Tender no.

11000039-HD-11370_Lighting Improvement_6 Gujarat Locations

1 :GENERAL ANDTECHNICAL SPECIFICATIONS, SCOPE OF WORK & WORKMANSHIP. 1.1 SCOPE OF WORK
1. Work as listed below, but not necessarily limited to, is included within the scope of this tender enquiry. 2. Installation, connecting, testing and commissioning of all electrical equipment required for locations e.g. High Mast, Flood Lighting Fixtures, FLP Light fittings, Control Gear Box, Lighting Distribution Board etc., as per the Bill of Quantities. 3. Laying of XLPE insulated cables in excavated / RCC trenches in RCC slits chipped out in RCC floors and on cable trays as required. 4. Supply of single / double compression / flameproof nickel plated brass cable glands and crimping type tinned copper cable lugs wherever required. Normally, equipment shall be received at site with cable lugs and glands. Where these are short supplied or wrongly supplied by equipment supplier these shall be provided by electrical contractor. 5. Excavation and back filling of cable trenches. 6. Termination of power, control and lighting cables. 7. Supplying, Erection, testing & commissioning of prefabricated High Mast lighting towers along with foundations and other flood light towers. 8. Fabrication of supports, cable racks, frames with supply of MS materials as required. 9. Supply, laying and connection of the complete Earthing system including supply of GI Earthing strips, connecting earth pits in a grid, testing earth pits, flexible Earthing conductors, etc. 10. Minor civil work including chipping, grouting, repairing of floor and walls damaged during electricalInstallation, as may be required to complete the work in all respect. 11. Supply and installation of any other items not specifically mentioned but found necessary by the Engineer-in-charge for satisfactory completion of work. 12. Any work not included in this tender but may be required as decided by the Site in- charge will be carried out. For such items rate shall be worked out at the market prevailing rates.

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1.2

GENERAL INSTRUCTIONS TO TENDERERS 1. This is augmentation job and the contractor has to work in a running highly hazardous plant. As such he has to obtain necessary Electrical work permit/safety work permit/working on Height permit of appropriate class from the Depot/Terminal I/C or Engineer in charge before starting of job and also the contractor and his men shall observe all safety precautions/ rules/ regulations as generally observed in running depots/terminals. 2. It is possible that contractor may not get shut down on the whole part for doing the erection/ Testing / commissioning work for a long stretch of time. They will, therefore, submit execution plan prior for approval from location where shut down of plant is required. 3. The offer shall be strictly as per specifications/data sheet/drawings/schedule of quantities etc. 4. Unfilled blocks/blank space provided in the NIT/specification/data sheet as applicable, to be filled up and furnished with the offer. Any unfulfilled data may lead to disqualification of the offer. 5. Any deviation from the technical details of the enquiry must be spelt out under heading TECHNICAL DEVIATIONS. 6. For supply items, certificates, drawings, sketch etc. Showing general arrangement, equipment layout, electrical scheme etc. should be enclosed to make the offer technically clear and complete. 7. Every component, material, hardware used in the equipment manufacturer/assembly/erection shall be of approved make, with distinct mark of quality and confirming to relevant Indian/International Standards and codes. The entire job shall be executed with good workmanship and sound engineering practices. 8. All the jobs shall be pre-planned and sketches for installations e.g., High Mast, Flood Lighting Fixtures, flameproof light fittings, Junction Boxes, Control Gear box, Lighting Distribution Board etc. Shall be made and submitted to Engineer-in-charge for approval. The entire installation shall be as per the approved erection drawings. 9. Any installation found unsatisfactory/defective/not as per the approved drawings/sketches have to be dismantled and re-done without any extra cost to the owner. 10. Stage and final inspection of all supply items like High Mast, Flood Lighting Fixtures, Cables, FLP materials like Junction Boxes, lighting fixtures, Control Gear box, Lighting Distribution Board etc. including GI strips, earth electrode shall be done at manufacturers works by TPI representative. Inspection charges shall be borne by Contractor. 11. In case specification/data sheet for any item of supply or erection is not enclosed with the NIT, relevant Indian Standard shall be applicable. 12. All electrical installation shall confirm to the latest Indian Electricity Rules, Factories Act and all statutory rules and regulations. 13. Technical particulars enclosed for Cables, High Mast and flameproof material is only for information and need not be filled. However successful tenderer has to fill up and comply with the technical particulars within 10 days from placement of LOI. 14. The territorial clearance from the State Electrical Inspector/CEE/OISD/CEA for new electrical equipment installed by the contractor shall be in scope of the contractor prior to commissioning.

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15. Copies of General Arrangement /CMRI & CCOE Certificates, Certificate of tests for degree of protection for enclosure (IP 55) etc. to be enclosed to make the offer technically complete and clear. 16. Lay out of the components, terminals shall be logical and the enclosure shall be liberally dimensioned so that cable terminations, operation and maintenance can easily be carried out. All hardware shall be of stainless steel. Paint shall be epoxy, Shade-631 as per IS-5. 17. The quantity indicated in the enquiry is tentative and it may be increased / decreased / deleted without further reference. 18. Wherever applicable, 4 copies of all the drawings shall be submitted by the successful tenderer within two weeks from the date of LOI for approval. Manufacture shall be as per approved drawings only. 19. Final drawings, test certificates, instruction manuals etc. (all in SIX SETS) with one reproducible of all electrical Schematic Drawing, to be furnished to HPC before dispatch of the equipment. 20. All the Lighting Fixture should have ISI marking, CMRI & CCOE No. and equipment S. No. punched in main name plate only failing which equipment will not be accepted. Pasting of plastic sticker are not acceptable. 21. CMRI No., cable size and make should be punched on the cable glands. 22. In case of conflicts between description / details of specifications in various clauses of this tender document higher specifications shall prevail. HPCL will consider the best practices in the market, IS codes and pertaining of clerical mistakes, etc. HPCLs decision in this regard shall be final and binding on the vendors.

1.3 JOB SPECIFICATION

1.3.1 HPSV/HPMV Lamp

1. The lamp to be accommodated in the luminary shall be 250/400 watt tubular clear type High Pressure Sodium Vapor (HPSV) or High Pressure Mercury Vapor 400W HPMV lamp, flame proof fixture required. 2. The lamp shall comply with the requirements of IEC 60662 together with all current amendments. 3. The minimum lumen output specifications of the lamp shall be as follows Lamp Cap Type E40 E40 E40 Colour Corrected Temperature CCT 2000K-2100K 2000K-2100K 3900K-4000K Lumen Output [Lm] Initial 100 Hrs After 2000 Hrs 28000 26500 48000 46000 23000 22000

Lamp 250W HPSV 400W HPSV 400W HPMV

4. The lamp shall not take longer than 4 minutes after the initial switch on to attain 80% of its guaranteed lumen output at the rated voltage 240 Volts, +5%, -10% and frequency 50 Hertz. The re-ignition period after an interruption of the supply shall not be longer than 1 minute to attain 80% of its lumen output. Page | 3

5. The average luminous flux of the lamp shall not depreciate more than 10% of initial value after 10,000 switched operating hours. 6. The average mortality rate for the 250/400 watt HPSV lamp shall not be greater than 10% at 12,000 switched operating hours.

1.3.2

Luminary Body Epoxy grey powder coated single piece die-cast aluminum housing, heat resistant toughened clear glass fixed to housing with silicone rubber gasket with MS Galvanized clips. Separate die-cast aluminum top cover hinged to the housing and fixed with state-of-art press fit clips. Side entry mounting for 50-60 mm OD pipe bracket. Reflector Electrochemically brightened, polished and finish computer aided pot optic aluminum reflector for tubular lamp. Degree of Protection IP 66 (Lamp compartment only).

1.3.3

1.3.4

1.3.5 Lamp holder And Associated Supports and Brackets 1. The lamp holder shall be made of non-metallic, heat resistant material and be rigidly fixed onto the optical compartment. 2. The lamp holder shall be an E40 type for the 250/400 W HPSV/HPMV lamp. The lamp holder shall be complete with an appropriate brake system to prevent loosening of the lamp. 3. The lamp holder together with its supports and brackets shall withstand normal usage throughout the life of the luminaries. 4. A lamp fully inserted shall be rigidly held with its axis substantially concident with that of the lamp holder under the normal conditions of wind, vibration and mechanical shock. 5. The E40 lamp holder shall be rated for 4.5kV pulse. 1.3.6 ELECTRICAL CONTROL GEAR

A. GENERAL 1. The luminaries shall be furnished complete with integral electrical control gear comprising of inductive ballast, capacitor and ignitor. 2. The electrical control gear shall be mounted on a suitable module unit and shall be easily removable and replaceable as a unit without the use of any special tools. 3. Electrical connection and disconnection of the electrical control gear unit from the luminaries shall be through a plug and socket type connection/terminal block such that incoming supply cables need not be removed when removing the electrical control gear module. B. BALLAST 1. The ballast shall be solidly filled with polyester compound and enclosed in a sheet steel or die cast aluminum container or vacuum impregnated with polyester resin of not less than thermal class H (180 C in accordance with IEC 60085). Page | 4

2. The ballast shall be reactor type and comply fully with IEC 60922 - Ballast for Discharge Lamps: General and Safety Requirements and IEC 60923 - Ballast for discharge lamps (excluding tubular fluorescent lamps) - Performance Requirements. 3. The rated voltage of the ballast shall be 240 Volt, 50 Hz (Nominal) and shall be suitable for operation on a 240 Volt, +5%, -10%, 50 Hz supply system. All terminals shall be of screw connector type. 4. The lamp current crest factor of the ballast shall not exceed 1.8 for 6% voltage variations. 5. The rated maximum operating temperature of the ballast winding (tw) shall not be less than 130 C whereas the maximum winding temperature rise (t) shall not be more than 70 C. C.IGNITOR 1. The ignitor shall be solid state, fully electronic, timed, superimposed multiple-pulse type which does not require the use of tapped ballast to ignite the HPSV/HPMV lamp. 2. The ignitor shall be fully encapsulated and totally sealed against the ingress of moisture. 3. The ignitor shall have a casing temperature rating of not less than 900C. 4. The case of the unit shall carry a label showing the connections and listing the operating voltage and the precautions to take during its removal. The ignitor shall be mounted with nut and lock washer. 5. The ignitor shall comply with and be tested to IEC 60926 and IEC 60927 together with all current amendments. D. CAPACITOR 1. The capacitors shall comply with and be tested to IEC 61048/61049. 2. The capacitors shall have a minimum voltage rating of 250 Volt and a casing temperature rating not less than 850C and shall be of sufficient capacity to raise the power factor of the circuit to not less than 0.85 lagging. The capacitors shall be housed in extruded aluminum or thermoplastic canisters and mounted with nut and lock washer. 3. Capacitors shall not be fused but incorporate a safety discharge resistor.

