DVC, Electricity Dept., Spec. No.

EDCON/EHV/L-37 & 38

TECHNICAL SPECIFICATION FOR SUPPLY OF TOWERS

A.
A.01

SCOPE OF SUPPLY Fabrication, galvanization and supply of steel structural members for all types of complete set of 220 KV KV Transmission towers, Gantry Towers, Gantry Trusses, Other Tower parts (i.e., Stub-setting templates, Muff-boxes, Hangers, Extn. Links, MS clamp plates, Shackles for conductor & ground wire, Bird-guard etc.) Tower accessories (i.e., Anticlimbing devices including spikes, Danger plates, Number plates, Phase plates, Circuit plates, Earthing materials for pipe and counterpoise earthing etc. complete) Bolts and Nuts, Spring washers, Pack washers, Step-bolts, U-Bolts etc. and delivery F.O.R. destination. Muff boxes, i.e. steel form boxes to be used as shuttering of tower foundations shall not be galvanized; instead they will be painted with redoxide paint. Preparation of Bill of Materials on the basis of detailed Structural / assembly drawings. Assembly drawings will be supplied by DVC to the successful tenderer. Detailed Technical Data are furnished in the Appendixes attach to this Section.

A.02

B.
B.01

TRANSMISSION TOWERS GENERAL DESCRIPTION The towers are fully galvanized lattice steel structures using bolted connections capable to be used as self supporting structures and designed to carry the line conductors with necessary insulators, earth wires and all fittings under all loading conditions. The 220 kV towers has been designed to suit conductor temperature of 85C for AAAC Zebra (61/3.31mm).

B.02

TYPE OF TOWERS The towers shall be classified as given below : a) A 2 Type Tangent Towers:
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

This type of tower shall be provided with suspension strings and are designed for angles up to 2 degree deviation at the normal ruling span.
b) S 15 Type Angle and Section Towers:
0

This type of tower shall be provided with tension strings and shall be used for angle of deviation in the line up to 15 with normal ruling span and also for longer spans with smaller angles. These towers may also be used for section towers.
c) B 30 Type Angle and Section Towers:
0

This type of tower will be similar to above S-15 type except for angle of deviation up to 30 in the line with normal ruling spans and also for longer spans with smaller angles.
d) C 600 Type Angle and Dead-end Towers:

This type of tower shall be provided with tension string and shall be used for angles of deviation in the lines up to 60 with normal ruling span and also for longer spans with smaller angles. These towers will also be used as terminal or dead-end towers. Only a common structure and common Cross-arm are designed both for dead-end condition and 60 deviation. For dead-end condition, towers are designed for no angle of deviation of the tower on line side and there will be up to 15 angles on slack span (Gantry) side.
e) D 900 Type Deviation and Dead-end Towers:

This type of tower will be similar to above C-type except for angle deviation up to 90 when used as angle tower and 30 angles on slack span (Gantry) side when used as dead-end.
f) Line X-ing Towers:

These towers shall be used for crossing another Transmission Line and they are designed for angle upto 5. Note: The above towers can also be used for longer span with smaller angle of deviations without infringement of ground clearance.
g) Special Towers :

The towers which will be specially designed for very long spans, which can not be crossed by normal tower with extensions like Major River crossings etc. .
B.03 TOWER EXTENSIONS

The above towers are designed so as to be suitable for extension at the base without reducing the specific factor of safety in any manner. The extension leg will have butt joints with normal towers. Such extension shall be needed where ground clearances are found to be inadequate or for power line / railway / river-crossing etc. The foundations of towers are so designed as to be suitable for towers with or without extensions.

DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

B.04

STUB-SETTING TEMPLATES

Stub-setting templates shall be supplied by the Contractor for all types of towers. Stub-setting templates for towers with extensions are of adjustable type. The stub-setting templates shall be fully galvanized. C
C.01

DEVELOPMENT OF DRAWING / BOM

GENERAL

The relevant drawings for all the towers and their extensions which will be furnished to the Contractor by DVC shall include Structural / assembly drawings with required fabrication details, Tower accessories, Muffboxes, Foundation working drawings in duplicate. The contractor should prepare their own bill of materials on the basis of Structural / assembly / erection drawings of various types of towers and extension portion to be supplied by DVC to the successful tenderer. The types of steel sections to be used for different types of towers / extensions are indicated in Structural Steel Requirement
C.02 DESIGN & DRAWINGS

The Structural / assembly drawings with required fabrication details for all the towers and their extensions will be given to the Contractor in two copies. The tower members can be directly fabricated from the Structural / assembly drawings. However, if the contractor is required to prepare the shop fabrication drawings in addition to the Structural / assembly drawings with required fabrication details, they have to prepare the same without any additional financial implication to DVC. Before taking up the mass fabrication, the Contractor shall arrange for one number proto-assembly for each type of towers and extensions which shall be inspected by DVC Engineer. The Contractor shall submit BOM and it will approved by DVC before carrying out the Proto Inspection.
C.03 SHOP DRAWINGS

