Revised RVNL`s Standard Technical Specification for material and

Transcription

ELECTRICAL ENGINEERING DEPARTMENT
STANDARD SPECIFICATIONS FOR
MATERIAL AND WORKS
VOLUME II
ELECTRICAL WORKS
29 January 2015
(Including A&C 1 dated 22.04.2016)
Specifications- Volume II (Electrical Works)
Dated 29.Jan 2015
RVNL
Page 2 of 429
RVNL
Standard Specifications for Materials and Works
Volume II-Electrical Works
INDEX
Chapter
No.
Specification
No.
Description
Page
Nos.
PART A- GENERAL SERVICES ELECTRICAL WORKS
A-3
A-4
A-5
GENERAL- Scope, Standards, site conditions, Safety Instructions, ManPower, Inspections of Equipments/materials. Pre Commissioning tests on
Equipment, Approval of Drawings, Completion Plan and Completion
Certificate
RVNL/Elect/GS/01
Internal Electrification Works
Luminaries/Equipments for Indoor/Outdoor
RVNL/Elect/GS/02
Electrifications Works
RVNL/Elect/GS/03
Overhead Works & Steel/GI Tubular Poles
RVNL/Elect/GS/04
Cable Laying
RVNL/Elect/GS/05
High Mast Lighting System
A-6
RVNL/Elect/GS/06
A-7
A-8
RVNL/Elect/GS/07
RVNL/Elect/GS/08
A-9
RVNL/Elect/GS/09
A-10
A-11
A-12
A-13
RVNL/Elect/GS/10
RVNL/Elect/GS/11
RVNL/Elect/GS/12
RVNL/Elect/GS/13
A-14
RVNL/Elect/GS/14
A-15
A-16
A-17
A-18
RVNL/Elect/GS/15
RVNL/Elect/GS/16
RVNL/Elect/GS/17
RVNL/Elect/GS/18
Modification of Power Line Crossing on Railways Tracks
Medium Voltage Switch Board (for Sub- Station)
Medium Voltage Feeder Pillar & Switch Board (Other
Than Sub-Station Work)
Distribution Board
Earthing System
Electrical Driven Sub-mersible Pumps
Power Distribution Transformer
Water Cooled Silent Diesel Engine Driven Alternator
Set with AMF Panel (30 Kva and above up To 500 kVA)
11 KV VCB HT Panel
Auto Power Factor Correction (APFC) Panel
Battery Chargers for Coaching Applications
Battery Charging and Pre-Cooling Points
A-19
RVNL/ Elect/GS/19
Solar Home and Street Lighting System
147-152
Solar Water Heater
153-158
A-0
A-1
A-2
A-20
RVNL/ Elect/GS/20
Dated 29.Jan 2015
Pre-Stressed Cement Concrete Poles for Modification of
Power Line Crossings
7-16
19-34
35-44
45-56
57-66
67-72
73-76
77-84
85-90
91-96
97-100
101-106
107-112
113-120
121-128
129-134
135-138
139-142
143-146
Page 3 of 429
A-21
A-22
A-23
A-24
A-25
A-26
A-27
A-28
A-29
RVNL/ Elect/GS/21
RVNL
Lightening Arrester
159-172
Control Switch Board for A.T
173-176
Specification for LED Type Luminaries
177-180
RVNL/ Elect/GS/24
Variable Refrigerant Flow (VRF) System for Building
Centralised Air-conditioning
181-188
RVNL/ Elect/GS/25
Machine Room Type Electric Traction Passenger Lift for
Buildings
189-216
RVNL/ Elect/GS/26
Machine Roomless & Gearless Version Electric
Passenger Lift
217-242
RVNL/ Elect/GS/27
Miscellaneous Specifications
RVNL/ Elect/GS/22
RVNL/ Elect/GS/23
RVNL/ Elect/GS/28
RVNL/ Elect/GS/29
Dated 29.Jan 2015
243-248
Approved Makes of Equipments and Materials
249-268
Important Indian Standards
269-280
Page 4 of 429
RVNL
PART B- RAILWAY ELECTRIFICATION WORKS
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-7(a)
B-7(b)
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
General Requirements for 25 kV, AC Overhead Equipment
Overhead Equipments
Foundations
OHE Structures
Equipment, Components and Materials-OHE and Switching Stations
Design and Drawings for OHE and Switching Stations
Erection and Installation of Equipments-OHE
Principles
Wiring Procedures
Inspection and Testing- OHE and Switching Stations
Switching Station Building
Traction Substation/Feeding Post, General requirements
Feeding Stations switching stations, booster transformer stations and L.T
supply transformer stations
Structures and steel works-TSS
Equipment, Components and Materials-TSS
Design & Drawings for Traction Sub-Stations
Erection & Installation of Equipment-PSI
Inspection & Testing of Traction Sub-Stations
Earthing
High Rise OHE
List of Standard Technical Drawings/ Specifications for Traction Sub stations/
Feeding Posts
List of Standards Technical Drawings/ Specifications for OHE Works
Miscellaneous instructions
Dated 29.Jan 2015
281-286
287-300
301-310
311-316
317-324
325-334
335-340
341-344
345-348
349-352
353-356
357-360
361-364
365-370
371-376
377-380
381-384
385-390
391-394
395-410
411-428
429
Page 5 of 429
Dated 29.Jan 2015
RVNL
Page 6 of 429
RVNL
PART –A
GENERAL SERVICE ELECTRICAL ENGINEERING
Dated 29.Jan 2015
Page 7 of 429
Dated 29.Jan 2015
RVNL
Page 8 of 429
RVNL
PART A: General Services Electrical Works
CHAPTER: A-0
GENERAL
1.0 Introduction
All electrification works shall be carried out in accordance with Indian Electricity Rules. Railway
Regulations, BIS Specifications and Code of Practices, National Electricity Code, Energy
Conservation Building Code (ECBC), National Building Code, Energy Conservation Act 2001with
latest amendments. The specifications issued here are meant for guidelines and does not
supersede any of the rules/regulations/codes/instructions issued by Railway Board/RDSO/CORE
etc from time to time and they shall be followed accordingly. All the equipments and materials
to be supplied shall be as per the specified approved makes and laid down specifications with
latest amendments.
2.0 Scope of work
The scope of general electrical works broadly consists of:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
External electrification works pertaining to cabling/overhead alignment & associated
works for extension of power supply, street lighting etc.
Modification to existing electrical installations as per site requirement.
Dismantling/relocation of electrical installations as per site requirement.
Modification to supply Authority’s power lines, up to & including 33 kV, to
bring them in conformity with the Regulations for Crossing of Railway Track, 1987
Provision of high mast lighting system with luminaries at circulating
areas/yards etc.
Availing new power supply connections/ augmentation of existing power supply
connections to cater for new facilities including strengthening of power distribution
system.
Electrification of un-electrified level crossings.
Provision of 11 kV/415 Volts electric sub-stations with equipments, panels etc.
Provision of pumping system for water supply.
Provision of battery charging and pre-cooling facilities.
Provision of temporary arrangements for lights & fans during non-interlocking period.
Coordination with supply authorities for modification of power line crossings &
availing/augmentation of load as required.
Survey of project section to identify electrical works.
Provision of DG sets, air cooling system, escalators, elevators, travelators and lifts etc.
3.0 Standards
The following standards as amended from time to time, shall apply:
i)
ii)
Bureau of Indian Standards (BIS) specifications and Code of Practices.
Indian Electricity Act 2003 and rules framed there under.
Dated 29.Jan 2015
Page 9 of 429
iii)
iv)
v)
Vi)
vii)
viii)
RVNL
Regulations laid down by the Chief Electrical Engineer of the concerned zonal railway/
Chief Electrical Inspector/local authorities.
Indian Electricity rules, 1956.
Energy Conservation Act 2001
Energy Conservation Building Code
National Building code
Standards/specifications, Guidelines/directions issued by Railway Board/RDSO from
time to time.
NOTE:
a) In case of any conflict between the above standards, the decision of Employer shall be final.
b) Henceforth in these Technical Specifications, wherever the BIS specification no. or any other
specification, Code of Practice etc. are referred to, they shall apply to the latest version
of the relevant standard, unless specifically stated otherwise.
c) Only the latest version of rules/standards/drawings/instructions shall be applicable unless
specifically stated otherwise. In case of any conflict between various instructions, decision of
the Employer shall be final. In case of any conflict/discrepancy between specifications
contained in this book and specifications as per above mentioned authorities, later shall
prevail.
Notwithstanding any approval of drawing or work by RVNL, the contractor shall be finally
responsible for following correct instructions and drawings as per latest amended details. In
case any mistake is found in the work/drawing later on which is not carried out/prepared in
accordance with laid down standards, rules and regulations, the Employer shall be free to
reject it at any stage of the work. The contractor shall be liable to dismantle/modify/redo the
rejected work without any extra cost as per directions of the Employer. The decision of the
Employer shall be final in this regard.
d) In this Technical Specification, the latest standards/drawings/instructions/letter/Code of
Practice etc. means latest of above issued up to the date 28 days prior to the deadline for
submission of bids.
3.1 Ratings of Components: All the equipments/components in the electrical system shall be of
appropriate rating of voltage/current and frequency as required. All the conductors, switches and
accessories shall be of such size as to be capable of carrying maximum current which will
normally flow through them without getting them over burdened/overheated.
4.0 Earthing
Earthing shall be provided as per Indian Electricity (IE) Rules, 1956.
5.0 Safety Instructions
5.1 Indian Electricity Rules 1956, are to be followed in their entirety.
5.2 The detailed instructions on safety procedures given in BIS Specifications,
Indian
Electricity Rules, respective Supply Authority’s regulations and Railway Rules, shall be
applicable, all with their latest amendments.
5.3 The Electrical Contractor/ Sub-Contractor shall hold a valid and relevant Electrical
Contractor’s License for LT/HT/EHT Voltage issued by any State Government. All the work
on electrical installations shall be done under the direct supervision of persons holding valid
certificates of competency issued by any State Government.
Dated 29.Jan 2015
Page 10 of 429
RVNL
5.4 No inflammable materials shall be stored in places other than the rooms specially
constructed for this purpose in accordance with the provisions of Indian Explosives Act.
5.5 Protective and Safety equipments such as rubber gloves, earthing rods, lineman’s safety
belt, high visibility jackets, portable artificial respiration apparatus etc., shall be provided
to all the working staff.
5.6 Caution boards such as “Man working on line”, “ Do not switch on” etc, shall be provided on
the HT/LT Panel Boards, for indication that the switch has been put to off position and
person has been allowed to work on line.