1.4
1.4.1

LIGHTING SYSTEM FLAMEPROOF LIGHTING INSTALLATIONS: Lighting Installations in licensed area shall conform to the area classification and surface temperature considerations. Fixture shall be firmly supported from roof trusses / structure in sheds. Support clamps / brackets may be bolted or welded to the existing steel members or inserts (in RCC roofs). Unless mentioned specifically in drawings, lighting fixtures shall be installed at a minimum height of 4 meters from the floor level. In the Pump House and TLF Sheds, where it may not be possible to maintain a minimum height of 4 meters, the lighting fixtures may be installed above 2.5 meters. However to the extent possible in each shed all fixtures shall be installed at the same height. The lighting lay out drawing indicates the requirement of fitting in particular area, but actual Page | 5

location of each fixture shall be finalized at site in consideration of lumen requirement for day to day work, any obstruction, uniformity in lighting distribution and aesthetic look. Cable glanding and termination in licensed area must be done only by qualified and highly skilled technicians. Re-fixing of cover and reassembly of parts, if required, of FLP and IP-55 lighting fittings, associated junction boxes etc. after cable glanding & termination shall be done in very careful manner so as to ensure total prevention of water ingress. Every FLP and IP-55 lighting fitting and junction box shall be checked for proper position of gasket, tightness of all screws, plugs etc. If the lighting fixtures have two cable entries, looping of the cables shall be done in the terminal box of the fitting and no junction box should be used for the same purpose. Where only one entry in such fittings is used the unused entry must be properly plugged with threaded FLP plug. Where the terminal is anti-vibration type, cable termination shall be done with suitable crimping type lugs supplied with the equipment. If lugs are not supplied, the contractor shall supply proper lugs and claim extra charges for the same as per the rate included in the Bill of Quantity. Cable glands for terminating cable at FLP and IP-55 electrical equipment shall be supplied by the equipment supplier. The cable glands for use with such equipment shall be brass / nickel plated double compression type and certified by CMRS for flame proof ness CMRS certificate No., Manufacturers name and cable size shall be embossed on the gland. In case of short supply of cable glands the contractor shall supply the required cable glands as described above and shall not claim extra. 1.4.2 LIGHTING IN SUBSTATION & UNLICENCED AREA All wiring for lighting in substation, DG Room and Fire Water Pump Hose shall be with XLPE A PVC (Cu cable, supported on wall, column structure etc.in cable trays) by providing adequate support at an interval of 250 mm. The wiring shall be neat an in straight line either horizontal or vertical avoiding criss-crossing. All cable shall be terminated in junction Box / lighting fixtures (to be supplied by the contactor) through double compression cable glands. The fixtures and junction boxes shall be earthed internally with third core of the cable. Circuit numbering of lighting fixtures to be done by the contactor within the rate quoted for installation. 1.4.3 TESTING AND COMMISSIONING The contractor shall be responsible for testing and commissioning of the entire lighting circuit. No lighting circuit shall be energized without proper testing of insulation resistance of the circuit with a 500 V meggar.

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1.5

INTERNAL WIRING, TERMINAL BLOCK AND EARTHING TERMINAL

A. Internal Wiring 1. The luminaries shall be completely pre-wired, requiring only the connection of the electrical power supply cables to the terminal and the earth continuity conductor to the Earthing terminal. 2. The control gear looping cables shall be non-hygroscopic heat resistant copper-core flexible cable, with a temperature rating of not less than 105 C and marked on the insulation and securely clipped. The minimum size of the cable shall not be less than 1 sq. mm. 3. PTFE insulation or the equivalent, rated to a minimum of 2500C shall be used for leads to the lamp holder. B. Terminal Block 1. A readily accessible barrier terminal block with the live and neutral connections clearly and indelibly marked for the connection of incoming supply cables shall be provided as close as possible to the point of entry of the supply cables. The terminal block shall be made of non-inflammable material. 2. A means of clamping the electrical supply cables shall be provided in the luminaries to relieve the terminations of strain where they are connected to the terminals. The cable clamp arrangement shall not damage the insulation of the cables. C. Earthing Terminal 1. A separate terminal for the connection of an earth continuity conductor, clearly and indelibly marked shall be provided. 2. All exposed metal parts and other parts accessible when the luminary is opened for maintenance and liable to become live in the event of an insulation fault shall be permanently and reliably connected to this Earthing terminal.

1.6 TECHNICAL SPECIFICATION FOR FLP WELL GLASSES LIGHTING FIXTURE

& CONTROL GEAR BOX ETC. 1.6.1 i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. SPECIFICATIONS FLAMEPROOF/WEATHERPROOF ROTARY SWITCH Designing Standards : IS 2148-2004 IEC 60079-1(2001) & IS 13346-2004 IEC 600790(2000) Current Utilization : 32 AMP 440 V EX-Protection : Ex-d Type Gas Gr. : I, IIA & IIB IIC Zone Classification : Zone 1 & Zone 2 IP Protection Class : IP65 MOC : Pressure Die Cast Aluminium Alloy LM6 Paint : Light Gray Epoxy Polyester Powder Coating Shade No. 631 Earthling : Internal-01 No. External-02 Nos. Cable Entry : 02 nos. for et O Ring : Endless Neoprene Hardware : In Stainless Steel Page | 7

1.6.2

SPECIFICATIONS FLAMEPROOF CONTROL GEAR BOX DESCRIPTION: Flame proof control gear suitable for 400 W HPMV & 250/400 HPSV/MH LAMP. i. DESIGNING STANDARDS : IS 2148-2004 IEC 60079-1(2001) & IS 13346-2004 IEC 60079-0(2000) ii. FINISH : Light Gray Epoxy Polyester Powder Coating Shade No. 631 iii. MATERIAL: DieCast Aluminum alloy LM 6 iv. CABLE ENTRY: 3 Cable entries 3/4 " B.S. Conduit v. GASKET /O ring: Endless Molded Neoprene. vi. EARTHING : Internal -01 No. External -02 Nos. vii. IP PROTECTION CLASS : IP 65 viii. GROUPS: I, II A & II B as per IS 2148-1981 ix. ZONE CLASSIFCATIONS: ZONE 1 & ZONE 2 x. CMRI. CERT. No.: C.M.R.I./T.C./H 1256 dated.- 14 Oct. 1999 CIMFR/TC/SR/H837 Dtd.23.01.08 / CIMFR/TC/S/697 Dtd.19.11.2008 xi. TEMP. CLASS: 400 MV/SV/MH -(T6) xii. CURRENT UTILIZATION : 400 W 220 V xiii. EX-PROTECTION : Ex-d Type xiv. HARDWARE : In Stainless Steel SPECIFICATIONS FLAMEPROOF WELL GLASS FITTING: DESCRIPTION: Flame proof weather-proof non-integral well glass suitable for 160/250/400W HPMV/HPSV lamp at 250 V AC (max.) i. MATERIAL: Die Cast Aluminium LM 6. ii. GLASS: Heat resistant and toughened well glass. iii. CABLE ENTRY: 2 way 3/4" B.S. Conduit. iv. HOLDER: GES Holder is provided as standard. v. SUSPENSION: Eye bolt/Bracket vi. HINGING: M.S. Chain is provided. vii. GASKET: Endless MouldedNeoprene. viii. IP RATING: IP 65 ix. FINISH: Light Gray Epoxy Polyester Powder Coating Shade No. 631. x. STANDARD: IS 2148-2004 xi. GROUPS: I, II A & II B xii. ZONE : Zone 1 & Zone 2 xiii. CMRI. CERT. No.: C.M.R.I./T.C./P/H382 dt. 18 AUG. 2006. xiv. TEMP. CLASS: 400W MV `T3, 400W SV/MH`T4, 250W SV/MH`T5

1.6.3

1.6.4

SPECIFICATIONS FLAMEPROOF FLOOD LIGHT FITTINGS DESCRIPTION: Flame proof weather-proof non-integral suitable for 160/250/400W HPMV/HPSV lamp at 250 V AC (max.) i. MATERIAL: Cast Aluminum Alloy LM6 ii. CABLE ENTRY: 02 way for et Page | 8

iii. iv. v. vi. vii. viii. ix. 1.6.5

HOLDER: PORCELAIN ES 40. GASKET: Endless MouldedNeoprene. IP RATING: IP 65 FINISH: Light Gray Epoxy Polyester Powder Coating Shade No. 631 As per IS:5 STANDARD: IS 9900 GROUPS: I, IIA & IIB ZONE : Zone 1 & Zone 2

DISTRIBUTION BOARDS For Distribution Boards the contractor shall level and grout foundation channels in the floor when the clearance is obtained from Engineer-in-charge. The Distribution Boards shall be assembled on leveled foundation, and aligned. Items recorded as short supply / damaged on transit shall be supplied and installed by contractor.

1.7
1.7.1

SPECIFICATIONS FOR 30m HIGH MAST SCOPE This specification covers the technical requirements of design of system, manufacture, testing at works, supply in well packed condition of high masts lighting structure, light fittings, lamps, control gears for movement / maintenance of light fitting, Earthing / lightning protection of units, aviation lights for towers / supply of spares for one year maintenance free operation and commissioning etc. for Cochin Terminal, Kochi in Kerala. The scope shall also include the erection including testing and commissioning of the system and also the supervision for erection, testing and commissioning of the system. The lighting fixtures given in the tender schedule are based on design done with a particular make (Crompton Greaves). The drawing showing illumination levels for the 3 locations is enclosed with the tender. In case the vendor supplies mast/fixtures of another approved make (as stated in approved vendor list), they should submit lighting design using software of that manufacturer for approval of HPCL. However, the type of fixtures proposed should be equivalent to the type(s) specified in the tender and the payment will be made for actual number of fixtures provided on item basis as per schedule of rates of tender.

1.7.2 A.

INSTRUCTION TO BIDDER The average illumination levels to be maintained in different areas be according to the following. The areas to be illuminated are as marked in the plot plan drawings: a) Truck movement Area - 20 lux b) Tank Farm Area/roads - 20 lux c) Other Area - 10 lux The illumination levels as mentioned shall be uniform as far as possible. The supplier is to consider the followings for Supply. a) Masts shall be of unipolar (single pole) structure. Special consideration shall be taken in respect of lamp replacement, operation and maintenance. b) Number of masts, their locations are indicated in layout are tentative. Page | 9

B.

C.

D.

E.

F.

G. H.

c) Number of fixtures has been decided based on the area, lux level and the obstruction in the considered area. d) 400 W HPSV lamps shall be used. e) The height of mast shall be 30 M. Manufacture of masts and components, light fittings, lamps, control gears for fittings, control gears for lantern carriage movement (i.e., raise / lower) with self-sustaining winch / stainless steel wire rope / flameproof motors / control PB stations and flexible cables, shall be as per relevant Indian / International Standards. Winch motor shall be in flameproof enclosures and the control gears shall be in flameproof enclosure. The FLP enclosures shall conform to groups IIA/IIB. Masts shall be hot dip galvanized, polygon shaped and sectionalized. Necessary Earthing and lighting protection of mast shall be provided. Routine tests shall be carried out on the supplied items at manufacture's works as per relevant standards. For imported items of masts, relevant routine test certificates need to be produced for the purpose. However, testing shall not absolve the supplier from his responsibility for making good any defect, which may be noticed subsequently. Site testing to demonstrate working & performance of the system shall also be carried out. The following documents shall be supplied with offer / for approval. a) Technical data of mast : With offer/For Approval/Final. b) Scheme diagram : With offer/For Approval/Final. c) Technical data of light fittings : With offer/For Approval/Final. d) Technical literature / Catalogues: With offer/For Approval/Final. e) Civil foundation data / details : With offer/For Approval/Final. f) Test Certificates : With offer/For Approval/Final. g) Guarantee Certificates : With offer/For Approval/Final. h) Earthing & Lightning Protection drg: With offer/For Approval/Final. 2 nos. earth pits shall be provided near each mast for lightning protection and Earthing. The connection from each pit to the mast shall be arranged by the Vendor by GI strips of size 50 X 6 mm. The earth pit shall be within 10 M of the mast. All Flameproof equipment being used shall be approved by CMRI, Dhanbad & CCOE, Nagpur,for use in hazardous area. This specification is to be read in conjunction with enclosed "Detailed Technical Specification for 30 M High mast lighting. DETAILED TECHNICAL SPECIFICATION FOR 30 M HIGH MAST LIGHTING:

1.7.3

A. SCOPE: The scope of this specification covers supply, installation, testing and commissioning of the complete lighting system, using Raising and Lowering type of High mast towers, including the civil works in foundation. All items required for the safe and efficient operation and maintenance of the lighting system, including the high mast, whether explicitly stated hereunder or not, shall be included by the Contractor. Control Panel at base including timer, cabling from control panel to the control gears / fittings as per price bid and aviation lamp / lightning protection shall be part of high mast item. Control Panel shall have facility to terminate two numbers of cables as specified in SLD. B. APPLICABLE STANDARDS: Page | 10