Shop drawings should clearly indicate the member sizes, length and marks, hole positions, gauge lines, bend lines, edge distances, amount of chipping, notching etc. For Gusset, separate individual item wise templates shall be made to facilitate fabrication as well as inspection. In case of members to be bent, shop drawings should indicate the provisions for variation in length. At the fabrication stage, care should be taken to see that the degree of bend given in any member is such that neither flange width nor thickness shall vary beyond permissible limits for the section. Items requiring steep bends can be cut and welded as per approved welding procedure.
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

C.04

BILL OF MATERIALS

Bill of material for each type of tower should be prepared separately. This should indicate grade of steel, mark numbers, sections sizes, member lengths, their unit & calculated weights, number of bolts, nut and washers and their sizes, total quantities required and structural drawing numbers. No reduction in weight due to drilling, punching of bolt holes, skew cuts, chipping, notching, chamfering etc., should be made while computing calculated weights of the members. All steel sections used should have dimensions as per IS:808. D. BOLTS, NUTS AND WASHERS : All tower members shall be joined together with Bolts and nuts. All hexagonal bolts and nuts shall conform to IS-12427. They shall have hexagonal head and nuts, the heads being forged out of the solid, truly concentric, and square with the shank, which must be perfectly straight. All bolts and nuts shall be galvanised as per IS:1367 (Part-13)/IS:2629 and The bolt shall be of 16/20/24 mm diameter and of property class 5.6 as specified in IS:1367 (Part-III) and matching nut of property class 5.0 as specified in IS:1367 (Part-VI). Bolts up to M16 and having length up to 10 times the diameter of the bolt should be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. The shear strength of bolts for 5.6 grade should be 310 MPa (minimum) as per IS:12427. Bolts should be provided with washer face in accordance with IS:1363 (Part-III) to ensure proper bearing. Nuts for hexagonal bolts should be double chamfered as per the requirement of IS:1363 Part-III. It should be ensured by the manufacturer that nuts should not be over tapped beyond 0.4mm oversize on effective diameter for size up to M16. Fully threaded bolts shall not be used. The length of bolts shall be such that the threaded portion will not extend into the place of contact of the members. All bolts shall be threaded to take the full depth of the nuts and threaded for enough to permit firm gripping of the members, but not further. It shall be ensured that the threaded portion of each bolt protrudes not less than 3mm and not more than 8mm when fully tightened. All nuts shall fit tight to the point where the shank of the bolt connects to the head. M/s. BI (Simplex) / ASP make bolts & nuts shall be used. Flat and tapered washers shall be provided wherever necessary. All pack washers shall be made of steel conforming to IS : 2062 Gr. A. (latest). The plain washers & heavy washers shall conform to IS : 2016 & IS : 6610 (latest) respectively. Spring washers shall be provided for insertion under all nuts. These washers shall be steel electrogalvanised,
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

positive lock type and 3.5mm in thickness for 16mm dia bolt and 4.5mm for 24mm bolt. To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect aggregate thickness of members more than three (3) times its diameter. Bolts at the joints shall be so staggered such that nuts may be tightened with spanners without fouling. It may be necessary to tack weld bolts & nuts upto bottom cross-arm level as a precaution against theft & sabotage. Contractor shall supply 2.5% extra of all sizes of bolts, nuts and washers to take care of losses during erection. No payment shall be admissible for these extra supplies. E. DETAILS OF FABRICATION The fabrication of towers shall be in conformity with the following: a) Except where hereinafter modified, details of fabrication shall conform to IS:802 (Part-II).The tower structures shall be accurately fabricated to connect together easily at site without any undue strain on the bolts. b) No angle member shall have the two leg flanges brought together by closing the angle. c) The diameter of the hole shall be equal to the diameter of bolt plus 1.5mm. All parts shall be accessible for inspection and cleaning. Drain holes shall be provided at all points where pockets of depression are likely to hold water. F.
F.01

OPERATIONS IN FABRICATION
GENERAL

Workmanship & finish shall correspond to the best modern transmission line practice. All similar parts shall be made interchangeable. All steel sections before any work is done on them shall be carefully leveled, straightened and made true by methods which shall not injure the material so that when assembled, the adjacent surface are in close contact throughout. No rough edges shall be permitted any where throughout the work.
F.02 STRAIGHTENING :

All material should be reasonably straight and, if necessary, before being worked, be straightened and/or flattened by pressure and be free from twists. Straightening should not damage the material. Adjacent surfaces of the parts when assembled should be in close contact throughout keeping in view the tolerances specified. Machines used for straightening are :5

DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

(1) For angle sections upto 110x110x10mm Roller Straightening Machine; (2) For higher sections Beam bending machine and Hydraulic Press.
F.03 CUTTING :

