Attachment-3

Technical Specification
HIGH MAST SYSTEM

Height of mast
No. of sections
Material construction
Base dia. and top diameter (A/F)
Plate thickness & section Length

:
:
:
:
:

Cross section of Mast

Standard for of galvanization
Size of opening and door at base
Diameter of base plate
Thickness of base plate
Lightning protection finial
Max.wind speed
Number of foundation bolts
PCD of foundation bolts
Type / diameter / length of foundation bolts

:
:
:
:
:
:
:
:
:
:

20 Meter
Two
S 355 grade as per BS-EN10 025
Top : 150 mm, Bottom : 460 mm
Top : 4 mm,
Bottom : 5 mm
20 side polygon.
As per BS EN ISO 1461
1200 x 250 mm
670 mm
25 mm
G.I single spike of length 1200 mm
62.5 m/s
8 nos.
590 mm
TS 600 / 32 mm dia / 850 mm long

:
:
:
:

50 NB ERW Class B - M. S. Pipe

710 mm (ID)
6 Arm, Welded, 2 sections
12 Luminaire

LUMINAIRES CARRIAGE
Material of construction
Diameter of carriage ring (mm)
Construction
Load carrying capacity

TRAILING CABLE
Conductor
Insulation
No. of circuits per mast

WINCH/ POWER TOOL

Type / SWL of winch
Method of operation
Motor capacity
No of speeds
Torque limitor

STAINLESS STEEL WIRE ROPE

Grade / construction
Number of ropes
Diameter (mm)
Braking load capacity

: Copper, 5 core, 4 sq mm
: EPR insulated PCP sheathed
: One

:
:
:
:
:

Double drum, SWL 750 Kg

Flame Proof Integral Motor
1.5 HP
6 Pole, Single speed
With mechanical tripping facility

:
:
:
:

AISI 316, 7/19 construction

Two continuous
6 mm
2350 kg x 2

Control panel will be of Flame proof type

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Attachment-3

EQUIPMENT SPECIFICATION
HIGH MAST LIGHTING
GENERAL:
The scope of this specification also covers the manufacture, transport,
installation, testing and commissioning of the complete lighting system, using
Raising and Lowering type of High mast Towers, including the Civil Foundation
Works. HPCL will only provide the supply point. However, all items required for
the safe and efficient operation and maintenance of the lighting system including
the high mast, whether explicitly stated in the following pages or not shall be
included by the Contractor.
HIGHMAST
STRUCTURE:
The High mast shall be of continuously tapered, polygonal cross section, at
least 20 sided. Presenting a good and pleasing appearance and shall be based on
proven In Tension design conforming to the standards specified, to give an assured
performance, and reliable service. The mast shall be with decorative type umbrella
and suitable for wind loading as per IS 875 Part 3 1987.
CONSTRUCTION:
The mast shall be fabricated from steel plates, cut and folded to form a
polygonal section, welded and shall be telescopically jointed by welding/stress fit
method. The procedural weld geometry and the workmanship shall be exhaustively
tested on the completed welds. Mast can be fabricated in multiple sections of
length approximately 10 metres. Thus a 20 M shall be delivered in two sections.
No site welding or bolted joint shall be done on the mast. The minimum Overlap
distance shall be 1.5 times the diameter at penetration. The mast shall be provided
with fully 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
galvanized, internally and externally. The thickness of galvanizing shall be a
minimum of 85 microns.
DOOR OPENING:
An adequate door opening 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, weatherproof door provided with a heavy
duty internal lock with special paddle key. The door opening shall be carefully 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. Size of door opening shall
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Attachment-3

be around 1200 x 250 mm and shall be strengthened, if required to avoid buckling of the
mast section under heavy wind conditions.
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 and shall be measured at a height of 10 metres
above ground level. The design life of the mast shall be a minimum of 25 years.
LANTERN CARRIAGE:
a) Fabrication

A fabricated Lantern Carriage shall be provided for fixing and holding the
flood light fittings and control gearboxes. 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 gearboxes, and also have a perfect self-balance. The Lantern Carriage can
be fabricated in two/three sections and joined by bolted flanges with stainless steel
bolts and nylon type stainless steel nuts to enable easy installation or removal from
the erected mast. The inner lining of the carriage shall be provided with suitable
protective 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 galvanized after fabrication. The design shall provide a
perfect balance for the lantern carriage during raising and to lowering also.