The following shall be the Reference Standards for the loading of the high mast:a. BS Code of Practice, CP-3, Gradient of wind related to height Chapter-V, Pt-II above ground. b. BS 4360 Grades of MS Plates c. BS 5135 Welding d. BD 729 Galvanizing e. Technical Report (TR) No.7 1996 Specification for Mast and Foundation. f. IS-875 (Pt-III) 1987 Code of Practice for Design Loads for structure. C. HIGH MASTSTRUCTURE: The High mast shall be of continuously tapered, polygonal cross section, at least 16 sided, presenting a pleasing appearance and shall be based on proven In- Tension design conforming to the Standards referred to above, to give an assured performance and reliable service. The mast height shall be 30 meters, with minimum diameters of 152mm at the top and 612mm at the bottom. Minimum plate thickness of bottom section shall be 5mm and Other sections 4mm. The PCD of the mast flange shall be minimum 740 mm. The structure shall be suitable for wind loading as per IS-875, pt-3, 1987. D. CONSTRUCTION: The mast shall be capable of safely withstanding the strong winds prevailing at site. The deflection at the top during heavy monsoon periods shall therefore be considered in the design and the mast designed in such way that the above deflection during worst periods is kept to a minimum value. The mast shall be fabricated from special steel plates, conforming to BS-EN10-025, cut and folded to form a polygonal section as stated above and shall be telescopically jointed and fillets welded. The welding shall be in accordance with BS:5135. The procedural weld geometry and the workmanship shall be exhaustively tested on the completed welds. The 30 meter size mast shall be delivered only in three sections, and shall be jointed together by slip-stressed-fit method at site. No site welding or bolted joint shall be done on the mast. The minimum over lap distance shall be 1.5 times the diameter at penetration. The mast shall be provided with full penetrated flange which shall be free from any Lamination or incursion. The welded connection of the base flange shall be fully developed to the strength of the entire section. The base flange shall be provided with supplementary gussets between the bolt holes to ensure elimination of helical stress concentration. For the environmental protection of the mast, the entire fabricated mast shall be hot dip galvanised, internally and externally, having a uniform thickness of 65 microns. E. DOOR OPENING: An adequate door opening approximately 1000 mm x 300 mm shall be provided at the base of the mast and the opening shall be such that it permits clear access to equipment like winches, cables, plug and socket, etc. and also facilitate easy removal of the winch. The door opening shall be complete with a close fitting, vandal resistant, weather proof door, provided with a heavy duty double internal lock with special paddle key. The door opening shall be carefully Page | 11

designed and reinforced with welded steel section, so that the mast section at the base shall be unaffected and undue buckling of the cut portion is prevented. F. DYNAMIC LOADING FOR THE MAST: The mast structure shall be suitable to sustain an assumed maximum reaction arising from a wind speed as per IS 875 (three second gust), and shall be measured at a height of 10 meters above ground level. The design life of the mast shall be a minimum of 25 years. G. LANTERN CARRIAGE: Fabrication: A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fitting and control gear boxes. The Lantern Carriage shall be of special design and shall be of steel tube construction, the tubes acting as conduits for wires, with holes fully protected by grommets. The Lantern Carriage shall be so designed and fabricated to hold the required number of flood light fittings and the control gear boxes, and also to have a perfect selfbalance. The Lantern Carriage shall be fabricated in two halves and joined by bolted flanges with stainless steel bolts and plastic lock type stainless steel nuts to enable easy installation or removal from the erected mast. The inner lining of the carriage shall be provided with protective PVC arrangement, so that no damage is caused to the surface of the mast during the raising and lowering operation of the carriage. The entire Lantern Carriage shall be hot dip galvanizedafter fabrication. H. Junction Box: Weather proof junction box with IP55 enclosure, made of Cast Aluminium shall be provided on the Carriage Assembly as required, from which the interconnections to the designed number of the flood light luminaries and associated control gear fixed on the carriage shall be made. I. Raising and Lowering Mechanism: For the installation and maintenance of the luminaries and lamps, it will be necessary to lower and raise the Lantern Carriage Assembly. To enable this, a suitable Winch Arrangement shall be provided, with winch fixed at the base of the mast and the specially designed head frame assembly the top. Winch: The winch shall be of completely self-sustaining type, without the need for brake shoe, springs or clutches. Each driving spindle of the winch shall be positively locked when not in use, gravity activated PAWLS. Individual drum also should be operated for fine adjustment of lantern carriage. The capacity, operating speed, safe working load of the recommended lubrication and serial number of the winch shall be clearly marked on each winch. The gear ratio may be according to manufacturers standard. However, the minimum working load shall be not less than 750Kg. The Winch shall be Selflubricating type by means of an oil bath and the oil shall be readily available grades of reputed producers. The winch drums shall be grooved to ensure perfect seat for stable and Page | 12

J.

tidy rope lay, with no chances of rope slippage. The rope termination in the winch shall be such that distortion or twisting is eliminated and at least 5 to 6 runs of rope remains on the drum even when lantern carriage is fully lowered and rested on the rest pads. It should be possible to operate the winch manually by a suitable handle and / or by an external power tool. It shall be possible to remove the double drum after dismantling, through the door opening provided at the base of mast. Also a winch gear box for simultaneous and reversible operation of the double drum winch shall be provided as part of the contract. The winch shall be type tested in presence of reputed Institution and the test certificate shall be furnished before supply of material. A test certificate shall be furnished by the contractor from the original equipment manufacturer, for each winch in support of the maximum load operated by the winch. K. Head Frame: The head frame which is to be designed as a capping unit of the mast, shall be of welded steel construction, galvanised both internally and externally after assembly. The top pulley shall be appropriate diameter, large enough to accommodate the stainless steel wire ropes and the multi-core electric cable. The pulley block shall be made of non-corrodible material, and shall be of die cast aluminium alloy (LM-6). Pulley made of synthetic material such as plastic or PVC is not acceptable. Self-lubricating bearings and stainless steel shaft shall be provided to facilitate smooth and maintenance free operation for a long period. The pulley assembly shall be fully protected by a canopy galvanised externally and internally. Close fittings guides and sleeves shall be provided to ensure that the ropes and cables do not dislodged from their respective positions in the grooves. The head frame shall be provided with guides and stops with PVC buffer for docking the lantern carriage. L. Stainless Steel Wire Ropes: The suspension system shall be essentially be without intermediate joint and shall consist of any non-corrodible stainless steel of AISI 316 or better grade. The stainless steel wire ropes shall be of 7/19 construction, the central core being of the same material. The overall diameter of the rope shall not be less than 8 mm. The breaking load of each rope shall not be less than 2350kg individually, giving factor of safety or over 5 for system at full load, the minimum recommended value as per the TR-7 referred to in the beginning of the specification. The end construction of rope to winch drum shall be fitted with talurit. The thimbles shall be secured on ropes by compression splices. Two continuous lengths of stainless steel wire ropes shall be used in the system and no intermediate joints are acceptable in view of the required safety. No intermediate joints, either bolted or else is provided on the wire ropes between winch and lantern carriage. M. Electrical System, Cable and Cable Connection: The electrical connections from bottom to top shall made by special trailing cable. The cable shall be EPR insulated and PCP sheathed to get flexibility and endurance. Size of the cable shall be 5 core, 4 mm, copper conductor. The cable shall be of approved make. Page | 13

A suitable FLP socket arrangement shall be provided at the bottom section of the Mast. The trailing cable also shall have FLP plug connected at the bottom end. Also suitable provision shall be made at the base compartment of the Mast to facilitate the operation of externally mounted, electrically operated FLP power tool for raising and lowering of the lantern carriage assembly. The trailing cables at the top shall be terminated in the weather proof junction box. Control Panel at the base shall be suitable to terminate cables as specified in SLD & cable schedule. Control Panel shall be flameproof. Control Panel shall be provided with timer, Auto manual off switch, start push button. The fittings including control gear shall be supplied by High Mast supplier. The wiring from control panel upto lighting fitting shall be done by High Mast supplier. Junction box shall be provided at the top of Mast. 3 core x 2.5 mm2 FRLS cable shall be used from junction box to lighting fitting. N. POWER TOOL FOR THE WINCH A suitable, high powered, electrically driven, externally mounted, flameproof (FLP) power tool, with manual operating handle, together with an operating stand shall be supplied for raising and lowering of the lantern carriage for maintenance purpose. The speed of power tool may preferably be of slow speed, of 1.5 to 1.8 mtr / minute, so that vibrations associated with high speed are avoided. The power tool shall be single speed, provided with a motor of required rating, suitable for trolley mounting. The power tool shall be supplied complete with flame proof push button type remote control switch, together with 6 (six) meters of power cable, so that the operation can be carried out from a safe distance of 5 (five) meters. The capacity and speed of the electric motor used in the power tool shall be suitable for lifting of the designed load installed on the lantern carriage. The power tool trolley shall be so designed that it will not only be self-supporting but also align the power tool perfectly with respect to the winch spindle during the operations. Also, a handle for the manual operation of the winches, in case of problems with electrically operated tool, shall be provided and shall incorporate a torque limiting device. There shall be a separate torque limiting device to protect the wire ropes from over stretching. It shall be mechanical with suitable load adjusting device. The torque limitor shall trip the load when it exceeds the adjusted limits. There shall be suitable provision for warning the operator once the load is tripped off. The torque limitor is a requirement as per the relevant standards in view of the overall safety of the system. Internal built -in type power tools shall not be acceptable. It is utmost importance that the complete power tool, including trolley, motor, PB station and lead etc. shall be designed, assembled / built and supplied as one unit by the original equipment manufacturer (OEM), to the Depot, through the Contractor. Locally assembled / built make-shift contraption, in lieu of the above, to be called as power tool by the Contractor, shall under no circumstances be accepted. O. LIGHTNING CONDUCTOR: One number heavy duty, hot dip galvanised lightning finial shall be provided for each mast The finial shall be minimum 1.2 M in length and shall be provided at the centre of the headframe. It shall be bolted solidly to the head frame to get a direct conducting path to the earth through the Mast body. The lightning finial shall, under no circumstances, be provided on the Page | 14

lantern carriage, in view of the safety of the system. Other lightning arrestor of the installation shall take into existence of these lightning arrestors and cone effect to be taken into account. P. LUMINAIRES: The number of fittings on each mast shall be as per schedule given. A set of Two Neon Aviation Obstruction shall be provided on top of each mast. Q. EARTHING TERMINAL: Three numbers Earthing terminals, using 12mm dia stainless steel bolts, shall be provided At a convenient location on the base of the mast, one exclusively for the lightening conductor and other two for Earthing the mast. R. TESTS: Routine tests shall be carried out as per relevant Indian Standards. Following routine tests shall be carried out on all components as per relevant standards. Functional test. Checking of dimensions, paint shade, bill of materials, circuit diagram etc. The measuring instruments used during the shop testing of panels shall be calibrated and their calibration must be valid. The calibration should be got done from any Govt. approved test house. The calibration reports must be furnished before conducting the shop test for our approval. S. TEST & GUARANTEE CERTIFICATE: Test certificate shall be furnished by the contractor, obtained from the original equipment manufacturer (OEM), for each winch including wire rope, in support of the maximum load operated by the winch. A separate guarantee certificate shall also be furnished by the Contractor, obtained from the OEM, for the quality and reliability of the total Mast system including the mast, accessories and associated civil works in foundation. T. TECHNICAL DATA FOR 30 MTR HIGH MAST AND COMPONENTS 1. HIGH MAST LIGHTINGS STRUCTURE a. Cross section of mast in polygon (no of sides) b. Overall height of mast (mm) c. No. of sections of mast d. Individual section, thickness /dia /length(mm) i. Top ii. Middle iii. Bottom e. Type of joints & length of overlap joints f. Weight in Kgs of mast (including base plate, door and head frame etc.,) Page | 15

g. Material construction h. Pollution treatment i. Thickness of galvanisation (min) j. Size of base opening door k. Locking arrangement of base opening door l. Size of base plate dia. / thickness m. Lighting protection device n. Aviation lighting deice o. Make / Enclosed Drawing reference 2. CIVIL DESIGN CONSIDERATION a. Max. wind speed (as per IS:875 1987) b. Max. gust speed time c. Factor of safety for wind load d. Factor of safety for other load e. Factor of safety of tower 3. Foundation Details a. Type of foundation b. Size of foundation c. Designed load bearing capacity d. Design safety factor e. Considered wind pressure (Kg/Mt) f. Consider wind speed (Km/Hr) g. Depth of foundation h. Average soil bearing capacity i. No. of foundation bolts j. PCD of Foundation bolts k. Type of foundation bolts / dia. 3. BOLT DIAMETER For tender purpose, the tenderer shall consider a Safe Bearing Capacity of 5 Tons/sq.m and depth of foundation of maximum 3 meters. The soil investigation report/recommendations shall be made available to the successful tenderer for designing the foundation. Any special treatment of soil required as per the soil investigation report such as providing hard core, sand layer, PCC, backfilling with imported earth, including piling etc. as required shall be carried out at no extra cost.