Cutting may be effected by shearing, cropping, flame cutting or sawing. The surfaces so cut should be clean, smooth and reasonably square and free from any distortion.
F.04 BENDING :

Mild steel angles sections (IS:2062-Grade A) up to 75x75mm (thickness upto 6mm) shall be bent cold upto and including bend angles of 10 degree; angles above 75x75mm (thickness upto 6mm) and upto and including 100x100mm (thickness upto 8mm) may also be bent cold upto the bend angle of 5 degree. All other angle sections not covered above should be bent hot. All plates upto 12mm thickness should be bent cold up to bend angle of 15 degree. Greater bends and/or other thicknesses should be bent hot.
F.05 PUNCHING & DRILLING :

Transmission line towers demand accurate drilling or punching of holes with high standard of workmanship and finish. Before any cutting work is started, all steel sections shall be carefully straightened and trued by pressure and not by hammering. They shall again be trued after being punched and drilled. Holes for bolts shall be drilled or punched with a jig but drilled holes shall be preferred. The punching may be adopted for thickness up to 16mm. For thicker sections, drilling should be done. Tolerances regarding punch holes are as follows:a) Holes must be perfectly circular and no tolerances in this respect are permissible. b) The maximum allowable difference in diameter of the holes on the two sides of plates or angle is 0.8mm. i.e. the allowable taper in a punched holes should not exceed 0.8mm on diameter. c) Holes must be square with the plates or angles and have their walls parallel. All burns left by drills or punch shall be removed completely. When the tower members are in position the holes shall be truly opposite to each other. Drilling or reaming to enlarge holes shall not be permitted. The edge security and bolt gauges should be maintained in all cases.
F.06 MARKING OF MEMBERS:

Each individual tower member shall carry a stamped mark (number) assigned to in the approved drawings. These stamping shall be done by a metal die of 16 mm size before galvanizing and on optimum depth so as to clearly
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

legible after galvanizing. Further more, the mark No. should be stenciled in indelible ink on each tower member after galvanizing. Erection Mark shall be AA-BB-C-DDD AA = BB C = =
Contractors Mark-a-Numeric ( maximum 4)

DVCs code assigned to the Contractors- Alphabet Tower Type Alphabet. Number mark to be assigned by Contractor - Numerical.

DDD =

Erection mark for high tensile steel members shall be prefixed by the letter H
F.07 SHOP ERECTION / PROTO-TYPE TOWER ASSEMBLY:

Before starting mass fabrication, one each of the different types of tower complete with maximum extensions, cross arms and stubs or part thereof shall be assembled horizontally in the shop to check the assembly, details and fabrication defects, if any, so that any modifications necessary in approved drawing can be incorporated and a fresh assembly presented to the Corporations Engineer or Inspector for inspection and approval. Mass fabrication shall only start after receipt of final approval of the check assembly. The prices quoted for the tower shall include all modifications to be carried out in the fabrication and assembly as a result of check assembly. The contractor shall give, at least two weeks notice to the Corporation for him to arrange for his Engineer or Inspector to check the assembly.

F.08

TOWER FINISH:

Contractor shall quote rates for supply of fully galvanized fabricated materials for towers/ structures including extensions, stubs and stub-setting templates etc. All bolts and nuts, washers, step bolts and attachments like hangers, shackles, earth wire, binding clamp, M.S. strip and pipe for earthing shall also be fully galvanized.

G.
G.01

TOLERANCE
TOLERANCE IN HOLES:

Holes for bolting should be cylindrical. The diameter of hole is equal to diameter of bolt + 1.5mm for bolts up to 20mm in diameters. For 24 mm dia bolts, the clearance between bolt shank and hole is 2.0 mm. While deciding the diameter of the hole whether drilled or punched, care should be taken in making allowance for thickness of galvanizing coat on bolts as well as in the holes and
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

for the tolerances in bolt shank diameter. It has been observed after series of measurements on bolt shanks that their diameter varies up to 0.3 mm above the nominal diameter. Thus, the final diameter of the holes to be punched/drilled at Black stage will be 1.5mm + bolt diameter + 0.3 mm for bolts up to 20mm in diameter. For 24 mm diameter bolts, the final diameter of the hole at Black stage will be equal to bolt diameter + 2.0 mm + 0.4 mm. Blocking of mis-punched/excess holes: Mispunched or excess holes not more than one on any one cross-sectional area should be blocked by proper welding technique by qualified welders. Total number of such blockings by welding may be limited to three holes in a member. No new holes should be permitted overlapping the plugged hole. The welding must be of proper quality and specification to ensure that strength of the welded member shall be not less than that of the normal member.

