor units, connected in series parallel combination to deliver the rated output, at normal rated system voltage, rated frequency and other rated system conditions.

(h) Series reactor (Harmonic Suppression Reactor)

A series reactor, shall be provided to limit the inrush current and surge voltage at the time of switching in the capacitor bank. The switching surge voltage shall not exceed 70 kVP. The series reactor which is also meant to filter a part of the harmonics generated by the traction loads shall have inductive reactance (XL) equal to or greater than 13% of capacitive reactance (XC) of the capacitor bank. The series reactor shall be natural air cooled, air cored. The feeder circuit breakers will from a part of the sub-station and will be covered by this specification.

(i) At the feeding station, the 25 kV supply will be fed to different sections of the traction

overhead equipments by means of interrupters. All interrupters will be remote controlled. (j) Normally, traction substation will be located alongside the Railway track. The feeding stations

will be located within the sub-station boundary and connected to the traction sub-station boundary and connected to the traction sub-station by extension of the 25 kv busbars. Where the traction sub-station is located some distance away from the track, the 25 kV supply will be extended to the feeding station by means of two overhead feeders carried on tower/masts. Each feeder line will comprise two conductors one called the 25 kV Feeder and the other return feeder.

(k) A small masonry building called the control room, will be provided at each sub-station to

house the control and instrument panels, remote control equipment, batteries, battery chargers, telecommunication terminal equipment, telephones and AC and DC LT distribution boards, capacitor bank equipment (if required to be indoors) etc. (See relevant drawing included in Annexure-1).

(l) For Fire protection, baffle wall shall be provided in between the two bays of the power

transformer as per RDSO Drg. No. ETI/C/0214 for wind pressure upto 112.5 kgf/sqm (brick baffle wall) and RDSO Drg. No. ETI/C/0213 for wind pressure beyond 112.5 kgf/sqm (RCC baffle wall).

(m) The entire traction sub-station and the control room will be protected by a fenced enclosure. A

railway siding from the nearest railway station will be terminated inside each-sub-station, where feasible, to enable unloading of heavy equipment at site. Road access will also be provided wherever possible.

10.8 (a) FEEDING STATION

Every feeding station has gantry with two or more main masts (Up-right). The interrupters are located behind the gantry. Isolators, Potential Transformers, station class lightning arrestors and pedestal insulators are mounted on the gantry. From the gantry, connections are made to various sections of overhead equipment by cross feeders and jumper connections. Feeding stations are unattended and remote controlled from a remote control center (see part-III). Feeding stations will be located within the traction sub-station premises. Control equipment, S&T terminal equipments, arrangement for termination of cables from feeding station equipments will be provided inside the sub-station control room.

10.8(b) SHUNT CAPACITOR BANK

Capacitor Bank, along with associated equipments, will be located inside traction sub-station premises. Capacitor Bank and series reactor shall be mounted on steel racks for connection 25 kV bus through single pole isolator and circuit breaker. The control panel for the capacitor bank shall be installed inside the control room of the traction sub-station.

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10.9 AUXILIARY SUPPLIES

(a)The following auxiliary supplies shall be provided at each traction sub-station: (i)110 V, 200 Ah battery for operation of switchgear.

(ii)Single phase 240 V Ac supply.

10.10 SCOPE OF WORK The traction sub-stations, feeding stations and 25 kV shunt capacitor banks when erected shall be in accordance with the specification and functionally complete in all respects. All works required in this connection shall be deemed to be a part of the scope of work of the contract, whether specifically stated or not.

TRACTION SUB-STATION & SHUNT CAPACITOR BANK

10.11 CLEARANCES

The minimum clearances in mm in air for live equipment shall be as under:

25 kV 66kV 100kV 132 kV 220 kV 1. Between phases - 630 900 1300 2400 2. Between one phase

and earth for rigid connection

500 630 900 1300 2100

3. Between any points where man may be required to stand to the nearest a)unsecured conductor in air(mm) b) Secured condition in air(mm)

3000

2000

3500 -

3500 -

4000 -

5000 -

4. Minimum height of bus bar. 3800 4600 4600 4600 5500

10.12 EQUIPMENT AND BUSBAR LAYOUT

The layout of equipment and bus bar arrangement for typical sub-stations is shown schematically in drawing incorporated in Annexure-1.

10.13 NUMBERING Each circuit breaker, potential transformer, current transformer, Traction power transformer ,

LT Supply Transformer, Isolator and Lightning Arrestor shall carry a vitreous enameled steel number plate of approved design (See Annexure-1). The Engineer will furnish the actual numbers to be allotted to the various switchgear installed at the sub-station.

10.14 BUS BARS All equipment to equipment connections on the 132 kV side as well as bus bars strung between

gantries/portals to which the HV terminals of the transformers shall be connected, shall comprise ACSR conductors and aluminium alloy tubes. The bus bars and bus bar connections on the 25 kV side shall consist of aluminium alloy tubes supported on pedestal insulators wherever necessary at intervals of not more than 4.5 m.

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CHAPTER: B-11

FEEDING STATIONS SWITCHING STATIONS, BOOSTER TRANSFORMER-STATIONS AND L.T. SUPPLY TRANSFORMER

STATIONS

11.1 DESCRIPTION

(a) Switching Stations Every switching station has a gantry with two or more main masts (Up-right). The interrupters are located behind the gantry. Isolators, Potential Transformers, station class lightning arrestors and pedestal insulators are mounted on a gantry. From the gantry, connections are made to various sections of overhead equipment by cross feeders and jumper connections. Switching stations are unattended and remote controlled from a remote control centre. A small masonary cubicle, called the control cubicle, shall be constructed at each switching station to house control equipment, batteries, battery charger, S&T terminal equipment, terminal board for terminating cables from the switching station equipment, a telephone and telephone equipment and AC 240 V distribution board. The switching station and its control cubicle (other than feeding posts) shall be enclosed by fencing.

(b) Booster Transformer Booster stations are provided for each track at the insulated overlap spans. The primary terminals are connected directly in series with the traction overhead equipment and the secondary terminals directly in series with the return conductors by means of flexible jumpers. Normally each booster station will be provided with one booster transformer which will be mounted on a gantry structure with two masts as indicated in a drawing listed in the Annexure to these Technical Specifications. Two 7.5 kV lighting arrestors for each booster transformer are also erected on the gantry and connected to the LT terminals of the booster transformer Single booster station will be located on either side of the track in a double track section. In multi-track sections where space does not permit location of a booster station, it may be provided with cross feeders for connections to the overhead equipment and return conductors as indicated in the relevant general arrangement drawing listed in the Annexure to these Technical Specifications.

(c) L.T. Supply transformer stations

The low tension supply required at switching stations will be obtained through L.T. supply transformers, mounted on steel structures and connected to the 25 kV side through rigid bus-bars of aluminum. In special cases where the length of connection is small, 50 sq. mm copper wire may be used for connection, with the approval of the Engineer. At locations other than at switching stations, wherever low tension supply is required, LT supply transformer stations may be provided along the track at isolated location. L.T. supply transformer stations shall essentially comprise of a mast mounted transformer connected to the traction overhead equipment through dropout fuse switches. The 240 V side shall be connected to a distribution board located at the remote control cubicle by means of a two-core, aluminum conductor, XLPE insulated, PVC sheathed and steel armoured heavy duty cable of requisite size, conforming to IS 7098/Pt. I/1988 or latest (see 5.20 (a). The general arrangement drawing for LT supply transformer stations for single/double and multi-track sections is included in the Annexure to these Technical Specifications.

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11.2 SCOPE OF WORK:

(a)Switching Staions.

The switching stations shall be complete in all respects in accordance with specifications. The work may also include, depending on the project requirement and as specified in the Bill of Quantities of the tender:-

(i) Filling up and leveling of the ground to the extent necessary. (ii) Provision of control cubicles for installation of remote control equipment for

switching stations. (iii) Provision of 240 V AC distribution board.

(iv) Provision of lights, plug points inside the cubicles. (v) Trench work inside the cubicles. (vi) Supply and spreading of gravel

(b) Booster Transformer Stations

The booster transformer stations will be complete in all respects, in accordance with the specifications. The work may also include the following, depending on the project requirement and as specified in the Bill of Quantities of the tender:-

(i) Filling up and leveling the ground to the extent necessary. (ii) Cable and cable connections in LT side.

(iii) Supply of L.T. supply transformer and other equipment as listed in the Annexure to these Technical Specifications.

11.3 SETTING OF GANTRIES: The gantries are normally aligned parallel to the track. The minimum distance of the face of the gantry from the center line of the nearest track is referred to as the ‘setting’ of the gantry. The setting shall normally be 3.5m. Setting of the individual gantries of different stations will be furnished by the Contractor.

11.4 DATUM LEVEL:

The datum level will be the finished level of the gantry mast foundation. All vertical dimensions shall be stated with respect to this datum level. Datum levels of individual stations will be indicated on the location and connection diagrams.

11.5 MOUNTING OF EQUIPMENT AND BUSBAR ARRANGEMENT:

(a) The interrupters and isolators shall be mounted in such a way that these can be manually operated conveniently by a person standing on the ground. The indicators showing the ‘OPEN’ or ‘CLOSED’ position of the equipment shall be so arranged as to be visible from out-side the fencing enclosure on the side of the main gantry.

(b) The bus-bar arrangement for typical switching stations is schematically indicated in a drawing included in the Annexure to these Technical Specifications.

11.6 FENCING & ANTICLIMBING DEVICES:

Every switching station, together with its associated control cubicle shall be enclosed by fencing except at feeding stations that are located within the traction sub-station premises. The fencing shall have an anti-climbing device also at top.

Transformer and L.T. supply transformer stations, suitable anti-climbing devices consisting of galvanized steel clamp fixtures shall be mounted on each mast. The device shall be fitted below the transformer supporting beam or steel work. The general arrangement drawings indicating the fencing and anti-climbing devices, are indicated in the Annexure to these Technical Specifications.

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11.7 NUMBERING: Each booster transformer, interrupter, potential transformer, LT supply transformer and isolator shall carry an enameled number plate of approved design. The Engineer will furnish the actual numbers to be allocated to the various equipments as per specification No. ETI/OHE/53 (6/88) with A&C slip No. 1 to 5.

11.8 INTERLOCKING ARRANGEMENTS:

An interlock shall be provided between each interruptor and its associated double pole isolator, to prevent operation of the isolator from the open to the closed position or vice-versa, unless the interruptor is locked in the open position and to prevent operation of interruptor either manually or by remote control unless the isolator is locked in the open or closed position. The interlocking device shall consist of a lock combined with an electrical contact to make or break the remote control circuit on the operating mechanism of the interruptor and a lock for the isolator operating mechanism and interlock key for the two locks.

11.9 CABLE CONNECTIONS: (a)All PVC cables provided outdoor shall be either laid in the trenches or neatly clamped to the

structures as approved by the Engineer. (b) Termination of cables The cables shall be terminated neatly and all the cores arranged and dressed properly. Suitable

indexed terminal lugs or ferrules shall be provided at all terminals to facilitate maintenance.

11.10 CLEARANCES: No part of the installations which is live at 25 kV shall be erected at a height less than 3 m from the datum level. Clearance between any part live at 25 kV and any part at earth potential (or part likely to be earthed ) shall not normally be less than 500 mm. This clearance may be reduced under special circumstances but in no case static clearance shall be less than 320250 mm and any dynamic vertical and horizontal clearances shall be less than 250 mm and any dynamic vertical and horizontal clearances 250 mm and 200 mm respectively. The clearance between any part live at 3 kV and any part at earth potential (or part likely to be earthed) shall be not less than 150 mm under static condition and 70mm under dynamic conditions.

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CHAPTER: B-12

STRUCTURES AND STEEL WORK-TSS

12.1 SCOPE:

This chapter deals with the design of all structural steel work including gantry structures, supporting structures and small parts steel work including chairs, brackets and other fabricated steel work for mounting various equipments, bus bars, cables etc. at traction sub-stations, feeding stations and shunt capacitor banks.

12.2 GENERAL The steel structures may be of riveted, bolted or welded construction as convenient for installation. The thickness of smallest steel section used shall not be less than 6 mm (or ¼”). Legs of gantry structures/portals and supporting steel work and uprights or bus bar supports shall generally be embedded in concrete foundation blocks and for equipment and in special cases secured by means of holding down bolts.

12.3 DESIGNS (a) All the steel structures like gantries/portals, other supporting members, small part steel work

etc. shall be galvanized after fabrication with a minimum value of average mass of zinc coating being not less than 610 g/m sq as per RDSO’s specification No. ETI/OHE/13 (4/84) with A&C slip No. 1 to 3.

(b)All designs for special steel work shall be furnished by the contractor for the approval of the Engineer. Designs for steel structures shall, except where otherwise provided, comply with the “Indian Standard Code of Practice for use of Structural steel in General Building Construction” – IS: 800-1984 or latest other relevant IS specifications and statutory regulations.

(c)For purposes of design, all possible loads which may occur in the worst combination shall be considered.

(d)Steel Structures For calculation of wind load on structures, conductors and equipment, the basic wind pressure shall be taken as per wind zone of the area indicated in the IS-875 Part-3 1987.

(e)For purposes of design of gantries, the tension in the 220 kV incoming/outgoing lines shall be taken as 200 Kg. at 4-degree C (without wind) in each conductor and 150 Kg. at 4 deg. C (without wind) in the earth wire. The tension in the 66 kV strung bus-bars and earth screen wire at 66/25 kV sub-stations shall not exceed 200 kg. At 4-degree C (without wind)

(f) Uprights and fencing posts Uprights carrying equipment such as potential transformers, current transformers, lightning

arrestors, bus bar support insulators, shall be made from standard metric steel sections viz. channels, angles or small joists, either single or fabricated.

(g) Notwithstanding the provisions contained in I.S. and other regulations referred to in para

12.3(b) above regarding permissible deflection, the following should apply.

The deflection at the top of the mast or structure shall be limited to one eightieth (1/80) of its height above foundation.

(h)The torsional rotation of the mast due to permanent loads shall not exceed 0.1 radian.

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12.4 STEEL

Steel conforming to IS: 2062-1992 or latest shall be used for all fabricated steel work. Steel should be to designation ST: 42-S.

12.5 STEEL WORK FOR FEEDING STATIONS AND GANTRIES (a)HORIZONTAL MEMBERS OF GANTRY Horizontal member of main as well as auxiliary gantry carrying isolator switches, insulators,

potential transformers etc. shall be made from steel sections viz. channels, angles and small joists, single or fabricated. They shall preferably be attached to masts by means of clamps to avoid drilling of masts sections.

(b)For purpose of design, all possible loads which may occur in the worst combination shall be

considered. The loads shall include the following: -

i) Weight of insulators, instrument transformers, isolator switches, bus- bars, and their accessories.

ii) Loads caused by feeders, along and across tracks, return feeders etc. (iii) Loads caused by anchorage due to guying of anchored masts (where applicable). (iv) Pull or push on the structures due to anchorage and radial tension (where applicable). (v) Wind load on the different structures, conductors and equipment. The wind pressure shall

be taken as that indicated in the bidding documents. (vi) Weight of men working on the structures. (vii) Weight of structure itself. (viii) Erection loads. (ix) Any other load or loads which may occur due to special equipment wherever they occur.

(c)TENSION OF CONDUCTORS For purpose of designs, the maximum tension of different conductors, without wind load, shall normally be as under: -

(i) Maximum tension in the cross feeders at switching stations under worst loading conditions: -

1) For spans less than 18m……100 kgf. 2) For spans more than 18 m…200 kgf.

(ii) Maximum tension in longitudinal feeders running parallel to the track at the switching

stations under worst conditions. 1,500 kgf. (iii)Tension in anchored overhead equipment in case of sectioning and paralleling

stations….2000 kgf.

(d) DEFLECTION OF GANTRY MASTS Deflection under permanent loads (at an average temperature of 35 deg. C (without wind) at

the top of the fabricated structures or masts shall be limited to one eightieth (1/80th) of its height above foundation.

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(d) Masts of the gantry at which feeder or overhead equipment will be anchored at the switching

station shall normally be provided with suitable guys, but struts shall not be permitted.

(f) CHAIRS AND BRACKETS Chairs, brackets and supporting steel work carrying potential transformers, lightning arrestors, insulators, etc. shall be made of fabricated steel and shall be mounted on the main auxiliary gantry preferably by means of clamps to avoid drilling of mast sections.

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CHAPTER: B-13

EQUIPMENT, COMPONENT AND MATERIALS-TSS

13.1 GENERAL This chapter deals with details and specifications of the equipments, components and materials to be used at the traction sub-station, feeding station and shunt capacitor bank. It does not cover foundations and structures which are dealt with in separate Chapters. The detailed specifications for various items of equipment and materials issued by the Railway may be bought separately from Research Design and Standards Organisation, Lucknow.

13.2 COMPLIANCE WITH STANDARD SPECIFICATIONS In the technical specifications of equipments references are made to the following standard specifications.

i) International Electro-technical Commission (abbreviated as IEC Publications).

ii) British Standards (Abbreviated as BS). iii) Indian Standards (abbreviated as IS/BIS).

13.3 INSULATION LEVEL All equipment including insulators to be used at the traction sub-stations, feeding station and shunt capacitor banks shall be suitable for the insulation level specified below:-

Service Voltage -------------------------------------------------------- 220 kV 132 kV 110 kV 66kV 25 kV -------------------------------------------------------

i) Power frequency 1 min. wet with 460 275 230 160 95 stand test- in kV(rms)

ii) Impulse (1.2/50 microsecond) 1050 650 550 350 250 withstand test positive and negative polarity (crest value) - in kV (peak).

13.4 INSPECTION All equipment, material etc, shall be inspected by RITES and the inspection charges

shall be borne by the contractor. 13.5 NIL 13.6 ROUTINE TESTS

These comprise inspection and tests conducted at the manufacturer’s works on every equipment/component /fitting supplied by the Contractor or as specified, for exercising quality control of manufactured items.

13.7 TEST CERTIFICATES

Three copies of the test certificates of successful prototype tests carried out at the manufacturer’s works on equipment/component/fitting shall be furnished to the Engineer within a month after completion of the prototype tests. Three copies of routine tests carried out on each equipment shall also be furnished, after the equipment is passed by the Engineer’s representative on inspection.