5.7 “Permit to Work” shall be got issued from the person in-charge of the installation, prior to
start of work, on energized electrical installations.
5.8 No work on live bus bar or switch boards shall be handled by a person below the rank of a
Licensed Wireman and such work shall be done in the presence of a competent Engineer.
5.9 When working on or near live installations, suitable insulated tools shall be used, and
special care shall be taken to ensure that tools do not drop on live terminals causing shock
or dead short.
5.10 The electrical switch boards/ distribution boards shall be clearly marked to indicate the
areas being controlled by them.
6.0
7.0
Man- Power
6.1 The contractor shall employ competent, licensed, qualified full time electrical engineers to
direct the work of electrical installations in accordance with the applicable specifications, IE
Rules, Acts and Railway Regulations. The Contractor’s Engineer(s)/ technician(s)/ Workmen
shall possess the necessary license/competency certificate issued by competent authority
including RVNL/Railways as required under rules/law etc.
6.2 The Contractor’s Engineer shall possess relevant knowledge/ experience in substation
work/ wiring of residential/ service buildings, illumination of streets/ railway yards/
circulating areas, designing of distribution system, mains/ sub-mains/ individual
distribution boards, modification of overhead power line crossings, stringing of overhead
mains and laying of underground cables etc. as applicable to the works included in the
scope of the contract.
Inspection of Equipments/ materials
7.1 The inspection of various Equipments/ materials as specified in relevant IS/Specifications
shall be carried out by the agencies as specified below provided the value of material is
more than specified limits as per Railway Board Letter No. 2000/RS(G)/379/2 dt 10/9/2013
(Rs. 1.5 Lakh as of now). In other cases, inspection shall be arranged by RVNL/its
Representative as per 7.3 below:
1
2
3
4
5
6
7
Power Distribution Transformers
H.T./ L. T Panels
High Mast Lighting Systems
Diesel Generating Sets
H.T./L.T Cables
Battery Chargers
APFC Panels
Dated 29.Jan 2015
RITES
RITES
RITES
RITES
RITES
RITES
RITES
Page 11 of 429
RVNL
8
9
10
11
12
13
14
15
16
17
18
19
20
21
ACSR conductor
Tubular Poles
Luminaries and Lamps
Fans and Regulators
Wiring Cables and accessories
Feeder Pillar and Switch Boards
Meter Board, Meters
G.I. Pipes
HT End Terminations
Insulators and Stays
Glow Sign Boards
Battery Charging system and
Points
Pumps
All other materials
Pre
Cooling
RITES
RITES
RVNL/
RVNL/
RVNL/
RITES
RVNL/
RVNL/
RITES
RITES
RVNL/
RVNL/
its Representative
its Representative
its Representative
its Representative
its Representative
its Representative
its Representative
RITES
RVNL/ its Representative
7.2 The inspection of the above items will be done at the manufacturer’s works or other
appropriate location decided by RVNL and inspection fees chargeable by Inspecting
Authority will be borne by the contractor as per relevant instructions/agreement. In
exigency of work or revision in Railway Board/RVNL policy, inspection authority may be
changed by RVNL. If the inspection is carried out by other than RDSO/RITES, the
inspection charges shall be recovered as per extent policy of RVNL.
7.3 OEM’s certificate and other papers, such as material challans etc. shall be furnished by the
Contractor, to establish the genuineness of the equipment/ material.
7.4 Nominated Inspector shall have free access to visit the manufacturer’s works at all
reasonable times to witness and inspect the testing of equipment/ materials. The
contractor shall provide all reasonable facilities and equipments/lab at his cost for proper
inspection of the material/equipment.
7.5 Item available as catalogued product in market like MCBs, MCCBs, wiring accessories, light
fittings, fan etc. will be acceptable on factory routine test report for the batch, certificate
from authorized dealer and manufacturer and visual inspection at site. However engineer
may decide to get any item under the scope of supply inspected by any agency
(RITES/RVNL/Rly) at manufacturer’s work if so required. And the cost of such test shall be
borne by contractor. If RVNL wants to get any special test done on any item other than at
manufacturer’s work, the cost of the same shall be borne by RVNL.
7.6 The Contractor shall ensure that all the equipments/materials supplied are tested as per
relevant BIS/ BS Specification and comply with instructions on energy star rating issued by
BEE wherever applicable. At per present RB instructions, all energy consuming equipments
should be procured with min 3 star energy rating.
7.7 The Contractor shall ensure that all the equipments/materials supplied is procured from
applicable approved list of sources. In case item is not featuring in approved list or
approved itself is not available, prior approval of RVNL/Railway shall be taken before
placing order. Detail guidelines of RNL/Railways issued from time to time shall be
applicable in this regard.
8.0
Pre- Commissioning tests on Equipment
8.1 The pre-commissioning tests on various equipments shall be carried out jointly by the
Contractor with the Engineer.
Dated 29.Jan 2015
Page 12 of 429
RVNL
8.2 The Contractor shall get the electrical installations checked and approved from the
Concerned Chief Electrical Engineer of Railways, Electrical Inspector/ local Authority/ CEA/
any other regulatory authority, as per requirement. The work will not be treated as
complete until such clearances are obtained by the Contractor. He shall also obtain any
other clearances that may be required from time to time. The installation shall be
energized, in the presence of the Engineer, only after the receipt of all such approvals.
9.0
Other Requirements
9.1 Care shall be taken by contractor to avoid damage to the building during execution of his
part of work. He shall be responsible for repairing all damages and restoring the same to
their original finish at his own cost. He shall also remove at his cost all the unwanted and
waste materials arising out of his work from the site. The Contractor shall dress up/repair
the site as per the existing surrounding ground/ floor/walls/ road surface etc. after
completion of the work and make good any damages that occurred during the execution of
works.
9.2 The work shall be carried out with minimum power shut downs. The required shut downs
from railway/other agencies will be arranged by the Engineer, with the active assistance of
Contractor, in consultation with user departments, and the charges if any & not mentioned
otherwise, shall be borne by RVNL.
9.3
Coordination with other Agencies:
The contractor shall coordinate with all other agencies so that work is not hampered due to
delay in his work. Recessed conduit and other works which directly affect the progress of
the main work should be done in time and on priority.
Wherever approval is to be taken from other department (s) of state/central
government, standards of work and approved list of equipments /materials should be
followed as per their requirement and approvals obtained.
9.4
Work in Occupied Buildings:
While working in the occupied buildings, there should be minmum inconvenience to the
occupants. Work should be programmed in coordination with the engineer and occupying
department. If required, work may have to be planned beyond normal working hours.
The contractor shall be responsible to abide by the regulations/restrictions regarding entry
into and movement within the premises.
9.5
The rates are deemed to be inclusive of all lead (except as otherwise specifically provided
in the description of the particular item), lifts ascend descend, handling, re-handling,
crossing of nullahs/streams/tracks or any other obstructions.
9.6
All enabling works for executing the work e.g. approach road to site, launching
arrangements, procuring right of way: arrangement of water and electricity etc. is to be
arranged by the contractor at his own cost and is deemed to be included in the quoted
rates.
9.7
Storage of Material: All the material at site shall be property stacked & stored so as to
facilitate inspection. The material should be properly protected from detrimental effects of
nature, fire, theft etc. The contractor shall be responsible for watch & ward and any loss or
Dated 29.Jan 2015
Page 13 of 429
RVNL
deterioration on account of above shall lead to rejection of material. In this eventuality, the
contractor shall have to replace the same at this own cost.
9.8
All minor items viz. hardware items, foundation bolts clamps, termination lugs for electrical
connections etc. as required and necessary for proper working of the equipment shall be
deemed to have been included in the Bill of Quantities, whether such items are specifically
mentioned or not. All hardware & M.S components should be either Galvanized or
Electroplated.
9.9
If any activity of work is essential for the satisfactory completion of the work but is not
mentioned specifically in the Bill of Quantities or elsewhere in the bidding documents, the
same shall be deemed to be included In the scope of work and shall be executed by the
contractor within the accepted cost. The work shall be handed over in a functional manner
complete in all respects.
10.0
Approval of Drawings and completion drawings
10.1
On award of contract, the successful bidder shall visit the site and prepare working
drawings as per site requirements. Drawings shall conform to the relevant standards and
details given in Indian Railway works Manual and prepared in Auto CAD. The drawings
which require prior approval shall be first prepared and submitted in three copies with one
soft copy as check drawings. The comments and corrections received back shall be
incorporated while preparing the final drawing on RTF sheets for signatures and approval.
10.2 The drawings of all equipments including HT/ LT panels, transformer, DG set, distribution
boards, pre-cooling/battery charging points, battery charger, wiring plan, route of laying of
cables, poles , and other items shall be got approved from the Engineer. Manufacturing of
the items can be taken in hand only after the approval of the drawings and samples. The
Contractor shall supply six copies in addition to one copy on RTF and soft copy of each of
these approved drawings before commencement of work.
After completion of the work, as erected completion drawings shall be submitted in
four copies in addition to two copies on RTF and soft copy.
11.0 Commissioning of Completed Works:
11.1
After completion of work, the Contractor shall ensure that the installations have been
commissioned only after due testing and approval of the Engineer.
12.0 Completion Plan and Completion Certificate:
12.1
After completion of works, the Contractor shall submit required sets of ‘As Erected’
drawings as per para 10.2 above in respect of all the electrical installation works.
12.2 Completion Certificate, in the following format, shall be jointly signed by the Engineer and
Contractor.
Completion Certificate
I/ We certify that the installation detailed below has been installed by me/ us and tested and
that to the best of my/ our knowledge and belief it complies with Indian Electricity Rules, 1956,
Electrical installation at ----------------------------------------Voltage and system of supply------------------------------------
Dated 29.Jan 2015
Page 14 of 429
RVNL
Particulars of work:
(a) Internal Electrical installation :
No.
Total load
System of wiring
i
Light point
ii
Fan point
iii
Plug point
iv
3 pin 5 Amp.
v
3 pin 15 Amp
vi
Other points
(b)
No
i
ii
iii
Motors
Total load
HP/KW
Type of starting
(c)
Other Plants
No
i
ii
(d)
(e)
No.
a
b
C
(f)
I
ii
iii
iv
v
Installation of over head line and underground cable
Overhead line
Total length and No. of spans.
No. of street lights and its description
Underground cable Make and Year
Total length of underground cable and its
size.
Number of joints
End point
Tee Joint
St. through Joint
Earthing
Details
Description of earthing electrode
No. of earth electrodes
Size of main lead
Test results- Insulation resistance
Insulation resistance of the whole system of
conductors to earth in Mega ohms
Insulation between the phase conductor and
neutral.