b) Junction Box

Weather proof junction box, made of Cast Aluminium shall be provided on

the Carriage Assembly as required from which the inter-connections to the
designed number of the flood light luminaires and associated control gears fixed
on the carriage shall be made.

c) Raising and lowering mechanism

For installation and maintenance of 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 the winch fixed at the base of
the mast and the specially designed head frame assembly at the top. Suitable end
limit switches shall be provided to trip the winch motor at both top & bottom ends
of the designed travel. Suitable thermal relay shall be provided to trip the
mechanism in case of overload.

d) Winch

The winch shall be of completely self-sustaining type, without the need for
brake shoe, springs or clutches. Individual drum also should be operated for fine
adjustment of lantern carriage. The capacity, operating speed, safe working load,
recommended lubrication and serial number of the winch shall be clearly marked
on each winch. The winch shall be self-lubricating type by means of an oil bath
and the oil shall be readily available grades of reputed producers. The winch drums
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Attachment-3

shall be grooved to ensure perfect seat for stable and 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 turns of rope remains on the drum even
then the 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 by an integral/
external power tool. It shall be possible to remove the double drum after
dismantling through the door opening provided at the base of the mast. Also, a
winch gearbox 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 a reputed Institution and the test certificates shall be furnished
before supply of materials. A test certificate shall be furnished by the Contractor
form the original equipment manufacturer, for each winch in support of the
maximum load operated by the winch.
e) Head Frame

The head frame, which is to be designed as a capping unit of the mast, shall
be of welded steel construction, galvanized both internally and externally. The top
pulley shall be of 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-corrodable material, like diecast Aluminium Alloy (LM-6). 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 galvanized internally and externally. Close fitting 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.

f) Stainless Steel Wire Ropes

The suspension system shall essentially be without any intermediate joint

and shall consist of only non-corrodable stainless steel of AISI 316 or better grade.
The stainless steel wire ropes shall be of multi strand construction, the central core
being of the same material. The overall diameter of the rope shall not be less than 6
mm. The breaking load of each rope shall have factor of safety of over 5 for the
system at full load. The end Constructions of rope to the 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 / terminations, either bolted or else, shall be provided on the wire ropes
between winch and lantern carriage.

ELECTRICAL SYSTEM, CABLE AND CABLE CONNECTIONS

A suitable terminal box shall be provided as part of the contract at the base
compartment of the high mast for terminating the incoming cable. Supply of Incoming
cable from the substation/ supply point to the highmast comes under the scope of the
party. All necessary items shall be supplied by the party for drawing power from the

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Attachment-3

dummy feeder at the substation. Cable laying in the trench, sand filling & brick laying
comes under the scope of the contractor.
The electrical connections from the bottom to the top shall be made by special
trailing cable. The cable shall have enough flexibility and endurance, and have copper
conductors. The cable shall be of reputed make. At the top there shall be weather proof
junction box(es) to terminate the trailing cable. Connections from the top junction box to
the individual luminaries shall be made by using 3 core flexible PVC cables of adequate
size. The system shall have in-built facilities for testing the luminaries while in lowered
position. Also, suitable provision shall be made at the base compartment of the mast to
facilitate the operation of externally mounted, electrically operated power tool for raising
and lowering of the lantern carriage assembly. The trailing cables of the lantern carriage
rings shall be terminated by means of specially designed, metal clad. Multi-pin plug and
socket provided in the base compartment to enable easy disconnection when required. A
distribution board with suitably rated 3-phase incomer MCB and separate MCB's
controlled folders for lighting and power tool shall also be supplied. The board shall
Incorporate timer for control of lighting and control circuit for winch operation with all
necessary contactors etc. The board shall have IP 55 protection with rainwater protections
canopy and epoxy powder coated suitable for outdoor mounting in coastal area. The work
shall also include necessary foundation cable glands,etc. complete as required.
POWER TOOL FOR THE WINCH
A suitable, high-powered, electrically driven internally mounted power tool, with
manual over ride shall be supplied for the raising and lowering of the lantern carriage for
maintenance purposes. The speed of the power tool shall suit the system. The power tool
shall be single speed provided with a motor of the required rating. The power tool shall be
supplied complete with push button type remote control switch, together with 5/6 metres
of power cable, so that the operations can be carried out from a safe distance of 5 (five)
metres. The capacity and speed of the electric motor used in the power tool shall be
suitable for the lifting of the design load installed on the lantern carriage. The power tool
mounting shall be so designed that it will be not only self-supporting but also aligns 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 the electricityoperated 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 mechanism with suitable load adjusting device. The torque limiter 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 limiter is a requirement as per the relevant
standards in view of the overall safety of the system. High mast shall have its own power
tool motor.
LIGHTNING FINIAL
One number heavy duty hot dip galvanized lightning finial shall be provided for
the mast. The lightning finial shall be minimum 1.2 M in length or as required so that the
lantern carriage also comes within the safety zone and shall be provided at the centre of
the head frame. It shall be bolted solidly to the head frame to get a direct conducting path
to the earth through the mast. The lightning finial shall not be provided on the lantern
carriage under any circumstances in view of safety of the system.
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Attachment-3