4. LANTERN CARRIAGE a. Material of construction b. Type of construction c. Diameter of carriage ring (m) d. Number of joints Page | 16

e. Buffer arrangement for carriage and mast f. Load carrying capacity (kg) g. Total weight of assembly with fittings(kg) h. Number of fittings i. Type of fittings/fixture 5. WINCH a. Make of winch & No. of winch / drums b. Gear ratio c. Capacity (kg) d. Operating Speed on full load e. Individual drum rotation f. Method of Operation g. Lubrication arrangement / type of lubricant h. Tested load per drum (kg) i. Kgs per drum ; ii. Kgs per winch i. SWL of winch at 200 rpm (Kg) 6. STAINLESS STEEL WIRE ROPE a. Make b. Grade c. Number of ropes d. Material and construction e. Centre core material f. Diameter (mm) g. Thimbles & Terminals h. Breaking load capacity (kg) i. Factor of safety (specified not less than 5) 7. CABLE a. Conductor, insulation/No. of cores b. Type c. Make d. Conductor Size / Current Capacity 8. POWER TOOL a. Mode / Type b. Input Supply (Volts) c. KW / HP d. Operating speed e. i) Remote control switch PB station ii) Length of control cable provided f. Max. Time taken for: i) Raising Page | 17

ii) lowering 9. TORQUE LIMITER a. Model b. Lifting capacity (kg) c. Adjustability / non-adjustable 10. AVIATION FITTINGS a. Type b. Type of lamps c. No. of Lamps/fittings.

1.8 EARTHING SYSTEMS

A. EARTHING ELECTRODE Earthing electrode and accessories shall be as per drawing enclosed. a. Size of the copper plate - 600x600x3mm b. GI (galvanized) pipe of 50 mm diameter is to be used. This will have a funnel at the top of the earth pit chamber. c. The earth pit to be dug for a depth of 3.75 mts. d. Copper plate is to be properly fastened with nuts and bolts to the copper wire ofsize 14 SWG. This copper strip/copper wire is laid upto Switch board. e. 50 Kg. of salt and approx. 100 Kg. of coal are to be filled in the pit, in layers, after the plate and the pipes are laid in the pit. f. Measure the earth resistance at the pit which has to be less than 2 Ohms. g. Cover be of CI with 750X750 mm size. Chamber should be 1000X1000 mm brickwork and bottom with PCC. B. EARTHING CONDUCTOR: The size and type of the Earthing conductors for main grid and equipment Earthing shall be as per drawings and specifications. C. EARTHING NETWORK MAIN GRID: The location of earth pits (electrodes) earth conductors, earth bus, earthing points on the equipment shall be determined at field, in consultation with the site- in- charge. Any changes in the arrangements, routes, size of conductors shall be made only with approval of Engineer-in-charge. Each earth pit shall be connected to the grid at least by two distinct connections. Where cable trays are available earth conductors may be laid on the tray, but the same shall be clamped firmly to the side of the tray. Joints and tapping of the earth conductors shall be made in such a way that reliable and good electrical continuity is permanently ensured. All joints below ground shall be welded Page | 18

and suitably protected with two coats of bitumen paint given immediately after welding and cleaning of welding slag. Welding must be with overlap of twice the width of GI strip and all four side of the overlap. All joints using Earthing cables shall be by means of lugs / connectors only. Excavation and filling the earth necessary for laying the underground earth conductors / grid shall be the responsibility of the contractor. D. EARTHING PRACTICES: Following codes of practice must be followed strictly: a) Minimum distance between two electrodes shall be twice the length of the electrode. b) Minimum distance of the electrode from any building or foundation or structure shall be equal to the length of the electrode c) For all electrical equipment minimum number of connection from earth grid : External Earthing Up to 250 Volts : One Above 250 Volts : Two Internal Earthing Flameproof equipment / lighting fixtures located in licensed area shall have an additional Internal Earthing done with extra core available. All lighting fixtures and associated junction boxes in unlicensed area earthed internally need not have external Earthing. E. TESTING All earth electrodes shall be individually tested by disconnecting from the grid with proper earth tester. The test shall be conducted during dry season and results shall be recorded. After connecting all electrodes to the ground resistance of the grid to earth shall also be tested with proper earth tester.

1.9 CABLES/WIRES FOR ILLUMINATION WORKS

a) Cable Laying And Termination The scope of the contract shall include laying of power and lighting cables, which shall be laid in trenches, cable trays or conduits as drawing and cable schedule or as per site conditions. Fabrication and erection of cable trays, supports as required shall be the responsibility of the Contractor. Power and control cables shall be separated by adequate spacing or taken through separate pipes.

Page | 19

Cable schedule indicate the most desirable route of each cable. The routes are marked on the plant lay out. However, there may be some obstruction or other problems at site. The most convenient route shall be decided in consultation with the Engineer-in-charge. Cable shall not be cut from a drum until the actual length required is ascertained. The lengths given in the cable schedule is only indicative. To the extent possible one length without any joint shall be laid from one terminal to the other. Wherever joint cannot be avoided, only Tropolin jointing kit of CCI / Mahindra Chemical or approved equivalent shall be used. Cables shall be neatly arranged and dressed in trenches, trays avoiding criss-crossing. Cables on the trays shall be clamped. Arranging the cables in the trenches / trays shall be responsibility of the contractor. Cables from trench to the equipment shall be taken through GI pipes of adequate size. Pipe shall be laid at angle of 45 max. to the trench for pulling of the cables with ease. Bends shall have large bending radius (> 12 times of cable OD). All cables will have identification tags close to their termination points bearing Run No. and cable size shall be punched on Aluminium sheet (100 X 25 X 2 mm) and fastened to the cable by nylon tie locking type. For the underground cable tag shall also be provided at each end before entry into the ground and at an interval of 30 meters. Routes of the underground cables in the yard shall be marked with the markers at interval of 30 meters and in turnings as well. Location of cable joints shall also be marked with markers. All temporary ends of cables must be protected against moisture / dirt to prevent damage to insulation. For this purpose, ends of all PVC insulated cables shall be sealed with cable compounds / PVC tape / rubber tape etc. Cable shall be handled carefully to avoid damage. Screw jacks and rollers shall be used for laying the cables. Cables shall be laid in the trenches as per the code of practice. Before the cables are placed the trench bottom shall be made level and covered with a 100 mm thick layer of sand. Cables shall be dressed avoiding crossing and making separate groups for power cables, control cables etc. Cables shall be covered with 100 mm of sand on top of the cable of largest OD. Class B Red bricks shall then be laid flat. The remainder of the trench shall then be back filled with soil, rammed and leveled. Cables shall not be cut from the drum without measuring the insulation resistance. After laying one layer of cables and before covering with sand for second layer, if required, all the cables shall be meggared again in presence of site-in- charge and results to be recorded. All wall opening / cable trenches, at the point of entry into a building shall be sealed effectively to prevent seepage of water into a building. Page | 20

Where cables rises from the trenches / underground pipes to equipments, they shall be taken through GI pipes of adequate size up to a minimum of 300 mm above the floor level or as directed by the Engineer-in-charge. Cable shall be pulled carefully through the pipes so that there is no damage to the cables. If required cable lubricant shall be used. Where cables pass through foundation wall of any underground structure, necessary ducts or opening shall be provided. However, should it be necessary to cut holes in existing foundation or structure the contractor shall obtain permission of Engineer-in-charge before cutting it. The contractor shall examine each drum on receipt and record discrepancies, if any, in respect of length, size, damages etc. The cable in drum shall be meggared and insulation resistance values shall be noted. In case of any discrepancy, the same shall be sorted out with the Engineer-in-charge before cable from such a drum is utilized. Proper account of all cables received and laid shall be maintained indicating Run No., Drum No., Length as per Cable Schedule, Actual length laid, insulation resistance w.r.t. Earth and between the cores with date of test and megger number and make. Cables laid above ground shall be run on trays, fixed on walls, ceiling or structures and shall be run parallel or at right angle to beams, walls or columns. Cable dressing is important and must be approved by Engineer-in-charge. In case the above conditions for exposed cables are not maintained, the site-in charge may direct to rectify / modify the same without any extra cost to the HPCL. Individual cables, group of cables, which run along a structure, may be directly clamped to structure by means of 16 SWG Al clamps on 25 X 6 mm MS saddle bars. The rates for cable laying should include consumable like saddle, saddle bar, binding straps nylon tie locking type etc. and no separate payment shall be made for such items. Proper nylon locking type or temporary fastening etc., Steel wires, cable armors etc. shall never be allowed for such purposes. Cables shall be supported adequately to avoid unsightly sagging. Normally the distance between two supports shall be 300 mm for cables of diameter up to 25 mm. For cable of higher sizes the distance may be up to 450 mm. However uniform distance shall be maintained for aesthetic consideration. All cables shall be supported near the glands, so that there is no undue stress on the gland. All exposed cables must be protected against accidental damage.

b) TERMINATION: All cables shall be terminated at flameproof equipment through FLP double compression cable glands only. In case, the contractor is required to supply the cable glands the same shall be of approved make, bearing CMRS certificate No., Name of make and cable size must be punched on the cable gland. Threads of the nipple of cable gland must match the thread at the cable entry of the equipment. Cable OD and diameter under armor must match the neoprene rings. Page | 21

All flameproof equipments are provided with the internal Earthing point and there is an extra core available in the cables for connecting the internal Earthing. Earth connection shall be taken from earth bus in the Electrical Panel. Al utilized cores of a control cable shall be identified at both ends by wire numbers indicated by PVC ferrules or self-sticking cable markers. Wire numbers shall be as per schematic / terminal wiring diagrams. Cable markers / ferrules shall be as per the sample approved by Engineer-in-charge. Cable leads shall be terminated at the equipment terminals with tinned copper lugs (CUS type) of Dowells or approved equivalent make. The lugs size is the same as cable size. The lug hole diameter shall match the stud or fastener size. For all power cable termination proper plain and spring washer must be used. Where anti-vibration terminals cable termination proper plain is provided the special lugs for such terminations are to be provided. In no case ordinary lugs shall be used with ant vibration terminals. In PCC the part of the cable between the gland and the terminal shall be properly clamped in the cable alley. No cable or wire shall be left hanging loose in the cable alley. All the unused cable entry in cable alley of PCC should be plugged after completion of cable laying. General 1 2 All the luminaries shall be designed, manufactured and tested in accordance with relevant IS specifications so far as they are applicable. All the luminaries shall be commercial / industrial type as per specific requirement. Specification for the various types of incandescent, mercury vapour, sodium vapour and fluorescent fittings mentioned in the schedule of quantities shall be followed. All the lighting fixtures shall be complete with all parts, including earthing arrangement and accessories for efficient performance whether specifically asked in the specification or in the schedule of items or not. Individual light fittings shall be provided with suitable arrangements for GI threaded conduit entry of 19 mm dia unless otherwise specified. Terminals of all fittings shall be suitable for taking 2.5 sq. mm flexible, copper conductor PVC insulated, PVC sheathed cable. Fittings shall be supplied with all inter connections made and fully wired upto the terminal block and shall be suitable for mounting on wall / column / ceiling / suspension (from the ceiling including suitable bracket). All types of light fittings shall be supplied with lamps. All live parts shall be provided with suitable sleeves to prevent accidental contacts. The earthing terminal in the fitting shall effectively earth the body of the entire luminaries. The clearance between the live parts and the enclosures earthing and other safety factors shall be governed by the latest revisions of the relevant IS specification and IE rules. The fixing arrangement of various components and lamps shall be in such a way that the maintenance and replacement jobs can be easily carried out. The luminaries shall be suitably designed to provide economically the required level of illumination on the working plane when mounted at normal standard height in accordance with the type of fixtures. Page | 22