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13.8 BULK MANUFACTURE

Bulk manufacture may be undertaken only after specific written approval of the Engineer or his representative has been obtained, indicating that tests on the prototypes are satisfactory. Where prototypes have already been approved in connection with electrification works already in progress, bulk manufacture may proceed after exemption from prototype tests is received from the Engineer in writing.

13.9 INTERCHANGEABILITY

Parts and components of similar equipments and all fittings shall be fully interchangeable. 13.10 TECHNICAL SPECIFICATIONS

The following specifications (latest revisions) will govern supply and testing of various items of equipment and materials except where otherwise specified in the Bidding documents or Railway specifications, which are listed at Annexure-1. Standard Specifications

General requirements for the supply of metals and metal products

IS: 1387-1993

Tin bronze castings IS:306 -1983 (grade G-2)

All aluminium conductor IS: 398 ( Part-I)-1996

Aluminium conductors galvanized steel reinforced IS: 398(Part-III) 1976

Aluminium conductors galvanized steel reinforced hard drawn stranded aluminium and steel –code aluminium conductors for over head power transmission purposes.

IS:398( Part-III)-1976 IS:398(Part-I)-1996

Disc Insulators IS: 3188-1980 IS: 731-1971

Aluminium and steel cored Aluminium conductors for overhead power lines.

IS:2121-1981(Part I &II)

Aluminium alloy for clamps and fittings, for connectors IS: 617-1994(A-6-M) Control cables (PVC insulated) IS:1554(Part-I)-1988 Structures and steel work IS:800-1984 Structural steel ( standard quality). IS: 2062-1992 Code of practice for General Construction of plain & reinforced concrete.

IS: 456-2000

Method of tests for strength of concrete IS:516-1959 Hard-drawn standard aluminium and steel-cored Al conductors for overhead power transmission purposes

IS: 398(Part- I)1996

Coarse and fine aggregate from natural sources for concrete.

IS: 383-1970

13.11 STEEL WORK AND PROTECTION AGAINST RUST. a) Galvanising

All ferrous components and fittings shall be hot-dip galvanized according to specification No. ETI/OHE/13 (4/84).

b) Rectification at site

If minor modifications, which would damage the protective coat, become necessary at site, these shall be carried out with the approval of the Engineer and in a manner to be specified by him in accordance with specification ETI/OHE/13(4/84) with A&C slip No. 1 to 3.

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13.12 BUSBARS a) ACSR Conductors

ACSR conductors used as bus bars or bus bar connectors shall be of ZEBRA ACSR size 61/3.18 mm (28.62 mm dia ) at 220/25 kV traction Sub-station.

b) Aluminium tubes Aluminium tubes used as bus bars or bus bar connectors shall be of dia 50x39 mm for traction sub-station and shunt capacitor banks of size 36mm x 28mm for feeding stations. The aluminium tubes shall be made of alloy 63401 to IS: 5082-1998 or latest and IS: 6051-1970 or latest or its equivalent. The maximum manufacturing tolerance on diameter and thickness of the tubes shall not exceed the values specified under Class-I of IS: 2673-1979.

c) Busbar junctions and connectors

Busbar junctions and connectors shall be made with aluminium alloy grade 4600 M to IS:617-1994 or equivalent.

d) General

The bus bar shall be clean, smooth mechanically sound and free from surface and other defects. No splices will be allowed in the bus bars unless the length of bus bar exceeds 6 m. The ends of the tubular bus bars shall be covered with suitable end caps. Provision shall be made where necessary to allow for expansion and contraction caused by temperature variation.

e) Joints The joints in bus bars where unavoidable, shall be mechanically and electrically sound, so that the temperature rise under normal working conditions does not exceed 40 degree C for a maximum ambient temperature of 45 degree C.

13.13 TERMINAL CONNECTORS

The equipments such as power transformers, circuit breakers etc. shall be supplied by the Engineer with suitable terminal connectors of approved design and of bimetallic type wherever required.

13.14 INSULATORS

The pedestal insulators for service voltage of 132 kV shall be of solid core type conforming to specification as indicated in Annexure-1. The pedestal insulators for service voltage of 25 kV shall be of the solid core type conforming to specification as indicated in Annexure-1.

13.15 NOMENCLATURE

All components/fittings supplied by the Contractor to Railway’s standard designs shall bear the standardized nomenclature and identification numbers, if any.

13.16 CABLES a) Cables for LT supply

240 V Ac supply from 10 KVA LT supply Transformer shall be brought and terminated on the LT AC distribution board in the Control room by a 2 core 70 sq.mm. Aluminium conductor cable. The cables shall be XLPE insulated, PVC sheathed and armored cables of 1100 V grade complying with IS:7098/Pt.I.1988 or latest.

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c) Control Cables

All control cables shall be of copper conductor 1100 V grade and PVC insulated (heavy duty), complying with IS: 1554(part-I)-1988. The sizes and number of cores of various control cables required are given in the table below for copper cables. Purpose Run Circuit

Voltage No. of core/section (Sq. mm)

Requirement

1. Control & indication of circuit breakers

From each circuit breaker to control board

110 V DC

7x 2.5 Three cables to be used.

2. Transformer alarm/trip circuits & tap changer control

From each 66/25 kV transformer to control board.

110 V DC

10x2.5 Five cable to be used

3. Transformer protection (bushing current transformer connections)

From each 66/25 kV transformer to control board

110 V DC

4x4.0 One cable for each CT to be used

4. Current transformer and neutral connections

From each current transformer to control board

110 V DC

2x4.0 One cable for each core of CT/ neutral CT

5. Potential transformer to connections

From each potential transformer to control board

110 V DC

2x2.5 One cable to be used

6. 110 VDC supply

i) Connection between battery chargers & DC distribution board ii) Connection between batteries & Dc distribution board iii) Connection from Dc distribution board to control board

110 V DC 110 V DC 110 V DC

4x4.0 4x4.0 4x 4.0

One cable to be used with two cores connected in parallel One cable to be used with two cores connected in parallel. Two cables to be used with each circuit and one cable for Dc supply to control boards.

7. Control & indication of bus coupler interrupter

From interrupter to control board.

110 V DC

7 x 2.5 Two cable to be used

8. 240 V Ac supply

Connection from Ac distribution board to control board.

240 V AC

2 x 2.5 One cable to be used.

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c) Cables for heater circuits The 240 V Ac supply to space heaters provided in control cabinets of various equipments shall

be provided by means of 4 sq.mm,2-core aluminium PVC insulated ( heavy duty) cables complying with IS: 1554 (part-I)-1988 or latest. Three circuits shall be provided on the LT AC. Distribution board for this purpose, one for the heaters in the control cabinets of 132 kV circuit breakers the second for the heaters in the control cabinets of 25 kV circuit breakers and bridging interrupters and the third for heaters in marshalling box of traction transformers. Each circuit shall be provided with a fuse of approved type and suitable rating in the LT AC distribution Board.

d) Cables for battery charger 240 V Ac supply to each of the battery chargers in the Control Room shall be provided by means

of 4 sq. mm 2 core PVC insulated, PVC sheathed (heavy duty) copper cables complying with IS: 1554 (Part-I)-1988 or latest. Two circuits each with a fuse of approved type and suitable rating in the LT AC. Distribution board shall be provided for the two battery chargers in the Control Room. The 240 V Ac supply to control board from Ac distribution board shall be provided by means of 2.5 sq. mm 2-core PVC insulated PVC sheathed (heavy duty ) copper cable complying with IS: 1554 ( Part-I) -1988 or latest.

e) Cables for blower fans 240 V Ac supply to blower fans fixed on the traction transformer shall be provided by means of 2 core 25 sq.mm. Aluminium conductor cables. The cables shall be XLPE insulated, PVC sheathed and armored cables of 1100 V grade complying with IS: 7098/PtI/1988 or latest. Separate cables shall be laid from the LT AC distribution board in the control room to marshalling box of each traction transformer. Individual circuits from the LT AC distribution board shall be provided for this purpose with each circuit protected by a fuse of suitable rating.

f) The cable shall be resistant to decay, mechanical abrasion, acids, alkalis and other corrosive materials.

13.17 INSTRUCTIONS AND TECHNICAL BOOKLETS The Contractor shall, within six months of issue of letter of Acceptance, supply 5 copies of booklets containing manufacturer’s instructions for operation and maintenance of each of the items of equipments, the supply of which is included in the contract. In addition, 25 copies of detailed schedule of components, catalogues and drawing of all parts of the equipment shall also be supplied.

13.18 ELECTRICAL CONNECTIONS FOR OHE AT FEEDING STATIONS

a)GENERAL DESIGNS All electrical connections between conductors shall be made by parallel clamps. The general

arrangements of connections are shown in the standard drawings listed in Annexulre-1 b) COPPER JUMPERS Copper jumpers shall be of any of the following type:

i) Large jumpers of annealed copper in accordance with specification ETI/OHE/3(2/94) with A&C slip No. 1 (4/95)

ii) Small jumpers of annealed copper in accordance with specification IS: 9968 (Pt.2)- 1981 or

latest

c) ALUMINIUM JUMPERS Aluminium jumpers wherever used, shall be of all Aluminium stranded conductor 19/7/1.4 mm

bare ¾ H generally conforming to IS: 8130:1984 or latest d) FEEDERS Feeders shall be of all aluminium conductor 19/3.99 mm (SPIDER). -------------------------------------------------------------------------------------------------------------

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CHAPTER: B-14

DESIGNS & DRAWINGS FOR TRACTION SUBSTATION

14.1 GENERAL a) This chapter deals with the procedure for approval of designs and drawings for traction sub-

stations, feeding stations and shunt capacitor banks.

b) The type designs shall be as few as possible to cover the largest field of application consistent with economic considerations.

c) In all drawings, as far as possible only internationally accepted symbols shall be used. 14.2 CONTRACTOR’S DRAWINGS

a) The Contractor shall submit to the Engineer for approval, except where otherwise specified below, all detailed designs and drawings which are necessary to ensure correct supply of equipments, components and materials and to enable correct and complete erection of sub-stations in an expeditious and economic manner.

b) It is to be clearly understood that all original designs and drawings shall be based on a thorough

site study. General designs and dimensions, shall be such that the contractor is satisfied about the suitability of the designs for the purpose. The Engineer’s approval will be based on these consideration and notwithstanding the Engineers acceptance, the ultimate responsibility for the correct design and execution of the work shall rest with the Contractor.

14.3 STANDARDS FOR DRAWINGS

All designs, legends, notes on drawings and schedules of materials shall be in English and shall be prepared in the metric system. All designs and drawings shall conform to RDSO specification No. ETI/PSI/31 (5/76).

14.4 BASIC DESIGNS

a) Normally contractor shall adopt latest standard specifications, designs and drawings of the RDSO and Railway as per broad list enclosed in Annexure-1. Where the Contractor adopts designs and drawings conforming to standard designs, drawings and specifications of Research Designs and Standards Organisation (RDSO), Manak Nagar, Lucknow-226011, he shall verify such designs and drawings and satisfy himself that these are correct and in line with the latest approved drawings in use. Within two months of issue of letter of Acceptance, the Contractor shall indicate to the Engineer the list of standard basic arrangement, components and fitting drawings, equipment drawings, employment schedule etc. which he will adopt for the purpose of work.

The Contractor for his use and reference shall obtain reproducible transparent film (50 microns)

each of such standard basic arrangement, components and fittings drawings, equipment drawings, employment schedule etc., from Chief Electrical Engineer, Railway Electrification, Allahabad on payment as per prescribed rates.

b) Deviations- Normally deviations from the standard drawings of the Railway will not be

accepted. However, in exceptional cases where the contractor desires to suggest improvements as a result of his experience, specific site conditions or any other developments, he shall justify his proposals with supporting explanatory notes.

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14.5 PARTICULARS AND WORKING DESIGNS A) Engineer’s location plans

a) FOR TRACTION SUB-STATIONS The location plans and schematic diagram of connections for each of the traction sub-stations will be furnished by the Contractor. These will indicate.

i) Position of incoming lines on the gantries to be erected inside the traction sub-station. ii) Location of switching station gantry showing where the 25 kV outgoing feeders will be

terminated.

iii) Schematic diagram of connections of Transformers, Circuit breakers, Isolators etc. iv) Position of the control room with respect to the traction sub-station. v) Fencing outline with gates.

b) FOR FEEDING STATIONS The location plans and schematic diagrams of connections for all the feeding stations, will be furnished by the Contractor. These will indicate the following as applicable:-

i) Overhead equipment layout in the vicinity of feeding stations. ii) Location of main masts. iii) Arrangement of cross feeders and longitudinal feeders to be anchored on the gantry if any,

including jumper connections to the overhead equipment. iv) Scheme of connections of interrupters. v) Position of the remote control cubicle with respect to the feeding stations.

c) FOR SHUNT CAPACITOR BANK

a) The location plans and schematic diagram of connections for capacitor bank installation at each of the traction sub-stations will be furnished by the Contractor. These will indicate.

i) Schematic diagram of connections of circuit breakers, isolators, LAs etc. ii) Position of the control room with respect of the traction sub-station. iii) Fencing outline with gates.

B) Contractor’s responsibility- The contractor shall satisfy himself about the correctness and

applicability of the location plans before adopting them for detailed designs.

14.6 DETAILED DRAWINGS (A) FOR TRACTION SUB-STATION, FEEDING STATIONS AND SHUNT CAPACITOR BANK The contractor shall submit the following drawings for approval of the Engineer:

a) Cross section drawings Cross section drawings shall indicate the transverse and longitudinal cross-section of the soil along the center line of the equipments, bus bar supports and cable trenches. These drawings shall be prepared after an accurate survey at site and shall indicate the nature of the soil, its bearing capacity, compactness and in case of loose soil, cross-section of the parent soil. In the preparation of the drawings, care shall be taken to show all obstructions to be removed, such as telegraph posts, underground pipes, cables etc. after collection of such information from the site.

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b) General arrangement drawings General arrangement drawings shall indicate the general arrangement of all equipments, run of

busbars, position of pedestal insulators and steel frame work. The drawings shall also give a schematic connection diagram and an isometric view of busbars and connections wherever required. The drawings shall include an elevation view of the traction sub-station, transverse cross section and plan views. The drawings shall have a schedule of all equipments required at the traction sub-station along with drawing references of the details of these equipments.

c) Structural drawings Structural drawings shall be prepared for each supporting steel frame work or pedestal. The

drawing shall include one elevation view of the steel frame work assembly from behind, a transverse cross section and plan view. In the assembly each component member shall be marked with its reference number. The drawing shall also have a schedule of components members along with drawing references of various members. The weight of the component members shall also be indicated. The drawings shall be made for each component and this shall include all fixing bolts, nuts and washers whose sizes will be mentioned on the drawing. Unit weight of the components shall also be given in the drawing.

d) Foundation layout and cross section drawings: Foundation layout and cross section

drawings for each traction sub-station shall indicate layout of all foundations in plan, longitudinal and transverse cross-sections of various foundations through centre line of gantry/portal legs, various equipment/bus bar supports, fencing uprights and cable trenches. All foundations shall be marked serially on the drawing indicating the volume of concrete for each foundation block.

e) Earthing layout drawings. Earthing layout drawing shall be prepared for each traction sub-station indicating the layout of

full earthing system in plan, the drawing shall show the location of earth electrodes and mark the runs of earth leads and connections to equipment, gantry/portal columns, fencing uprights, structural supports etc. All components shall be marked with their reference numbers. For further details of the run of conductors and connections, separate drawings which may be common to all traction sub-stations may be made and references to these drawings marked on the layout. A schedule of components shall be made out in the drawing giving drawing references of components. These drawings shall be prepared duly taking into account the actual soil resistivity of the respective traction sub-station area, measured in the presence of the Engineer’s representative in accordance with the procedure laid down in IS: 3043-1987 or latest. The necessary design calculations for the proposed earthing system of the traction sub-station shall also be submitted by the Contractor for Engineer’s approval.

f) Cabling & Wiring drawings

Cabling and wiring diagrams for each traction sub-station shall indicate the schematic arrangement and physical disposition of equipment, run of cables and wires for inter-connections between various equipments both indoor and outdoor, colour coding and the index scheme adopted for terminals. The drawings shall also indicate the sizes of wires and grades of insulation. The quantity of various cables required shall be indicated on the drawings.

g) Fencing layout drawings Fencing layout drawings for each traction sub-station shall indicate the layout of entire fencing

and anti-climbing device in plan. Each upright, fencing panel and fixture on the upright shall be indicated on the drawing by its reference number. A schedule of components viz. uprights, gates, panels fixtures and barbed wires shall be included in the drawing indicating the drawing reference of the components. Type drawings shall be prepared for the various fencing components. An individual drawing shall be made for each type of panel, fencing post, gate and fixture of mounting the anti-climbing device. The drawing of each fencing post shall indicate the unit weight of the fencing post.

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h) Equipment drawings: Equipment drawings shall be applicable to all traction sub-stations complete with drawings of components/parts. The Contractor shall submit 5 copies for distribution to field office and one transparent print and soft copy on CD for the equipments to be supplied by the contractor. Drawings should be dimensioned and should indicate:

1) Fixing or mounting hole dimensions & arrangement. 2) Net weight of the equipment. 3) Characteristics and ratings including those of motors and resistors Etc. 4) Schematic and detailed circuit diagrams. 5) Overall dimensions and other important dimensions. 6) Height and disposition of all exposed live parts, height of the bottom most point of all bushings and insulators. 7) Notes explaining the operation of the equipment.

i) Miscellaneous Drawings

These drawings shall include the drawings or sketches made for study of clearances, isolator alignment details, number plates of various equipments, caution or instruction boards, non-standard bus bar connectors, clamps and U- bolts for cable mounting etc.

j) Schedule of Quantities On receipt of approval of relevant drawings for each traction sub-station, the following schedules of quantities relating to each traction sub-station shall be submitted by the Contractor within a fortnight of receipt of approval.

i. Schedule of foundations, showing volume of each type and total volume.

ii. Schedule of steel work, indicating types, weights of each member and total weight. iii. Schedule of type and number, weight of different types of masts for each gantry, iv. Schedule of quantities of those items of Bill of Quantities that are not included in items(i) &

(ii) above. v. Any other items required to satisfactorily commission the works but not included in the Bill of

Quantities.