Between Phase R and neutral
Between phase Y and neutral
Between phase B and neutral
Dated 29.Jan 2015
Qty with unit
----- Mega ohms
------ Mega Ohms
------ Mega Ohms
------ Mega Ohms
------ Mega Ohms
Page 15 of 429
RVNL
vi
vii
vii
Between phase R and phase Y
Between phase Y and phase B
Between phase B and phase R
------ Mega Ohms
------ Mega Ohms
------ Mega Ohms
(g) Polarity test- Polarity of non-linked single pole branch switches.
(h) Earth Continuity test –Maximum resistance between any point in the earth continuity
conductor including metal conduits and main earthing lead---Ohms.
(i)
Earth electrode resistance – Resistance of each earth electrode:
No.
i)
ii)
iii)
iv)
v)
…….. Ohms
…….. Ohms
……. Ohms
…. Ohms
…. Ohms
Signature of the Engineer
Note:
Signature of Contractor
For obtaining EIG approval for energizing HT installations, the EIG application format of the
concerned Railway shall be followed.
13.0 Concrete and Cement
(a) All the foundations [except as per details given in (b)], for masts of street lighting, solar
lighting, LT/HT over head conductors, Guy wires, stays, steel/GI Tubular poles, Battery
charging poles and pedestals, protective fencing shall be as per the approved drawings of the
RVNL. In these type of foundations, normally M-10 cement concrete (except where specified
otherwise) conforming to IS-456 with 20 mm coarse aggregates shall be used. The cement to
be used shall be ordinary Portland cement of 43 grade (conforming to IS-8112) or 53 grade
(conforming to IS-12269) or PPC conforming to IS 1489(Part 1/Part 2) as approved by RVNL
based on requirement and availability and date of manufacturing shall not be older than three
months.
(b) Where foundations of equipments are to be laid as per OEM recommendations/standard
drawings of the Railway/SEB, grade of cement, size of aggregate, concrete grade and
foundation dimensions etc shall be as per their recommended standard such as High mast
lighting system, H pole structures used for power line crossings.
The contractor shall use concrete mixer, proper shuttering and vibrators for
compaction for foundations of high mast lighting system, large pumping installations etc as
directed by Engineer. For smaller foundations detailed at (a) above, manual concrete mixing
and compaction may be adopted.
------------------------------------------------------------ -----------------------------------------------
Dated 29.Jan 2015
Page 16 of 429
RVNL
TECHNICAL SPECIFICATIONS
Dated 29.Jan 2015
Page 17 of 429
Dated 29.Jan 2015
RVNL
Page 18 of 429
RVNL
Tech. Spec. No. -RVNL/Elect/GS/01
INTERNAL
ELECTRIFICATION
WORKS
Dated 29.Jan 2015
Page 19 of 429
Dated 29.Jan 2015
RVNL
Page 20 of 429
RVNL
CHAPTER: A-1
Technical Specification No. RVNL/Elect/GS/01
INTERNAL ELECTRIFICATION WORKS
1.0
Scope
This specification pertains to internal electrification of residential and service buildings on 3
phase, 415 volts or single phase, 230 Volts, 50 Hz Ac supply system, including provision of
conduits with accessories, metal boxes and Boards, wiring, metering, protection, switchgear,
UPS, stablizers, energy savers, provision of fans & luminaries, pre-commissioning/
commissioning tests and handing over. Separate conduits shall be laid for:
i) Emergency and non emergency circuits
ii) Power and lighting circuits
1.1
Regulations and standards
The system shall be governed by IS:732, I.E. Rules 1956, National Electric Code (NEC), ECBC,
National Building code, relevant BIS Standards and Codes applicable to internal electrification
and distribution works.
1.2
The definitions of terms shall be in accordance with IS:732-1989 ( Indian Standard Code of
Practice for Electrical Wiring), except for the definitions of point wiring, circuit, sub-main and
main wiring.
The conventional signs & symbols for technical work shall be indicated in the working and as
erected drawings.
1.3 GENERAL CONDITIONS:
a. Before starting wiring work approval of site drawings shall be obtained regarding layout, no. of
points to be wired and location of switchboards etc.
b. All switchboards shall be of GI box type/ PVC box compatible with modular switches/plug
points. No wooden switchboards shall be used.
c. The wiring shall be done from a distribution system through main and/or branch distribution
boards. The system design and location of boards will be properly worked out and approved by
site supervisor.
d. Each main distribution board and branch distribution board shall be controlled by an incoming
circuit breaker. Each outgoing circuit shall be controlled by a circuit breaker/switch with fuse. All
Main/sub distribution boards shall be double door recess type.
e. For non-residential buildings, as far as possible, DBs shall be separate for light and power.
Only MCCB/MCB type DBs shall be used. Kitkat fuse, glass fuse, Re-wirable type fuses shall not
be used.
f.
Three phase DBs shall not be used for final circuit distribution as far as possible.
g.
'Power' wiring shall be kept separate and distinct from light wiring, from the level of circuits
(Sub-main), i.e., beyond the branch distribution boards. Conduits for light/power wiring shall be
separate.
h. Essential/non-essential/UPS distribution each will have a completely independent and separate
distribution system starting from the main, switchboard up-to final wiring for each system.
i.
Generally, no switchboard will have more than one source of incoming supply.
j.
Each MDB/DB/Switch Board will have spare outgoing ways for future expansion.
k. All M.S clamps/structures/hardware should be hot dip galvanized. If not possible special
structures cold galvanization paint shall be applied.
Dated 29.Jan 2015
Page 21 of 429
RVNL
1.4
Wiring
1.4.1 (a) Main wiring: Main wiring shall mean the wiring from one main/distribution switchboard to
another.
(b) Sub-main wiring: Sub main wiring shall mean the wiring from the distribution board to
the 1st tapping point inside the switch box, from where point wiring starts.
(c) PVC insulated, multi stranded, Heat resistant fire retardant (HRFR), low smoke, flexible
copper conductor cables of 1.1 kV grade, conforming to IS: 694/1990, ISI marked shall
be used. The size/s shall be as specified in the Bill of Quantities (BOQ).
(d) Minimum size of wiring cable/s for light and power points shall be as
•
•
•
•
•
•
•
below:
Light/ Fan wiring
- 1.5 Sq. mm
Light plug point
- 2.5 Sq. mm
Circuit wiring for Light/ Fan Point
- 2.5 Sq. mm.
Circuit wiring for Light plug point
- 4.0 Sq. mm
Group Point wiring
- 2.5 Sq. mm
Power wiring
- 4.0 Sq. mm
Power wiring with more than 1 kW load – the size shall be assessed by the
contractor based on load calculations and approved by the Engineer.
(e) Flexible cable – Copper conductor, 3 core flexible cables shall be used for connecting
single phase appliances etc.
Sizes of single core (copper conductor) cable for point, circuit and sub main wiring, circuits,
distribution board/s, etc. for Qrs.
Nos. of points and size of wiring cables
Nos. of circuits and size of wiring
cables
Size of point wiring cable
(copper conductor)
Size of circuit wiring cable
(copper conductor)
LP TLP FP CBP
EFP PP5A
PP 15A GP
PP32A For L&F For 5A For 15A. For
32A.
(ACP)
Plug Plug
AC
Size of Sub main
wiring cable
For
L&F
Load
For
Power
load
For geyser
Phases
and
neutral
1.5 sq.mm
2.5sq
mm
4sq
mm
6sq
mm
6sq
m
m
2.5 sq.
mm
4sq.
mm
4sq.m
m
6sq
.
mm
6 sq.mm
4 sq mm 10 sq mm
Continuo
us earth
1.5 sq.mm
2.5sq
mm
4 sq
mm
6 sq
mm
6sq
m
m
2.5sq
mm
4 sq
mm
4
sq
mm
6sq
mm
6 sq.mm
4 sq mm 10 sq mm
Dated 29.Jan 2015
Page 22 of 429
RVNL
1.4.2 Point wiring:
(i) Definition: A point (other than plug point) shall include all work necessary in complete wiring to
the following outlets from the controlling switch or MCB:
a. Ceiling rose or connector (in the case of points for ceiling/exhaust fan points, prewired
light fittings, and call bells).
b. Ceiling rose (in case of pendants except stiff pendants). Standard specification for
Electrical (General) Works
c. Back plate (in the case of stiff pendants).
d. Lamp holder (in the case of goose neck type wall brackets, batten holders and fittings
which are not prewired).
e. Main and sub-main wiring as described above.
f.
Distribution boards of reputed make as required, modular switchboard, RCCBs in Main
distribution board of adequate capacity of ABB/Siemens/Legrand/L&T make.
(ii) Scope:
Point Wiring shall include:
a. Conduit/channel as the case may be, accessories for the same and wiring cables between
the switch box and the point outlet, loop protective earthing of each fan/light fixture.
b. All fixing accessories such as clips, screws, Phil plug, rawl plug etc. as required.
c. Metal or PVC switch boxes for control switches, regulators, sockets etc., recessed or
surface type, and phenolic laminated sheet covers over the same.
d. Outlet boxes, junction boxes, pull-through boxes etc. but excluding metal boxes if any,
provided with switchboards for loose wires/conduit terminations.
e. Control switch or MCB, as specified.
f. 3 pin or 6 pin socket, ceiling rose or connector as required.
g. Connections to ceiling rose, connector, socket outlet, lamp holder, switch etc.
h. Bushed conduit or porcelain tubing where wiring cables pass through wall etc.
i.
Main and sub main wiring of appropriate size.
j.
Pre wired MDB and DBs of ABB/Legrand/L&T make as required including MCBs. RCCBs for
MDBs will not be paid separately.
k. Earth wire run as per requirements.
(iii) Point wiring for plug points:
a. 16A plug points shall be mounted on separate modular board. 6 A plug point can be
mounted on light/fan point switchboard or separately. Not more than 1(one) 6A plug
point will be allowed on common switchboard.
b. The 6A plug point wiring shall include, controlling switch, socket and necessary wiring
from sub main including earthing of third pin.
c.
The 16A plug point wiring shall include separate board as approved consisting of
controlling switch, socket, MCB, earthing.
1.4.3 System of wiring :
a. Wiring shall be done only by the looping system. Phase/live conductors shall be looped at
the switch box. For point wiring, neutral wire/earth wire looping for the 1st point shall be
done in the switch box; and neutral/earth looping of subsequent points will be made from
point outlets.
b. In wiring, no joints in wiring will be permitted anywhere, except in switch box or point
outlets, where jointing of wires will be allowed with use of suitable connector.
c. The wiring throughout the installation shall be such that there is no break in the neutral
wire except in the form of linked switchgear.
d. Colour coding:- Following colour coding shall be followed in wiring:Phase
Live
Neutral
Earth
Dated 29.Jan 2015
Red/Yellow/Blue. (Three phase wiring)
Red (Single phase wiring)
Black
Green/Yellow-green.