5 6 7 8 9

10 11 12

13 14

15

16

17 18 19 20 21 22 23 1.9.1 a)

The luminaries shall be suitable for operating at normal supply voltage of 240 V, single phase, 50 Hz with voltage variation of +/- 6% or at voltages as specified. The lamp holders of the fittings shall be suitable to take the lamp supplied. All types of Fluorescent lamp fittings shall be supplied with necessary controlgear housing polyester filled electronic ballast. P.F improvement capacitor spring loaded rotary lamp holders starter holders metallic starters all pre wired to suitable terminals All types of fluorescent and well glass fittings shall be suitable for mounting on wall / column or suspension from ceiling/false ceiling as required. The light fittings shall include the mounting accessories like chain, down rods for fittings mounted in false ceilings anchor bolt and all erection accessories required for complete installation. Only energy efficient electronic ballast shall be used. In case the same is not manufactured for a particular type of lighting fixture then copper ballast shall be used as the next option. Wherever inserts are available in the roof slab/column/wall, the same shall be used for supporting the mounting accessories like down rod/brackets/chains etc., and in other places where there are no inserts. Anchor bolts shall be used for supporting the mounting brackets from the ceiling and grouting on wall / column shall be provided for mounting the fitting on wall / column in consultation with the site engineer. GI/MS/PVC conduits shall be complete with all accessories as required. Due to the highly corrosive atmosphere the fittings shall be provided with two coats anti corrosive epoxy painting over two coats of primer. Bulk head Luminaries suitable for Compact Flourescent fittings. Anti-Corrosive Type Fluorescent Light Fitting Industrial Fluorescent Light Luminaries With Stove/Vitreous Enamelled Reflectors Compact Fluorescent Lamp & Fittings Flame proof well glass & bulkhead luminaries suitable for HPMV/CFL fitting. SPECIFICATION FOR CABLES INSTRUCTIONS TO BIDDERS: 1. The cables covered under this specification shall confirm to ES-8160. 2. The tenderer shall submit cable data of the cables offered as per the Technical Particulars enclosed. 3. The Routine and Acceptance tests as per ES-8160 shall be conducted in presence of TPI representative at venders works before dispatch of cables. 4. The drum lengths of various cables indicated in the enclosed Specification Sheet shall be complied with subject to tolerance as indicated in ES-8160. 5. Any deviation from specification shall be clearly indicated. 6. The following details to be embossed on the outer sheath of the cables : i) Make / Trade Mark ii) Voltage Grade iii) Size of cable iv) Sequential Marking Page | 23

v) b)

Year of Manufacturing Failing which, the cable will not be accepted.

SCOPE OF WORK 11.2.1 This standard covers the technical requirements of design, manufacture, testing at works and dispatch in well packed condition of power and control cables. 11.2.2 The standard shall be read in conjunction with relevant specification sheets and other relevant references as specified therein.

c)

STANDARDS TO BE FOLLOWED The design, manufacture and testing of cables covered by this standard shall comply with the latest issue of following Indian Standards, unless otherwise specified. Equipment complying with equivalent IEC standards shall also be acceptable. i. IS: 1554 Part (I) -- PVC insulated (heavy duty) electric cables for working voltages upto and including 1100 volts. ii. IS: 1554 Part (II) -- PVC insulated (heavy duty) electric cables for working voltages from 3.3 KV upto and including 11 KV. iii. IS: 7098 Part (I) -- Cross linked polyethylene insulated PVC sheathed cables for working voltages upto and including 1100 volts. iv. IS: 7098 Part (II) -- Cross linked polyethylene insulated PVC sheathed cables for working voltages from 3.3 KV upto and including 33 KV v. IS: 7098 Part (III) -- Cross linked polyethylene insulated thermoplastic sheathed cables for working voltages from 66 KV upto and including 220 KV vi. IS: 692 -- Paper insulated lead sheathed cables for rated voltages upto and including 33KV vii. IS: 694 -- PVC insulated cables for working voltages upto and including 1100 volts viii. IS: 5831 -- PVC insulation and sheath of electric cables The design and operational features of the cables offered shall also comply with the provisions of latest issue of the Indian Electricity Rules and other relevant Statutory Rules & Regulations. The supplier shall, whenever necessary, make suitable modification in the cables to comply with the above mentioned rules. Wherever any requirement, laid down in this standard, differs from that in Indian Standard Specifications, the requirement specified herein shall prevail.

d)

OPERATING REQUIREMENTS The cables shall be suitable for operating continuously at the rated capacity as specified in relevant I.S. under the ambient conditions in specification sheet without exceeding the permissible temperature rise and without any detrimental effect on any part.

e)

GENERAL DESIGN AND CONSTRUCTIONAL FEATURES The design, manufacture and workmanship of cables shall be in accordance with the latest practice. Page | 24

All materials to be used shall be new, unused and of the best quality. i. Conductors : The power cables shall be of stranded Aluminium / copper round or shaped conductors and control cables shall be of annealed high conductivity stranded copper round conductors. The conductors shall comply with the requirements of IS: 8130. ii. Insulation : The conductor insulation shall be type A/C as indicated in specification sheet and shall comply with relevant IS. iii. Fillers : The cables shall have suitable fillers wherever required, laid up with conductors to provide substantially circular cross section before the inner sheath is applied. iv. Inner Sheath : Inner sheath, wherever applicable shall be ST1/ ST2 type compound applied by extrusion process except for paper cables for which it shall be of lead or lead alloy. v. Armouring : All power and control cables shall be armoured as specified in specification sheet. The single core cables shall be armoured with hard drawn Aluminium taps/ wires or any other suitable nonmagnetic material. All other cables shall have galvanized steel wire / strip armouring. vi. Outer Sheath : The outer sheath shall be ST1/ ST2 type compound applied by extrusion process and suitable to withstand atmospheric pollution, resistance to termites, fire retardant and coloured black. vii. Screening : Screening over conductor and insulation shall be provided as per relevant standard unless specified otherwise. The screening for control cables if specified shall be of Aluminium, Mylar or equivalent and provided with tinned drain wire which shall be continuous and permanently connected to the screen. viii. Identification : The individual cores of cables shall be coloured as per relevant IS. Where it is not possible to distinguish the cores by colour, coloured strip shall be applied on the cores or core nos. shall be marked on each core at regular intervals. All cables shall carry the manufacturers name or trade mark, the cable size, voltage rating and year of manufacture at intervals not exceeding 100 meters. Running meter markings shall also be provided throughout the length of the cable. ix. Dimension : The overall dia. and dia. under armour of the cables shall be indicated by the vendor in the technical particulars. These shall be guaranteed with a tolerance of 5% but not exceeding 2 mm. The cut ends of the cables shall be sealed by means of non-hygroscopic materials. f) SPECIAL PURPOSE CABLES a) Flame Retardant Low Smoke Cables (FRLS) : Flame retardant low smoke cables, where specified in specification sheet, shall have outer sheath of PVC having following values. - Minimum oxygen index - 29% - Minimum temperature index - 250C - Maximum acid gas generation - 20% - Maximum smoke density rating - 60% b) Heat Resistant Cables Heat resistant cables, where specified in specification sheet, shall be of silicon rubber insulated laid circular with asbestos worming and overall glass fibre braided and varnished. Page | 25

Silicon rubber insulating compound shall conform to IS:6380 and the constructional features shall conform generally to IS:9968. g) CABLE DRUM a) The cables shall be supplied in non-returnable wooden drums (or steel drums if specified) of heavy construction. The wood used for construction of the drums shall be properly seasoned, sound and free from defects. b) Cables shall be supplied in specified drum lengths. Where no such indication is given, standard drum lengths may be offered. c) The tolerance on each drum of cable shall not exceed 2.5%. However, no negative tolerance on HV cables is acceptable. d) All cable drums shall have stenciled data as per relevant IS as well as the purchasers order no., item no. & drum no.

h)

TESTS AND INSPECTION a) The following tests shall be carried out on the cables as per relevant IS. i) Routine Tests - On all cables ii) Acceptance tests - On representative length of each size iii) Type tests - Wherever specified on one cable drum of each size b) In addition, the following tests shall be carried out on all fire retardant low smoke cables as per IS or as per the following standards: i) Oxygen and temperature index test as per ASTM-D-2863 ii) Acid gas emission test as per IEC-754 Part-I iii) Smoke density test as per ASTM-D-2843 iv) Flammability test as per IEC-332 Part-I or IS-10810 c) All the above mentioned tests shall be carried out in the presence of Third Party. In addition, the cables shall be subjected to stage inspection at works and inspection at site for final acceptance. d) These tests and inspections shall, however, not absolve the vendor from their responsibility for making good any defect which may be noticed subsequently. DEVIATIONS i. Deviations, if any, from this standard shall be clearly indicated in the offer with reasoning. ii. Deviations, if any, from the data furnished in specification sheet shall be indicated therein beside the data by encircling it.

i)

1.10 CONTROL SWITCHES

Decorative type Single pole decorative type, 5A, or 15A switches shall be used for light/fans/socket outlets points in office premises / non plant buildings and shall be of approved type, make and color. All branch switches shall be placed in line conductor of the circuit and no single switch or fuse shall be inserted in the neutral conductor of the circuit. Page | 26

1.11 SWITCH BOARDS (FOR DECORATIVE SWITCHES AND SOCKETS)

The switch board shall be made of 1.6 mm thick sheet steel & painted including supports for switches, sockets, fan regulator etc., but excluding front cover in case of decorative switches & sockets which will be of FRP sheet of approved quality, design and colour. Clear depth of the box shall not be less than 60 mm, but adequate for easy mounting of fan regulators. All fittings shall be in flush pattern in case of concealed wiring. The FRP cover sheet thickness shall not be less than 3 mm.