AVIATION OBSTRUCTION LIGHTS

Approved LED type Single dome Aviation Obstruction Lights of reliable design
and reputed manufacturer shall be provided on top of each mast.
EARTHING TERMINALS
Suitable earth terminal using 12 mm diameter stainless steel bolts shall be
provided at a convenient location on the base of the Mast, for lightning and electrical
earthing of the mast. The mast shall be provided with duplicate earthing including
necessary earth pits as per IS.
FOUNDATION FOR HIGH MAST
The scope also includes supplying all materials and casting of RCC foundation
along with necessary Anchor bolts etc. The detailed drawing for the foundation should be
submitted and got approved by HPCL before starting of the work.
FEEDER PILLAR DISTRIBUTION BOARDS
DESIGN CRITERIA:

The feeder pillar distribution boards shall be sheet steel enclosed, outdoor
type having suitable canopy for rain water protection, pedestal type, FLP type
conforming to IP: 55 suitable for use on 415V, 50 Hz., 3 phase, 4 wire AC system.
The board shall have TPN / DP isolator / switch fuse unit / MCB as incoming and
TPN / SP MCB as outgoing feeders. These boards are meant for lighting the High
Masts. These shall be factory built standardized boards or fabricated based on
specification and approved drawing. The feeder pillar box shall be approved by
CCOE. The feeder pillar box shall have required interface for remote control PB
station through cable for raising and lowering of lantern carriage. The feeder pillar
box shall be mounted on a raised concrete platform above ground level at min
height of 1 meter. The light fittings provided on the light mast shall have
individual switch controls in the feeder pillar box to have the flexibility to put the
selected light fittings ON / OFF. Three phase supply to be equally distributed to
the 12 light fittings alternatively (eg: light Fittings 1,4,7,10 to R-phase; 2,5,8,11 to
Y-Phase; 3,6,9,12 to B-Phase ) to ensure equal light coverage in all directions even
if one phase supply is available. One Feeder pillar at VDS requires separate
provision for outgoing supply through 4 core cable to the feeder pillar of second
highmast.

CONSTRUCTIONAL DETAILS:
a) The lighting distribution boards shall be pedestal mounted type made of
minimum 1.6 mm thick sheet steel totally enclosed rain, dust and vermin proof
construction having separate chambers for incoming and outgoing feeders.
b) The board shall conform to IP: 55 class of protection as per IS: 2147and suitable
canopy for rain water protection.
c) The board shall be fabricated using high quality CRCA sheet steel. Suitable
neoprene gaskets shall be provided for all doors and covers for making the board
dust proof.
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Attachment-3