14.7 SUBMISSION OF DESIGNS AND DRAWINGS a) The submission of designs and drawings for approval shall be done in the manner indicated

below . In every case the Contractor shall send all correspondence calculations, explanatory notes, other documents and drawings, in triplicate to the Design Office of the Engineer. In case Contractor wishes to deviate from standard drawings he should submit to the Engineer revised drawings with full details of deviation sought explaining the necessity of deviation, calculations and other supporting documents. The Engineer, if satisfied about the necessity and adequacy of deviations, shall refer the matter to RDSO for necessary approval. In case of deviations on working drawings decision shall be communicated by the Engineer to the Contractor. In respect of working drawings prepared on the basis of approved typical drawings other special drawings and schedules, all the three copies shall be submitted to the Design office of the Engineer. The Engineer will return one copy each of their drawings either with approval, subject to modification where necessary, or with comments. The Engineer shall endeavor to return this copy within a period of 15 days from the date of receipt and shall normally return the copy within a month. Where drawings are returned with comments or approved subject to modifications, the Contractor shall submit to the Engineer within 15 days of receipt of such advice, revised drawings for approval taking into account the comments or modifications. Also the Contractor shall, as far as possible, avoid correspondence on such comments and shall endeavor, to settle any difference or opinion on the comments by discussions with the Engineer’s Engineers. No drawings shall be re-submitted without incorporating the modifications required by the comments of the Engineer, unless the Engineer has agreed to the deletion of such comments.

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b) Distribution copies On receipt of Engineer’s unqualified approval to the Contractor’s drawings and schedule of

quantities, the Contractor shall submit original tracings of these drawings and schedules for the signature of the Engineer in token of approval within 7 days of the receipt of the approval. On receipt of these tracings from the Engineer, the Contractor shall submit 9 copies for distribution to field officers other departments within 7 days of receipt of approved tracings.

In all the above cases, the Contractor has the option to supply only five copies of the approved

drawings provided one of them is a transparent paper print. c) Drawings approved by the Engineer shall not be modified without prior consent in writing from

the Engineer. Drawings incorporating approved modifications shall be resubmitted for formal approval of the Engineer in the same manner as original drawings.

14.8 COMPLETION DRAWINGS AND SCHEDULES After completion of works, all drawings and schedules of quantities, submitted by the

Contractor and approved by the Engineer shall be made upto date incorporating actual supply and erection particulars. Such drawings and schedules shall then be verified and corrected, if necessary, by the Contractor jointly with the Engineer’s representatives. The verified and corrected drawings shall be supplied in four sets, two of which shall be transparencies on linen or any other durable material approved by the Engineer.

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CHAPTER: B-15

ERECTION AND INSTALLATION OF EQUIPMENTS-PSI

15.1 SCOPE This chapter deals with the method of erection and installation of equipments, including casting of foundation and erection of structures.

15.2 METHOD OF ERECTION

All work shall be done in accordance with standard acceptable methods of erection and installation of electrical equipment.

15.3 INSPECTION

All erection and installation work shall be subject to inspection by the Engineer to ensure that the work is done in accordance with specifications, approved designs and drawings and is of the best quality suitable for the purpose.

15.4 MEASUREMENT

All measurements for location of structures and foundations shall be made with the aid of the steel tapes.

15.5 BOLTS, NUTS ETC. All bolts, nuts and locknuts, screws, locking plates, split pins, etc., shall be properly tightened

and secured. No bolt may project more than 10 mm beyond the nut/locknut after full tightening,. Contractor shall carry out systematic inspection of this aspect of work after the installation is completed and prior to offering completed traction sub-stations, feeding stations and shunt capacitors banks to the Engineer for inspection and testing.

15.6 DAMAGE TO GALVANISING/PAINTING

The loading, transport and erection, all galvanized/painted materials shall be handled with care to avoid damage to galvanizing/painting. If galvanizing/painting is damaged in spite of all care taken, the damaged part or component shall be put for inspection, to obtain permission from the Engineer to carry out repairs as per 5.7 (b).

15.7- FOUNDATIONS a) Soil Sampling The Contractor shall carry out soil pressure tests in accordance with the method approved by

the Engineer to determine permissible bearing pressure of various representative types of soils in the presence of the Engineer’s representative during pegging out or site inspection. He shall adopt only accepted values for the design of foundations.

b) Location The location of each foundation shall be correctly set out in accordance with the approved

foundation layout drawings in the presence of the Engineer’s representative.

c) Method of installation The foundation bolts for erection of gantries, portals and other supporting frames, if any, shall

be grouted into the foundation in cored holes left in foundation blocks. Cored holes shall be left in foundation blocks for gantry legs or other steel work to be embedded. In any case, the method of casting foundation blocks and erection of gantries, portals and other supporting frames shall be subject to the approval the Engineer.

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d) Concreting All concreting or grouting shall be done in accordance with para 3.3 with aggregate graded for

the purpose specified in para 3.5. The concrete shall be poured and compacted properly in accordance with the method approved by the Engineer. The Contractor shall arrange to provide concrete testing samples for tests as and when required by the Engineer to determine the crushing strength after 28 days’ curing. Testing shall be arranged by the Engineer at his own cost.

e) Foundation level The top of all foundations and anchor blocks shall always be above the level of the ground and

of adequate height, not less than 15 cm. to afford reasonable protection during rainy season. The top of foundation shall be finished to make a smooth surface sloping 1/20 outwards to drain rain water.

f) Suitable grooves or niches shall be provided in the foundation blocks at the time of casting, to enable embodiment of earth strips without calling for chipping of the blocks subsequently.

g) Conduits of approved size should be embedded in the foundation blocks even in the initial stages to avoid chipping and breaking of the foundation blocks for embodiment subsequently.

h) All foundations will be cast in the presence of the Engineer’s representative with regard to fixed datum level.

i) Gantry Structures, Mast & fabricated structure at feeding station: Foundations for the gantry structures/portals, mast of gantries at feeding station shall be as per RDSO drawing included in Annexure-1 of specification, the base of which shall rest on consolidated soil.

j) Equipment Pedestals for power transformers shall be made of mass concrete with base resting on

consolidated soil. Foundations for Circuit Breakers supported on steel structures and for other items of equipment such as isolators, instrument transformers, bus bar support insulators etc. shall be of the pure gravity type, the base of which shall rest on consolidated soil, and shall be left with core holes into which the legs of the supporting structures shall be suitably fixed by grouting.

k) Cable trenches

The reinforced concrete cable trench shall rest on original ground if the depth of unconsolidated soil is less than 0.5 m. If the depth of the unconsolidated soil is more than0.5 m the cable trench shall be supported at suitable intervals on concrete pillars. Cable trench details are shown in a drawing included in Annexure-1 to these technical specifications.

l) Fencing posts Foundations for fencing posts shall rest on consolidated soil if the depth of unconsolidated soil is

less than 1.5m below the datum level and shall be rectangular parallel-piped in shape. If the depth of the unconsolidated soil is more than 1.5m the foundation block shall rest on reinforced concrete piles cast-in-situ or reinforced concrete foundation may be adopted as desired by the Engineer.

15.8 Structures

a) Erection The structures shall be embedded in the foundation blocks for the correct length specified in approved drawings.

b) Alignment The legs of gantries and other supporting frames shall be carefully aligned to enable easy and good assembly of top booms and other fabricated steel work.

c) Alignment of Mast at Gantries The main masts of gantries shall be carefully aligned to enable easy and good assembly of fabricated steel work.

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15.9 Equipment The installation of the equipment shall be carried out strictly in accordance with the instructions issued by the Manufacturer. The equipment shall be leveled carefully before being fixed finally in position. The bushings of equipments shall be protected adequately during erection of equipment to avoid chipping or damage to the porcelain. The following methods shall be adopted for mounting the various equipments.

Equipment Method of mounting

i) Main power transformer On two 90 lb/yd or higher capacity flat-footed rails laid on concrete foundations with a spacing of 1676 mm between the inner face of the rails.

ii) 220/110/66 kV Circuit breaker On steel supports mounted on concrete foundation with operating mechanism kiosk on concrete pedestal where necessary.

iii)25 kV Circuit breakers & Interrupters

On fabricated steel supports erected on concrete foundations.

iv) Isolators, potential transformers, current transformer LT supply transformers, 25 kV fuse switches & lightning arrestors.

On steel supports mounted on concrete foundations.

v) Shunt capacitor bank & series reactor

On steel racks which in turn shall be mounted on a concrete plinth with suitable base frame.

(The circuit breakers, interrupters and isolators shall be mounted in such a way that they can be manually operated conveniently by a person standing on the ground or on a concrete pedestal of suitable height)

15.10 BUSBARS AND CONNECTIONS

a)The bus bar connections on the incoming side, shall be as tight as possible, all similar connections in adjacent bays being uniformly shaped and bent to give a good appearance.

The tubular Aluminium busbars shall be supported at a uniform height through out. Wherever

tubular busbars are required to be bent, the radius of the bend shall not be less than 375 mm. b)All aluminium bus bar joints shall be made carefully, The contact surfaces of the bus-bars and

the connectors shall be cleaned vigorously either by hand with a dry coarse emery cloth or by power driven wire wheel brush. The surfaces shall be smeared with a suitable corrosion inhibiting joint compound approved by the Engineer. The joint closed-up as soon as possible thereafter and a final light application of joint compound shall be made. Similar procedure shall be followed while connecting the equipment terminals to be bus-bar by means of bi-metallic connectors.

15.11CABLING

a) Laying of Cables All cables provided out-door shall be either laid in trenches or neatly clamped to the structures as approved by the Engineer. If it becomes necessary to take the cable connections along the steel supports for the equipment, the cables shall be laid through bent or shaped GI pipes embedded in concrete while the foundations are being cast. All cables in the cable trenches and along the structures shall neatly secured with proper clamping arrangement at suitable intervals. Each cable in the cable trench/on the structure shall also be provided at suitable intervals with identification labels of durable material bearing indelible engraved or punched markings to facilitate easy identification.

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b) Termination of cables The cables shall be terminated neatly and the cores arranged and dressed properly. Suitable terminal strips and ferrules made of PVC or other durable materials shall be provided on terminals and wire ends respectively to facilitate identification. The marking on the terminals strips and ferrules shall be either engraved or punched so as to be indelible.

c) Indoor wiring

As far as possible all cables shall be laid in the trenches/pipes provided for the purpose in the Control Room. Wherever necessary indoor wiring on walls shall be clamped neatly on MS flats fixed to the wall by means of rag bolts grouted in the wall. The typical clamping arrangement is shown in the relevant drawing listed in Annexure-1.

15.12 EARTHING OF CONTROL ROOM

The earthing of control room shall conform to the guidelines laid down as per para 17.5(i). 15.13 SCADA SYSTEM

RDSO guidelines for increasing SCADA speed from 600/1200 bps to at least 9600 bps issued vide letter no. TI/SPC/RCC/SCADA/0130 (Rev.2) dated 07/2016 with A&C 1 (10/2016) or latest should be followed.

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CHAPTER: B-16 INSPECTION AND TESTING of TRACTION SUB-STATION

16.1 GENERAL

a) This chapter deals with the inspection and testing of completely erected sub-stations.

b) Reasonability The general tests of overall performance are only supplementary to other tests on structures,

foundations, equipments, components and fittings as specified elsewhere in these specifications or in standard specifications and are to be complied with. Any testing and acceptance by the Engineer of overall performance shall be subject to general terms of guarantee, which shall continue to be valid as provided for in the Bidding Documents.

c) INSPECTION AND TESTING CHARGES:

All inspection and testing charges shall be borne by the Contractor.

16.2 INSPECTION AND TESTS

(A) SUB-STATION (a) General As soon as a sub-station is ready for inspection and testing, the Contractor shall advise the

Engineer in writing. Tests will be carried out by the Engineer jointly with the Contractor. These shall include the tests which the Engineer may like to conduct with a view to assure himself of the soundness of the equipments and their erection in compliance with these specifications. Testing equipments such as these indicated below and staff required for the tests shall be provided by the Contractor free of charge.

1. Oil testing equipment. 2. 5000 V, 2500 V and 500 V meggers. 3. Earth megger and accessories. 4. Continuity test apparatus. 5. Avometer. 6. Relay testing kit. 7. Primary injection test set.

The Contractor shall take full responsibility for these tests inter-alia his other responsibilities.

(b) Visual Inspection Visual inspection which shall include check for satisfactory workmanship shall cover all

connections, painting, plastering, cleanliness of all insulators etc. and compliance with Indian Electricity Rules.

(c) Correctness of connections Correctness of connections of relays, alarm circuits, annunciator indications etc., shall be

thoroughly checked.

(d) This test will be conducted on every individual item of equipment such as Circuit Breakers, Isolators, Relays etc. to ensure that the equipment as whole is functioning properly and is mechanically sound, e.g. in the particular case of Isolators the fixed contact and knife blade have been correctly aligned and operation does not cause undue strain on the equipment. The operation tests will be carried out with the high tension installation disconnected from the supply, but by actuating power devices where such are provided. Continuity test of high tension connections after setting each Circuit breaker and Isolator in its respective position shall also be conducted as part of the operation tests.

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(e) Insulation The strength of insulation of the various items of equipment, cabling and of the entire

installation as a whole shall be tested with 5000/2500/500 V megger, as required. (f) The di-electric strength of the oil of instrument transformers (except if they are of sealed

construction) auxiliary transformers and Circuit breakers at each sub-station shall be tested before commissioning.

(g) Isolators All Isolators will be tested for smooth and trouble-free operation. Correct functioning of inter-

locking devices shall also be checked. (h) Instrument transformer Tests shall be conducted to check the polarity of Current and Potential transformers. (i) Ammeter and Voltmeter The Calibration of Ammeters and Voltmeters provided on the control board shall be checked. (j) Protective relays The Contractor, shall arrange for all protective relays to be tested and calibrated in a

recognized test laboratory at his own cost, just prior to installation on the control board, and shall submit six copies of the test certificates to the Engineer.

(k) Secondary injection tests Operation of all protective relays, auxiliary relays and trip and close coils for circuit breakers

shall be tested for satisfactory performance with the respective equipments de-energised. Correct functioning of all electrical interlocks inter tripping etc. shall also be checked during these tests.

(1) Actual fault tests The performance of the protective equipment for the 25 kV feeder circuits shall be checked

by putting a direct fault on the overhead equipment as below: i) Close to the feeding posts and ii) At the farthest point of feed and closing the feeder circuit breaker on the faulty section.

(B) FEEDING STATIONS a) GENERAL As soon as a feeding station, is ready for inspection and testing, the Contractor shall advise the

Engineer in writing. Testing will be carried out by the Engineer jointly with the Contractor. These shall include the tests which the Engineer may like to conduct with a view to assure himself of the soundness of the equipments and their erection in compliance with these specification. However, testing equipments such as those indicated below and staff required for the tests shall be provided by the Contractor free of charge.

i) Oil testing equipment. ii) 2500 V & 500 v meggers. iii) Earth megger and accessories. iv) Continuity test apparatus. v) Avometer;

The Contractor shall take full responsibility for these tests inter-alia his other responsibilities.

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(b) VISUAL INSPECTION Visual inspection which shall include check for satisfactory workmanship shall cover all connections, Painting, plastering, Cleanliness of all insulators etc. and compliance with Indian Electricity Rules.

(c) OPERATIONS TEST This tests will be conducted on every individual items of equipment such as interrupters,

isolators, relays etc. to ensure that the equipment as a whole is functioning properly and is mechanically sound, i.e. in the particular case of isolators the fixed contact and knife blade have been correctly aligned and operations does not cause undue strain on the equipment. The operation tests will be carried out with the high tension installation dis-connected from the supply, but by actuating power devices where such are provided. Continuity test of high tension connections after setting such interrupter and isolator in their respective positions shall also be conducted as part of the operation test.

(d) INSULATION The strength of insulation of the various items of equipment and of the entire installation as a

whole shall be tested with a 2500 V/500 V meager, as required. (e) ISOLATORS All isolators will be tested for smooth and trouble free operation. (f) INTERRUPTORS Operation of trip and close coils for interrupters, shall be tested for satisfactory performance

with the respective equipments de-energised. (C) SHUNT CAPACITOR BANK a)General

As soon as a capacitor installation is ready for inspection and testing, the Contractor shall advise the Engineer in writing. Tests will be carried out by the Engineer jointly with the Contractor. These shall include the tests which the Engineer may like to conduct with a view to assure himself of the soundness of the equipments and their erection in compliance with these specifications. Testing equipments and staff required for the tests shall be provided by the Contractor free of charge. The Contractor shall take full responsibility for these tests inter-alia his other responsibilities.

(b)Visual Inspection

Visual inspection which shall include check for satisfactory workmanship shall cover all connections, painting, plastering, cleanliness of all insulators etc., and compliance with Indian Electricity Rules.

(c)Correctness of Connections Correctness of connections of relays, alarm circuits, annunciator indications etc. shall be

thoroughly checked. (d)Operation test These test will be conducted on every individual item of equipment such as circuit breakers,

current transformers, potential transformers, isolators, relays etc. to ensure that the equipment as whole is functioning properly and is mechanically sound, e.g. in the particular case of isolators the fixed contact and knife blade have been correctly aligned and operation does not cause undue strain on the equipment. The operation tests will be carried out with the high tension installation disconnected from the supply, but by actuating power devices where such are provided. Continuity test of high tension connections after setting each circuit breaker and isolator in its respective position shall also be conducted as part of the operation tests.

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(e)Insulation The strength of insulation of the various items of equipment, cabling and of the ensure

installation as a whole shall be tested with 5000/2500/500 V megger as required. (f)The di-electric strength of the oil of instrument transformers (except if they are of seated

construction) shall be tested before commissioning. (g)Isolators Isolators will be tested for smooth and trouble free operation. Correct functioning of inter-

locking devices shall also be checked.

(h)Instrument transformer Tests shall be conducted to check the polarity of current and potential transformers. (i) Ammeter and Voltmeter The calibration of ammeters and voltmeters provided on the control board shall be checked. (j) Protective relays The contractor shall arrange for all protective relays to be tested and calibrated in a recognized

test laboratory at his own cost, just prior to installation on the control board, and shall submit six copies of the test certificates to the Engineer.