Page 23 of 429
RVNL
e.
Termination of Sub main circuit into switchboard:-Sub-main (Circuit) will consist of
phase/neutral/earth wire. Sub-main (Circuit) will terminate in a switch board (first
tapping point, where from point wiring starts) & the switchboard will have phase, neutral
and earth terminal to receive phase/ neutral/earth wire.
1.4.4 Run of wiring:
a. The type of wiring shall be as specified in the tender documents/detailed at site namely,
surface conduit/concealed conduit, MS/PVC, channel (Casing/Capping).
b. Surface wiring shall run as far as possible along the walls and ceiling, so as to be easily
accessible for inspection.
c. Above false ceiling, in no case, open wiring shall be allowed. Wiring will be done in
recessed conduit or surface steel conduit.
d. In concealed conduit system, routes of conduit will be planned, so that various inspection
boxes provided don't present a shabby look. Such boxes can be provided 5 mm above
plaster level, and they can be covered with plaster of Paris with marking of junction
boxes.
e. Generally conduits for wiring will not be taken in floor slabs.
1.4.5 Passing through walls or floors :
When wiring cables are to pass through a wall, these shall be taken through a protection
(steel/PVC) pipe of suitable size such that they pass through in a straight line without twist or
cross in them on either end of such holes. The ends of metallic pipe shall be neatly bushed with
PVC or other approved material.
All floor openings for carrying any wiring shall be suitably sealed after installation.
1.4.6 Joints in wiring :
a. No bare conductor in phase and/or neutral or twisted joints in phase, neutral, and/or
protective conductors in wiring shall be permitted.
b. There shall be no joints in the through-runs of cables. If the length of final main or submain is more than the length of a standard coil, thus necessitating a through joint, such
joints shall be made by means of approved mechanical connectors in suitable junction
boxes.
c. Termination of multi stranded conductors shall be done using suitable crimping type
thimbles.
1.4.7 Capacity of Circuits ( Sub-main) :
a. Lighting circuit from each sub main shall feed light/fan/call bell/6A outlet points. Each
circuit shall not have more than 800 Watt connected load or more than 8 points.
b. Power sub main circuit will have only one 16A outlet per circuit. Not more than 4 Nos. 6A
outlets outlet shall be allowed from one sub-main.
c.
All Loads more than 1 KW each shall be controlled by suitably rated MCB and cable size
shall be decided as per calculations.
1.4.8 Measurements
Measurement of point wiring for light points, fan points, exhaust fan points, group points, light
plug points, power plug points & call bell points shall be done on unit basis by counting only.
Measurement of twin control point wiring shall be done on unit basis by counting.
1.4.9 Circuit Wiring
Circuit Wiring shall mean the wiring from the distribution board to the first tapping point inside
the switch Board, from where point wiring starts. Looping of switch boards in the same circuit
shall also be measured along the length of conduit for circuit wiring as per relevant BOQ item.
Dated 29.Jan 2015
Page 24 of 429
RVNL
1.4.10 Sub main Wiring
(a) Sub main wiring shall mean the wiring from the meter board or main board/ sub main
board to Distribution board/ Sub distribution board as the case may be. Looping of
distribution boards/ sub distribution boards shall also be provided along the length of
conduit for Sub Main wiring.
Main Distribution Boards, Sub Distribution Boards shall be double door recess type. MCB
and LCCBs of requisite rating should be provided in the distribution board.
(b) Circuit Wiring/ Sub main wiring cable/s along with earth wire cable/s shall be of the
capacity specified in Bid document/RVNL standard. Wiring of each circuit wiring/ sub/
main wiring cable/ s along with earth wire cable/s shall be drawn into an independent
conduit. Drawn boxes of suitable size shall be provided at convenient locations to
facilitate easy drawing of the circuit wiring/ sub main wiring cable/s. Cost of junction
Board/ draw Boxes are deemed to be included in the rates of circuit wiring/ sub main
wiring cables along with earth wire cable/s. Single phase circuits shall have single
earth wire whereas three-phase circuits shall be provided with two earth wires.
(c)
Where sub- main, circuit wiring and point wiring cables are connected to the switch/
switchgear etc, sufficient extra length of cable/s ( not less than 150 mm ) shall be
provided to facilitate easy connection and maintenance.
1.5
Joints in the Wiring
All joints in the wiring shall be made at main switch boxes and distribution boards only. No
joint shall be made in conduits and junction Boxes or in the length of wiring cable. Wiring
cable shall be continuous from outlet to inlet. All joints shall be made by use of connectors
and lugs. All wire ends to be provided with lug and connected with requisite fasteners. Lugs
should be crimped properly with crimping tools.
1.6
Conduit System
1.6.1 Type and Size of Conduit
1.6.1.1 The Conduit wiring shall be carried out as under:
All the non-metallic conduit pipes and accessories shall be of suitable materials complying
with IS-2509:1973 and IS-3419:1989 for rigid conduits and IS-9573 (Part 5):2000 for flexible
conduits. Internal wiring in the buildings shall be done with ISI marked PVC rigid conduit of
size not less than 25 mm diameter and thickness 2.0 mm (Nominal size). PVC conduit shall be
used with all its associated accessories such as bends, couplers, saddles, metal deep boxes
(100 mm deep for ceilings), PVC bends etc.
1.6.1.2 Normally, concealed wiring shall be provided in all the buildings. Surface conduit wiring shall
be provided if specifically given in BOQ or where it is not practicable to provide concealed
wiring with approval of the RVNL.
1.6.1.3 Limitations
The maximum number of PVC insulated 650/1100 V grade copper conductor cables that can
be drawn in conduit pipes shall be limited to 45 % of the capacity of the conduit. Table
indicating the capacity is as under:S. No.
1.
2.
Size of Conduit
25 mm
32 mm
100 % capacity in Sq mm
490
804
45% capacity in Sq mm
220
362
1.6.1.4 Conduit joints :
Conduits shall be joined by means of screwed or plain couplers depending on whether the
conduits are screwed or plain. For conduit fittings and accessories reference may be made to
the good practice (IS : 2667, IS:3419, IS:9537 Pert-I II III).
Dated 29.Jan 2015
Page 25 of 429
RVNL
1.6.1.5 Fixing of conduits :
Conduit pipes shall be fixed by heavy gauge saddles, secured to suitable PVC plugs with
screws in an approved manner at an interval of not more than 600mm, but on either side of
couplers or bends or similar fittings, saddles shall be fixed at a distance of 300 mm from the
center of such fittings except that the spacing between saddles or supports is recommended
to be 600 mm for rigid non-metallic conduits.
1.6.1.6 Bends in conduits :
Wherever necessary, bends or diversions may be achieved by bending the conduits or by
employing normal bends, inspection bends, inspection boxes, elbows or similar fittings.
Conduit fittings shall be avoided, as far as possible, on outdoor systems.
1.6.1.7 Outlets :
In order to minimize condensation or sweating inside the conduit, all outlets of conduit
system shall be properly drained and ventilated, but in such a manner as to prevent the
entry of insects.
1.6.1.8 Heat may be used to soften the conduit for bending and forming joints in case of plain
conduits. As the material softens when heated, sitting of conduit in close proximity to hot
surfaces should be avoided.
1.6.1.9 Fixing of conduit in chase (concealing in plaster of wall):
The conduit pipe shall be fixed by means of staples or by means of non-metallic saddles
placed at not more than 80 cm apart or by any other approved means of fixing. Fixing of
standard bends or elbows shall be avoided as far as practicable and all curves shall be
maintained by sending the conduit pipe itself with a long radius which will permit easy
drawing in of conductors. At either side of bends, saddles/staples shall be fixed at a distance
of 15 cm from the center of bends.
1.6.1.10 Inspection boxes (for concealed wiring):
Suitable inspection boxes to the nearest minimum requirements shall be provided to permit
periodical inspection and to facilitate replacement of wires, if necessary. The
inspection/junction boxes shall be mounted flush with the wall or ceiling concrete. Where
necessary deeper boxes of suitable dimensions shall be used. Suitable ventilating holes shall
be provided in the inspection box covers, where required.
Table 1
Maximum No. of single core cables in Rigid metallic/non metallic conduit
Size of wires
mm2
no. & dia
1.5
1/1.4
2.5
3/1.06
4
7/0.85
6
7/1.06
10
7/1.40
16
7/1.70
25
7/2.24
35
7/2.50
50
19/1.80
Dated 29.Jan 2015
16
3
2
2
20
5
5
3
2
Size of conduit (dia in mm)
25
32
40
50
10
14
8
12
8
10
5
8
3
5
3
6
2
6
4
6
3
5
60
7
6
Page 26 of 429
RVNL
Table 2
Maximum Number of Single-Core Cables that can be Drawn into Casing and
Capping
Size of wires
Size of Casing
Mm2
no. &dia
10/15mm
20mm x
25mm x
30mm x
40mm x
50mm x
x 10 mm
10 mm
10mm
10mm
20mm
20mm
1.5
1/1.4
3
5
6
8
12
18
2.5
3/1.06
2
4
5
6
9
15
4
7/0.85
2
3
4
5
8
12
6
10
16
7/1.06
7/1.40
7/1.70
25
35
50
70
7/2.24
7/2.50
19/1.80
1.6.2
a)
b)
c)
1.6.3
1.6.4
2
1
3
2
1
4
3
2
6
5
4
9
8
6
1
3
2
1
1
5
4
3
2
Surface Conduits
Surface or open conduit pipes shall be fixed by heavy gauge saddles, secured to suitable
approved plugs embedded in walls/ firmly secured with tresses etc. with screws in an
approved manner at an interval of not more than 60 cm on either side of the coupler or
bends or similar fittings. The saddles shall be fixed at a distance of 30 cm from the center of
such fittings. Open conduit wiring shall be laid parallel/ perpendicular to the walls and
suitable clamps shall be fixed properly. For 25 mm diameter conduit, width of clamp shall be
19 mm and of 20 SWG wall thickness. For conduits of 32 mm and above, width of clamp
shall be 25 mm and of 18 SWG wall thickness.
Where conduit pipes are to be laid along trusses, steel joints etc., the same shall be secured
by means of special clamps made of mild steel. Where it is not possible to drill holes in the
truss members, suitable clamps with bolts and nuts shall be used.