G.02

TOLERANCE IN FABRICATION:

(a) On straightness (camber) 0.4% of the length of sections of sizes up to 100x100mm. 0.2% of the length of sections of sizes over 100x100mm. (b) The maximum allowable difference in diameter of the holes on the two sides of plate or angle shall be 0.8mm; i.e., the allowable taper in a punched hole shall not exceed 0.8mm on diameter. (c) On overall length of angle members (d) On consecutive holes (e) On first hole to last hole in member (f) On gauge distances : 2mm : 1 mm : 2 mm : 1mm

(g) On specified hole diameters on the punch side : 0.3 mm / -0.0 mm (in black) or where drilled The fabrication tolerances in general shall conform to IS: 7215. In case of deviation beyond prescribed tolerance, the assembly of the members may be made as per Structural Drawings and if the overall dimensions of the structure are within limits, such items can be accepted. For leg member joint holes, a manufactured cleat may be taken at random and placed over the member. The bolt should pass at right-angle to the surface of member. For corner cuts, notches, flanged cuts etc., a tolerance of 2.0 mm is allowed.

DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

H
H.01

TOWER ACCESSORIES:
Anti climbing Device:

Barbed wire type anti climbing device, as per DVCs drawing shall be provided and installed by the Contractor for all towers. The barbed wire shall conform to IS-278 (size designation A1). The barbed wires shall be given chromating dip as per procedure laid down in IS:1340.
H.02 Danger, Number, Circuit and Phase plates :

Danger Plates, Number plates, circuit plates (for double circuit line only) and phase plates as per DVCs drawing shall be provided and installed by the Contractor. a) Each tower shall be fitted with a danger plate, number plate and two sets of phase plates for double circuit tower. Circuit plates shall also be provided on all the Double Circuit towers. b) The letters, figures and the conventional skull and bones of danger plates shall conform to IS-2551 and shall be in a signal red on the front of the plate. The number plate, phase plate and circuit plate shall conform to IS 5613. c) The corners of the danger, number and circuit plates shall be rounded off to remove sharp edges. d) The letters of number and circuit plates shall be red enameled with white enameled background e) One set Phase plate consists of 3 plates having red, blue and yellow colours. One set Circuit plate consists of 2 plates with marking I & II for double circuit tower.

INSPECTION
General

All standard tests, including quality control tests, in accordance with appropriate Standard, shall be carried out unless otherwise specified. a) The Contractor shall keep DVC informed in advance about the time of starting and of the progress of manufacture and fabrication of various tower parts at various stages, so that arrangements could be made for inspection. b) The acceptance of any part of items shall in no way relieve the Contractor of any part of his responsibility for meeting all the requirements of the Specification. DVC representative shall have free access at all reasonable times to those parts of the Contractors works which are concerned with the fabrication of the DVCs material for satisfying himself that the fabrication is being done in accordance with the provisions of the Specification. Unless
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

specified otherwise, inspection shall be made at the place of manufacture prior to dispatch and shall be concluded so as not to interfere unnecessarily with the operation of the work. If any member of the structure is found not to comply with the supplied design, it shall be liable to rejection. No member once rejected shall be resubmitted for inspection, except in cases where the DVCs authorized representative considers that the defects can be rectified. Defect which may appear during fabrication shall be made good with the consent of, and according to the procedure proposed by the Contractor and approved by DVC. All gauges and templates necessary to satisfy DVCs authorised representative shall be supplied by the contractor. The specified grade and quality of steel shall be used by the Contractor. To ascertain the quality of steel used, the inspector may at his discretion get the material tested at an approved laboratory. In general, all measurements are done with steel winding tapes in accordance with IS: 1270 For inspection of galvanized material, the manufacturer should provide galvanized coupons enabling the Inspector to carry out tests on the coupons. The coupons should be taken from the batches corresponding to the fabricated material under inspection. However, galvanizing test will also be carried out on samples drawn from the finished material. J.
J.01

STRUCTURAL STEELWORK
MATERIAL

a)

STEEL:

IS Steel Sections of tested quality of conformity with IS:2062 (Designated Y.S. 250 MPa) or / and IS:8500 grade 490 (Designated Y.S. 350 MPa) are to be used in towers, extensions and stub setting templates. The chequered plates shall conform to IS : 3502-1994. The material shall be of tested quality, recent manufacture & free from scales, slag intrusions, pitting, flake, rusts etc. Steel sections produced by main producers like SAIL / IISCO / TISCO / RINL shall be used in general. However, steel sections from the DVC approved re-rollers may also be used. Procurement of all steel materials required for fabrication of towers, such as angles, plates, rounds etc. shall be arranged by the contractor himself at his cost. The rate quoted for supply of towers shall include the cost of steel. b) ZINC:

The Contractor shall arrange for procurement of Zinc required for galvanizing the structure by himself. The rate of fabrication shall be inclusive of the cost of Zinc and galvanization.