1.12 HAZARDOUS AREA

General All the equipment's installed and accessories used shall conform to the requirements stipulated under relevant Indian Standards and STEC regulations for the type / category of installation. All the equipments and accessories installed in these areas shall be certified by CMRI, Dhanbad for using in that particular type of hazardous atmosphere like flammable gas / vapor or hazardous dust. All the equipments installed shall not attain more than the maximum permissible surface temperature specified for that area elsewhere in the specification, if not the maximum permissible temperature may be assumed as 100 degree C. It shall be ensured that overheating / sparking whether in normal use or under fault condition is confined within the approved housing of wiring system and electrical item concurred. If any equipment is likely to produce more than the prescribed maximum permissible surface temperature due to abnormal conditions of operation or during fault conditions, all such fittings shall be fitted with a thermal device to disconnect the appropriate circuit before the maximum safe temperature is exceeded. This bimetal thermally operated cutout device shall preferably be included in the enclosure containing choke and other control gears liable to be over heated. THIS THERMAL DEVICE SHALL NOT BE AUTOMATIC SELF-RESETTING TYPE. If control gears are not integral with the fitting the enclosure for the control gears also shall be suitable for use in that particular type of hazardous atmosphere and certified by CMRS, Dhanbad. For all the equipments where cast iron body is specified, cast Aluminium alloy (LM-06) is also acceptable. All the equipments if constructed out of Aluminium alloy, its external surfaces shall be smooth finished to be free from frictional sparking hazard. All the equipments shall have markings, warning inscriptions and interlocks, specified as per relevant I.S, inscribed either by raised lettering or cast integrally with or by a plate permanently attached to the body of the fitting. Copy of CMRS, Dhanbad, and certificate for each type of fitting should be submitted. Light Fittings Flame Proof Bulk Head Fitting The fitting shall have a cast iron/Aluminium enclosure with integral control chamber housing the terminal box. The toughened impact resistant clear glass cover provided in the front shall be cemented to retaining ring. The retaining ring shall be suitable for fixing to the main body with the help of screws, which can be opened, only with the help of special tools. The ES porcelain lamp holder shall be suitable for the type of lamp specified. The fittings shall have suitable cable entry provision as required. Suitable plugs to close the non-used entries shall also be provided along with the fitting. A suitable chrome plated integral Page | 27

reflector shall be supplied along with the fitting. In case the above fitting suitable for HPMV lamps are specified suitable flame proof control gear is to be supplied along with the fitting. Earthing studs one inside the terminal box and one outside shall be provided. Wiring General For general requirements for wiring refer to the details stipulated under specifications for wiring for Ordinary (non-hazardous) area elsewhere in this specification. Additional requirement for carrying out wiring in the hazardous areas are as specified below Using Armored Cables 1. 1100V grade HR PVC/XLPE insulated PVC sheathed round wire armored PVC overall sheathed cable with copper conductors shall be used for wiring wherever surface laid cables are specified for connecting from distribution board to light fittings and other equipment. 2. While carrying out surface wiring using armored cables, cable shall be supported 500mm apart to avoid sag. The cables shall be neatly clamped and should not create a shoddy appearance. 3. Nylon/ plugs shall be used for fixing cables to ordinary wall / ceiling. The plugs shall be fixed using the correct size of drills and screws as specified by the manufacturer. Using of wooden plugs is not permitted. 4. Cables shall be laid in such a manner to avoid crossing / jumping of cables and shall provide a very neat and tidy appearance. 5. Suitable size double compression brass glands (Approved by CMRS as suitable for flameproof area) shall be provided for cable entry / exit to any of the flameproof apparatus. 6. The cables used shall have multi strand copper conductor. 7. The rate quoted shall include the cost of accessories required like FLP junction boxes, saddles, consumables, etc., for supply and installation of complete wiring system. 8. 1.13 FLOOD LIGHT 1.13.1 GENERAL A. Description : This specification covers the requirements for floodlighting poles of metal construction for areas with explosion risk and safe areas as specified in the requisition. Applicable Conditions and Regulations: All applicable standards of the country stated in the requisition. All other national and/or local regulations applicable to this type of work. Conflicting Requirements: Page | 28

B.

C.

In case of conflicts between the conditions and documents above or between these and the specification in hand the severest requirements will govern. In case of conflicts between this specification and the requisition, the requirements of the requisition will govern. Purchaser is not committed to check vendors documents etc. Purchaser will review them. It will remain vendors responsibility manufacture the poles in accordance with this specification and requisition in a completely functional and workmanlike manner. A deviation from the requisition (of which this specification forms part) will only be acceptable when vendor has specified in his quotation under the heading deviations from specification or requisition the requirements he cannot meet and Company has accepted this deviation in writing before placement of order or in the order. Failure to do so will be interpreted by Purchaser as confirmation that Manufacturer will comply under conditionally with this specification. D. Drawings and Data to be Furnished with the Quotation: a) Outline drawing showing overall dimensions, location of holes, exact dimensions of service doors etc. b) Weight of each type of lighting pole. 1.13.2 CONSTRUCTION i. All poles and brackets shall be made of metal. ii. Poles and brackets shall be thoroughly cleaned of rust and scale. iii. Interior of the poles and brackets shall be coated with a non-leaching bituminous material. iv. Exterior of the pole base, up to 30 cm above grade, shall be wrapped and asphaltcompounded. v. The outside of the remaining parts of the poles and the brackets shall be painted with 2 layers of red lead. vi. The shaft shall be weld able grade (ASTM A-500 Grade C) hot rolled commercial quality carbon steel tubing with a minimum yield of 55,000 psi. Uniform wall thickness of 0.1196" or 0.1793". Shafts shall be one piece with a longitudinal electric weld and uniformly square in cross-section with flat sides, small corner radii and excellent torsional qualities. Available shaft widths shall be 5 inches. vii. Pole base shall be provided with 2 slotted holes of 100 x 50 mm at a depth of 50 cm below grade. viii. Each pole shall be supplied complete with a separate footing. Footing shall consist of a tube (of proper size to fit the pole) welded to a plate of 500 x 500 x 6 mm. Provisions shall be made to fix the pole with 3 bolts to the footing. (Size for bolt at least ). ix. Pole shall be provided with an inspection door. Behind that door, a mounting plate or an explosion proof box shall be mounted as specified in the requisition. Mounting plate shall be provided with terminals, fuse holder E27 with fuse, Earthing screws, wiring, saddles, etc. Explosion proof box shall contain terminals, automatic circuit breaker, earthing screws, wiring, explosion proof glands, etc. x. An automatic switch will control the supply outside the explosion proof box of the pole. xi. Rubber cable 3 cores 4 sq.mm between mounting plate or box and fixture(s) will be furnished by others. 1 core will be used for Earthing purposes. xii. For floodlight poles, the clamps as per given figure will form part of the supply. Page | 29

xiii. xiv. xv.

All internal wiring (2 sq.mm black PVC-insulated) forms part of this specification. Purchaser will only connect feeder cable(s) and rubber cable inside the pole. Boxes and mounting plates shall be easily removable for installation purposes. For explosion proof boxes test certificates with indication of gas-group classification will be required.

1.14 EQUIPMENT HANDLING:

The contractor shall make his own arrangements to safe transportation of equipment to erection site including loading / unloading etc. Equipment shall not be taken out of the cases unless the foundation has been made ready. The cases shall be opened only in presence of Engineer-in-charge. Any damage / short supply detected shall be recorded in joint report duly signed by Engineer-in-charge immediately. No dispute shall be entertained on a later date.

1.15 ERECTION AND INSPECTION:

All supply items shall be third party inspected and Inspection reports to be submitted to Engineer In Charge. Minor items like hardware MS materials for racks, support etc. shall be inspected at site by HPCL representative. No item shall be installed / used until the same is approved by HPCL representative. After completion of erection of each piece of equipment shall be offered for inspection to the owner before testing and commissioning. HPCL on finding any defect / inconvenience shall point out the same for rectification. The contractor shall inform the HPCL site in charge in writing the rectification carried out. Any work not confirming to execution drawings, specifications, standards, or codes shall be rejected and the contractor shall rework / rectify the same at his own cost.

1.16 TESTING & COMMISSIONING:

All equipment installed / connected by the contractor shall be tested and commissioned as per instruction of Engineer in-charge. After completion of erection a check-list indicating the checks / tests proposed to be carried out before commissioning of the equipment shall be submitted to the Engineer-in-charge for his approval. The contractor shall carry out the test as per technical specification, manufacturers instruction manual, relevant Indian / International standards and instruction of the HPCL. All tests shall be conducted in presence of the Engineer in-charge. The contractor shall provide all necessary tools, testing equipment, labour, competent technical personnel, and consumable materials etc. for tests. All the test results shall be recorded on approved proforma by the contractor and counter signed by the HPCL authorised representative. On successful completion of tests, the test results shall be furnished in four copies in the form of Test Certificates.

Page | 30

Page | 31

Page | 32

2 :LIST OF APPROVED VENDORS

A. LIST OF APPROVED MAKE / BRAND FOR CIVIL WORKS S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Note : NAME OF MATERIAL Cement Reinforcement Steel / Structural steel Cement paint PVC / UPVC pipe GI pipe / MS pipe Gun metal gate valve / check valve G.I. Fittings Brass hardware Aluminium hardware C.I. Pipes & fittings MS structural steel small sections as specified Anchor bolts Nuts & bolts Electrodes APPROVED MAKE Ultratech, Birla, RAMCO, CCI, ACC TISCO, SAIL, TSRM, VIZAG STEEL,JISCO, JVSL, LLOD STEEL, ESSAR Snowcem / Asian paint / Berger / Nitco Supreme / Prince / Finolex / Oriplast Tata / Zenith / GST / Jindal Leader / GG (ISI marked)/Audco/IVC/Fludiline R-Brand, K- Brand, Unik Saifee, tube & hardware Nov Bharat ,Jayant, E.C.I.E &Zaofa NECO, BIC Conforming IS:2062 as approved by EIC Conforming to IS:2062 as approved by EIC TVS, GKW, UNBREAKO Conforming to IS as approved by EIC

Regarding selecting the make against each item among the approved makes as specified above, decision of HPCL shall be final.

Page | 33

B. LIST OF APPROVED MAKE / BRAND FOR ELECTRICAL WORKS S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 24 25 Note : NAME OF MATERIAL MCCB SFU / FSU / HRC fuses / MCCB MCB Distribution Boards MCB/ELCB PVC Conduits and accessories PVC insulated copper wire Switch / Sockets Angle holder / batten holder / ceiling rose LT cables Light fittings / ballast / lamps Ceiling fans (double ball bearing) Emergency light KWH meter Ammeter / Voltmeter Indicating lamps (LED type) GI pipes / MS pipe Street light poles Change Over Switch Cable Gland Lugs Meter Boards / MV panels / MCC Capacitors APPROVED MAKE L&T L & T / Havells / Alsthom / Havells MDS / Havells / Standard Electricals Ltd., / Hager / MK SENTRY MDS / Havells / Standard Electricals Ltd., / Hager / MK SENTRY ISI / FIA approved make V plast / Finolex Anchor Roma / Mk India / Legrand Anchor CCI / UNIVERSAL / NICCO / FINOLEX / GLOWSTAR / OMEGA PHILIPS / BAJAJ / CROMPTON/WIPRO Crompton / Usha / Khaitan / Bajaj BPL BHEL / SIMCO / India Meter L & T / AE / IMP / MECO L&T, Crompton Greaves, Philips Jindal / GST / Tata / Zenith Bombay poles or ISI approved make. LT / Siemens / Havells Gripwel , Baliga , FCG , EMI Dowells CPRI tested Manufacturers Universal / Asian

Regarding selecting the make against each item among the approved makes as specified above, decision of HPCL shall be final

Page | 34

3 : IS CODES & STANDARDS

STANDARDS FOR ELECTRIFICATION JOBS: Materials and equipment to be supplied by the contractor for this work shall be in accordance withrelevant IS specifications. The following standards shall be applicable to various instruments. S.No. 1 2 3 4 5 6 7 8 9 10 11 12 IS Code IS: 2516 IS: 4047 IS: 1818 IS: 2607 IS: 2208 IS: 3072 IS: 3106 . IS: 4237 IS: 375 IS: 2705 IS: 1248 IS: 2419 Job/Equipment Specification for AC Circuit Breakers Specification for Heavy duty air break switches and fuse for voltage notexceeding 1000 V Specification for AC Isolators and earthing switches Air Break Isolators for voltages not exceeding 1000V HRC Cartridge fuses links up to 650V Code practice for installation and maintenance of Switchgear Code of practice for selection, installation and maintenance of fuses (Voltagesnot exceeding 650V) General requirements for switchgear and control gear for voltages not exceeding1000V Marking and arrangement for switchgear busbars, main connection and auxiliaryWiring Current transformers Direct acting electrical indicating instruments Dimensions of electrical indicating instruments

Erection of equipment and material whether supplied by owner or contractor shall be in accordance with the best engineering practice, conforming to respective provisions of IS codes. Site testing shall conform to relevant IS code. In addition the work shall conform to the following: i) Indian Electricity rules and Acts. ii) Fire insurance regulations. iii) Requirements of Electrical Inspector. iv) Requirements of State Electricity Boards. v) Requirements of Factory Inspector vi) Requirements of State/Central/Local Authorities vii) Requirements of Chief Controller of Explosives Nagpur.