Where conduit pipes are to be laid above false ceiling, conduit pipes shall not be clamped to
false ceiling frame work and shall be suspended with suitable supports from the suffix of
slab. For conduit pipes to run along with wall , the conduit pipe shall be clamped to wall
above false ceiling in uniform pattern with special clamps approved by the Engineer at site.
Installation of Conduit system :
Common aspects for both concealed and surface conduit works:
a.
The erection of conduits of each circuit shall be completed before the cables are drawn
in.
b.
All joints shall be sealed/ cemented with approved cement. Damaged conduit
pipes/fittings shall not be used in the work. Cut ends of conduit pipes shall have neither
sharp edges nor any burrs left to avoid damage to the insulation of conductors while
pulling them through such pipes.
c.
Bends in conduit : All bends in the system may be formed either by bending the pipes
by an approved method of heating, or by inserting suitable accessories such as bends,
elbows or similar fittings, or by fixing non-metallic inspection boxes, whichever is most
suitable. Where necessary', solid type fittings shall be used.
d.
Radius of bends in conduit pipes shall not be less than 7.5 cm. No length of conduit shall
have more than the equivalent of four quarter bends from outlet to outlet.
e.
Care shall be taken while bending the pipes to ensure that the conduit pipe is not
damaged, and that the internal diameter is not effectively reduced.
f.
Outlets: All switches, plugs, fan regulators etc. shall be fitted in flush pattern. The fan
regulators can be mounted on the switch box covers, if so stipulated in the tender
specifications, or if so directed by the Engineer.
g.
Painting: After installation, all accessible surfaces of metallic accessories shall be
painted.
Dated 29.Jan 2015
Page 27 of 429
RVNL
1.7
Casing and Capping:
PVC casing and capping shall conform to BIS Specification No.14927 Part 2 and for wiring
application with the required accessories viz. bends and tees etc., as per site conditions. They
should be properly fitted along with the required accessories viz. couplers, junction box,
bends, tees, PVC round blocks, sockets, clamps, bolts, nuts, screws etc., as per the site
conditions. They shall be used in suitable size to accommodate the wiring and shall be laid
straight horizontally/vertically on the wall/roof etc.
1.8
Accessories
1.8.1 Control Switches for lights/ fans etc.
a) All 5/6 and 15/16 Amp switches/ sockets ( 5 pin/6 pin) including bell push shall be modular
type suitable for use on 230 Volts A.C. supply system. Switch plate shall be matching with
modular switches/sockets. All switches, sockets, etc., shall normally be of white finish or as
approved considering matching with the colour of walls/surface.
b) All the switches controlling the lights/fans etc. shall be connected to the phase wire of the
circuit. Switches for lights and 5/6 Amp & 15/16 amp outlets shall be located at 1250 mm
above finished floor level and the sub distribution boards (SDB), distribution boards (DB) shall
be at 1500 mm above finished floor level, unless otherwise instructed by the Engineer.
1.8.2
1.8.3
1.8.4
Ceiling Rose
The ceiling rose shall be of Bakelite, 5 amps, 250 volts, conforming to latest version of
IS:371/1999(ISI marked). The colour shall normally be of white finish or as approved
considering matching with the colour of wall.
Lamp Holder
The lamp holder shall be Polycarbonate of model as approved (ISI Marked). The colour shall
normally be of white finish or as approved.
Call Bell
Call bell shall be fixed on metal box of approved size with 3mm Phenolic laminated sheet on
top ( conforming to IS: 2036:1995) fixed with brass screws and brass cup washers and shall
be suitable to work on 230 V AC, single phase 50 cycle. Piano type bell push shall be fixed at
the entrance door.
1.8.5 Attachment of fittings and accessories :
a. Conduit wiring system: All accessories like switches, socket outlets, call bell pushes and
regulators shall be fixed in modular sheets in boxes. Accessories like ceiling roses, brackets,
batten holders etc. shall be fixed on outlet boxes.
b. Steel/iron screws shall be used to fix the accessories to their bases.
c. Fixing to walls and ceiling: Wooden plugs for fixing to wall/ceiling will not be allowed. Fixing
will be done with the help of PVC sleeves/Rowel plugs/ dash fasteners as required.
d. Drilling of holes shall be done by drilling machines only. No manual drilling of hole will be
allowed.
e. PVC spacers shall be provided during fixing of fittings and other items on wall.
1.9
For termination of cables, crimping type cable socket/lugs shall be provided and soldered if
necessary/ instructed.
1.10
Load Balancing:
Balancing of circuits in three–phase installation shall be planned before the commencement of
wiring and shall be strictly adhered to.
1.11
Colour code for Wiring:
Colour code for wiring installation shall be maintained as Red, Yellow and Blue for three
phases, Black for neutral and green only for earth in case of insulated earth wire.
Dated 29.Jan 2015
Page 28 of 429
RVNL
1.12
Earthing of Non- current Carrying Part
All the non-current carrying metal parts of electrical installations shall be earthed properly. All
metal enclosures, cable armour, switchgear, distribution boards, light fittings and all other
parts made of metal shall be bonded together and connected by means of specified earthing
conductors to an efficient earthing system.
1.13
Earth Conductor
Every earthing conductor shall be of copper single core pvc wire / G. I of suitable size.
1.14
Testing of Wiring:
Wiring system shall be tested as per IS:732 for:
i) Continuity of all circuits,
ii) Earthing after the wiring is completed and before energizing,
iii) Polarity test of switches etc.
1.15
Testing
After completion of work, the entire installation shall be subjected to the following tests:
• Insulation Resistance Test.
• Earth Continuity Test.
• Earth Resistance Test.
Besides the above, any other tests specified in BIS Standards or as required by the local
Authority/ Engineer shall also be carried out.
1.15.1 Insulation Resistance Test
a) The insulation resistance shall be measured by applying between earth and the whole system
of conductor or any section thereof with all fuses/MCB in place and all switches closed and
except in earthed concentric wiring, all lamps in position of both poles of the installation
otherwise electrically connected together, a direct D. C. Voltage not less than twice the
working voltage, provided that it does not exceed 500 Volts for medium voltage circuits.
Where the supply is derived from 3 wires (AC or DC) or polyphase system, the neutral pole of
which is connected to earth, either direct or through added resistance the working voltage
shall be deemed to be that which is maintained between the outer or phase conductor and the
neutral.
b) The insulation resistance in mega ohm of an installation measured as in ‘a’ above, shall not be
less than 50 divided by the number of points on the circuit, provided that the whole
installation need not be required to have a insulation resistance greater than one meg ohm.
c) The entire installation shall be tested and shall comply with the requirements of specifications,
IS code and IE norms.
1.15.2 Testing of Earth Continuity Path:
The earth continuity test of metallic envelopes shall be done for electrical continuity.
Electrical resistance of the same, along with the earthing lead, excluding any added resistance
of earth leakage circuit breaker, measured from the connection with the earth electrode to
any point in the earth conductor in the completed installation, shall not exceed one Ohm.
1.15.3 Polarity Test of switch
In a two-wire installation, a test shall be made to verify that all switches in every circuit have
been fitted in the same conductor through out, and such conductor shall be labeled or marked
for connections to the phase conductor or to the non-earthed conductor of the supply.
In a three or four wire installation, a test shall be made to verify that every non-linked single
pole switch is fitted in a conductor which is labeled or marked for connection to one of the
phase conductors of the supply.
1.15.4 Earth Resistance Test
Earth Resistance Test shall be carried out in accordance with Indian Standard Code of Practice
for earthing IS 3043 – 1966. All tests shall be carried out in the presence of the Engineer.
Dated 29.Jan 2015
Page 29 of 429
RVNL
1.15.5 After testing of installation, test results shall be recorded and jointly signed by the Contractor
and the Engineer.
1.16
SCALE OF ELECTRICAL FITTINGS FOR QUARTERS
Details of Points as Sanctioned by Railway Board
Type
LP Tube
Tot FP PP
PP
Call
Exh.
Geyser
of
Fan
al
5A 15A Bell
Quart
er
1
2
3
4
5
6
7
8
9
10
11
I
No. of
6
2
8
2
2
2
0
0
0
Points
II
6
2
8
2
3
2
1
0
0
III
7
3
10
3
3
3
1
0
0
IV
11
5
16
3
4
4
1
1
1
V
15
6
21
5
6
5
1
1
2
Dated 29.Jan 2015
AC
(32A)
Total
Points
12
0
0
0
1
2
13
14
16
20
31
43
Page 30 of 429
RVNL
Nos. of points
Single phase Double Door Earth
Distribution board (4
Electrode
incomer +8 outgoing)
Nos. of circuits
FP
CBP
EFP
PP
5A
PP
15A
GP
I
6
2
2
0
0
2
2
0
0
II
6
2
2
1
0
3
2
0
III
7
3
3
1
0
3
3
0
2
0
0
5
0
2
2
2
0
0
6
1
Incoming MCB DP20 Amp with RCCB
100 mA and O/G -- 6-16amps. MCB
SP -6 Nos
0
3
2
3
0
0
8
1
I/C MCB DP-20
Amp with RCCB
100 mA and O/G -- 6-16amps. MCB
SP - 8 Nos.
Dated 29.Jan 2015
For 32A
AC
1
For 15A.
Plug
2
PP32A
(ACP)
Total Ckt.
TLP
Details
For geyser
LP
For 5A Plug
Type
of
Quat
er
For Lights Fans
&
call bell
Qty
1
Incoming MCB DP- (a) Single unit
20 Amp with RCCB Quarter --- 1 No
100 mA and O/G -(b) two units
- 6-16amps. MCB
Quarter
SP -5 Nos.
- 1 No,
(c)Three/four
units quarter -2 Nos.
Page 31 of 429
RVNL
IV
11
5
3
1
1
4
4
1
1
4
2
4
1
1
12
1
( for
L&F)
1
( for
power
circuit)
1
(for
L&F)
15
6
5
1
1
6
5
2
2
6
3
5
2
2
18
V
1
(for
Power
circuits)
Dated 29.Jan 2015
I/C MCB DP32Amp with RCCB
100 mA and
Outgoing - (i)
MCB SP 6-16amps
---6 Nos,
I/C MCB DP32Amp with RCCB
100 mA and
Outgoing - (i)
MCB SP 16amps --4 Nos,(PP15A)
(ii) MCB SP 20
amps -- 1
No.(Geyser)
(iii) MCB SP 32
amps -- 1
No(AC/WC)
I/C MCB SPN32Amp with RCCB
100mA and
Outgoing –(i) MCB
SP 6-16 amps – 12
Nos,
I/C MCB TPN-40
Amp with RCCB
100 MA mA and
Outgoing – (i) MCB
SP 16amps -6 nos,
(PP15A) (ii) MCB
SP 20 amps – 2
nos (Geyser) (iii)
MCB SP 32 amps –
2 No (AC)
One Number for
each quarter
Two Numbers
for each quarter
Page 32 of 429
RVNL
Abbreviations
LP
Light point with 18 watt CFL with inbuilt
choke.