(k) Primary & Secondary injection tests. Operation of all protective relay, auxiliary relays and trip and close coils for circuit breakers shall

be tested for satisfactory performance with the respective equipments de-energised. Correct functioning of all electrical interlocks inter tripping etc. shall also be checked during these tests.

(l) Performance tests To verify the performance of the complete capacitor bank, tests as specified vide Clause 13.8

of RDSO specification No TI/SPC/PSI/FC&SR/01100 shall be carried out at site after installation.

16.3 EARTHING

Earth resistance will be measured separately for each earth electrode and when they are connected together and to the equipment at each sub-station, feeding station and shunt capacitor bank.

16.4 PROFORMA FOR TESTS

The contractor shall submit the results of tests at each sub-station feeding station and shunt capacitor bank in the performa, which will be furnished by the Engineer, in quadruplicate.

16.5 Measurement of contact resistance and opening/closing time of CBs/BMs during commissioning of TSS/switching post shall be done as per ACTM para 20908 and OEM. This is to be done as per pre-commissioning test.

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CHAPTER: B-17

EARTHING

17.1 EARTHING ARRANGEMENTS: Earthing of switching stations, booster transformer stations and LT supply transformer stations

shall generally comply with the code of practice for earthing IS: 3043-1987 or latest & RDSO spec. No. ETI/PSI/120(2/91) with A&C slip /no. 1 (10/93) except where otherwise specified below.

17.2 Switching Stations

(i) Earthing System At each switching station, two separate and independent earth circuits shall be provided, one for

earthing the HT equipment and the other for earthing the LT equipment. The general arrangement of earthing connections at a typical switching station is shown in the relevant drawing included in the Annexure to these Technical Specifications.

(ii) Earth Circuits Each earth circuit shall take the form of a closed ring and shall be provided with a minimum of

two earth electrodes. Each earth electrode shall consist of galvanized iron pipe, 40mm nominal bore at least 3.1 m long provided with a spike at one end and welded lug suitable for taking minimum size of 50x6 mm mild steel flat, directly at the other. The pipe shall be embedded into the ground. The earth electrodes of the HT and the LT earth circuits shall be located as far apart as it is possible. The drawing of typical earth electrode is included in the Annexure to these Technical Specifications.

(iii)HT earth Circuit The resistance to earth of the HT earth circuit shall be less than 2 ohms. If this value cannot be

achieved with a maximum of four separate but inter connected earth electrodes then the additional earth electrodes shall have the surrounding earth treated with charcoal and salt filling. All masts, structures, fencing uprights and equipment pedestals shall be connected with two separate and distinct connections to the closed loop of the earth bus. Earth bus and connections to it shall be of MS flats of a minimum size 50mm x 6 mm. Potential transformers and lightning arrestors shall be bonded to masts/ structures by 25 mm x 3 mm copper strips.

iv) LT earth circuits The LT earth circuit shall also comprise of a minimum of two inter-connected earth electrodes as

described in para (iii) above and the total resistance to earth of the earth circuit shall be less than 2 ohms. All low tension equipment, control boards, one terminal of the secondary of the potential and LT supply transformers, metal casing of battery chargers, shall be connected with earth bus through 8 SWG galvanized iron wire. The section of the LT earth bus shall be the same as that of the HT earth circuit.

(v) Earth strips The earth bus and connections of Ht earth circuit shall be painted with two coats of red oxide

zinc chromate primer to IS2074:1992 or latest with a minimum thickness of 1.5 mils (40 microns) and with two finishing coats of bitumen 85/25 (blown grade to IS: 702:1988 or latest with 20% mica to a thickness of about 15 mills (375 microns) either by hot application or by brushing a solution of it with suitable viscosity to obtain the thickness in minimum number of coats. It shall be buried at a depth of 300 mm below the ground level.

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The earth bus of the LT earth circuit shall run along the wall fixed on PVC plug rolls at a height of 300 mm from the floor. The connections to equipment will run from the bus along the wall and in processes in the floor. All recesses will be covered with cement plaster after finishing the work. The connection of earth strips to each other shall be made by 10 mm dia. Steel rivets or by welding. The connections to the various items of equipment and structures or fencing posts shall be made with GI bolts. The earth connection to the structural members shall be made at a height of about 150mm above the foundation.

(vi) Inter connection

The HT and LT earth systems shall be interconnected. In addition, at all switching stations, the HT earth shall be connected by two independent mild steel flats each of minimum size 50mm x 6 mm painted with two coats of red oxide zinc chromate primer to IS:2074:1992 or latest and finished with two coats of bitumen 85/25 blown grade as described above, to the non-track circuited rail in a single-rail-track-circuited section and to the neutral point of an impedance bond provided by the Engineer where double-rail-track circuiting is employed so as to limit high potential gradients developing in the vicinity of switching stations in the event of a fault.

17.3 Booster Transformer Stations

(i) Earthing System The earthing system shall comprise of a minimum of two inter-connected earth electrodes. The

general arrangement of earthing connections at a typical booster Transformer stations is shown in the relevant drawing included in the Annexure to these Technical Specifications. Each earth electrode shall consist of one galvanized iron pipe 40 mm nominal bore at least 3.1 m long provided with a spike at one end and welded lug suitable for taking a minimum size of 50 mm x 6 mm mild steel flat directly at the other end. The pipe shall be embedded into the ground. The earth bus interconnecting the two earth electrodes, shall consist of a minimum size of 50 mm x 6 mm mild steel strip. Each mast of the gantry shall be connected at the bottom to this earth bus by a minimum size of 50 mm x 6 mm M.S. flat. The resistance to earth of the earth circuit shall be less than 2 ohms as described in para (b) (iii) above. The transformers and the lightning arrestors shall be bonded to the gantry mast by means of copper strips of size 25mm x 3 mm. In addition, the earth circuit shall be connected to the non-track circuited rail in the case of single rail track circuit or to the mid point of impedance bond in case of double rail track circuit section.

(ii) Earth Strips The earth strips shall be painted with two coats of red oxide zinc chromate primer to

IS:2074:1992 with a minimum thickness of 1.5 mils (40 microns) and with two finishing coats of bitumen 85/25 (blown grade to IS:702:1988 or latest) with 20% mica to a thickness of about 15 mils (375 microns) either by hot application or by brushing a solution of it with suitable viscosity to obtain the thickness in minimum number of coats. They shall be buried at a depth of 300 mm below the ground level. The connection of earth strips to each other shall be made by 10mm dia. steel rivets or by welding. The earth connections to the structural members shall be made at a height of about 150mm above the foundation.

17.4 L.T. supply Transformer Stations. The earth arrangement of a pole mounted LT supply transformer station shall comprise interconnected earth electrode/electrodes having a resistance not exceeding 2 ohms. If this value can not be achieved with two electrodes, additional electrodes shall be provided and surrounded earth treated with charcoal and salt filling. The transformer and lightning arrestor shall be connected to the supporting steel structure by means of 2 independent connections at the top by means of 25mm x 3mm copper strip. At the bottom, the steel structures shall be connected to the inter-connected earth electrodes and to the nearest traction rail by means of two independent connections of mild steel flats having a minimum size of 50 mm x 6 mm. In addition, the earth electrode should be connected to the traction rail by means of a minimum size of 75 mm x 6mm mild steel flat. The mild steel flat shall be painted with two coats of red oxide zinc chromate primer to IS:2074:1992 or latest with a minimum thickness of 1.5 mils (40 microns) and with two finishing coats of bitumen 85/25 (blown grade to IS: 702:1988) or

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latest with 20% mica to a thickness of about 15 mils (375 microns) either by hot application or by brushing a solution of it with suitable viscosity to obtain the thickness in minimum number of coats.

17.5 EARTHING OF TSS

a) Earthing of traction substation shall generally comply with the code of practice for earthing- IS: 3043-1987 or latest and RDSO’s code of practice No. ETI/PSI/120(2/91) with A&C Slip no. 1 except where otherwise specified. The earthing system shall also conform to Indian Electricity Rules 1956 with latest amendments.

b) Earthing System At each substation, two separate earth circuit will be provided, one for earthing the HT

Equipment and the other for earthing the LT Equipment inside the control room. c) HT earthing grid A combined resistance of earthing system, in any sub-station shall not be more than 0.5 Ohms.

To ensure this, the Ht earthing grid shall be formed by means of bare mild steel rods of appropriate size as indicated in Clause (d) below buried at a depth of about 600 mm below the ground level and connected to earth electrodes by means of two separate and distinct connections made with 75mmx 8mm Ms flats. The connection between the Ms flat and Ms rod shall be made by welding, while that between, the earth electrodes and the Ms flats through Ms links by bolted joints. As far as possible the earthing grid conductor shall not pass through the foundation block of the equipments. All crossings between longitudinal conductors and transverse conductors shall be jointed by welding. The transverse and longitudinal conductors of the earthing grid shall be suitably spaced so as to keep the step and touch potentials within acceptable limits. The overall length of the earthing grid conductor shall not be less than the calculated length as per the code of practice. The earth electrodes shall be provided at the outer periphery of the grid as indicated in the sketch enclosed in Specification No. ETI/PSI/120(9/91) with A&C slip No.1. The earth electrodes shall be embedded as far away as possible from each other. Mutual separation between them shall usually be not less than 6 m. The contractor shall submit detailed design calculation for the earthing system and obtain approval of the design/drawings.

d) Earthing Grid Conductor The size of the earthing grid conductor shall be decided based on the incoming system voltage

and fault level. The size of the grid conductor for fault level upto 12000 MVA will be 32 mm dia and above 12000 upto 160000 MVA 36 mm dia and above 16000 upto 20000 MVA, 40 mm dia Ms rod respectively.

e) Earth Electrodes The earth electrodes shall normally be of mild steel galvanized perforated pipe of not less than

40 mm nominal bore of about 3 m length provided with a spike at one end and welded lug suitable for taking directly Ms flat of required size at other end. The pipe shall be embedded vertically into the ground as far as possible except in case of hard rock, where it may be buried inclined, the inclination being limited to 30 degree from the vertical. The connection of Ms flats to each electrode shall be made through Ms links by bolted joints. A typical drawing number of one earth electrode installation is included in Annexure-1. If the value of earth resistance specified may not be achieved with a reasonable number of electrodes connected in parallel such as in rocky soil or soil of high resistivity, the earth surrounding the electrodes shall be chemically treated by alternative layers of finely divided coke, crushed coal or charcoal and salt at least 150mm all around. However, coke treatment shall be used only where absolutely necessary and such electrodes shall not be situated within 6 m of other metal work. In high embankments, use of electrodes longer than 3 m shall be considered so as to reach the parent soil to achieve earth resistance as specified.

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f) Buried Rail A steel rail of section 52 kg/m and length about 13 m shall be buried near the track at the

traction sub-station at a depth of about 1 m to form part of the earthing system. Two separate and distinct connections shall be made by means of 75mm x 8 mm Ms flats between the earthing grid and the buried rail. The buried rail shall also be connected by means of two separate and distinct connections made with 75mm x 8mm Ms flats to the non-track circuited rail in a single rail track-circuited section and to the neutral point(s) of impedance bond(s) in a double-rail track circuited section. In case where the feeding post is located separately away from the traction substation, the buried rail shall be provided at the feeding post (where one terminal of the secondary winding of the traction power transformer is grounded).

g) System earthing One terminal of the secondary winding of each traction transformer shall be earthed directly by

connecting it to the earth grid by means of a 75 mm x 8 mm Ms flat and to the buried rail by means of another 75 mm x 8 mm Ms flat. One designated terminal of the secondary of each potential, current and Lt supply transformer shall also be connected to earth grid by means of two separate distinct earth connections made with 50 mm x 6mm MS flat.

h) Equipment earthing The metallic frame work of all outdoor equipments such as transformers, circuit breakers,

Interrupters & Isolators, as well as steel structures shall be connected to the earth grid by means of two separate and distinct connections made with MS flat of size 50 mm x 6 mm up to 10000 MVA and by 75 mm x 8 mm MS flats above 10000 MVA upto 20000 MVA. Equipments on the secondary side of the traction power transformer and steel structures shall be connected to the earth grid by means of two separate and distinct connections made with Ms flats of size 50 mm x 6 mm. One connection shall be made with the nearest longitudinal conductor while the other shall be connected with the transverse conductor.

i) Earthing inside the control room

An LT earth circuit shall be provided inside the Control Room by means of 50 mm x 6 mm mild steel flat and connected to the main earth ring by two independent connections made with 50 mm x 6mm mild steel flat. The metallic frame work of control panels, Lt AC and Dc distribution boards, battery chargers, remote control equipment, cabinets, etc. shall be connected to the earth ring by means of 8 SWG galvanized steel wire.

J) Earthing of Lightning arrestors

In addition to the earth electrodes provided for the main earth grid, an independent earth electrode shall be provided for each lightning arrestor. The earth electrode shall be connected to the ground terminal of the lightning arrestor as well as the main earth grid by means of two separate and distinct connections made with 50 mm x 6mm Ms flat for 25 kV side lightning arrestor. The earth electrode shall be provided as close as possible to the lightning arrestor and the connection shall be as short and straight as possible avoiding unnecessary bends. For lightning arrestors provided for the traction transformers, there shall also be a connection as direct as possible from the ground terminal for the lightning arrestor to the frame of the transformer being protected by means of two separate and distinct connections made with 50 mm x 6 mm Ms flat for 25 kV side arrestor and with 75mm x 8 mm Ms flat for primary side arrestor.

k) Earthing of fencing uprights and panels Each metallic fencing uprights shall be connected to the main by means of two separate and

distinct connection made with 50 mm x 6 mm Ms flat. In addition, all the metallic fencing panels shall be connected to the uprights by means of two separate and distinct connections made with 6 SWG GI wire.

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l) Method of Jointing All the joints between the MS flats, Ms rods or between Ms flat and Ms rods shall be made by

welding only. No soldering shall be permitted. For protection against corrosion, all the welded joints shall be treated with red lead and afterwards thickly coated with bitumen compound.

m) Painting of Ms Flats For protection against corrosion, all the exposed surfaces of earthing connections (MS flats)

above ground level shall be given all around two coats of painting to colour black of IS: 5/2004 or latest.

n) EARTH SCREEN The area covered by outdoor sub-station equipment shall be shielded against direct strokes of

lightning by an overhead earth screen comprising 45 tonne quality 7/9 SWG, 19/2/5 mm galvanized steel stranded wire strung across pinnacles of the metallic structures as indicated in the drawings included in Annexure-1. The earth screen wires shall be fixed not less than 2.5 m above the live conductors so as to provide an angle of protection, not exceeding 30 degree to the equipment/busbar below and shall be solidly connected to the sub-station earth circuit by means of 50 mm x 6mm Ms flats.

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CHAPTER: B-18

High Rise OHE 18.1 GENERAL RDSO has issued Design Handout for Overhead equipment for running Double stack container & Three Tier Car under electrified route (High Rise OHE) with speed potential 140 KMPH. Some important parameters of High Rise OHE are as given below- OHE Parameter

i Height of Double Stack Container : 7100 mm ii Height of Contact Wire at support from Rail Level : 7570 mm iii Height of Contact Wire at mid span from Rail

Level : 7520 mm

iv Height of Catenary Wire at support from Rail Level

: 8970 mm

v Pre sag at mid span : 50 mm vi Max stagger at Tangent Track : + 150 mm vii Max stagger at Curves : + 250 mm viii Standard Encumbrance : 1.40 metres ix Speed : 140 KMPH x Type of Mast : B-150/B-175/

B-200/ B-225/B-250 xi Mast Length : 11.4 metres xi Min Implantation : 2.8 metres xii Max Tension Length : 1.5 Km xiii Catenary Wire : 65 sq mm xiv Contact Wire : 107 sq mm Merging with Existing Conventional OHE For Mainline OHE (Height of Contact Wire at

support) : 5.80 metres

For High Rise OHE (Height of Contact Wire at support)

7.57 metres

The High Rise OHE shall be merged with conventional OHE with the contact wire gradient @ 10mm/metre.

18.2 HIGH RISE OHE FOR RUNNING DOUBLE STACK CONTAINERS UNDER ELECTRIFIED

ROUTE (WITH SPEED POTENTIAL OF 140 KMPH)

Design, installation and erection of High Rise OHE shall conform as per RDSO’s Design Document No-TI/DESIGNS/OHE/2014/00001(Rev 1), Dec 2014. Further RDSO has issued drawings for 11.4 meter masts, Portals, TTC, Employment Schedule, Foundations & Anchor Arrangement etc which shall be followed while executing the work.

1. The type of foundations shall remain same. However, the work to be done as per the relevant drawings issued by RDSO. Payment shall be made in cum under relevant BOQ.

2. Structures: RDSO has issued the drawings of 11.4m high masts, which shall be paid under relevant BOQ items. However, the additional erection rate shall be paid as NS item as per condition of agreement.

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List of Standard Technical Drawings of High Rise OHE

SN Name of Drawing Drg No.