CODES AND STANDARDS FOR CABLES Page | 35

The design, construction, manufacture and performance of XLPE insulated cables shall comply with all currently applicable statutes, regulations and safety codes of the locality where cables will be installed.The cables shall conform to the applicable Indian, IEC. The relevant Indian standards are: S.No. IS Code Job/Equipment 1 IS: 613 (1984) Copper rods and bars for electrical purposes 2 IS:1885-(Part32) (1993) Electro Technical vocabulary - electric cables 3 IS: 2633 (1986) Method of testing uniformity of coating on zinc coated articles. 4 IS:3961-(Part4) (1968) Recommended current ratings for Polyethylene insulated cables. 5 IS: 3975 (1988) Mild steel wire, formed wires and tapes for armouring of cables. 6 IS: 5831 (1984) Specification for PVC insulation and sheath of electric cables. 7 IS: 6474 (1984) Specification for Polyethylene insulation and sheath of electric cables. 8 IS:7098-(PartI) (1988) Specification for cross-linked Polyethylene insulated, PVC sheathed cables. (For working voltages up to and including 1100 volts) 9 IS: 8130 (1984) Conductors for insulated electric cables and flexible cords. 10 IS: 10418 (1982) Drums for electric cables. 11 IS: 10462 (Part 1) (1983) Fictitious calculation method for determination of dimensions of protective coverings of cables 12 IS: 10810 (Pt 58) Methods of test for cables : Part 58 Oxygen Index test 13 IS: 10810 (Pt 61) Methods of test for cables : Part 61 Flame retardant test 14 IS: 10810 (Pt 62) Methods of test for cables : Part 62 Flame retardant test for bunched cables 15 IEC:60540& 60540A Test methods for insulation & sheaths of electric cables 16 IEC: 230 (1966) Impulse tests on cables and their accessories 17 IEC: 60332 (3 parts) Tests on electric cables under fire conditions 18 IEC: 811 (5 parts) Test methods for insulating and sheathing materials of electric cables. 19 IEC: 840 (1988) Tests for power cables with extruded insulation for rated voltages above 30KV upto 150KV 20 ASTM: D2863 Standard method for test for flammability of plastics using oxygen index method 21 IECAS-61-402 Thermoplastic insulated wire & cable for transmission & NEMAWC5 distribution of electrical energy 22 IECAS-66-524 Cross linked thermosetting poly ethylene insulated wire & NEMAWC5 cable for transmission & distribution of electrical energy 23 IEC: 840 (1988) Tests for power cables with extruded insulation for rated voltages above 30KV up to 150KV Page | 36

The cables & accessories shall also confirm to the provisions of the Indian Electricity Rules and other statutory regulations in force in the country. In case of any contradiction between various referred standards/ specifications/ data sheets and statutory regulations, the following order of priority shall be given: - Statutory regulations - Data sheets - Unit Specifications - This Specification - Codes & Standards Relevant Indian standards, Acts and Codes for Earth work excavation Sl.No. IS Code IS: 383 1970 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
IS 2720 (Part- 2)1973 IS 2720 (Part4-4 ) 1985 IS 2720 (Part-5 ) 1985 IS 2720 (Part-6 ) 1972 IS 2720 (Part-7 ) 1980 IS 2720 (Part-8 ) 1983 IS 2720 (Part-14 ) 1983 IS 2720 (Part-21 ) 1977 IS 2720 (Part-23 ) 1976 IS 2720 (Part-24 ) 1976 IS 2720 (Part-27 ) 1977 IS 2720 (Part-29 ) 1975 IS: 3764 1992 IS: 4081 1986 IS: 4701 1982 IS: 9759 1981 IS: 10379 1982

Job/Equipment
Specification for coarse and fine aggregates from natural sources for concrete. Methods of test for soils-Determination of water content Methods of test for soils-Grain size analysis Methods of test for soils-Determination of liquid limit & plastic limit Methods of test for soils-Determination of shrinkage factors Methods of test for soils-Determination of water content-Dry density relation using light compaction Methods of test for soils- Determination of water content-Dry density relation using heavy compaction Methods of test for soils-Determination of dry index(relative density) Methods of test for soils-Determination of total soluble solids Methods of test for soils-Determination of calcium carbonate Methods of test for soils-Determination of cation exchange capacity Methods of test for soils-Determination of total soluble sulphate Methods of test for soils-Determination of dry density of soil inplace by core cutter method Safety code for excavation work Safety code for blasting and related drilling operations Code of practice for earth work on canals Guide lines of dewatering during construction Code of practice for field control of moisture and compaction of soils for embankment and sub grade Indian Explosives Act 1940 as updated.

Page | 37

Relevant Indian Standards for Plain Cement Concrete and Reinforced Cement Concrete: S.No. 1 2 3 4 Job/Equipment Specification for paving bitumen Specification for coal tar pitch Specification for 33 grade Ordinary Portland cement Specification for mild steel wire for general Consultanting Purposes IS: 383 1970 Specification for coarse and fine aggregates from natural sources for concrete IS:432 (Parts I) 1982 Specification for mild steel medium tensile steel bars and hard drawn steel wire for concrete reinforcement Mild steel & medium tensile bars IS: 432(Parts II) 1982 Specification for mild steel medium tensile steel bars and hard drawn steel wire for concrete reinforcement - Hard drawn steel wire IS: 455 1989 Specification for Portland slag cement IS: 456 2000 Code of practice for plain and reinforced concrete IS: 457 1957 Code of practice for general construction of plain & reinforced concrete for dams & other massive structures IS: 516 1959 Method of test for strength of concrete IS : 650 1991 Specification for standard sand for testing of cement IS: 702 1988 Specification for industrial bitumen IS : 737 1986 Wrought aluminium and aluminium alloy plate for generalConsultanting purposes IS: 800 1984 Code of practice for general construction in steel IS: 816 1969 Code of practice for use of metal are welding for generalconstruction in mild steel IS: 1161 1998 Specification for steel tubes for structural purpose IS: 1199 1959 Methods of sampling and analysis of concrete IS: 1200 (Part-II) 1974 Method of measurement of building and civil Consultanting works- Concrete works IS: 1200 (Part-V)1982 Method of measurement of building and civil Consultanting works- Form work IS: 1200 (Part- Method of measurement of building and civil VIII)1993 Consultanting works- Steel work & iron work IS: 1200 (Part- Method of measurement of building and civil XVIII)1974 Consultanting works- Demolition & dismantling IS: 1322 1993 Specification for bitumen felts for waterproofing and damp proofing IS: 1363 (Part 1) 2002 Hexagon head bolts, screws and nuts of product grade C Hexagon head bolts (size range M 5 to M 64) IS: 1363 (Part 2) 2002 Hexagon head bolts, screws and nuts of product grade C Hexagon head screws (size range M 5 to M 64) Page | 38 IS Code IS: 73 1992 IS : 216 1961 IS: 269 1989 IS: 280 1978

5 6

8 9 10 11 12 14 15 16 17 18 19 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25

IS: 1363 (Part 3) 2002 IS: 1489 (Part-I) 1991 IS:1489 (Part-II) 1991 IS : 1566 1982 IS : 1609 1991 IS : 1786 1985 IS : 1791 1985 IS: 1834 1984 IS : 1838 (Part-I) 1983

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

IS: 2016 1967 IS: 2074 1992 IS : 2386 (Part 1) 1963 IS : 2386 (Part 2) 1963 IS : 2386 (Part 3) 1963 IS : 2386 (Part 4) 1963 IS : 2386 (Part 5) 1963 IS : 2386 (Part 6) 1963 IS : 2386 (Part 7) 1963 IS: 2386 (Part 8) 1963 IS : 2438 1963 IS : 2502 1963 IS : 2505 1992 IS : 2506 1985 IS : 2514 1963 IS : 2571 1970

Hexagon head bolts, screws and nuts of product grade C Hexagon nuts ( size range M5 to M 64) Specification for Portland-pozzolana cement: Fly ash based Specification for Portland Pozzolana Cement: Calcined clay based. Specification for Hard-drawn steel wire fabric for concrete reinforcement. Code of practice for laying damp proofing treatment using bitumen felts. Specification for high strength deformed steel bars and wires for concrete reinforcement. General requirements for batch type concrete mixer. Specification for hot applied sealing compound for joints in concrete Specification for preformed fillers for expansion joints in concrete pavements and structures (non extruding and resilient type).- Bitumen impregnated fibe Plain washers Specification for ready mix paint, air drying, red oxide zinc chrome Methods of test of aggregates for concrete Particle size & shape Methods of test of aggregates for concrete Estimation ofdeleterious material and organic impurities Methods of test of aggregates for concrete Specific gravity,Density, voids, absorption and bulking Methods of test of aggregates for concrete Mechanical properties Methods of test of aggregates for concrete Soundness Methods of test of aggregates for concrete Measuring mortar making properties of fine aggregates Methods of test of aggregates for concrete Alkali aggregate reactivity Methods of test of aggregates for concrete PetrographicExamination Specification for roller pan mixer. Code of practice for bending and fixing of bars for concrete reinforcement. General requirements for concrete vibrators, immersion type. General requirements for concrete vibrators, screen board type. Specification for concrete vibrating table. Code of practice for laying in-situ cement-concrete Page | 39

42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

IS : 2645 2003 IS : 2722 1964 IS : 2750 1964 IS : 2751 1979 IS: 2812 1993 IS : 3025 (Part 22) IS : 3025 (Part 23) IS : 3037 1986 IS : 3150 1982 IS : 3370 (Part I) 1965 IS : 3370 (Part II) 1965 IS : 3384 1986 IS : 3414 1968 IS : 3550 1965 IS : 3558 1983 IS : 3696 (Part I) 1987 IS : 3696 (Part II) 1991 IS : 4014 (Part I) IS : 4014 (Part II) IS : 4031 (Part 1) 1996 IS : 4031 (Part 2) 1999

63 64

IS : 4031 (Part 3) 1988 IS : 4031 (Part 4) 1988

flooring. Specification for Integral cement water proofing compounds for cement mortar and concrete Specification for portable swing weighs batchers for concrete. (single and double type) Specification for steel scaffoldings. Code of practice for welding of mild steel plain and deformed bars for reinforced concrete construction. Recommendation for manual tungsten inert gas arc welding of Aluminium and aluminium alloys 1986 Methods of sampling and test (physical & chemical) for water & waste water Acidity 1986 Methods of sampling and test (physical & chemical) for water & waste water Alkalinity Specification for bitumen mastic for use in water proofing of roofs Specification for hexagonal wire netting for general purposes. Code of practice for concrete structures for the storage of liquids General requirements Code of practice for concrete structures for the storage of liquids-Reinforced concrete structures Specification for bitumen primer for use in waterproofing & damp proofing. Code of practice for design and installation of joints in buildings. Methods of test for routine control for water used in Industry. Code of practice for use of immersion vibrators for consolidating concrete. Safety code for scaffolds and ladders Scaffolding Safety code for scaffolds and ladders Ladders Code of practice for steel tubular scaffolding Definition & materials Code of practice for steel tubular scaffolding - Safety Regulation for scaffolding Methods for physical tests for hydraulic cement Determination of finess by dry sieving Methods for physical tests for hydraulic cement Determination of fineness by specific surface by Blaine air permeability method Methods for physical tests for hydraulic cement Determination of soundness Methods for physical tests for hydraulic cement Determination of consistency of standard cement paste Page | 40