PP5A
Light plug point complete with socket
and switch
TLP
Tube light point with 1x28 watt T-5
Luminary complete with electronic choke
and T-5 lamp.
PP15A
Power plug point complete with socket
and switch
FP
Ceiling Fan point with 1200/1400 mm fan
with 300 watts electronic regulator
PP32A
(ACP)
Air Conditioner point with Industrial
type iron clad plug 32 amps & 20A DP
MCB in metal clad box
CBP
Call bell point with ding dong type call bell
GP
Geyser point with 25 liters storage
geyser.
EFP
Exhaust fan point with 300 mm Exhaust
fan
------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 33 of 429
Dated 29.Jan 2015
RVNL
Page 34 of 429
RVNL
Tech. Spec. No. RVNL/ELECT/GS/02
LUMINARIES & EQUIPMENTS
FOR
INDOOR/OUTDOOR
ELECTRIFICATION WORKS
Dated 29.Jan 2015
Page 35 of 429
Dated 29.Jan 2015
RVNL
Page 36 of 429
RVNL
CHAPTER: A-2
LUMINARIES & EQUIPMENTS
FOR
INDOOR/OUTDOOR ELECTRIFICATON WORKS
2.0
Scope
This specification covers supply and fixing of
various electrical luminaries and other
equipments for installing inside/outside the service buildings, staff quarters, platforms,
passenger shelters, sheds, foot-over bridges (FOB) etc. The luminaries to be provided include
compact fluorescent lamps (CFL), LED Lighting System, T-5 type energy efficient luminaries,
metal halide luminaries etc. Electrical equipment includes fans, geysers, water coolers, Meter
boards etc.
2.1
Ceiling Fan
a) Ceiling fans shall be provided with suspension hook arrangement in the concrete slab/roof
members at appropriate stage before casting of roof at locations indicated on the working
drawings prepared by the contractor. Co-ordination has to be maintained with civil
engineering contractor authorities for the dates of casting of roof in order to provide fan
box with MS hook as approved.
b)
Ceiling fans shall be continuous duty type with double ball bearings, copper wound motor,
complete with canopies, down rod, 3 blades, capacitor etc ( as per BOQ item) conforming
to IS 374/1979, suitable for operation on 230 Volt +/- 10 %, 50 Hz, A. C. supply and star
rated. Fans shall be generally off-white.
2.2
Normally 1400 mm ceiling fans shall be provided in service buildings/ passenger
shelters/waiting halls or rooms and 1200 mm sweep ceiling fans in residential buildings.
2.3
Stepped type electronic regulator ( as per BOQ item) shall be provided for control of speed of
fan at locations other than passenger shelters/ sheds as per Engineer’s decision.
2.4
2.4.1
Exhaust fans
Exhaust fans shall be heavy-duty type, suitable sweep (as specified in BOQ.) , 900 rpm (as
per BOQ item), noise free with fibre/steel body, star rated (if available in India), double ball
bearing and conforming to IS 2312-1967. Exhaust fan shall be complete with copper wound
motor, capacitor and louver/shutter, frame and mounting bracket and shall be suitable for
operation on 230 volt +/- 10 %, 50 Hz, single phase AC supply system. The color of the
exhaust fan shall be preferably matching with the wall or as decided by engineer.
2.4.2
A suitable hole shall be provided in the wall to suit the size of the frame, which shall be fixed
by means of rag bolts embedded in the wall. The size of the rack bolt and spacing shall match
with the holes on the frame of exhaust fans. The hole shall be neatly finished to the original
shape of the wall.
2.5
Light fittings
Light
fittings
shall
conform
to
IS-10322
and
RDSO
specification
RDSO/PE/SPEC/PS/0100(REV.1)-2011. Light fittings shall be fixed on 3mm thick round
Dated 29.Jan 2015
Page 37 of 429
RVNL
phenolic laminated cover provided on conduit junction Board. Adequate length of copper
conductor PVC insulated cable shall be provided for pendant fittings connections and earthing.
2.6
2.6.1
Surface type T-5, Energy Efficient Luminary with Tube/s
The surface type luminary shall be epoxy white powder coated, CRCA sheet housing with
reflector, pre-wired, indoor type, single/double 28 watts ( as per BOQ item) suitable to
operate on 230 volts, 50 c/s AC supply system. Luminary shall be complete with T-5 tube/s,
electronic ballast/s, holder/s, etc. conforming to IS-15111.
2.6.2
The connections and earthing of the fitting shall be done with 1.5 sq. mm single core, PVC
insulated, multi stranded, flexible copper conductor cable/s of 1.1 kV grade with FR properties
as per IS: 694/1990.
2.6.3
The fitting shall be fixed to the wall by suitable approved arrangement. The fitting, if required
to be suspended from the roof, shall be suspended with 2 numbers of 19.0 mm diameter 16
SWG MS conduit pipes ( conforming to relevant latest IS) with ball and socket arrangements,
double check nuts to hold the luminary in position, non-metallic bushing at cable entry to
prevent damage to the flexible cable. The other end of the conduit tubes shall be fitted with
the luminary.
2.6.4
Where false ceiling is being provided, the luminaries shall be recess type with mirror optic
reflector and LED / CFL / T5 lamps with complete fittings of 1 feet/ 2feet/ 4 feet length as
approved by engineer.
2.7
2.7.1
Street Light Type T-5 Energy Efficient Luminary with T-5 Fl. Tube Light/s
Weather proof, street light luminary shall be of aluminium housing with epoxy white powder
coated CRCA sheet steel tray, clear acrylic cover, pre-wired, outdoor type with degree of
protection not less than IP-54. It shall be provided with T-5 tubes and electronic ballast (as
per BOQ item) suitable to operate on 230 volt 50 c/s, AC supply system. The luminary shall
also be provided with holder/s, etc. as required and shall conform to the latest version of the
relevant BIS specification.
2.7.2 The connections of the fitting shall be done with 1.5 sq. mm single core PVC insulated, multi
stranded, flexible copper conductor cable/s of 1.1 kV grade, with FR properties as per IS:
694/1990.
2.7.3 The earthing to the fitting shall be done with 1.5 sq mm single core PVC copper conductor
cable of 1.1 kV grade, flame retardant as per IS: 694/1990.
2.7.4
The luminary shall be mounted on the pipe bracket of pole/wall and connection to luminary
shall be done from junction box of pole/over head line/ ceiling rose of point wiring etc., as the
case may be.
2.7.5
In case, the luminary is to be provided on a wall, 450/600 mm long shaped G.I. pipe bracket
of class ”B” ISI marked of diameter matching with the inlet hole of the luminary shall be
provided.
2.8
Street Light Metal Halide (MH) Luminary with Lamp
a) The metal halide luminary shall be single piece, deep drawn aluminium housing, POT
optics with toughened heat resistant glass cover. The lamp compartment shall consist of
electrochemically brightened and anodized aluminium reflector with center ribs for better
uniformity and high optical efficiency. It shall consist of stainless steel toggles for fixing
cover with housing. It shall have degree of protection not less than IP 54 for lamp and
gear compartments and conform to the relevant BIS specifications.
Dated 29.Jan 2015
Page 38 of 429
b)
RVNL
The metal halide luminary shall be suitable for operation on 230 volt AC, single phase, 50
Hz supply and complete with all accessories, toughened heat resistance glass including
copper wound polyester ballast, power factor improvement capacitor, electronic ignitor,
terminal block, lamp holder and metal halide lamp etc (as per BOQ item).
2.9
Low Bay Metal Halide (MH) Luminary with Lamp
The housing of the luminary shall be fabricated from CRCA MS sheet and finished in white
stove enamel both from outside and inside with scientifically designed aluminium reflector.
The control gear compartment shall house a removable gear tray prewired with a copper
wound polyester ballast, power factor improvement capacitor and mains connector. The
housing shall be fitted with a toughened heat resistant clear glass cover. It shall be suitable
for operation on 230 volt AC, single phase, 50 Hz and shall be complete with metal halide
lamp etc.
2.10
High Bay Metal Halide (MH) Luminary with Lamp
The housing of the luminary shall be of cast aluminium, LM6 with spherical control gear
housing, finished in stove enamel gray and shall be provided with a spun aluminium reflector.
The control gear housing shall be prewired with replaceable copper wound VPIT ballast, power
factor improvement capacitor etc. mounted on a serviceable gear tray for ease of
maintenance. For suspension, an eye bolt shall be provided on capsule cover with antiloosening arrangement with a rubber bushing to damp vibrations. The luminary shall be
suitable for operation on 230 volt AC, single phase, 50 Hz and shall be complete with Metal
Halide lamp etc. Reflector shall be electrochemically brightened and anodized for longevity
and high photometric performance.
2.11 LIGHTING on PLATFORMS:
2.11.1 All the luminaries having light spread more than 75 degree angle from vertically down outside
COP shall be provided with additional 1.2 mm Stainless / 2 mm thick Anodised Aluminium
reflector outside covering luminare with top surface painted black as per approved design.
2.11.2 The orientation of luminaries outside COP shall be perpendicular to track whereas the
luminaries inside COP shall be parallel to track to avoid bright glare to loco pilots of
approaching trains.
2.12 LED type luminaires:
The LED luminaires with lamp should generally be in line with the RDSO draft Specification No.
RDSO/PE/SPEC/PS/0123 (Rev’0’)-2009 enclosed separately. The luminaire should be suitably
fitted based on the type of LED fitting such as lamp type, recess type, street light type as per
details given for respective type fitting given above. The electrical connections etc also shall
be as per respective fitting details mentioned above.
2.13 Solar Photovoltaic LED based Street light system:
Refer detail specifications in relevant chaptor of this specification.
2.14
Geyser
a) Geyser (storage type water heater) shall be suitable to operate on 230 V AC, single
phase, 50 Hz supply. Geysor shall have copper/SS inner shell and fibre body outer shell.
Geyser orientation shall be of vertical / Horizontal type as per site requirement and shall
be of specified capacity (as per BOQ item) conforming to IS:2082, ISI marked of
approved make and star rated. It should be provided with inlet and outlet PVC (with steel
mesh) water connections. The geysers shall be provided with a suitable thermostat
control on which the range of temperature is indicated. The thermostat control shall have
an adjusting knob for setting the temperature of water to the desired level. The water
temperature indicator shall be available on geyser body. At the set temperature, the
thermostat shall cut off the power supply automatically. The geyser shall be provided
with an LED/ LCD lamp to indicate that the power supply is ON/ OFF. The body of the
geyser shall be provided with an earth connection to protect leakage of current.