d) The operating handle of the incoming switch fuse unit shall be accessible from
the front side.Operating handle shall be suitably interlocked mechanically with the
door of the incomer chamber so that the door can be opened or closed only when
the switch is in 'OFF' position. A manual interlock defeat shall also be provided.
e) The outgoing MCB's shall be housed in a separate chamber. The operating
knobs of the MCB's shall be accessible through front door. The outgoings chamber
shall be covered completely with FRP sheet. The 4mm thick FRP sheet provided
shall effectively shroud all the live parts against accidental contact. The door shall
have pad looking facility.
f) Bus bars shall be of Tinned copper. Bus bars shall be shrouded. Phase & neutral
Busbars shall have the same cross sections. The earth bus shall have the same size
as the Neutral bus.
g) The incoming compartment door shall have 3 Nos. (for 3 phase) 1 No. (for
single phase) Neon indicating lamps (red colour).
h) Safety clearances as per IE rules shall be provided for components of the board.
i) Board shall have continuous earth bus of size same as that of neutral.
j) Link between neutral and earth shall be provided.
PAINTING : The final painting of all boards shall be light siemens grey RAL 7032 IS: 5
unless otherwise specified.
TESTING : All the distribution boards shall be tested as per IS:8623 at factory site.
FLOOD LIGHT LUMINAIRE (SUITABLE FOR HPSV/MHT LAMPS)
The flood light fitting shall be integral or non-integral type, complete with suitable
weatherproof control gearbox. The fitting shall consist of a lamp compartment
housing a reflector made of spun aluminium electrochemically brightened and
anodized. Flat toughened front glass suitable to withstand the high temperature and
humid conditions shall be fixed to the housing using neoprene gasket. Focusing
knob to help in adjusting the lamp center shall be provided. Mild steel cradle shall
be mounted on the control gear. The control gear shall consist of heavy-duty
polyester filled copper choke suitable for lamp wattage specified p.f. improvement
condensers. The minimum power factor required is 0.9 for all light fixtures
connectors and fittings duly wired with provision of cable entry provided. The
provision for relamping is to be made in such a way that aiming angles not
disturbed. The chokes shall be manufactured from high quality silicon laminations
with tapping at 200/220/240V; this shall conform to IS 6616. Holders shall be
made out of porcelain and shall have brass contacts. These shall be rated for 240V.
The tip of the holder shall be spring-loaded. Capacitors shall be of 250 V rating.
This shall have fiberglass covered wire of suitable cross section to withstand high
temperature generated in the control gear/lamp holder. The main supply shall be
connected to the terminal book made out of porcelain/ bakelite of suitable quality.
The terminal block housing shall have flexible conduit for taking the main supply
leads. The control gear and lamp holder housing shall be provided with a sufficient
number of vertical fins to dissipate heat produced. A protractor plate with degrees
marked on it shall be provided to enable the fitting to be tilted to any required
angle. Rotating of the fitting shall be limited to 360-degree horizontal and 180degree vertical and locking arrangement shall be provided for both vertical and
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Attachment-3

horizontal position. All hardware shall be made of mild steel and passivated. The
fitting shall be complete and suitable for taking HPSV lamp, provided with gaskets
to make the unit weatherproof. All the cast aluminium parts shall be finished in
epoxy powder coating, 3 x 2.5 sq.mm PVC cable, copper conductor shall connect
the terminals of the luminaries with sub circuit at 240 V via the control gear unit, 1
no. earthing terminal shall be provided. Both the luminaries and the control
gearbox shall conform to IP 54 or better and suitable for outdoor application. The
control gearbox shall have the required electronic igniter for starting of the lamp.
FLOOD LIGHT LUMINAIRE (SUITABLE FOR LED LAMPS)
The flood light fitting shall be integral or non-integral type, complete with suitable
weatherproof control gearbox. The fitting shall consist of a lamp compartment
housing a reflector made of spun aluminium electrochemically brightened and
anodized. Flat toughened front glass suitable to withstand the high temperature and
humid conditions shall be fixed to the housing using neoprene gasket. The
minimum power factor required is 0.9 for all light fixtures connectors and fittings
duly wired with provision of cable entry provided. The control gear and lamp
holder housing shall be provided with a sufficient number of vertical fins to
dissipate heat produced. All the cast aluminium parts shall be finished in epoxy
powder coating, 3 x 2.5 sq.mm PVC cable, copper conductor shall connect the
terminals of the luminaries with sub circuit at 240 V via the control gear unit, 1 no.
earthing terminal shall be provided. Both the luminaries and the control gearbox
shall conform to IP 54 or better and suitable for outdoor application. Proper Surge
and over current protections to be provided for the lumaire. The luminaire shall be
approved by Site-engineer/ project incharge of HPCL.
TIMER
Timer (Time switch) shall be accurate & quartz driven. The timer shall have a
built-in chargeable Ni-Cd cells for 150 hours continuous operation in the event of
power failure. The timer shall be suitable for switching ON/OFF highmast etc. at
predetermined time. The timer shall be supplied with enclosure or panel mounted
as required.
CONTROL PANEL HOUSING, CONTROL CKTS
A suitable control panel housing for control circuits shall be provided for safe &
efficient Operation of the highmast. It should also consist suitable control for the power
tool motor with Contactors.
LAMP
SODIUM VAPOUR LAMP :