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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

The Zinc required for galvanizing shall be of quality Zn 99.99 and shall conform to IS: 209 latest.

c)

BOLTS & NUTS :

All M.S. Bolts & Nuts shall conform to IS: 6639 (latest) & IS: 12427 (latest). The step bolts should conform to IS: 10238 (latest). The bolts shall be of property class 5.6 as specified in IS : 1367 (Pt.-III)(latest) & nuts shall be of property class 5 as specified in IS : 1367 (Pt.-VI)(latest).. All bolts & nuts shall be galvanised & tested in accordance with IS : 2633 (latest) & shall have hexagonal heads & nuts, the heads being forged out of the solid, truly concentric & square with the shank which must be perfectly straight. Fully threaded bolts shall not be used. The length of bolts shall be such that the threaded portion will not extend into the plane of contact of the member. Diameter of bolt shall be 16/20/24 mm. unless noted otherwise.

d)

WASHERS :

All pack washers shall be made of steel conforming to IS : 2062 Grade-A( latest ). The plain washers & heavy washers shall conform to IS : 2016 & IS : 6610 ( latest ) respectively. Spring washers shall be steel electrogalvanised, positive lock type and 3.5mm in thickness for 16mm dia bolt and 4.5mm for 24mm bolt. It shall conform to IS : 3063 ( latest ). Spring washers shall be Electro-galvanized in accordance with Service Condition IV of IS : 1573 ( latest ). . Contractor shall supply 2.5% extra of all sizes of bolts, nuts and washers to take care of losses during erection. No payment shall be admissible for these extra supplies

e)

STEP BOLTS & LADDERS :

Each tower shall be provided with step bolts conforming to IS : 10238 of not less than 16mm diameter and 175mm long, spaced not more than 450mm apart and extending from 2.5 meters above the ground level to the top of the tower. For double circuit tower, the step bolts may be fixed on two diagonally opposite legs up to top of the towers if shown in the drawing. Each step bolt shall be provided with two nuts on one end to fasten the bolt securely to the tower and button head at the other end to prevent the feet from slipping away. The step bolts shall be capable of withstanding a vertical load not less than 1.5 KN. For special towers, where the height of the super structure exceeds 50 meters, ladders along with protection rings as per DVC approved design shall be provided in continuation of the step bolts on one face of the tower from 30 meters above ground level to the top of the special structure. From 2.5m to 30m height of super structure step bolts shall be provided.
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

Suitable platform using 6mm thick perforated chequered plates along with suitable railing for access from step bolts to the ladder and from the ladder to each cross-arm tip and the ground wire support shall also to be provided. The platform shall be fixed on tower by using counter-sunk bolts.

J.02

PROCUREMENT OF RAW MATERIALS

The contractor must procure the materials from the manufacturers mentioned in the approved vendor list. The contractor shall not obtain without written permission of the Corporation any material for the purpose of this contract from manufacturers other than those approved by the purchaser. All raw materials required for fabrication, galvanizing etc and for complete execution of work shall be stocked in adequate quantities by the contractor to ensure that the progress of work is not hampered. While designing the towers, rationalized steel sections has been used. During execution of the project, if any particular section is not available, the same shall be substituted by higher section at no extra cost to DVC and the same shall be borne by the Contractor. However, design approval for such substitution shall be obtained from DVC before any substitution.

K.
K.01

TESTING OF MATERIALS:
STRUCTURAL STEEL :

Original copies of the test certificates of steel should be sent to the office of the Director (Technical), DVC Towers, VIP Road, Kolkata 700 054. Steel collected should be properly stacked to avoid corrosion and kept for physical verification of the Corporations Engineer. Contractor shall offer all assistance in regard to the Corporations inspection and proper care shall be taken so that steel collected for Corporations work is not mixed up with the steel for other agencies works. Samples from fabricated and / or raw steel for each type should be tested if required by the Corporation at Govt. Test house or any DVC approved Testing Laboratory free of cost to the Corporation. Such samples will be collected by the authorized representative of the Corporation. Test should be made in accordance with provisions of concerned ISS (latest). The various testing to be performed are as follows : 1. Material Specification as per IS-2062(Grade-A) and tolerances as per IS1852. 2. Sampling shall be as per IS-2500. 3. Physical properties : i) Verification of Mill Test Certificate. ii) Actual Test Certificate from Laboratory.
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

4. Dimensional and visual inspection shall be in accordance to IS-808 and IS1852. 5. Chemical Property in accordance to IS-2062 (Grade-A)
K.02 BOLTS AND NUTS

Producers routine test certificates for bolts, nuts, washers etc. as laid down in relevant ISI code approved by the Corporation, shall be submitted by the contractor. In addition, minimum ten numbers of random sample tests for bolts and nuts for proto-type test tower and bulk supply shall be performed by the contractor either in Governmental Test House or any approved Test Laboratory, free of cost to the Corporation. Sample bolts and nuts will be collected by the Engineer or its authorized agent. The various Testing to be performed are as follows: 1. Materials Specification: IS-6639 / IS-1363 / IS-1367(Part III) 2. Sampling shall be as per IS-1367(Part XVII) 3. Visual Inspection. 4. Dimensional Checking for Bolts & Nuts in accordance to IS-6639 and IS-1363 respectively. 5. Physical Test: i) Bolts To property class 5.6 as per IS-1367(Part III) ii) Nuts To property class 5 as per IS-1367(Part VI) 6. Galvanising Test in accordance to IS-1367(Part XIII)

K.03

SPRING WASHERS

Producers routine test for spring washers shall be submitted by the contractor. In addition minimum ten numbers of random sample tests shall be performed by the contractor as directed by the Corporation. Sample spring washers will be collected by the Engineer or its authorized agent.