Dated 29.Jan 2015
Page 39 of 429
RVNL
b) The geyser shall be mounted vertically /horizontally on the wall by providing rack bolts
embedded in the wall. The water connection shall be provided to the inlet port from the
nearest water pipe line in order to maintain water supply to the geyser continuously. The
outlet of the geyser shall be connected to water pipe line for drawing hot water.
c)
2.15
The geyser shall be provided with suitable length of 3 core flexible cord and power plug of
16 A. The power supply shall be through MCB provided in the SDB to protect the geyser
from overloads and short circuits.
Water Cooler
a) Water cooler conforming to IS-1475 (Part-I)/2001 shall be complete with hermetically
sealed type, suction cooled compressor (conforming to IS 10617/Part-I/2013), with
overload protection and and star rated and all connected standard fittings, accessories,
etc. It shall be suitable to operate on 230 volt AC, single phase, 50 Hz supply.
b)
Cooling capacity of water shall be 150 liter per hour or as specified in the relevant BOQ
item. The tank shall be manufactured from stainless steel of minimum 0.8 mm thickness.
The cabinet of the water cooler shall be made of stainless steel sheet not less than 1.0
mm thick. The front panel below the water outlet & drain pan shall be made of stainless
steel of 0.8 mm thickness. The bottom pedestal shall be made of thickness not less than
2.65 mm. Power factor of water cooler shall not be less than 0.85 at the rated capacity of
the cooler. The thermostat shall conform to IS 113338/1985 and the setting shall be
adjustable through rotary switch from 10 to 25 degree C which shall be marked suitably.
The thermostat control shall have an adjusting knob for setting the temperature of water
to the desired level. At the set temperature, the thermostat shall cut off power supply
automatically. The body of the water cooler shall be distinctly provided with an earth
connection to protect from leakage of current.
c)
The water cooler shall be provided with a suitable length of 3 core flexible cord and a
power plug of 16 A and earthing. The power supply shall be through MCB provided in the
SDB to protect the water cooler from overloads and short circuits.
d)
2.16
The water cooler shall be placed on brick masonry platform. The water connection to be
given shall be provided to the inlet port from the nearest water pipe line in order to
maintain water supply to the water cooler continuously.
e) Water cooler shall be provided with 5 KVA electronic auto voltage stabliser, suitable for
operation on single phase 160 to 260 volts input supply,with provision for time delay
start, voltmeter, instant start etc.
Meter Board
a) The meter Board shall be suitable to operate on 230/415 volts Ac, single / three phase,
50 Hz supply system (as per BOQ item) and complete with all equipments including
meter/s, MCB’s etc. (as per BOQ item).
b)
The meter Board shall be out door type, weather proof, fabricated with 1.6 mm CRCA
sheet & compartmentalized for accommodating each unit. It shall be flush mounting type
with degree of protection not less than IP-54. Each compartment shall have its own door
with insulated thumb screw. MCB compartment shall be suitable to accommodate each
MCB directly mounted on DIN channel in its own chamber. Meter compartment shall be
suitable to accommodate each energy meter in its own chamber and have provision of
concealed lock for sealing the individual compartment. Suitable provision shall be made
on the front of the door to record the meter reading by providing a glass window 6 mm
thick. The provision to be made for padlock/ seal. Meter and meter box should be
provided with anti temper single use seal with sr no. Provision of suitable glass/fiber
window shall be made for meter reading with out opening the meter board.
Dated 29.Jan 2015
Page 40 of 429
RVNL
c) The meter compartments shall be with vertical formation and cable alley shall be in the
centre of the meter Board. Bus bar compartment shall be on the lower side of
accommodate incoming cable for termination on incoming MCB. Outgoing MCB
compartment/s for each quarter shall be on upper side (on top).
d)
Connections from bus bars to meters and from meter to MCB shall be housed in flexible
MS/ PVC conduit through cable alley.
e)
The meter Board shall be provided with detachable gland plates on top & bottom with
knock outs and earthing terminal etc. as required. Bottom plate shall be provided with
cable gland for incoming cable. Suitable knock outs shall also be provided on upper
portion and on back side of MCB compartment to connect outgoing wiring/conduit.
f)
The bus bar chamber, incoming and each outgoing MCB chamber shall have double
doors. It shall be possible to operate the MCBs only after opening of the outer door.
g)
Neutral supply to be provided with link in the all distribution boards. No MCB or fuse
should be provided in the neutral circuit.
Meter board shall be manufactured to meet the requirement/s as per site conditions i.e. for
one/two/three/four unit blocks etc.
NOTE:
Prior to bulk manufacturing, one sample of each type of meter Board shall be got approved
from the Engineer.
2.17:
Air Circulators:
Air circulators shall be Heavy duty wall mounting, oscillating type fan 600 mm sweeps (24”)
complete with guard without regulator. Air-circulators should be supported on wall,
pillars/poles with suitable mounting arrangements like brackets, clamps and hardware as
approved by employer with all connected accessories viz. pipes, brackets, hook/clamps, bolts,
nuts, washers, split pins, rubber pads etc. The fan shall be electrically connected to 3 terminal
ceiling rose and from the ceiling rose to the Air Circulator by 3 core flexible copper cable run in
suitable size PVC flexible hose.
2.18
Evaporative Air Coolers:
Air coolers should be evaporative type fibre body conforming to IS 3315:1994 (Reaffirmed
2004) Edition 3.2 incorporating Amendt.Nos 1&2, ISI Marked, to operate on 230V, 1∅ 50Hz
AC supply, with all connected accessories viz. clamps, bolts, nuts, washers, rubber packing,
honeycomb cooling pads and full function remote. It should have arrangement for water level
indicator, low water alarm, air direction control in horizontal and vertical directions, indication
for power ON with independent switches for exhaust fan and pump. The fan shall have three
speed control viz low/medium and fast. Fan, filter pads, water pump etc. should conform to IS
3315:1994(Reaffirmed 2004) admt 1&2., The water pump shall conform to IS:
11951:1987(Reaffirmed 2007) with admt 1 to 4.
Depending on need, these can be room, window or tower type.
2.19
Window and Split Air Conditioners:
Window and split type AC shall conform to IS-1391 pt I/1992 (amdt 1,2) and IS-1391 ptII/1992 (Amdt-1) respectively and star rated, remote control suitable to operate on 230V 1∅
50Hz AC supply and includes all connected accessories viz. clamps, bolts, nuts, washers,
angulars, iron stand/frame, rubber packing, brackets, copper pipe etc. The AC shall be fitted
Dated 29.Jan 2015
Page 41 of 429
RVNL
with adequate length of copper pipe which should be covered with insulation of suitable
thickness. Suitable draw pipes should be provided for draining out condensate water in PVC
pipes or G.I / Plastic / Fibre trays as per site conditions and as per instructions of employer.
The AC shall be installed with suitable rated voltage stabilizer. The windows shall be properly
sealed with insulating material after installation of AC.
2.20
Cassette type Air Conditioner:
These ACs are designed to be installed on ceiling. They should operate on 230V 1∅ or 440V,
3∅ 50Hz AC supply depending on its rating. AC should be star rated, remote controlled with
suitable mounting arrangements on ceiling. The AC shall be fitted with adequate length of
copper pipe which should be covered with insulation of suitable thickness. Suitable draw pipes
should be provided for draining out condensate water in PVC pipes or G.I / Plastic / Fibre trays
as per site conditions and as per instructions of employer.
The AC shall be installed with suitable rated voltage stabilizer to protect it from voltage
fluctuations.
2.21
Package type Air Conditioner:
These ACs are designed to be installed inside room on the floor. The AC should be suitable to
work on 440V, 3∅ 50Hz AC supply and shall be suitably rated. AC should be star rated,
remote controlled. The AC shall be fitted with adequate length of copper pipe which should be
covered with insulation of suitable thickness. Suitable draw pipes should be provided for
draining out condensate water in PVC pipes or G.I / Plastic / Fibre trays as per site conditions
and as per instructions of employer. The package units may be air/water cooled type as
specified in BOQ.
2.22
AIR COOLING SYSTEMS
(a) The air-cooling system is provided in the waiting halls, station buildings, service buildings,
running rooms and rest houses etc.
(b) The air cooling system in Waiting Room and Lounge at stations shall conform to RDSO
Specification No. RDSO/2009/EM/SPEC/0001, (Rev.‘0’)Amdt-1.
(c) The air cooling system in other places like service buildings, running room and rest house
shall also generally conform to above RDSO Specification. Prior approval of RVNL should
be taken for any changes in the RDSO specification suiting to local requirement and
specific to the building.
2.23
ENERGY SAVERS:
The ENERGY SAVERS consists of Street light /High Mast controller complete with infrared
sensors, contactors and MCB, terminal board etc. for 25 KW load. Energy Pack, should be a
lighting control device for outdoor luminaries. It should optimize the switching ON/OFF cycle,
automatically, using Nature Switch having space grade infra red sensor, as per seasonal
variation of daylight. It should be suitable for automatic, group control of outdoor luminaries,
eliminating the need for any manual operation. Auto switch ‘ON’ of light at dusk Auto switch
‘OFF’ at dawn or after selected duration. No clock setting or clock tuning should be required.
It should have operating voltage range from 185 to 275 V. the enclosure shall be IP 54
protected.
2.23.1 Constructional Features
Dated 29.Jan 2015
Page 42 of 429
RVNL
Metallic/plastic molded housing to accommodate power contactor, overload protection devices,
terminal blocks, MCB for three phases etc. Front opening door shall be with clear transparent
window for sensing variation of daylight by the nature switch.
MS plates should be fixed to the housing for pole mounting. Front door shall be provided with
unique lock and key arrangement for safety.
2.23.2 Technical Specifications
Sr No Parameter
Details
1
Operating Voltage Range
185 - 275V AC, 50-60 Hz
2
Maximum Load
15KW (3 Phase)
3
Endurance at rated load
Minimum 5000 cycles
4
Operating Illuminance Levels
a) For Switching ON
<60 lux for
b) For Switching OFF
>10 lux for >30 sec (per Std Test procedure)**
5
Max. Device Power Consumption
1 Watt at 230V AC
6
Insulation Resistance
Minimum 5 Mega Ohms
7
Operating Temperature Range
-10 C to +60 C
8
Operating Humidity Range
Up to 95% RH at 40 C
9
Over Voltage trip levels
10
>30 sec (per Std.