The lamps shall be suitable for universal burning position and shall be
colour corrected and shall have caps E-40 with ES/GES threads. All the lamps
shall be suitable for external igniter. Lamps shall be ovoid or tubular type as
specified. The approved makes of lamps is limited to the following only.
1.) Philips
2.) Crompton
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Attachment-3

3.) Bajaj
HIGH POWER LED LAMP :
LED luminary shall be a High power LED type and of 200W rating. LED inside
the lamp shall be of Philips/Osram make with proper surge and over current protection.
The lamp shall be approved by Site-engineer/ project incharge of HPCL.

EARTHING
Earthing shall confirm to IS 30431987.
MATERIAL REQUIRED FOR AN EARTH PIT
a) 65 mm diameter, Gl pipe, 3.00 meters long in one single piece with (40 x 6)/ (25
x 6) mm GI flat of required length welded to the pipe on top and 12 mm holes
made on all sides of the pipe at 150 mm apart upto height of minimum 2.5 meters
from bottom ... 1 No.
b) Bolts, nuts, washers and sockets for earthing connection .... 1 set.
c) Charcoal of not less than 12 mm size
d) Salt granular .
e) 80 mm long funnel having suitable diameter with wire mesh welded at top and
GI nut welded at bottom (to fit the GI pipe electrode).
f) RCC cover for earth pit chamber 1 no.
METHOD OF ERECTION
a) The pit for an earth electrode will be dug with its center normally at minimum
2.5 meters away from the edge of any building/ masonry work.
b) The GI pipe will be erected vertically at the center of the pit, with top of the
pipe minimum 200 mm below ground level.
c) Alternate layers of charcoal and salt each 150 mm, will be put into the pit
beginning from the bottom of pit, around the pipe to cover the same upto minimum
3.0 meters length from bottom. Alternately charcoal and salt shall be thoroughly
mixed at site and poured into earth pit.
d) The space above the salt / charcoal layers will be filled with loose sandy soil,
upto a level of 550 mm from ground level.
e) A cement concrete chamber of inner dimension 350 x 350 mm will be erected
around the top of the earth pipe so that top surface of the chamber is flushed with
the outside finished ground level.
f) A GI earthing strip (40 x 6) I (25 x 6) mm, of required length size will be tightly
connected to the electrode GI plate by means of GI bolt. nuts and washers. End of
this GI strip will be welded to the earthing ring GI wires / strip.
In areas of rocky terrain, where it is not possible to vertically drive the
electrode, horizontally installed electrode at a minimum depth of 1000 mm may be
provided as per the instruction offsite engineer. Alternately bentorite or chemical
treatment to obtain ohmic value-as required shallbe done.
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Attachment-3

EARTHING RING MAIN

The earthing ring shall be made by GI strip/ insulated single core cable of
specified size. The ring shall be laid in the cable trench along with lighting cable
and connected to all the earthing pits.
EARTHING OF FEEDER PILLAR DISTRIBUTION BOARDS
The distribution board shall be provided with two separate earth terminals.
An earth busbar of appropriate cross section shall be provided inside the lighting
board and connected to the earth terminals provided on either side of the board.
Adequate number of holes/ terminals shall be provided on earth bus with suitable
provision for terminating the earth wire. GI strip/ GI wire insulated single core
cable of suitable size shall be used for earthing the lighting board, by connecting
the two earth terminals separately to the earthing main in the shop/earth pit.
EARTHING OF LIGHT FIXTURES
The single core PVC insulated wire/ bare copper wire or 14 SWG GI wire
and the third core of the flexible wiring cable shall be used for earthing the light
fixtures.
EARTHING OF METAL BOXES & BRACKETS
Not less than 14 SWG Gl wire or suitable size PVC insulated copper wire
shall be used for earthing a U metal boxes and brackets.

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