1 11.40 m long Standard Traction mast (Fabricated with Batten Plates) ‘B’ series For High Rise OHE

TI/DRG/CIV/B- Mast/00001/13/0 dtd 18.03.2014

2 Drilling schedule for S-6 H mast (length 13.0m) (For High Rise OHE)

ETI/C/HR/0181 dtd 23.01.2015


ETI/C/HR/0182 dtd 23.01.2015


ETI/C/HR/0183 dtd 23.01.2015

5 Two Track Cantilever structure (TTC) (General arrangement) For High Rise OHE

TI/DRG/CIV/TTC/00001/13/0 Sh 1dtd 06.05.2014

6 Two Track Cantilever structure (TTC) Details of upright, For High Rise OHE

TI/DRG/CIV/TTC/00001/13/0 Sh 2 dtd 06.05.2014

7 Anchor arrangement with dwarf mast for Conventional and High Rise OHE

ETI/OHE/HR/G/01402 Mod A dtd 01.07.2015

8 Standard arrangement of Drop Arm for supporting cantilevers on the boom of portal & TTC (For Normal and High Rise OHE)

ETI/C/HR/0076 dtd 12.12.2014

9 Volume Charts and Equivalent chart of foundations (Side Bearing, Side gravity & WBC ) For High Rise OHE

TI/DRG/CIV/FND/00001/13/0 Sh 1 dtd 14.05.2013

10 Volume Chart and Equivalent chart of foundations (N G Type) For High Rise OHE


11 Volume and Equivalent chart of foundations for Dry Black Cotton Soil Only (NBC type) For 16500 & 11000kgf/ m² 3.0 m DEPTH For High Rise OHE


12 Volume Charts and Equivalent Chart of New Pure Gravity (500 mm exposed) For High Rise OHE


13 Volume and Equivalent Chart of foundations for Type Dry Black Cotton Soil Only (8000 Kgf/ m²) NBC type 2.5 m DEPTH For High Rise OHE

TI/DRG/CIV/FND/00001/13/0 Sh5 dtd 14.05.2013

14 Standard ‘N’ Type Portal General Arrangements For High Rise OHE

TI/DRG/CIV/N PORTAL/00001/13/0 Sh 1 dtd 31.03.2014

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15 Standard ‘N’ Type Portal Rod Laced Details of Upright Part ‘A’ For High Rise OHE

TI/DRG/CIV/N PORTAL/00001/13/0 Sh 2 dtd 31.03.2014

16 P- Type Portal General Arrangement & Details of Upright & End Pieces (High Rise OHE)

TI/DRG/CIV/P-Portal/00001/13/0 dtd 17.12.2014

17 Standard ‘O’ Type Portal General Arrangements For High Rise OHE

TI/DRG/CIV/O PORTAL/00001/13/0 Sh 1 dtd 31.03.2014

18 Standard ‘O’ Type Portal Rod Laced Details of Upright Part ‘A’ For High Rise OHE

TI/DRG/CIV/O PORTAL/00001/13/0 Sh 2 dtd 31.03.2014

19 Standard ‘R’ Type Portal General Arrangements For High Rise OHE

TI/DRG/CIV/R PORTAL/00001/13/0 Sh 1 dtd 31.03.2014

20 Standard ‘R’ Type Portal Rod Laced Details of Upright Part ‘A’ For High Rise OHE

TI/DRG/CIV/R PORTAL/00001/13/0 Sh 2 dtd 31.03.2014

21 G-Type Portal Special Upright and End Piece For High Rise OHE

TI/DRG/CIV/G- PORTAL/00001/13/0 dtd 06.05.2014

22 Special BFB portal For 5 tracks (General arrangement) For High Rise OHE

TI/DRG/CIV/BFB- PORTAL/00001/13/0 Sh 1 dtd 06.05.2014

23 Special BFB portal Details of Upright Part ‘A’ For High Rise OHE

TI/DRG/CIV/BFB- PORTAL/00001/13/0 Sh 2 dtd 06.05.2014

24 Portal more than 36 m and upto 46.5 m Issued by RDSO vide letter no. TI/CIV/MS/2015 dtd 12.01.2015

i. C1012-FDN-01 Rev 1

ii. C1012-FDN-01b Mod B iii. C1012-FDN-03 Mod 0 iv. OHE/8B/SW/1001 Mod A v. OHE/8B/SW/1002 Mod 0

vi. OHE/8B/SW/1003 Mod A vii. OHE/8B/SW/1004 Mod A

viii. OHE/8B/SW/1005 Mod A ix. OHE/8B/SW/1006 Mod A x. OHE/8B/SW/1007 Mod A

xi. OHE/8B/SW/1009 Mod A xii. OHE/8B/SW/1010 Mod A

25 High Rise OHE Employment Schedule Mast (11.4 m) (Wind pressure 178 Kgf/ m²) (Basic Wind speed 50 m/s) without return conductor and without earth wire)

TI/DRG/CIV/ES/00001/13/0 Sh 1 dtd 17.04.2014

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30 Dropper Schedule Encumbrance 1.4m/1.4m (For 25 kV AC OHE) (65 & 107 SQ MM) Conventional and High Rise OHE

TI/DRG/DROP/00001/ 10/1 (Rev 1) dtd 29.09.2014





33 Schedule Anchor Block for BG Tracks (For High Rise OHE)

TI/DRG/OHE/GUYHR/RDSO/00001/ 14/0 SH-1 dtd 19.09.2014

34 Schedule Anchor Block for BG Track Black Cotton Soil (For High Rise OHE)

TI/DRG/OHE/GUYHR/RDSO/00001/ 14/0 SH-2 dtd 19.09.2014

35 Guy Rod ¢ 25 mm For High Rise OHE TI/DRG/OHE/GUYHR/RDSO/00001/ 14/0 SH-3 dtd 19.09.2014

36 DROPPER SCHEDULE ENCUMBRANCE 1.4m/1.4m Tension 1100/1100 KgF (For 25 kV AC REGULATED (65 & 107 SQ MM)

TI/DRG/ OHE/DROP/00001/17/0 dtd 17.10.2017





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CHAPTER: B-19

Annexure-1

List of Standard Technical Drawings/Specifications For

Traction Sub stations/Feeding Posts This Annexure contains reference to standard, typical and particular drawings referred to in various paragraphs of the specification and specifications issued by the Engineer.

S No. Brief Description Drawing Mod.

No. Series Number

1 2 3 4 5

1. Typical location plan and general arrangement for a feeding station

ETI/PSI 006 E

2. Typical earthing layout of a feeding station -do- 203 B

3. Typical layout of 132 /27kv Traction sub-station (Type-I)

TI/DRG/PSI/TSSLO/RDSO/ 00001/01 0

4. Typical layout of 132 /27kv Traction sub-station (Type-II)


5. Typical layout of 132 /27kv Traction sub- station (Type-III)


6. Typical layout of 132/27kv Traction Sub-station (Type IV) (with outgoing feeders and metering Facilities)


7. Typical layout of 132/27kv Traction Sub- station (Type V)

TI/DRG/PSI/TSSLO/ RDSO/ 00005/02 0

8. Typical layout of 132/27kV traction sub-station (Type VI)


9. Typical layout of 132/27kV traction sub-station (Type VII)


10. Typical layout of 132/27kV traction sub-station (Type-VIII)


11. Typical layout of 132/27kV traction substation with single transformer (Type -IX)


12. Typical layout of 132/27kv Traction Sub- station with 132kv Switching Station (Type x)

TI/DRG/PSI/TSSLO/ RDSO/ 00010/02 0

RVNL



13. Typical layout of 220/27kV traction substation (Type -I)

ETI/PSI 0240-1 Nil

14. Mounting arrangement of 100KVA 25kv/240V LT supply transformer at TSS

ETI/PSI 0312 B

15. Typical schematic diagram of protection for double Transformer traction sub station

ETI/PSI 024-1 Nil

16. Typical layout for 25kV Shunt capacitor with series reactor to be installed at 132/25kV TSS

ETI/PSI 223 E

17. High speed auto reclosing scheme for feeder circuit breaker at 25kV A.C TSS

ETI/PSI 0231-1 A

18. Structural layout of 132/25 KV traction sub-stations (Type I to VI)

ETI/C 0200, SH.No.-1

H

19. Structural layouts of 132/25 kV traction sub-stations (Type VI to X)

ETI/C 0200, SH.No.-2

D

20. Line Diagram of Structural layouts of 220/25kV Traction sub-station

ETI/C 222 A

21. Typical schematic diagram of protection for single transformer traction sub-station

ETI/PSI 0228-1 Nil

22. Scheme of Interlocking arrangement for 25kV circuit breakers at Traction Sub-Station

ETI/PSI 5214 B

23. Structural layout of 220/27kV traction sub- station (Type-I)

ETI/C 0222-1 Nil

24. Typical general arrangement of earth screen wire termination at Traction substation

ETI/PSI 0225 C

25. Typical termination arrangement for strung bus "Spider" (AAC) conductor at TSS.

ETI/PSI 0226 B

26. General arrangement & terminal connection for 25kV PT Type-II at TSS

ETI/PSI 0227 A

RVNL



27. General arrangement and terminal connection for 25kV Potential Transformer at TSS (220kV)

ETI/PSI 0227-1 Nil

28. Typical return current connection to buried rail at 220/25kV TSS.

ETI/PSI 0242 A

29. Typical termination arrangement for strung bus (ZEBRA ACSR) conductor at TSS (220kV)

ETI/PSI 0243 A

30. Typical general arrangement of earth screen wire termination at 220/25kV traction sub- station.

ETI/PSI 0244 Nil

31. Bimetallic terminal connector to suit 'ZEBRA' ACSR conductor and 30 dia Cu stud of CT/CB/traction power transformer.

ETI/PSI/P 11010 C

32. 220kV system bimetallic terminal connector to suit 'ZEBRA' (28.58 Dia ) ACSR conductor & Al./Cu. pad of Isolator /CT/CB.

ETI/PSI/P 11030 C

33. 220kV system tee connector to suit 'ZEBRA' (28.58 dia ) ACSR conductor on both ways.

ETI/PSI/P 11040 C

34. 220kV system rigid connector on SI to suit ZEBRA (28.58 dia) ACSR conductor

ETI/PSI/P 11050 C

35. Detail of rigid type bimetallic terminal connector suitable for 50 dia Al. tubular busbar to 30 dia Cu. Stud of 25kV CT.

ETI/PSI/P 11070 B

36. Rigid bimetallic terminal connector suitable for 50 dia Al. tubular busbar to terminal pad of 25kv Isolator/ CT

ETI/PSI/P 11090 C

37. Rigid through connector to suit 50 dia Al. Tubular bus bar and ‘SPIDER’ AAC conductor for 25kv PT Type-II

ETI/PSI/P 11110 C

38. 25kv system tee connector to suit 50 O/D Al. Tube and 'SPIDER' 'AAC' conductor

ETI/PSI/P 11140 B

39. 25 K.V system Tee connector to suit 50. O/D AL. tubular busbar to 50 O/D AL tubular busbar

ETI/PSI/P 11150 B

40. 25Kv System Rigid bus splice connector to suit 50 O/D Al. tube on both ways

ETI/PSI/P 11180 B

41. 25 kV System Sliding clamp for 50mm O/D Aluminium Bus bar

ETI/PSI/P 11190 C

RVNL



42. 25Kv System Rigid connector on S.I to suit 50 mm O/D Al.Bus bar

ETI/PSI/P 11200 C

43. 25kv system expansion bus coupler on SI to suit 50 O/D Al. tube.

ETI/PSI/P 11210 D

44. Details of structure for 132kv double pole Isolator

ETI/C 310 G

45. Details of structure for 132kv support insulators

ETI/C 320 E

46. Details of structure for 132 kV Current transformer

ETI/C 330 F

47. Details of structure for 120 kV Lightning Arrestor

ETI/C 340 F

48. Details of structure for 25 kV Current transformer

ETI/C 360 F

49. Typical return current connection to buried rail at 132 kV/25 kV Traction Sub-Station.

ETI/PSI 0212-1 NA /Nil

50. General scheme of supply for 25 kV 50 Hz Single Phase AC Traction System

ETI/PSI 702-1 D

51. Part Plan for Details of position of feeder Bus coupling interrupter at TSS

ETI/PSI/SK 272 Nil

52. Terminal connector for 220kV equipments (Typical drawing)

ETI/PSI/SK 324 Nil

53. Expansion type terminal connector for 25 kV, 60mm dia terminal for traction power transformer.

ETI/PSI/P 11220 D

54. Details of Beam B/1 ETI/C 201 D

RVNL



55. Details of beam B/2 and column C/1 for 132/25kV traction sub-station.

ETI/C 208 E

56. Details of baffle wall at TSS (WP-112.5kg/sq.m) and WP (75kg/sq.m)

ETI/C 213 D

57. Details of RCC baffle Wall at TSS (WP- 150kg/sq.m)

ETI/C 214 B

58. Details of structure and foundation for 25kV DP Isolator at TSS

ETI/SK/C 0180 B/C

59. Transformer oil drainage arrangement at sub-stations

ETI/C 216 B

60. Drilling schedule for S-1 mast ETI/C 0030 F

61. Drilling schedule for S-2 mast -do- 0031 D

62. Drilling schedule for S-3 mast (length 11. 4 m)

-do- 0180 C

63. Drilling schedule for 8” x 6” x 35 1bs. RSJ mast 8.0 m long for booster transformer station Type S-4

-do- 0036 E

64. Drilling schedule for S-5 mast (11.4m long) -do- 0042 E

65. Drilling schedule for S-6 mast (length 12.4m)

-do- 0181 C


-do- 0182 C


-do- 0183 C


-do- 0184 C

69. Typical cable run layout of a feeding station -do- 303 B

RVNL



70. Typical details of cable run at a two transformer TSS with Shunt Capacitor

ETI/PSI 325 Nil

71. Typical details of cable run at two transformers Traction Sub-station with Shunt capacitor (220kV)

ETI/PSI 326 Nil

72. Typical details of cable run at a two transformer TSS

ETI/PSI 323 E

73. Typical cable trench and foundation lay out of 132/25kv TSS

ETI/C 210 F

74. Typical earthing, cable trench & foundation layout of 132/25kv TSS

ETI/PSI 224 E

75. Typical earthing cable trench and foundation layout of 132/25kV traction sub-station with Shunt Capacitor bay

ETI/PSI 229 Nil

76. Details of foundation for fencing upright -do- 0032 B

77. Typical fencing layout at traction Sub-station (Details of fencing panel, door, anticlimbing device etc.)

ETI/PSI 121 F

78. Typical fencing , door and anticlimbing device details of traction sub-station

CORE/ALD/PSI 1 D

79. Typical earthing arrangement for equipment/structure at TSS

ETI/PSI 228 A

80. Typical arrangement of an earth electrode. ETI/PSI 222-1 Nil

81. Typical number plate for circuit breaker ETI/PSI/P 7523 Nil

82. Typical number plate for Auxiliary Transformer

ETI/PSI/P 7525 Nil

83. Typical number plate for Power transformer at TSS

ETI/PSI/P 7526 Nil

84. Typical number plate for PT at TSS ETI/PSI/P 7527 A

85. Typical number plate for CT at TSS ETI/PSI/P 7528 A

86. Typical number plate for Isolators at TSS ETI/PSI/P 7529 A

87. Typical number plate for interrupter and double pole isolator

-do- 7520 B

RVNL



88. Typical number plate for potential transformer Type

-do- 7521 B

89. Gillsans Letters and Figures RE/33 527 A

90. Standard Post Insulator for clean area ETI/OHE/P 6090-1 C

91. Remote Control Cubicle at Stn, Foundation, RCC slab, Building plant & Steel door

-do- 0067 B

92. Typical layout of Control Room at tractionsub-station.

TI/DRG/PSI/CPROOM/ RDSO/

00001/01 0

93. Standard plan of control room at traction sub-station (General arrangement and RCC details)

RE/Civil S-144 6

94. Control Room for Traction substation ETI/C 0225 Sheet-1

Nil

95. Control Room for Traction Sub-station(RCC details)

ETI/C 0225 Sheet-2

Nil

96. Typical details of pressed steel door, window and ventilator

RE/Civil/S 129/ 2001

R2

97. Typical layout of control room at TSS TI/DRG/PSI/CPROOM/ RDSO

00001/01 0

98. Details of Tower T 1 ETI/C 202 H

99. Details of Tower T 2 ETI/C 203 G

100. Details of small part steel for switching station

ETI/C 0034 Sh.1

K

101. Typical general arrangement of a three interrupter switching station

ETI/PSI 004 F

102. Typical location & schematic connection diagram for a three interrupter switching station

ETI/PSI 003 C

103. Typical earthing layout of sub-sectioning and paralleling station

-do- 201 B

RVNL



104. Details of pre-cast cable trench for switching station

-do- 0038 E

105. Typical cable run layout of a sub-sectioning & paralleling station

-do- 301 C

106. Typical cable run layout of a sectioning and paralleling station

-do- 302 C

107. General arrangement & details of fencing panels & gate for switching station

-do- 0186 Sh.1

E

108. Details of fencing uprights and anti-climbing device for switching station

-do- 0186 Sh.2

E

109. Typical fencing and anti-climbing arrangement at switching stations

ETI/PSI 104 E

110. Typical location plan & general arrangement for sectioning & paralleling station

-do- 005 F

111. Typical earthing layout of a sectioning and paralleling station

-do- 202 B

112. Typical drawing for a terminal board -do- 501 C

113. 36 mm Aluminum Bus terminal for 25kv Isolator (Rigid type)

ETI/PSI/P 6480 C

114. 36 mm Aluminum Bus splices -do- 6490 B

115. 36 mm Aluminum Bus Tee connector -do- 6500 C

116. 36 mm Aluminum Bus Tee terminal -do- 6510 D

RVNL



117. 36/15 mm Top connector -do- 6520 B

118. 36mm Aluminum flexible bus splice -do- 6550 B

119. 36 mm Aluminum bus splice cum tee connector

-do- 6560 B

120. 25kv D.O. Fuse switch assembly ETI/PSI 032 D

121. Details of Rigid terminal connector suitable for 20 dia Al. Conductor to terminal pad of 25 kV PT Type I & II

ETI/PSI/P 11120 C

122. 25 kV drop out fuse switch details ETI/PSI 038 C

123. Operating pole for 25kV drop out fuse switch ETI/PSI 039 B

124. Flexible connector for 25 kV circuit breaker 25kV Interrupter & 25 kV side of 13.5/20 MVA traction transformer.

ETI/PSI/P 6570 F

125. Earthing details for interrupter L.T. supply transformer 25 KV Lightning Arrestors P.T. Type- I (S-100 masts, S-101 mast, fencing upright and main mast)

-do- 204 C

126. Details of anchor beam of SP, SSP, & FP -do- 0033 D

127. S-100 fabricated mast for mounting LT supply transformer and drop out fuse switch at switching station

-do- 0043 B

128. S-101 details of mast for supporting Isolator inside switching station

ETI/C 0044 A

129. Details of structure for 42kV, 10KA LA & 25 kV support insulator

ETI/C 0370 Sheet-1

J

130. Black Weight of Structure for 42kV,10KA LA & 25kV support insulator.

ETI/C 0370 Sheet-2

Nil

131. Details of structure for 25 kV Single Pole isolator

ETI/C 0380 F

RVNL



132. Details of structure for 25kV Potential transformer

ETI/C 0390 E

133. Typical schematic diagram for TSS, FP, SSP and SP with 21.6 MVA or 30 MVA transformers for three lines.

TI/DRG/PSI/3L-TSS/RDSO 00001/07 1

134. Typical layout of Remote Control cubicle at a switching station

ETI/PSI 0010 E

135. Typical layout of remote control cubicle at switching stations.

ETI/PSI 0010 E

136. Schematic inter connection diagram for remote control of power gear & supervision equipments at TSS.

ETI/PSI 644 C

137. Schematic inter connection diagram for remote control of power gear and supervision equipments at controlled station (SP & SSP)

ETI/PSI 645 C

138. High speed Auto reclosing Scheme for feeder Circuit Breaker at 25 kV a.c. Traction Sub-station.

ETI/PSI 0231-I A

139. Control desk arrangement for 2 work stations of SCADA system.

ETI/PSI/SK 337 Nil

*****

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LIST OF STANDARD RDSO’s SPECIFICATIONS FOR PSI & SCADA

S.No. DESCRIPTION SPECIFICATION NO. LAST REV.