The various Testing to be performed are as follows : 1. Materials Specification : IS-3063. 2. Sampling shall be as per IS-1367(Part XVII) 3. Visual Inspection. 4. Dimensional Checking. 5 Permanent Set Test. 6. Twist Test .
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

7. Hardness Test. 8. Galvanising Test in accordance to IS-1573 Service condition IV.

K.04

GALVANIZING Fabricated Tower Parts & Stubs

The tower parts, stubs and pack washers shall be hot dip galvanized .The galvanization shall be done as per requirements of IS 4759 after all fabrication work is completed. The contractor shall also take guidelines from the recommended practices for hot dip galvanizing laid down in IS 2629 while deciding and implementing galvanizing procedure. The mandatory requirements however, are specified herein. The zinc coating shall be adherent, reasonably uniform, smooth, continuous and free from imperfections such as black/ bare spots, ash rust strains, bulky white deposits / wet storage strains and blisters. The surface preparation for fabricated tower parts and stubs for hot dip galvanizing shall be carried out as indicated herein below: (i) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface, wherever required, shall be carried out in accordance with clause 4.1 of IS 2629-1985.After degreasing the article shall be thoroughly rinsed. However, if acidic degreasers are used rinsing is not required. Pickling: Pickling shall be done using either hydrochloric or sulphuric acid as recommended at clause 4.3 of IS 2629 -1985. The actual concentration of the acids and the time duration of immersion shall be determined by the Contractor depending on the nature of material to be pickled. Suitable inhibitors also shall be used with the acids to avoid over pickling. The acid concentration, inhibitors used, and maximum allowable iron content shall form part of plant standard to be formulated and submitted to Purchaser along with Quality Assurance Program. Rinsing: After pickling, the material shall be rinsed, preferably in running water to remove acid traces, iron particles or any other impurities from the surface. Two rinse tanks are preferable, with water cascading from the second tank to the first to ensure thorough cleaning. Wherever single tank is employed, the water shall be periodically changed to avoid acid contamination, and removal of other residue from the tank. Fluxing: The rinsed article shall be dipped in a solution of Zinc ammonium chloride. The concentration and
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(ii)

(iii)

(iv)

DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

temperature of the flux solution shall be standardized by the contractor depending on the article to be galvanized and individual circumstances. These shall form part of plant standard to be formulated and submitted to Purchaser along with Quality Assurance Program. The specific gravity of the flux solution shall be periodically monitored and controlled by adding required quantity of flux crystals to compensate for drag-out losses. Free acid content of the flux solution also shall be periodically checked and when it is more than two (2) grams of free acid per litre of the solution, it shall be neutralized. Alternatively, ph value should be monitored periodically and maintained between 5.0 to 5.5. (v) Drying: When dry galvanizing is adopted the article shall be thoroughly dried after fluxing. For the purpose of drying, the contractor may use hot plate, air oven or any other proven method ensuring complete drying of the article after fluxing and prior to dipping in the molten zinc bath. The drying process shall be such that the article shall not attain a temperature at which the flux shall get decomposed. The article thus dried shall be galvanized before the flux coating picks up moisture from the atmosphere or the flux layer gets damaged or removed from the surface. The drying procedure, time duration, temperature limits, time lag between fluxing, drying, galvanizing etc shall form part of plant standard to be formulated and submitted to Purchaser along with Quality Assurance Program. Quality of Zinc: Any one or combination of the grades of zinc specified in IS 209 or IS 13229 or other comparable international standard shall be used for galvanizing. The contractor shall declare the grade(s) of zinc proposed to be used by them for galvanizing. The molten metal in the zinc bath shall contain minimum 99.5 % zinc by mass. It shall be periodically measured and recorded. Zinc aluminum alloy shall be added as per IS 2629. Dipping Process: The temperature of the galvanizing bath shall be continuously monitored and controlled. The working temperature of the galvanizing bath shall be maintained at 450+/ - 10 degree C .The article should be immersed in the bath as rapidly as possible without compromising on safety aspects. The galvanizing bath temperature, immersion angle & time, time duration of immersion, rate of withdrawal etc shall be monitored and controlled depending upon the size , shape, thickness and chemical composition of the article such that the mass of zinc coating and its uniformity meets the specified
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(vi)