65 66

IS : 4031 (Part 5) 1988 IS : 4031 (Part 6) 1988

67

IS : 4031 (Part 7) 1988

68

IS : 4031 (Part 8) 1988

69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84

IS : 4031 (Part 9) 1988 IS : 4031 (Part 10) 1988 IS : 4031 (Part11) 1988 IS : 4031 (Part12)1988 IS : 4031 (Part13)1988 IS : 4031 (Part14)1989 IS : 4031 (Part15)1991 IS : 4130 1991 IS : 4218 (Part 3) 1999 IS : 4326 1993 IS : 4461 1998 IS : 4656 1968 IS : 4671 1984 IS : 4925 1968 IS : 4990 1993 IS : 4995 (Part I) 1974

85 86 87 88

IS : 5256 1992 IS : 5525 1969 IS : 5624 1993 IS : 5871 1987

Methods for physical tests for hydraulic cement Determination of initial and final setting times Methods for physical tests for hydraulic cement Determination of compressive strength of hydraulic cement (other than masonry cement) Methods for physical tests for hydraulic cement Determination of compressive strength of masonry cement Methods for physical tests for hydraulic cement Determination of transverse and compressive strength of plastic mortar using prism Methods for physical tests for hydraulic cement Determination of heat of hydration Methods for physical tests for hydraulic cement Determination of drying shrinkage Methods for physical tests for hydraulic cement Determination of density Methods for physical tests for hydraulic cement Determination of air content of hydraulic cement mortar Methods for physical tests for hydraulic cement measurement of water retentivity of masonry cement Methods for physical tests for hydraulic cement Determination of false set Methods for physical tests for hydraulic cement Determination of fineness by wet sieving Safety Code for demolition of buildings. ISO general purpose metric screws threads Basic dimensions Code of practice for earthquake resistant design and construction of buildings. Code of practice for joints in surface hydro-electric power stations. Specification for form vibrators for concrete. Expanded polystyrene for thermal insulation purposes Specification for batching and mixing plant. Specification for plywood for concrete shuttering work. Criteria for design of reinforced concrete bins for the storage of granular and powdery materials General requirement & assessment of bin loads Code or practice for sealing joints in concrete lining on canals. Recommendations for detailing of reinforcement in reinforced concrete work. Specification for foundation bolts. Specification for bitumen mastic for tanking and damp Page | 41

89 90 91 92 93 94 95

IS : 6461 (Part 1) 1972 IS : 6461 (Part 2) 1972 IS : 6461 (Part 3) 1972 IS : 6461 (Part 4) 1972 IS : 6461 (Part 5) 1972 IS : 6461 (Part 6) 1972 IS : 6461 (Part 7) 1973

96 97 98 99 100 101 102 103 104 105

IS : 6461 (Part 8) 1973 IS : 6461 (Part 9) 1973 IS : 6461 (Part10) 1973 IS : 6461 (Part 11) 1973 IS : 6461 (Part 12)1973 IS : 6494 1988 IS : 6509 1985 IS : 7193 1994 IS : 7293 1974 IS : 7634 (Part 3) 2003

106 107 108 109 110 111 112

IS : 7861 (Parts I) 1975 IS : 7861 (Parts II) 1981 IS: 8042 1989 IS: 8043 1991 IS: 8112 1989 IS : 9103 1999 IS : 9417 1989

proofing Glossary of terms relating to cement concrete Concrete aggregates Glossary of terms relating to cement concrete Materials (other that cement and aggregates) Glossary of terms relating to cement concrete Concrete reinforcement Glossary of terms relating to cement concrete types of concrete Glossary of terms relating to cement concrete Formwork for concrete Glossary of terms relating to cement concrete Equipment, tools & plant Glossary of terms relating to cement concrete Mixing, Laying, Compaction, Curing and other construction aspects Glossary of terms relating to cement concrete Properties of concrete Glossary of terms relating to cement concrete Structural aspects Glossary of terms relating to cement concrete Tests & testing apparatus Glossary of terms relating to cement concrete restressed concrete Glossary of terms relating to cement concrete Miscellenaneous Code of practice for water proofing of underground water reservoirs and swimming pools. Code of practice for installation of joints in concrete pavements. Specification for glass fiber base coal-tar pitch and bitumen felts. Safety code for working with construction machinery. Code of practice for Plastic pipe selection, handling, storage and installation for potable water supplies Laying and jointing of PVC pipes Code of practice for extreme weather concreting Recommended practice for hot weather concreting Code of practice for extreme weather concreting Recommended practice for cold weather concreting Specification for White Portland cement Specification for hydrophobic Portland cement Specification for 43 Grade Ordinary Portland Cement Specification for concrete admixtures Recommendations for welding cold-worked steel bars Page | 42

113 114 115 116 117 118

IS : 9595 1996 IS : 10262 1982 IS : 11384 1985 IS : 12118 1987 IS : 12118 1987 IS : 12200 2001

119 120 121 122 123 124

IS : 12269 1987 IS: 12330 1988 IS : 12600 1989 SP : 23 1982 SP : 24 1983 SP : 34 1987

forreinforced concrete construction. Recommendations for metal-arc welding of carbon and carbon manganese steels Recommended guidelines for concrete mix design. Code of practice for composite construction in structural steel and concrete. Specification for two-part poly-sulphide based sealants General requirements Specification for two-part poly-sulphide based sealants Methods of test Code of practice for provision of water stops at transverseconstruction joints in masonry and concrete dams Specification for 53 Grade ordinary Portland cement. Sulphate resisting Portland Cement Specification for low heat Portland cement Handbook of concrete mixes. Explanatory Handbook on IS: 456 Handbook on concrete reinforcement and detailing.

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ELECTRIC LAMPS AND THEIR AUXILLIARIES

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

IS 418 : 1978 IS 1258 : 1987 IS 1534 : (pt. 1) 1977 IS 1569 : 1976 IS 2262 : 1963 IS 2407 : 1963 IS 2418 : 1977 (pt-1) IS 2418 : 1977 (pt-2) IS 2418 : 1977 (pt-3) IS 2418 : 1977 (pt-4) IS 3323 : 1980 IS 3324 : 1982 IS 6616 : 1982 IS 7027 : 1984 IS 8913 : 1978 IS 9206 : 19790 IS 9900 (pt-1) : 1981 IS 9900 (pt-2) : 1981 IS 9900 (pt-3) : 1981 IS 9900 (pt-4) : 1981 IS 9974 (pt-1) : 1981 IS 9974 (pt-2) : 1981 IS 10276 (pt-1) : 1982 IS 10276 (pt-2) : 1982 IS 12449 (pt-1) : 1988 IS 12449 (pt-1) : 1988 DOC : STD 23 (3174) IS 1032 (pt-1) : 1991 IS 1032 (pt-2) : 1991

Tungsten filament general service electric lamps Bayonet lamp holders Ballasts for fluorescent lamp : part 1, for switch start circuits. Capacitors for use in tubular fluorescent HPMV & LPSV discharge lamp circuit. Transformers for high voltage luminous discharge tubes Photometric integrators Tubular fluorescent lamps for general lighting service : Part 1, Requirements & Tests Tubular fluorescent lamps for general lighting service : Part 2, Standard lamp data sheets Tubular fluorescent for general lighting service: Part 3, Dimensions of G-5 & G-13 bi-pin caps Tubular fluorescent lamps for GLS : Part 4, Go & No go gauges for G-5 & G-13 bi-pin caps Bi-pin lamp holders for tubular fluorescent lamps Holders for starters for tubular fluorescent lamps Ballasts for HPMV lamps Tranistorised ballasts for fluorescent lamps. Methods of measurement of lamp cap temperature rise Dimensions of caps for tungsten filament general service electric lamps HPMV lamps : Part 1, Requirement & Tests HPMV lamps : Part 2, Standard lamp data sheet HPMV lamps : Part 3, Dimension of lamp caps HPMV lamps : Part 4,Go & No go gauges of lamp caps HPSV lamps : Part 1, General Requirements & Tests. HPSV lamps : Part 2, Standard lamp data sheets Edison screw lamp holders : Part 1, Requirements & Tests. Edison screw lamp holders : Part 2, standard data sheets for lamp holders and gauges Starting devices (others tha glow starters): Part 1, General & safety requirements Starting devices (others tha glow starters): Part 2, Performance requirements Tungsten filaments for incandescent lamps A C Supplied electronic ballasts for FTL's Part 1, General & safety requirements A C Supplied electronic ballasts for FTL's Part 2, Performance requirements Page | 44

ILLUMINATION ENGINEERING & LUMINARIES

30. 31. 32. 33.

IS 1777 : 1978 IS 1913 (pt-1) : 1978 IS 1944 (pt-1) : 1970 IS 1944 (pt-5) : 1981

34.

IS 1944 (pt-6) 1981

35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56.

IS 2206 (pt-1) : 1984 IS 2206(pt-2) : 1976 IS 2206(pt-4) : 1987 IS 2672 : 1976 IS 3287 : 1965 IS 3528 : 1966 IS 3528 : 1966 IS 3646 (pt-1) IS 3646 (pt-2) : 1966 IS 3646 (pt-3) : 1968 IS 4012 : 1967 IS 4013 : 1967 IS 4347 : 1967 IS 5077 : 1969 IS 6665 : 1972 IS 7569 : 1987 IS 7678 : 1975 IS 8030 : 1976 IS 8224 : 1976 IS 9583 : 1981 IS 10322 (pt-1) : 1982 IS 10322 (pt-2) : 1982

Industrial luminaries with metal reflectors General & Safety requirements for luminaries : Part 1, Tubular fluorescent lamps Code for lighting of public thoroughfare : Parts 1 & 2 for main &secondary roads (group A & B) Code of practice for lighting of pyblic thoroughfare Part 5, Lighting for grade separated junctions, bridges and elevated roads (group D): Code of practice for lighting of public thovaughfave : Part 6, Lighting for towns & city centers & areas of civic importance (group E) Flameproof electric lighting fittings : Part 1, Well glass and bulkhead types Flameproof electric lightings : Part 2, Fitting using glass tubes Flam proof electric lighting fittings : Part 4,Protable flam proof hard lamps Code od partice for linary lighting Industrial lighting fitting with plastic reflectors Waterproof electric lighting fittings Watertight electric lighting fittings Code of practice for interior illumination : Part 1, Principal for good lighting & aspects of design Code ofpratice for interior illumination : Part 2. Schedule of illumination & glare index Code of practice for interior illumination of coefficient of utilization & glare index Dust proof electric lighting fittings Dust tight electric lighting fittings Code of practice for hospital lighting Decorative lighting outfits Code of practice for industrial lighting Cast acrylic sheets for use in luminaries. Method of photometric testing of incandescent luminariesd for general lighting service Luminariesd for hospitals Electric lighting fitting for division 2 areas Emergency lighting units Luminaries Part 1, General requirements Luminaries Part 2, Constructional requirements Page | 45

57. 58. 59. 60. 61. 62.

IS 10322 (pt-3) : 1984 IS 10322 (pt-4) : 1984 IS 10322 (pt-5 / sec 1) : 1987 IS 10322 (pt-5 / sec 2) : 1987 IS 10322 (pt-5 / sec 3) : 1987 IS 10322 (pt-5 / sec 4) : 1987

Luminaries Part 3, Screw &screwiess terminations Luminaries Part 4, Method of tests Luminaries Part 5, particular requirements, section General purpose Luminaries Luminaries Part 5, particular requirements, section recessed luminaries. Luminaries Part 5, particular requirements, section Luminaries for road & street lighting Luminaries Part 5, particular requirements, section Protable general purpose luminaries

1, 2, 3, 4,

63. 64. 65. 66.

IS 10322 (pt-5 /sec-5) : 1987 IS 10894 : 1984 IS 10957 : 1984 IS 11116 : 1984

Luminaries Part 5, particular requirements, section 5, flood lights. Code of practice for lighting of educational institutions. Code of practice for lighting for ports &harbours. Code of practice for lighting of airport aprons

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