1 Battery charger for 110 Volt battery, 40 AH. ETI/PSI/1(6/81)

2 25 kV Dropout fuse switch ETI/PSI/14(1/86) with A&C slip no 1 of (4/87)

1

3 25kV/240 V Auxiliary Transformer, 5kVA, 10kVA, 25kVA & 50 kVA

ETI/PSI/15(08/2003) -

4 25kV/240 V Auxiliary Transformers 100 VA. ETI/PSI/ 15A (7/82) with A&C slip no 1

1

5 Battery charger for 110V. battery 200 AH. ETI/PSI/24(6/81) -

6 Standards for drawings for Power Supply Installation.

ETI/PSI/31(5/76) -

7 Current transformer, 132 kV ( type-II). ETI/PSI/36(5/75) -

8 Control & distribution panel for colour light signaling supply in 25 kV ac traction systems.

TI/SPC/PSI/CLS/0020(12/02) with A&C slip No. 1, 23 & 4 of (07/10)

4

9 Standards for electrical distribution system in stations & yards where 25 kV ac traction is to be introduced.

ETI/PSI/44(12/73) -

10 Control and relay panel for 25 kV ac TSS including specification for numerical type protection relays for traction transformer, 25 kV shunt capacitor bank and transmission line for 25 kV Ac TSS on Indian Railways.

TI/SPC/PSI/PROTCT/ 6071(2/15) -

11 Shunt Capacitor equipment for Railway traction sub-stations.

TI/SPC/PSI/FC&SR/0100(01/10) -

12 Hollow porcelain insulators & Bushing. ETI/PSI/70 (11/84) -

13 Metal oxide gapless type lightning arrester for use on 25 kV Side of Railway traction sub-stations and switching stations.

TI/SPC/PSI/MOGTLA/0101 (02/2015)

-

RVNL



14 Electric power connectors for AC Traction power system.

ETI/PSI/72 (9/85) -

15 25 kV, 50 Hz single phase series Compensation Equipment.

ETI/PSI/75(10/97) -

16 25 kV ac 50 Hz single phase oil filled current transformers with ratio of (i) 1000-500/5 A, (for general purposes, (ii) 1500-750/5 A (for heavy duty), (iii) 200-100/5A (iv) NCT ratio 2/1 and 5/1 A (v) 2 core PS Class 3000-1500/5 A (vi) 2 core PS Class 1500-750/5 A (vii) Single Core PS Class 1500-750/5 A.

ETI/PSI/90 (6/95) with A&C Slip No.1, 2,3,4,5,6,7 (08/2007) & 8 (April 2009).

8

17 100 KVA, and 150 KVA 25 kV single phase 50 Hz, oil filled booster transformer.

ETI/PSI/98(8/92) 3

18 Trivector meter and maximum demand Indicator for Railway AC Traction.

ETI/PSI/99(4/89) -

19 Specification for 25 kV AC Single pole and Double pole motorized isolators for Railway Electric traction

TI/SPC/PSI/ISOLTR/1060(08/06) with A&C Slip No.1 (Dec 2014).

-

20 Dynamic reactive power compensation equipment for Railway traction sub-stations (for development of prototype only).

TI/SPC/PSI/DRPC/0050(08/05) -

21 Gas Chromatograph for use in analysis of dissolved gases of transformer oil.

ETI/PSI/105(7/93) -

22 Capacitance bridge and dissipation factor bridge for the measurement of solid insulation of insulating oil.

ETI/PSI/106 (10/87) -

23 Current transformer

i) 220 kV, 200-100/5 ii) 132 kV, 400-200/5 iii) 110 kV, 400-200/5 iv) 66 kV, 800-400/5

ETI/PSI/117 (7/88) with A&C Slip No.1 (11/88), 2 (3/89), 3 (12/89), 4 (4/90), 5 (6/90), 6 (9/92), 7 (8/05), 8 (08/2007) & 9 (July 2008).

9

24 Power transformer 21.6 MVA, single phase 50 Hz, 220/132/110/66/27 kV for traction substation.

ETI/PSI/118 (10/93) with A&C Slip No.1 to 10 (08/12) or latest

10

RVNL



25 Code of practice for earthing of power supply installation for 25 kV. AC. 50 Hz single phase traction system.

ETI/PSI/120 (2/91) with A/c Slip No1 (10/93)

1

26 Specification for 245/145/123/72.5 kV double pole and triple pole isolators.

ETI/PSI/122 (3/89) with A&C Slip No.1(4/90)

1

27 21.6 MVA, 220/132/110/66 kV/2x27 kV, single phase, 50 Hz traction power transformer for ‘AT’ feeding system

ETI/PSI/123(9/93) with A&C Slip No.1(1/94)

1

28 54 MVA, 220/2x27 kV Scott-connected power transformer for 2 x 27 kV ‘AT’ feeding system.

ETI/PSI/124(7/95) -

29 8 or 5 MVA, 2x 27 kV 50 Hz, auto transformer for 2x27 kV ‘AT’ feeding system.

ETI/PSI/125(7/97) -

30 25 kV shunt capacitor equipment for 2x25 kV ‘AT’ feeding system.

ETI/PSI/126(8/89) ) with A&C Slip No.1&2 (9/90)

2

31 Series capacitor equipment for 2x25 kV ’AT’ feeding system.

ETI/PSI/127(8/89) ) with A&C Slip No.1 (1/90)

1

32 Resonance suppressing C-R device for 2x25 kV ’AT’ feeding system.

ETI/PSI/128(8/89) with A&C Slip No.1,2&3 (1/90)

3

33 Control & relay panel including Numerical

type protection relays for scott connected single phase traction transformers, OHE protection & shunt capacitor bank protection for 2x25 kV traction sub-station.

TI/SPC/PSI/PROTCT/7100 (07/2012)

-

34 25 kV ac double pole isolators for 2x 25 kV ’AT’ feeding system.

ETI/PSI/133(8/89) with A&C Slip No.1&2 (10/91)

2

35 ‘AT’ Boost up current ratio type fault locator for OHE for 2x 25 kV ’AT’ feeding system.

ETI/PSI/135(8/89) with A&C Slip No.1 (1/90)

1

36 Metal oxide gapless type lightning arresters for use of 220/132/110/66 kV side of railway ac traction substation.

ETI/PSI/137 (8/89) with A&C Slip No.1 (1/90), 2(2/91), 3(12/91), 4(8/94) 5 & 6 (9/05) & 7(07/2007)

7

RVNL



37 Technical specification for leakage current monitor for lightning arrester

TI/SPC/PSI/LCMLA/0030 Rev. 1 (7/10)

1

38 25 kV ac double pole outdoor Sf6 interrupters for 2 x 25 kv ’AT’ feeding system.

ETI/PSI/139 (12/89) 4

39 Technical specification for Microprocessor based Numerical integrated feeder Protection Module comprising DPR, INST, OCR, PTFE, & Auto Re-closure Relay for 25 kV. AC single phase 50 Hz traction Sub-station.

TI/SPC/PSI/PROTCT/5070 Rev. 1 (9/14)

1

40 Supervisory control and data acquisition (SCADA) system for 2x2 5 kV ‘AT’ Traction Power Supply.

ETI/PSI/144(12/91) -

41 Specification for 11 kV current transformer with ratio 500/5 for 2x 25 kV ‘AT’ feeding system.


1

42 Specification for 25 kV current transformer with CT ratio 100-50/5 for shunt capacitor banks in 2x 25 kV ‘AT’ feeding system.


1

43 Specification for SF6 gas leakage detector. ETI/PSI/148(4/92) -

44 25 kV ac 50 Hz single pole outdoor pole mounted vacuum interrupter.

ETI/PSI/159 (10/94) 1

45 21.6 MVA, 100/27 kV OR 220/27 kV single phase, 50 Hz, ONAN traction power transformer

ETI/PSI/163 (4/97) with A&C Slip No.3 (5/2000)

3

46 25 kV, 50 Hz single pole outdoor interrupter for Railway Traction switching station.

TI/SPC/PSI/LVCBIN/0120 1

47 Magnetic actuator type 25 kV. AC 50 Hz single pole outdoor vacuum interrupter for railway traction switching station.

TI/SPC/PSI/VACINT/0040(05/05) -

48 Specification for Delta-I type High Resistive Fault Selective Relay for 25 kV ac single phase 50 Hz traction system.

TI/SPC/PSI/PROTCT/1982(12/03) with A&C Slip No.1 (10/13)

1

RVNL



49 Specification for panto flashover protection relay for 25 kV ac single phase 50 Hz traction system.

TI/SPC/PSI/PROTCT/2983(09/01) -

50 Control and relay panel for protection system of Mumbai area for 50 Hz Ac traction power supply system including parallel operation on 25 kV side.

TI/SPC/PSI/PROTCT/4050(11/05) -

51 Specification for SCADA, 25 kV single phase 50 Hz ac traction power supply

TI/SPC/RCC/SCADA/0130 (Rev 2) July 2016 with A&C 1

2

52 Specification for 220 kV, or 132 kV, or 110 kV, or 66 kV or 25 kV potential transformer.

TI/SPC/PSI/PTS/0990 with A&C Slip No.1,2,3,4,& 5 (April 09)

5

53 Outdoor 220/132/110/66/kV Double/Triple Pole Outdoor SF-6 circuit breaker for Indian Railways.

TI/SPC/PSI/HVCB/0120 (June, 2014) with A&C slip No. 1 & 2 (Oct 2016) or latest

0

54 30 MVA, 220/27 kV single phase traction power transformer.

TI/SPC/PSI/30TRN/0030(06/03) -

55 30 MVA, 110 /27 kV single phase traction power transformer with on load tap changer ( for use in Mumbai sub-urban area)

TI/SPC/PSI/30TRN/1050(12/05) -

56 30 MVA, 220/27 kV, 110/27 kV, & 66/27 kV single phase traction power transformer ONAN/ONAF with on load tap changer (for use in TSSs other than Mumbai area).

TI/SPC/PSI/30TRN/2070(10/07) -

57 25 Core Armoured Optic Fibre cable for use in Indian Railways traction installation systems.

TI/SPC/PSI/OFC/0050(10/05) -

58 Technical specification for power quality analyzer and Recorder with Remote display.

TI/SPC/PSI/PQAR/0080(09/08) - RVNL



59 Technical specification for Supervisory control and data acquisition system (SCADA) for 25 kV single phase 50 Hz ac traction power supply for Mumbai area.

TI/SPC/RCC/SCADA/0130 (Rev. 2) July 2016 with A&C 1 No.1

2

60 Relay testing kit for testing of Static/ Electromagnetic / Micro-processor based numerical protection relays used for 25 kV ac, 50 Hz, single phase traction system of Indian Railways.

TI/SPC/PSI/TESTKIT/1080(12/08) -

61 Manufacture and supply of 132 kV XLPE underground cable and accessories.

TI/SPC/PSI/CABLE/0090(02/09) -

62 Technical specification for 50/75/150 MVA, ONAN/ONAF/OFAR 220/132 kV, 3-Phase oil immersed type Auto transformer.

TI/SPC/PSI/AUTOTR/0090 (02/09) -

63

25 kV Single Pole Vacuum Circuit Breaker

TI/SPC/PSI/LVCB/0120 (Dec, 2013) with A&C slip No. 1 (Oct 2016) or latest

0

64

25 kV Single Pole Vacuum Interrupter

TI/SPC/PSI/LVCB/0120 (Dec, 2013) with A&C slip No. 1 (Oct 2016) or latest

0

Note- For structural steel (standard quantity), please refer IS: 2062-1992.

*****

RVNL



CHAPTER: B-20

ANNEXURE-2 LIST OF STANDARD DRAWINGS AND SPECIFICATIONS FOR OHE WORKS

All references to drawings charts schedules of specifications given in this Annexure shall be taken to the latest version of such drawings, charts, and schedules of specifications as issued by the purchaser.

A) LIST OF STANDARD DRAWINGS

Sl. No.

Brief Description Drawing Mod. No. Series Number

1 2 3 4 5 1. Extra allowance for setting of structures on curves

(1676 mm Broad gauge) ETI/OHE/G 00111

Sh.1 C

2 Standard setting of structure in the vicinity of signals (broad gauge)

ETI/OHE/G 00112 C

3 Typical design of bearing foundation. ETI/OHE/G 00131 - 4 Deleted - 5 Typical design of cantilever mast. RF/33/G 00141

Sh.3 -

6 Standard drilling schedule of OHE masts 9.5 m long RSJ and BFB respectively.

ETI/OHE/G 00144 Sh.3

C

7 Span and stagger chart for (conventional) OHE, Cad. CU catenary & Cu cont. wire) wind pressure 75,112.5 &150 kgf/sq.m

ETI/OHE/G 00202 -

8 Employment schedule for Cantilever mast Regulated OHE cat. 65/Cu and Cont 107/Cu WP 112.5 kgf/sqm without EW & without RC.


E

9 Employment schedule for cantilever mast regulated OHE cat. 65/Cu & cont. 107/GC, WP 112.5 kgf/sq.m with EW & without RC.

ETI/OHE/G 00153 E

10 Employment schedule for cantilever mast regulated OHE Cat. 65/Cu & cont 107/Cu, WP 112.2 kgf/sq. m with EW & with RC


E

11 Employment schedule for cantilever mast regulated OHE Cat 65/Cu & cont 107/Cu, WP 112.2 kgf/sq.m with EW & with RC


D

12 Employment schedule for cantilever mast unregulated OHE Cat 65/Cu & cont 107/Cu, WP 112.2 kgf/sq.m at 35 deg. C and with 28 kgf/sq.mat 4deg. C without EW & with RC

ETI/OHE/G 00154 D

13 Employment schedule of bracket tubes regulated pressure Conventional OHE (Cd Catenary & Cu Contact wire 1000 kgf tension each)

ETI/OHE/G

00158 Sh.1

(for wind pressure 75kgf/ sq.m)

ETI/OHE/G

Sh.2 (for wind

pressure 112.5

RVNL



ETI/OHE/G kgf/sq.m Sh.3 (for

wind pressure

150 kgf/sqm.

14 Dropper schedule for – uninsulated, overlap spans

ETI/OHE/G 00169 A

15 Dropper schedule for insulated overlap spans

ETI/OHE/G 00170 A

16 Dropper schedule for conventional regulated OHE with Zero presag (1400/1400)

ETI/OHE/G 00177 A

17 Adjustment chart of Regulating equipment 3-pulley type 3:1 ratio

ETI/OHE/G 00195 A

18 Schematic arrangement of regulated OHE

ETI/OHE/G 02101 A

19 Schematic arrangement of un-insulated overlap (3&4 span overlaps)

ETI/OHE/G 02121 Sh-4

A

20 Schematic arrangement of insulated overlap ETI/OHE/G 02131 Sh.3

A

21 Termination arrangement of OHE with 3 pulley type regulating equipment (3:1 ratio)

ETI/OHE/G 01212 B

22 General distribution of droppers.

ETI/OHE/G 0101 A

23 Outline of pantograph (broad gauge and metre gauge).

RE/33/G 00181 A

24 General formation of single track embankments and cutting (broad gauge).

RE/33/G 01101 Sh.1

A

25 General formation of double track in embankments and cutting (broad gauge)

RE/33/G 01102 Sh.1

A

26 General formation of multiple tracks (1675 mm gauge)

RE/33/G 01103 Sh.1

A

27 Standard anchor arrangement

RE/33/G 01401 E

28 Schedule of anchor block for BG track. ETI/OHE/G 01403 Sh. 1

D

29 Double guy rod arrangement with anchor block for BG track.

ETI/OHE/G 01403 Sh 2

C

30 Schedule of anchor block for BG track (black cotton soil)


B

31 Standard guide tube arrangement on a mast and structures.

ETI/OHE/G 01505 -

32 Trapezoidal counter weight arrangement on OHE structures.

ETI/OHE/G 01502 -

33 Arrangement of 3 kV & 25 kV pedestal insulator supports on OHE masts and portals.

ETI/OHE/G 01601

34 Details of foundation in hard rock for portals

ETI/C 0080 A

RVNL



35. Standard arrangements for mounting of number plate on OHE structures

ETI/OHE/G 01701 A

36. Schematic arrangement of regulated overhead equipment.

ETI/OHE/G 02101 A

37. Typical arrangements of OHE on cantilever masts for double track section

ETI/OHE/G 2102 -

38 Typical arrangement for fixing of bracket assembly on 9.5 m mast and structure to set raising of tracks (in future)


39 Mast on platforms (1676mm gauge). ETI/OHE/G 02104 Sh.1

A

40 Details of bracket arrangement on tangent and curved tracks


A

41 Details of bracket arrangement for OHE (High speed).


C

42 Single bracket assembly on structures and dropped arms.

RE/33/G 02107 D

43 Box type cantilever Arrangement. ETI/OHE/G 02108 A 44 Arrangement at anti-creep. ETI/OHE/G 02111 A 45. Standard cantilever arrangement for boom anchor

anti-creep location. ETI/OHE/G 02113 -

46 Schematic arrangement of uninsulated over lap (type-1) 3&4 span overlaps.

ETI/OHE/G 02121 sh.1

F

47 Schematic arrangement of insulated overlap. ETI/OHE/G 02131 sh.1

A

48 General arrangement of regulated OHE at turn-outs (overlap &crossed type).

ETI/OHE/G 02141 C

49 General arrangement of regulated OHE at cross over (overlap &crossed type)

ETI/OHE/G 02151 -

50 Arrangement of neutral section ETI/OHE/G 02161 Sh.1 of

2

-

51 Arrangement of neutral section assembly (PTFE Type)at SWS.

ETI/OHE/G 02162 -

52 Arrangement of short neutral section. ETI/OHE/G 02161 Sh.2 of

2

-

53 Schematic arrangement of unregulated overhead equipment.

ETI/OHE/G 03101 -

54 Standard termination of OHE (regulated & un regulated)

ETI/OHE/G 03121 E

55 General arrangement of unregulated OHE at turnouts (crossed & overlap type).

ETI/OHE/G 03151 -

56 General arrangement of unregulated OHE cross overs and diamond crossings (overlap and crossed type).


-

57 General arrangement of unregulated OHE at diamond crossing


-

58 General arrangement of pull off ETI/OHE/G 03301 A 59 General arrangement of head span ETI/OHE/G 03201 - 60 In span jumper connection between catenary &