(vii)

DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

requirements and the galvanized surface is free from imperfections and galvanizing defects. (viii) Post Treatment: The article shall be quenched in water. The quench water is to be changed / drained periodically to prevent corrosive salts from accumulating in it. If water quenching is not done then necessary cooling arrangements should be made. The galvanized articles shall be dipped in chromating solution containing sodium dichromate and sulphuric acid or chromic acid base additive at a predetermined concentration and kept at room temperature to retard white rust attack. The temperature of the chromate solution shall not exceed 65 degree C. The articles shall not be stacked immediately after quenching and dichromating. It shall be ensured that the articles are dry before any further handling operation. Storing, Packing and Handling: In order to prevent white rust formation sufficient care should be exercised while storing handling and transporting galvanized products. The articles shall be stored in an adequately ventilated area. The articles shall be stored with spacers in between them and kept at an inclination to facilitate easy drainage of any water collected on the articles. Similar care is to be taken while transporting and storing the articles at site.

(ix)

The Contractor shall prepare a detailed galvanizing procedure including Flow Chart with control parameters and all plant standards as required above and submit to DVC for approval as part of Quality Assurance Plan. The various testing to be performed on the finished galvanized materials : 1. Visual Inspection in accordance to IS-2629. 2. Uniformity of coating ( Preece Test) as per IS-2633 3. Magnetic Gauge Test (Elcometre). 4. Stripping Test. 5. Adhesion of coating as per IS-2629. Contractor shall perform routine test at least three samples from each Batch of production and record the result in separate registered book. Engineer or its authorized agent will be present at the time of test. Contractor should submit regularly the result of all the tests performed to the Corporation for approval. Fasteners: For fasteners, the galvanizing shall conform to IS-1367(Part-13). The galvanizing shall be done with centrifuging arrangement after all mechanical operations are completed. The nuts, may however be tapped (threaded) or rerun after galvanizing and the threads oiled .The threads of bolts & nuts shall
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

have a neat fit and shall be such that they can be turned with finger throughout the length of the threads of bolts and they shall be capable of developing full strength of bolts. Spring washers shall be electro galvanized as per Grade-IV of IS-1573.
K.05 OPTIONAL TESTS

DVC may like to send samples of smelter drawn from the galvanizing bath to the National Test House, Kolkata or similar Test Laboratories for Chemical analysis as per samples drawn in accordance to IS : 209, in which case the contractor shall furnish the samples to the Corporation as desired by the latter. The cost of one such test shall be borne by the contractor and that of any additional test by the Corporation. L. CALCULATION OF WEIGHT FOR PAYMENT The weight of tower shall mean the weight of tower calculated by using the black sectional (i.e. ungalvanised) weights of all steel members of the sizes indicated in the Structural / assembly / erection drawings and bill of materials without taking into consideration the reduction in weight due to drilling of bolt holes, notches, skew cuts, chamfering, etc. or increase in weight due to galvanizing, but taking into consideration the weight of the Bird guard, D shackles, hangers, strain plates, extension links, pack plates, gusset plates etc. The weight of stub and cleats also shall be calculated in similar manner. For bolts and nuts along with spring washers, Pack washers, U-bolts and step bolts, the weight per tower shall be calculated from the bolt schedule applicable to each type of towers and body extensions as approved by DVC. The contractor is permitted to get inspected and supply upto 2.5% extra fasteners to take care of losses during erection. No payment shall be admissible for these extra supplies.

M.

PACKING The material shall be boxed or bundled for transport in the following manner : a) Angle shall be packed in bundles securely wrapped four times around at each end and over 900 mm with No. 9 SWG gauge wire with ends twisted tightly. Gross weight of any bundle shall not exceed approximately 450 Kg and length of any individual members 6000 mm.

b) Cleat angles, brackets, fillet plates and similar small loose pieces shall be tested and bolted together in multiples, and securely wired together through holes wrapped round at least four times with No. 9 SWG steel wire and ends

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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

twisted tightly. Gross weight of each bundle shall not exceed approximately 70 Kg.

c) The correct numbers of bolts, nuts and washers plus 2.5% extra for each tower shall constitute a packing unit and shall be dispatched packed in crates or wooden boxes strong enough to withstand the normal vigorous transit and handling. The various sizes of bolts, nuts and washers shall be kept in separate bags in side the main container. Each container shall carry a list of the bolts contained therein printed in water-proof ink, resistant to moisture. The weight of each container shall not exceed 70 Kg. N. MARKING OF PACKAGES Each bundle or package shall have the following details marked on it. a) b) c) The name, designation and address of the Consignee. Ultimate destination as required by the Corporation. The relevant marks and number of tower members or reference of bolts, nuts and small component like gusset plates, various attachments etc. for easy identification.