contact wire. ETI/OHE/G 05101 -

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61 Continuity jumper connection at uninsulated overlap ETI/OHE/G 05102 C 62 Arrangement of anti-theft jumper ETI/OHE/G 05107 A 63 Connection at turn outs ETI/OHE/G 05103 B 64 Potential equalizer connection at insulated overlap

and neutral section ETI/OHE/G 05104 -

65 Connections at diamond crossing. ETI/OHE/G 05106 A 66 General arrangement of connections to OHE by

copper cross feeder (150). ETI/OHE/G 05121

Sh.1 C

67 General arrangement of connections at switching station on double track section by copper cross feeder (150).


C

68 General arrangement of connections at switching station on multiple track section by copper cross feeder (150).


C

69 Suspension of 25 kV feeder (spider on OHE masts. ETI/OHE/G 05143 B 70 Termination of feeder, return conductor & return

feeder (copper & aluminium) RE/33/G 05145

Sh.1 A

71 Arrangement of suspension of double spider 25 kV feeder and return feeder between substation and feeding station

RE/33/G 05152 C

72 Assembly of section insulators RE/33/G 05181 C 73 General arrangement of earth wire on OHE mast. ETI/OHE/G 05201 A 74 General arrangement of earth wire on OHE mast ETI/OHE/G 05201-1 - 75 Arrangement of transverse bonds ETI/OHE/G 05251 A 76 Connection of return conductor to track ETI/OHE/G 05306 F 77 Suspension arrangement of aluminium return

conductor (spider) on traction Structures. ETI/OHE/G 05307 B

78 Suspension of return conductor (spider) from boom of structures (with clevis type disc insulators)

ETI/OHE/G 05312 A

79 Connections between OHE and aluminium return conductor at booster stations

ETI/OHE/G 05413 B

80 Mounting of 25 kV Isolators on OHE structures (General arrangement )


A

81 Details of small part steel work for supporting 25 kV Isolator on new TCC boom


A

82 Connection from isolator to OHE ETI/OHE/G 05516 A 83 Characteristics of conductors/bus-bar for 25 kV Ac

traction ETI/OHE/G 05600 A

84 Arrangement of mounting 25 kV/240 , 10 KVA LT supply transformer.

ETI/OHE/G 05522 -

85 Employment Schedule for Cantilever Mast regulated OHE Cat 65 Cu Cad, 107 /Cu WP 75 kG/sq.m

ETI/C ETI/C ETI/C ETI/C

0702(OHE only) (Sh.1)

OHE+EW. (Sh. 2)

OHE+RC),Sh.3)

OHE+EW/RC,Sh.4

A A A A

86 Employment Schedule for Tramway type regulated OHE (WP 75 kgf/sqm) without Ex. & without RC.

ETI/C 0704 A

87 Employment Schedule for 8” x 8” x 35lbs FBB (9.5 M. long) WP 112.5 kgf/sq.m Cat. 65/Cu & Cont. 107/Cu.

ETI/C 0708 A

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88 Employment Schedule for OHE mast overlap central location with 3.0 m implantation. Cat. 65/Cu & Cont. 107/Cu.WP 75 kgf/sqm

ETI/C 0709 A

89 Employment schedule for OHE mast overlap center location with 3.0M implantation, Cat. 65/Cu & cont. 107/Cu. WP 112.5 kgf/sq.m

ETI/C 0710 A


ETI/C 0711 A


ETI/C 0712 A

92 Employment schedule for 9.5 m long OHE mast overlap center location with 3.0M implantation, Cat. 65/Cu & cont. 107/Cu. WP 75 kgf/sq.m

ETI/C 0713 A

93 Employment schedule for 9.5 m long 200x200x44.9 kg mast Cat. 65/Cu & cont. 107/Cu. WP 112.5 kgf/sq.m

ETI/C 0714 A

94 Employment schedule for OHE mast overlap anchor location with 3.0M implantation, Cat. 65/Cu & cont. 107/Cu. WP 75 kgf/sq.m

ETI/C 0715 A


ETI/C 0716 A

96 Employment schedule 0721 for regulated OHE mast(9.5 m) wind pressure 75kgf sq.m for composite OHE(1000+1000) kgf tension

ETI/C 0721 (OHE

only)(Sh.1)

-

97 Employment schedule for regulated OHE mast (9.5m) wind pressure 75 kgf/sqm. For composite OHE with extra setting distance overlap anchor location.

ETI/C 0722 -

98 Employment Schedule for regulated OHE mast (9.5m) wind pressure 75 kgf/sqm for composite OHE with extra setting distance. Overlap centre location.

ETI/C 0723 -

99 Employment Schedule for regulated OHE mast (9.5m) wind pressure 75 kgf/sqm for composite OHE with extra setting distance. Overlap inter location.

ETI/C 0724 -

100 Employment schedule for pre-stressed concrete mast (PC 42) 9.5 long. For conventional OHE, Normal Location (WP 150, 112.5 and 75 kgf/sqm.07253

ETI/C 0725 A

101 Standard portal (NO, PRG & Double FBF type) ETI/C 0064 - 102 Special BFB portal for 5 tracks (general C

arrangement) ETI/C 0026

sh1 C

103 Protective screen at foot-over bridge and road over-bridge.

ETI/C 0068 H

104 Chart for portal foundation ETI/C 0005/68 - 105 Muff for OHE structures ETI/C 0007/68 E 106 Structures muff for sand core foundations ETI/C 0012/69 E 107 9.5 m standard traction mast (fabricated ‘K’ series) ETI/C 0018-2 D 108 Remote Control Cubicle at switching station,

foundation, RCC slab Building plan & steel door. ETI/C 0067 B

RVNL



109 9.5 m standard traction mast fabricated with batten plates ‘B’ series)

ETI/C 0071 E

109A 9.5 m long standard traction mast (fabricated with batten plate)- “TM” series.

ETI/C 0078 Sh. I

-

109B 9.5 m long standard traction mast ( fabricated with batten plate)- “ TM” series( Weight scheduled).

ETI/C 0078 Sh. 2

109C 10.85 m long standard traction mast ( fabricated with batten plate)- “ B” series.

TI/DRG/CIV/B-MAST/RDSO

00001/08/0

110 Details of OHE foundation in soft rock (bearing capacity 45,000 kgf/sq. m)

ETI/C 0059 C

110A Details of OHE foundation in Hard rock (bearing capacity 90,000 kgf/sq. m)

ETI/C 0060 D

111 Details of foundation for fencing upright ETI/C 0032 B 112 Employment schedule for switching and booster

station main masts ETI/C 0185 B

113 Drilling schedule for S-1 mast ETI/C 0030 F 114 Drilling schedule for S-2 mast ETI/C 0031 D 115 Drilling schedule for S-3 mast (length 11.4m) ETI/C 0180 C 116 Drilling Schedule for 8” x 6” x 35 lbs. RSJ mast 8.0 m

long for booster transformer station Type S-4. ETI/C 0036 E

117 Drilling schedule for S-5 mast (114 m long) ETI/C 0042 E 118 Drilling schedule for S-6 mast (length 12.4 m) ETI/C 0181 C 119 Drilling schedule for S -7 mast (length 12.4 m long) ETI/C 0182 C 120 Drilling schedule for S -8 mast (length 12.4 m long) ETI/C 0183 C 121 Drilling schedule for S -9 mast (length 9.4 m long) ETI/C 0184 C 122 General arrangement & details of fencing panels &

gate for switching station ETI/C 0186

sh.1 E

123 Details of fencing upright and anti-climbing device for switching station

ETI/C 0186 sh.2

E

124 S-100 fabricated mast for mounting LT supply transformer and drop out fuse switch at switching station.

ETI/C 0043 B

125 S-101 details of mast for supporting isolator inside switching station

ETI/C 0044 A

126 Details of anchor beam on SP, SSP, & FP ETI/C 0033 D 127 Details of small part steel for switching station ETI/C 0034

Sh.1 K

128 Details of bracing for switching &BT masts. ETI/C 0034 sh.2

B

129 Details of small parts steel of out rigger for switching stations and booster transformer stations.

ETI/C 0037 C

130 Details of small parts steel for booster transformer stations.

ETI/C 0040 E

131 Details of pre-cast cable trench for switching station ETI/C 0038 E 132 Standard ’R’ type portal rod laced general

arrangement ETI/C 0011/69

Sh.1 C

133 Standard ’G’ type portal special upright and end piece.

ETI/C 0066 C

134 Short bored pile foundation for traction mast (permissible BM & volume)

ETI/C 0062 B

135 Chart for portal foundations in dry black cotton soil safe bearing capacity 16500 kg/sqm.

ETI/C 0063 b

RVNL



135A Details of foundation for 132 kV traction substation structures.

ETI/C 0209 C

136 Dwarf mast foundation on wet & dry black cotton soil RE/ALD/OHE/SK/C

02 -

137 Typical design of new pure gravity foundation. ETI/SK/C 131 A 138 Typical design of side gravity foundation. ETI/SK/C 142 A 139 Rock Anchor for BG Track. ETI/SK/C 208 - 140 Bracket fitting for PSC Masts capacity 4200 kgm. ETI/SK/C 214

sh.2 -

141 SPS details for earth wire clamp on PSC mast. ETI/SK/C 214 Sh.2 of

2

-

142 Special arrangement of OHE under overline structure ETI/OHE/SK 529 D 143 Earthing and bonding of PSC mast. ETI/OHE/SK 537Sh.1

of 2 A

144 Typical Earthing arrangement in spun D PSC mast with 18mm dia rod.

ETI/OHE/SK 537 Sh.1 of

2

D

145 Arrnagement of antitheft jumper at overlap ETI/OHE/SK 566 - 146 Catenary dropper assembly ETI/OHE/P 1190 B 147 Parallel clamp (20/20) ETI/OHE/P 1550 E- 148 Standard guide Tube assembly. ETI/OHE/P 5060-2 C 149 Standard anti-wind clamp ETI/OHE/P 2550-

1/2 L

150 Multiple cantilever cross arm assembly RE/33/P 3224 H 151 Anchor fitting Assembly on rolled sections ETI/OHE/P 3230 C 152 Anchor fitting Assembly on ‘K’ series TCC mast and P

type portal upright . ETI/OHE/P 3240 D

153 Anchor assembly on ‘N’ and ‘O’ type portal spans. ETI/OHE/P 3250 D 154 Structure bonds ETI/OHE/P 7000 F 155 Earthing station ETI/OHE/P 7020 B

155A Earth Electrode ETI/OHE/P 7021 A 156 Longitudinal rail bond ETI/OHE/P 7030 F 157 Short super mast assembly ETI/C/P 7020 B 158 Long super mast assembly ETI/OHE/P 8010 G 159 Bracket attachment assembly on portal upright

(NORPG& BFB type ) ETI/OHE/P 8030 B

160 Super mast assembly on portals ETI/OHE/P 8050 C 161 Medium super mast assembly ETI/OHE/P 8060 C 162 Compensating plate ETI/OHE/P 5191-

1/2 D

163 Suspension clamp RE/33/P 1160 J 164 Double suspension clamp RE/33/P 1170 K 165 Double suspension lock plate. RE/33/P 1172 C 166 Catenary splice(65) ETI/OHE/P 1090 - 167 Typical location & schematic connection diagram for a

three interruptor switching station. ETI/PSI 003 C

168 Typical general arrangement of a three interruptor switching station

ETI/PSI 004 F

169 Typical location plan & general arrangement for- sectioning & paralleling station

ETI/PSI 005 F

RVNL



170 Typical location plan and arrangement for a feeding station

ETI/PSI E

171 Typical general arrangement at a booster transformer stn. (with 4 cross feeder) type III

ETI/PSI 013 B

172 Typical general arrangement of 280 KVA Booster booster transformer stn. (with 4 cross feeder) type III

ETI/PSI 018 A

173 Typical general arrangement at a booster transformer stn. (without cross feeder) type I

ETI/PSI 011 C

174 Typical fencing and anti-climbing arrangement at switching station

ETI/PSI 104 E

175 Typical earthing layout of sub-sectioning and paralleling station

ETI/PSI 201 B

176 Typical earthing layout of a sectioning and paralleling station.

ETI/PSI 202 B

177 Typical earthing layout of a feeding station ETI/PSI 203 B 178 Earthing details for interruptor LT supply transformer

25 kV lightnig arrestors PT type- I ( S-100 masts, S-101 mast, fencing upright and main mast)

ETI/PSI 204 C

179 Typical earthing layout at a booster transformer stations (without cross feeder ) for Type-I and II

ETI/PSI 211-1 A

180 Typical cable run layout of a sub-sectioning & paralleling station.

ETI/PSI 301 C

181 Typical cable run layout of a sectioning & paralleling station

ETI/PSI 302 C

182 Typical cable run layout of a feeding station ETI/PSI 303 B 183 Typical earthing layout of a booster transformer

station (with 4 cross feeder for type III, IV and V) ETI/PSI 212 B

184 Typical drawing for a terminal board ETI/PSI 501 C 185 36 mm Aluminium Bus terminal ETI/PSI/P 6480 C 186 36 mm Aluminium Bus splices ETI/PSI/P 6490 B 187 36 mm Aluminium Bus Tee connector ETI/PSI/P 6500 C 188 36 mm Aluminium Tee terminal ETI/PSI/P 6510 D 189 36 /15 Tap connector ETI/PSI/P 6520 B 190 36 mm Aluminium flexible bus splice ETI/PSI/P 6550 B 191 36 mm Aluminium bus splice cum tee connector ETI/PSI/P 6560 B 192 Typical number plate for interruptor and double pole

isolator ETI/PSI/P 7520 B

193 Typical number plate for potential transformer Type-I ETI/PSI/P 7521 B 194 Typical number plate for booster transformer ETI/PSI/P 7522 B 195 Standard plan Remote Control cubicle at a switching

station RE/Civil/BS-11/95

-

196 Typical details of pressed steel door, window and ventilator

RE/Civil/S-115/95

R1

197 Bolted base connection for portals located in drains. ETI/C 0010 C 198 Details of base plate for mast on drains in station

yards. ETI/C 0002 A

RVNL



(B) LIST OF STANDARD DRAWINGS FOR TRAMWAY TYPE OHE (REGULATED) 199 Span and stagger chart for Tramway type OHE

(regulated) ETI/OHE/G 04201 -

200 Drilling schedule of OHE mast 8.5m & 9 m long RSJ) and BFB respectively.


C

201 Schematic arrangement of (regulated) tramway type OHE

ETI/OHE/G 04203 C

202 Arrangement of bracket assembly for Tramway Type OHE (Regulated)

ETI/OHE/G 04204 B

203 Arrangement for anti-creep for Tramway Type OHE ( Regulated)

ETI/OHE/G 04205 B

204 Arrangement of anti-creep for Tramway OHE (regulated alternative arrangement )

ETI/OHE/G 04206 B

205 Arrangement of section Insulator for Tramway Type OHE (regulated)


B

206 Small parts steel for supporting section insulator assembly for regulated tramway type OHE.


B

207 General arrangement of turnouts for Tramway type OHE ( regulated)

ETI/OHE/G 04208 B

208 Adjustment chart for Tramway type OHE (regulated) ETI/OHE/G 04209 209 Bridle wire clamp (6 mm) ETI/OHE/P 1070-1 B 210 Large suspension clamp 20 mm (with armour rod) ETI/OHE/P 1580

Sh-1 -

211 Large suspension clamp 20 mm (with armour rod) ETI/OHE/P 1580 Sh-2

-

212 BFB steady arm assembly for Tramway OHE (Regulated)

ETI/OHE/P 2540-1 -

213 Anti wind clamp for tramway OHE (regulated) ETI/OHE/P 2550-3 E 214 Counterweight assembly (light) ETI/OHE/P 5090-3 F 215 Counter weight assembly with pulley type regulating

equipment (3:1 ratio) ETI/OHE/P 5090-6 B

216 Employment schedule for tramway type regulated OHE without RC and EW(WP 112.5 kgf/sqm)

ETI/C 0705 A

217 Protective screen at FOB/ROBs. ETI/C 0068 H 218 (i) Standard Plan – Height Gauge for Level Crossing

(for clear span upto 7.3m) Details of structure & foundation.

(ii) Standard Plan – Height Gauge for Level Crossing (for clear span above 7.3m upto 12.2 m) Details of structure & foundation.

(iii) Height Gauge at Level Crossing upto 7.3m.

(iv) Standard Plan – Details of Height Gauge for span 7.3 m to 10.0 m with Rail Type for location where TVU less than 1,00,000.

(V) Standard Plan – Height Gauge for level crossing (for clear span 7.3m to 10m) Details of structure & foundation.

TI/DRG/ CIV/H.GAUGE

/RDSO

TI/DRG/ CIV/HGAUGE

/RDSO

CORE Drg No:

RE/CIVIL/S

CORE drg No.-RE/CIVIL/S-

TI/DRG/CIV/H.GAUGE/

RDSO

00001/ 05/0

00002/ 05/0

138-04

146/0008

00001/ 14/0

- -

(Mod R-1)

(Mod-R1)

RVNL



219 Anchor arrangement with dwarf mast for conventional and High rise OHE

ETI/OHE/HR/G

01402 A

220 Employment schedule of bracket tube regulated conventional OHE (Cd-Cu catenary and Cu contact wire (1000 kgf tension each ) for wind pressure 150 kgf/ sq. m at 10 deg. C

ETI/OHE/G 00158 Sh-3

-

221 Employment schedule of bracket tubes unregulated unconventional OHE (Cd.CU-catenary) and CU-contact wire.

ETI/OHE/G 00159 Sh -3

-

222 Standard arrangement of supporting cantilevers on the boom of portals and TTC (to avoid Bird’s nesting)

ETI/C 0076 C

223 Volume charts and equivalent chart of foundation (side bearing, side gravity & WBC)

TI/CIV/FND/RDSO

00001/12/0 sh1

-

224 Volume chart and equivalent chart of foundations(NG type)

TI/CIV/FND/RDSO

00001/ 12/0 sh2

-

225 Volume and equivalent chart of foundations for dry black cotton soil only (NBC type)

TI/CIV/FND/RDSO

00001/ 12/0

sheet -3

-

226 Volume chart & equivalent chart of new pure gravity foundations (500 mm exposed)

TI/CIV/FND/RDSO

00001/ 12/0 sh-4

227 Volume & equivalent chart of foundations for dry black cotton soil only (8000 kg/sq. m) NBC type 2.5 m depth

TI/CIV/FND/RDSO

00001/ 12/0 sh-5

228 Volume charts and equivalent chart of foundations (side bearing, side gravity &WBC)

TI/DRG/CIV/FND/RD

SO

00001/ 04/0 sh1

229 Volume charts and equivalent chart of foundations(NG type)

TI/DRG/CIV/FND/RD

SO

00001/ 04/0

sheet-2

230 Volume and equivalent chart of foundations for Dry black cotton soil (NBC type) for 16500 &11000 kgf/ sq m, 3.0 m depth

TI/DRG/CIV/FND/RD

SO

00001/ 04/0

sheet-3

231 Volume chart and equivalent chart of new pure gravity foundations (500 mm exposed).

TI/DRG/CIV/FND/RD

SO

00001/04/0

sheet-4

232 Volume and equivalent chart of foundations for Dry black cotton soil only (8000 kg/ sq m) NBC type 2.5 depth

TI/DRG/CIV/FND/RD

SO

00001/04/0

sheet-5

233 Employment schedule for OHE mast (9.5 m) for wind pressure 150 kgf/ sq m copper OHE

ETI/C 0726 Sh -1

-

234 Employment schedule for OHE mast (9.5 m) for wind pressure 150 kgf/ sq m copper OHE & EW

ETI/C 0726 Sheet-2

-

235 Employment schedule for OHE mast (9.5 m) for wind pressure 150 kgf/ sq m copper OHE &RC

ETI/C 0726 Sheet-3

-

236 Employment schedule for OHE mast (9.5 m) for wind pressure 150 kgf/ sq m copper OHE,RC&EW

ETI/C 0726 Sheet-4

-

237 Employment schedule for OHE mast (9.5 m) for wind pressure 150 kgf/ sq m copper OHE, with higher implantation overlap anchor location

ETI/C 0727 -

238 Employment schedule for OHE mast (9.5 m) for wind pressure 150 kgf/ sq m copper OHE with higher implantation overlap inter location

ETI/C 0728 -

RVNL



239 Employment schedule for tramway type regulated OHE WP 150 kgf/ sq m without RC &EW.

ETI/C 0706 A

240 Raised register arm clamps . ETI/OHE/P 1370-1 F 241 Parallel clamp (90/50). ETI/OHE/P 1040-3 B 242 Contact wire parallel clamp(Part small). ETI/OHE/P 1041-2 D 243 Parallel clamp (150/160) . ETI/OHE/P 1050-3 A 244 Parallel clamp Part (150/105-150). ETI/OHE/P 1051-2 C 245 Parallel clamp (105/240). ETI/OHE/P 1530-1 C 246 Steady Arm hook BFB (forged). TI/DRG/OH

E/FTGFE/ RDSO

00003/ 0 0/0

247 Tabular stay sleeve (forged).. TI/DRG/OHE/FTGFE/

RDSO

00004/ 03/0

248 Register Arm Eye piece 25 mm (Forged). TI/DRG/OHE/FTGFE/

RDSO

00002/ 00/0

249 Mast fittings for hook insulator ( forged). TI/DRG/OHE/FTGFE/

RDSO

00005/ 04/0

250 Modified BFB steady arm assembly with 25 mm drop bracket ( ID-2306).

TI/DRG/OHE/FTGFE/

RDSO

00006/ 05/0

251 Terminal clamp (15 mm) –compression type. TI/DRG/OHE/FTGNF/

RDSO

00001/ 02/1

252 Terminal clamps( 19mm) compression type. TI/DRG/OHE/FTGNF/

RDSO

00002/ 02/1

253 Feeder splice ( 150). TI/DRG/OHE/FTGNF/

RDSO

00003/ 03/0

254 Feeder splice sleeve. TI/DRG/OHE/FTGNF/

RDSO

00004/ 03/0

255 Feeder joint socket left. TI/DRG/OHE/FTGNF/

RDSO

00005/ 03/0

256 19 mm bus terminal clamp ( compression type). TI/DRG/OHE/FTGNF/

RDSO

00006/ 03/0

257 Parallel clamp (dia 20 mm/ 18.75mm) . TI/DRG/OHE/FTGNF/

RDSO

00006/ 03/0

258 18mm single clevis assembly modified. TI/DRG/OHE/FTGFE/

RDSO

00001/ 00/0

259 Signals at neutral sections. TI/DRG/OHE/NS/RDSO

00001 /00/01

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260 Schedule anchor block for BG track. TI/DRG/OHE/GUYROD

/RDSO

00001/ 07/0

261 Double guy rod arrangement with anchor block for BG track.

TI/DRG/OHE/GUYROD

/RDSO

00002 /07/0

262 Schedule of anchor block for BG track black cotton soil.

TI/DRG/OHE/GUYROD

/RDSO

00003/ 07/0

263 Guy rod dia 25 mm. TI/DRG/OHE/GUYROD

/RDSO

00004/ 07/0

264 Typical Layout of 132/27 kV (Type – IV) ( without going feeder and metering facilities)

TI/DRG/PSI/TSSLO/ RDSO/

00004/ 02/1

Mod A

265 Typical Layout of 132/27 kV (Type – V) ( without going feeder and metering facilities)

TI/DRG/PSI/TSSLO/ RDSO/

00005/ 02/1

Mod A

*****

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(C) LIST OF STANDARD RDSO’s SPECIFICATIONS FOR OHE

Sl. No.

DESCRIPTION SPECIFICATION NO. LAST REV.

1. Technical Specification for annealed stranded copper conductors for jumper wire for Electric Traction

ETI/OHE/3(2/94) with A&C slip No.1of (4/95)

1

2. Specification for Copper bus bar. RE/30/OHE/5 (11/60) -

3. Specification for Steel tubes. ETI/OHE/11 (5/89) -

4. Specification for Hot dip zinc galvanization of steel masts (Rolled & fabricated). Tubes and fittings used on 25 kV ac OH

ETI/OHE/13(4/84) with A&C slip No. 1of (5/86),2 of (4/90) & 3 of (4/90)

3

5. Specification for Stainless steel wire ropes for Regulating Equipment.

TI/SPC/OHE/WR/1060(06/2006) with A&C slip No 1 of (11/06) & 2 of (05/07)

2

6. Specification for solid core porcelain insulators for 25 kV ac 50 Hz single phase overhead traction lines.

TI/SPC/OHE/INS/0070 (04/2007) OR ETI/OHE/15(9/91) with A&C slip No.1 (5/99), No..2 of (2/2000) and 3 of (2/2000).

-

7. Specification for 25 kV ac single pole and double pole isolators for Railway Electrification.

ETI/OHE/16(1/94) with A&C slip No.1 of (06/2000) & 2 of (3/2004)

2 RVNL



8. Specification for steel and stainless steel bolts, nuts .

TI/SPC/OHE/Fasteners/ 0120 OR ETI/OHE/18(4/84) with A&C slip latest.

-

9. Aluminum alloy section and tubes for 25 kV Traction Overhead Equipment.

ETI/OHE/21(9/74) -

10. Specification for Dynamometers. RE/OHE/22(9/61) -

11. Specification for Light weight Section insulator assembly.

TI/SPC/OHE/LWTSI/0060 (08/06)

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12. Specification for Enameled steel plates. ETI/OHE/33(8/85) -

13. Specification for retro-reflective structure Number plates.

ETI/OHE/33A(12/97) with A&C slip 1 to 8

8

14. Performances specification for modular cantilever assembly.

TI/ SPC/OHE/MCS/080 -

15. Specification for Galvanized steel wire rope. ETI/OHE/36(12/73) with A&C Slip No.1 of (5/98)

1

16. Specification for Hard drawn copper catenary. ETI/OHE/37(12/73) -

17. Technical specification for hard drawn grooved contact wire for electric traction (jointed/welded contact wire).

ETI/OHE/42(6/97) -

18. Specification for three pulley type regulating equipment with modified Pulley group (3:1 Ratio) for 1100 KgF Tension

TI/SPC/OHE/ATD/0060 1

19. Technical specification for exothermic welding connection for bonding, earthing/ drilling

TI/SPC/OHE/Exothrm bond/0100(04/10)

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20. Technical specification for Fittings for 25 kV ac OHE

ETI/OHE/49(9/95) with A&C Slip No 1 of (3/97) and CORE's A&C slip No. 2 of (4/2000), 3 of (08/01) 4 of (03/2002) & 5 of (10/2010).

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21. Technical Specification for cadmium copper conductors for overhead Railway traction.

ETI/OHE/50(6/97) with A & C Slip No 1 to 5 (9/16)

5

22. Technical Specification for 37/2.25mm Hard Drawn Stranded copper conductor

TI/SPC/OHE/HDCSCF/0030(06/03)

-

23. Specification for Discharge/earthing pole assembly for 25 kV ac traction.

ETI/OHE/51(9/87) 1

24. Specification for interlocks for ac traction switchgears.

ETI/OHE/52(10/84) -

25. Principles for OHE layout plans and sectioning diagrams for 25 kV ac traction.

ETI/OHE/53(6/88) with A&C slip no.1 of (6/88), 2 of (6/88), 3 of (6/90), 4 of (8/92) & 5 of (11/2006)

5

26 Specification for 19/2.79 mm all aluminum alloy. Stranded

ETI/OHE/54(2/85) with A&C slip No. 1 of (11/89) &2 of (10/92)

2

27 Specification for Bimetallic (aluminium-copper) strip.

ETI/OHE/55(4/90) -

28 Technical specification for 4 wheeler overhead equipment inspection car 1676 mm gauge

TI/SPC/OHE/4WDHTW/0070 (06/07)

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29 Specification for hand operated lifting and swiveling platform.

ETI/OHE/58/1(1/95) -

30 Technical specification for 8 wheeler OHE inspection car 1676 mm gauge

TI/SPC/OHE/8WDEIC/0090(2/09)

1

31 Specification for Short Neutral Section Assembly (phase Break)

TI/SPC/OHE/SNS/0000 of Rev 1 (06/16)

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32 Specification for solid core cylindrical post insulators for systems with nominal voltages of 220 kV, 132 kV, 110 kV & 66 kV

ETI/OHE 64(10/88) 1

33 Specification for continuous cast copper wire rods. ETI/OHE/65(8/87) with A & C Slip No 1 to 4 (9/16)

4

34 Technical Specification for hard drawn grooved contact wire for electric traction drawn out of continuous cast copper (CCC) wire rods.

ETI/OHE/76(6/97) with A & C Slip No 1 to 9 (11/16)

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35 Gearless hand operated pulling and lifting machines (TIRFOR)

TI/SPC/OHE/TOOLPL/0990 1

36 Galvanised steel stranded wire (GSSW) for Anchoring of Traction Mast

TI/SPC/OHE/GSSW/0090 (10/2009)

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37 Rachet lever Hoist ( Pull-lifts) TI/SPC/OHE/TOOLPL/1990 -

38 Specification for Insulated Cadmium Copper Catenary 19/2.1 mm Dia meter for provision under over line structures in the 25 kV ac Electric traction

TI/SPC/OHE/INSCAT/0000 (04/00) with A & C Slip No. 2 (9/16)

2

39 Technical specification for infrared imaging system for handheld application.

TI/SPC/OHE/TIPS/0010 (03/01)

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40 Technical specification for infrared imaging system for stationary Installation.

TI/SPC/OHE/TIPS/1030 (06/05) Rev. 1

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41 Specification for Loco mounted analysis system TI/SPC/OHE/TIPS/2030 (08/03)

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42 Technical specification for galvanized steel stranded wire for traction bonds for 25 kV ac Electric traction system

TI/SPC/OHE/GALSTB/ 0040 (09/04)

1

43 Technical specification for Silicone composite insulators for 25 kV ac 50 Hz single phase overhead traction lines.

TI/SPC/OHE/INSCOM/ 1070 (01/07)

-

44 Specification for Retro-Reflective structure number plate on FRP base

TI/SPC/OHE/FRPNP/0060 -

45 Technical specification for on Board Equipment for line scanning for thickness of contact wire used in 25 kV ac traction.

TI/SPC/OHE/CW/WEAR/0080(02/80)

-

46 Technical specification for Gas Auto tensioning device.

TI/SPC/OHE/GATD/0080(9/08)

-

47 Specification for Testing load testing Machine 25 kV Porcelain & Composite insulator before installation.

TI/SPC/OHE/INSTEST/0090(02/09)

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48 Specification for Solid core Porcelain cylindrical Post Insulators with nominal Voltage of 66 kV, 110 kV, 132 kV & 220 kV

TI/SPC/OHE/POST/0100 (01/10)

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49 Technical specification for propelled Auger vehicle for digging of foundations of over-head lines

TI/SPC/OHE/AUGER/0090 (02/09)

-

50 Technical specification for propelled road Rail vehicle for maintenance of over-headlines.

TI/SPC/OHE/RRV/ 0090 (05/09)

-

51 Technical specification for self-propelled mast Erection machine vehicle for running on (1676 mm) Routes of Indian railways.

TI/SPC/OHE/MEMV/ 0090 (03/09)

-

52 Technical specification for galvanized steel stranded wire for traction mast

TI/SPC/OHE/GSSW/0090 (10/2009)

-

53 Technical specification for roof mounted infrared thermal imaging system for on live line scanning of ac OHE system.

TI/SPC/OHE/ITIC/0100 (02/2010)

-

54 Technical Specification for self-propelled intelligent OHE parameter recording cum Inspection Car (Dhanwantari)

TI/SPC/OHE/8WDEITC/ 0012(07/2012)

-

55 Technical specification for self-propelled wiring train for paying of contact & catenary wire of overhead lines on BG ( 1676 mm )

TI/SPC/OHE/WIRING/0090(02/2013)

-

56 Technical specification for 8-Wheeler Diesel Electric Tower Wagon (Under Slung)

TI/SPC/OHE/8WDETC/ 0090 (02/2009 )

1

57 Technical Specification for spun pre stressed cement concrete (PSC) OHE traction mast.

ETI/ C/2(8/94) -

58 Indian Railway standard specification for spraying zinc coating on the OHE mast.

ETI/C/3(5/83) -

59 Draft Indian Railway Standard specification for cold roll formed mast for Railway electrification.

ETI/C/4(8/90) -

60 Specification for Flo-Coat Tube. ETI/C/5(5/88) 1

61 Corrosion Resistant Paint System for outdoor structures of Traction Distribution and traction rolling stock.

TI/SPC/CIV/POR/0080(08/2008)

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CHAPTER: B-21

Miscellaneous instructions

21.1 RAILWAY BOARD/RDSO INSTRUCTIONS TO BE FOLLOWED IN RAILWAY ELECTRIFICATION WORKS (REF. RB letter D.O. NO. 2013/RE/161/9FTS-74851 DATED 09.04.2013).

Sr.No.

General Deficiencies in RE Works Rly. Board/RDSO Guidelines

1. Availability of 120 mts distance between stop signal and central line of insulated overlap/ section insulators.

Railway Board’s letter BNo. 2010/l3c(G)/ 148/5 dated 11.6.12 para 30.2 ACTM vol. II part.II

2. Comprehensive policy regarding insulators for 25 kV ac traction on IRs ( vandal/ Pollution prone area)- regarding use of composite insulators

Railway Board letter No. 2002/Elec.(G)/161/21 Vol. II Pt. dated 04.07.12

3. Trimming/ cutting of trees in electrified sections

Railway Board letter No. 2008/Elect. (G)/161/8 Pt. dated 05.09.12.

4. To avoid provision of splice in large span wires.

Railway Board letter No. 2008/ Elec.(G)/161/8 Pt. Vol. II Pt. dated 26.09.12.

5. Insulated catenary to be provided under all ROBs/FOBs

TI/MI/0036(09/99) Rev. 0

6. Provision of pipe on hex-Tie rod at cross overs and short tension length ATDs.

TI/MI/0035(09/01) Rev. 1.

7. Testing of 25 kV porcelain and composite insulators before installation.

TI/MI/0042(12/2008) Rev.0

8. Modified protection scheme to be provided at all FOB/ROB.

ETI/C/0068(07/09) Rev. H

9. Increasing data transfer speed upto 2 Mbps of traction SCADA system

TI/SPC/RCC/SCADA/0130 (Rev.2) July 2016 with A&C 1

10 Provision of long cross type G – jumpers on parallel run side instead of crossover/turnout site.

ETI/OHE/G/5102 Rev. C

11. Separate DJ close boards for MEMU/EMU Required for MEMU/EMU operation 12. Ensuring projection of RT at pull of i.e.

negative stagger location to be beyond the vertical plane of contact wire.

RDSO Drg. No. ETI/OHE/G/02106 Rev. C

13. Fixing arrangement for mast anchor fitting for anti-falling device for three pulley modified ATD

RDSO Drg. No. TI/DRG/OHE/ATD/RDSO /0000/05/0

14. Catenary wire in place of GI wire at ACC locations in polluted area.

RDSO Drg. No. TI/DRG/OHE/GENL/RDSO /000001/12/0 Rev.0 ref. ETI/OHE/G/ 02111 Rev. A dated 23.10.2012.

15. Gap between mast fitting for hook insulators and top of the mast

Drg. No. RE/33/G/000141

16. Measurement of contact resistance and opening/closing time of CBs/BMs during commissioning of TSS/switching posts.

As per ACTM para 20908 Vo. II, Part I and OEM’s this is to be done in the pre conditioning test.

17. Provision of double eye distance rod. TI/MI/00008 Rev. 0 18. Soft copy of LOP, Power supply diagrams

and other relevant drawings in Auto - CAD software.

For better accessibility and re productivity.

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