The marking shall be stenciled in indelible ink on the top member 0f the bundle of tower steel and on wooden boxes or gunny bags containing smaller components. Details dispatch instructions shall be asked for by the contractor from the Corporation 4 weeks ahead of the Schedule date of dispatch. Corporation shall, in no case, be responsible for loss of any package or bundle during transit. It shall be the responsibility of the contractor to replace the lost items free of cost. O. STANDARDS

The design, manufacturing, fabrication, galvanising, testing, erection procedure and materials used for manufacture and erection of towers, design and construction of foundations shall conform to the following Indian Standards (IS) which shall mean latest revisions, with amendments/changes adopted and published, unless specifically stated otherwise in the Specification. In the event of supply of material conforming to Standards other than specified, the Bidder shall confirm in his bid that these Standards are equivalent to those specified. In case of award, salient features of comparison between the Standards proposed by the Bidder and those specified in this document will be provided by the Contractor to establish their equivalence. 1. 2. 3. IS:209-1992 IS:278-1991 IS:800-1991 Specification for Zinc Galvanised Steel Barbed wire Code of Practice for General Building Construction in Steel .
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

4(a)

IS:802(Part1)

Sec 1-1995 Sec 2-1992 4(b) IS:802-1990 (Part 2) 4(c) 5. 6. 7. 8. 9. 10 11. 12 13 14 15. 16. 17. 18. 19. 20. IS:802-1990 (Part 3) IS:808-1991 IS:875-1992 IS:1363-1990 IS:1367-1992 IS:1573-1991 IS:1852-1993 IS:2016-1992 IS:2062-1992 IS:2074-1992 IS:2551-1990 IS:2629-1990 IS:2633-1992 IS:3757-1992 IS:4759-1990 IS:5369-1991 IS:5613-1993

21. 22. 23 24.

IS:6610-1991 IS:6623-1992 IS:6639-1990 IS:102381989

Code of Practice for General Building Construction in Steel in Overhead Transmission line Towers : Section 1 : Materials and loads Section 2 : Permissible stresses Code of practice for use of structural steel in Overhead Transmission Line : Fabrication, Galvanising, Inspection and Packing Code of practice for use of structural steel in Overhead Transmission Line Towers Testing. Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle Sections Code of practice for Design Loads (other than Earthquake) in Building and Structures. IS: 1363-1990 Hexagon Nuts (size range M5 to M36) Technical Supply Conditions for Threaded Steel / Fasteners. Electro Plated Coatings of zinc on iron and Steel Rolling and Cutting Tolerance of Hot Rolled Steel Products. Plain Washers ISO/R887 Steel for general structural purposes. Ready Mixed Paint. Air Drying, Red Oxide, Zinc Chrome, Priming Specification Danger Notice Plates Recommended Practice for Hot Dip Galvanizing of iron and Steel. Method of Testing Uniformity of Coating of Zinc Coated Articles High Strength Structural Bolts Specification for Hot Zinc coatings on structural steel and other Allied products. General Requirements for plain Washers. Installation and Maintenance of Overhead Power line. Section 1 : Design part 2 Section 2 : Installation and Maintenance. Specification for Heavy Washer for Steel Structures. High Strength Structural Nuts. Hexagon Bolts for Steel Structure. Step Bolts for Steel Structures.
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DVC, Electricity Dept., Spec. No. EDCON/EHV/L-37 & 38

25. 26. 27

IS:124271988 Publication No. 19(N)/700

Bolts for Transmission Line Towers. Indian Electricity Rules. Regulation for Electrical Crossing of Railway Tracks.

P
P.01

STRUCTURAL STEEL REQUIREMENT SCHEDULE The various steel sections to be used for fabrication of 220 KV D/c transmission towers are given below : Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Section size ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA 45 x 30 x 4 45 x 30 x 5 45 x 45 x 4 45 x 45 x 5 50 x 50 x 4 50 x 50 x 5 50 x 50 x 6 55 x 55 x 4 55 x 55 x 5 60 x 60 x 4 60 x 60 x 5 60 x 60 x 6 65 x 65 x 5 65 x 65 x 6 75 x 75 x 5 75 x 75 x 6 75 x 75 x 8 80 x 80 x 6 80 x 80 x 8 90 x 90 x 6 90 x 90 x 8 100 x 100 x 6 Sl. Section size No. 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 ISA 100 x 100 x 8 ISA 100 x 100 x 10 ISA 110 x 110 x 8 ISA 110 x 110 x 10 ISA 110 x 110 x 12 ISA 130 x 130 x 10 ISA 130 x 130 x 12 ISA 150 x 150 x 10 ISA 150 x 150 x 12 ISA 150 x 150 x 16 ISA 150 x 150 x 20 ISA 200 x 200 x 16 ISA 200 x 200 x 20 CHQ PLATE 6 PLATE 2MM PLATE 4MM PLATE 5MM PLATE 6MM PLATE 8MM PLATE 10MM PLATE 12MM PLATE 16MM

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