A) Auto High Voltage Sense and Trip
Above 270V
B) Auto High Voltage Sense and Reset
Below 255V AC AC
Test Procedure)
Under Voltage trip levels
(a)Auto Low Voltage Sense and Trip
Below 150V AC
(b)Auto Low Voltage Sense and Reset
Above 165V AC
11
Selectable res. for switching off from dusk
4 Hrs to 8 Hrs with a resolution of half an hour
12
Override facility for continuous ‘ON’ and
continuous ‘OFF’ for maintenance
Yes
------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 43 of 429
Dated 29.Jan 2015
RVNL
Page 44 of 429
RVNL
Tech. Spec. No. RVNL/Elect/GS/03
OVERHEAD WORKS
&
STEEL/GI TUBULAR POLES
Dated 29.Jan 2015
Page 45 of 429
Dated 29.Jan 2015
RVNL
Page 46 of 429
RVNL
CHAPTER: A-3
OVERHEAD WORKS & STEEL/GI TUBULAR POLES
3.0
SCOPE
The scope covers overhead power lines, including stays and poles, MS cross arms (brackets),
ACSR conductors, insulators, earth wire (GI wire), guarding etc. All materials, fittings, etc,
used In the installation shall conform to relevant BIS specifications, wherever they exist. In
those cases, where there are no BIS specifications available, the items shall conform to
specifications approved by the Engineer.
3.1
Route of overhead Line
3.1.1 As far as possible, the route of distribution line as well as the location of stay sets shall
be decided taking into consideration the present and future requirements of other
agencies and utility services affected by it.
3.1.2 The route of distribution line shall generally follow the route of roads.
3.1.3 Poles for distribution lines may be located alongside the road on the road berm, a little
away from the road edge and drain.
3.1.4 Normally there shall be a pole located at road junction.
3.1.5 The route shall be so chosen as to avoid use of struts and continuous curve as far as
possible.
3.1.6 Junction of main road and service lane shall be preferred for location of pole to
facilitate street light of service lane as well.
3.1.7 Front of entrance to building shall be avoided for locating poles.
3.1.8 The clearances shall be in accordance with the Indian Electricity Rules. 1956.
3.1.9 Normally, no road crossing shall be done by overhead lines in Railway Area. Road
crossing by cable is given in chapter 4.
3.2
Spacing of Poles
Spacing shall be in accordance with Indian Electricity Rules 1956. Normally poles shall be
erected at distances as indicated below *:i
ii
iii
iv
For platform lighting
For street /Road lighting
For distribution line
For other location
20 meters
30 to 35 meters
35 meters
as decided by the Engineer and approved
employer
by
* Note:-These are general guidelines. However spacing of poles should be chosen judiciously
so as to ensure specified lux levels is achieved and lighting is uniform as per RB letter
no-2004/Elect(G)/109/1 dt 18/5/2007 for station area and as per the requirement of
the Division.
3.2.1 Where distribution line and street lighting fixtures are erected on the same support, the
span shall not normally exceed 40 m.
3.2.2
Spans shall be chosen such that in a residential area adequate street lighting is
provided as per IS and as approved by Railway/Employer.
3.3(a) Excavation and back filing for foundation
Dated 29.Jan 2015
Page 47 of 429
RVNL
3.3.1
General
3.3.1.1
3.3.1.2
3.3.1.3
The excavation work shall be taken up after the locations of poles/stays are decided.
Every care shall be taken to see that the pits are not oversized while digging.
Suitable caution signals/boards, red lights and other protective measures, as decided
by the Engineer, shall be provided near the pit to warn the pedestrians/vehicular
traffic till such time the pit is back filled and surface leveled.
3.3.1.4
The size of the pit shall be made as per approved drawing of the foundation OR as
specified in the standard tables given below. Wherever specific depth of foundation is
not specified, the depth of the pit shall be such that normally 1/6th of the length of
pole is buried in the ground as specified in IS: 2713.
3.3.1.5
The foundation pit shall be generally excavated in the direction of the lines.
3.3.1.6
All supports shall be correctly aligned before concreting or the back filling of the pit
with excavated earth.
3.3.1.7
The pit for support/stay/strut shall be filled up or concreted only in the presence of the
Engineer.
3.3 (b) Foundation
(i)
While erecting the poles on platforms and within station limit/area, the latest
schedules of dimensions (SOD) as per IRSOD-2004 with latest ammendments shall be
strictly followed.
(ii)
Foundation for erection of pole shall be constructed at the approved location. Drawing
of pole foundation shall be got approved from the Engineer prior to casting of
the foundation and erection. However, the responsibility of adequate design &
drawing shall rest with the contractor.
(iii)
After excavation of pit of suitable size, cement concrete bed of approx. 50mm
thickness, using cement concrete of M-10 grade shall be first provided at the bottom of
the pit. Square foundation shall be made with cement concrete of M-10 grade of size
given below:
(a)
For hot dip Galvanized Pole- as specified in the table of standard dimensions of
pole given below. The foundation shall be made up to 150mm above ground
level
(b)
For Steel/GI Tubular poles- as per approved drawing. If approved drawing is
not available, square foundation of such size where edge of foundation shall
not be less than 150mm from edge of the pole. The depth of the foundation
shall be 1/6th of the length of pole. Circular muffing of 150 mm thickness
around the mast shall be made for 300 mm height above ground and sloped at
the top.
(iv)
It shall be ensured that the GI/HDPE pipe/s for the cable/s entry is/are placed in
position. Muffing shall be plastered, finished and also cured.
(v)
After foundation work, the pit shall be filled with excavated earth. During back filling of
earth, ramming and watering shall be done.
Dated 29.Jan 2015
Page 48 of 429
RVNL
3.3 (c) ERECTION OF POLE:
(i)
The pole shall be erected in plumb and top of all the poles shall be at the same level to
maintain uniformity.
(ii)
The Hot Dip Galvanized poles shall be erected and bolted on casted foundation with a
set of four bolts.
3.4
Stays and Staying Arrangement
3.4.1 A stay shall consist of stay rod, anchor plate, bow tightener, thimbles, stay wire and
strain insulator. The entire stay assembly shall be galvanized. The stay wire shall be
hard drawn galvanized of 7/3.15 mm dia GI (as specified in the relevant BOQ item)
conforming to IS 2141-2000. The anchor plate shall be of galvanized MS and not less
than 30 cm x 30 cm x 8 mm thick and the size of stay rod shall be not less than 1.80
m (6 ft.) long and 19 mm dia.
3.4.2
The position of pit shall normally be such that the stay makes an angle within the
range of 45 degree to 60 degree with the ground. If the site conditions are such that
the angle as stated may not be possible, special stays such as foot stays, flying stays
or struts may be used.
3.4.3 The depth and size of the pit shall be suitable for the foundation of stay.
3.4.4 A stay shall be provided at all angle or terminal poles.
3.4.5 The stay rod shall be set in position in the excavation pit.
3.4.6 Stay rod shall be embedded in cement concrete of M-10 grade vertically with square
foundation 300 mm x 300 mm above the anchor plate lying over 15 cm thick cement
concrete base. The stay rod shall be bent only at the unthreaded portion such that the
stay wire and the bent portion of stay rod are in correct alignment. Care must be
taken to avoid sharp bend or danger to galvanization.
3.4.7
After concrete has set, back filling shall be done with excavated earth and ramming in
layers of 20 cm using water as required.
3.4.8
The surface of foundation above ground shall be finished and
3.4.9
The stay clamp shall be located near about the centre of gravity of the load of the
overhead conductors.
cured.
3.4.10 One end of stay wire shall be fixed to the bow tightener of the stay grip of the stay
rod and the other end to the stay clamp fixed to the pole. By means of well spliced
joint units, GI thimbles. A strain insulator shall be provided at a height of 3 meters
above ground level. For high voltage lines, however, the stays may be directly
anchored.
3.4.11 The stay wire shall also be connected and bonded properly to the continuous earth
wire.
3.4.12 Normally one stay shall be provided at angle pole.
3.4.13 Double stays shall be provided at all dead ends and at any other place as required by
the Engineer. In such cases, these shall, as far as possible, be set parallel to each
other at a distance of approx. 600 mm or as approved by the Engineer.
Dated 29.Jan 2015
Page 49 of 429
RVNL
3.4.14 If the stay rod cannot be erected in accordance with the above clauses due to
roadways or obstructions of buildings etc. bow stay, fly stay or strut whichever is
suitable to the location, shall be used.
3.5
Cross Arm (Bracket)
3.5.1 Cross arm shall be made of MS angle iron of size not less than 50 mm x 50 mm x 6
mm thick ( for LT overhead)/ MS channel iron of size not less than 75mm x 40 mm x
6.4 kgs per meter/100x50x6.4 mm for V-type cross arm ( for modification of power
line track crossings/HT lines) as specified in the BOQ item. The length of the cross arm
shall be suitable for accommodating the required number of insulators with the
spacing of the conductors being in accordance with the clearances required. A
minimum distance of 8 cm for LV/ MV lines and 10 cm for HT lines shall be left from
the centre of the extreme insulator pin hole to the end of the cross arm. The cross
arm shall be complete with clamp made of MS flat of size not less than 50mm x 6mm
with necessary bolts of 16 mm and nuts & washers. The cross arm shall have holes as
required to accommodate insulator pin etc.
3.5.2
The length of cross arm for carrying guard wire shall be such that the guard wire shall
always run not less than 30 cm beyond the outer most conductor of the configuration.
3.5.3 The cross arm and the pole clamp shall be treated with one coat of red oxide primer
before erection and finished with two coats of approved paint after erection along with
other hardware. Iron nuts and bolts shall be used for fixing of clamps.
3.5.4 The cross arms shall be clamped to the support properly, taking into consideration the
orientation of the lines.
3.6
Insulators
3.6.1 The porcelain insulator shall conform to IS 1445-1977 suitable for overhead power
lines below 1000 volts and IS 731-1971 for overhead power lines with a nominal
voltage greater than 1000 volts. The insulator shall be complete with galvanized iron
hardware etc. as required.
3.6.2
The insulators shall be of the following types as specified in the relevant BOQ item:
a)
b)
Pin and shackle insulator for LT & MV lines.
Pin and disc type for HV lines.
3.6.3 The minimum size of shackle insulator shall be 90 mm dia x 75 mm high and shall be
complete with GI clamps, nuts & bolts etc.
3.6.4 The minimum size of pin insulator shall be 65 mm dia x 100 mm high and complete
with GI pin, nuts and bolts etc.
3.6.5 Pin insulator/ shackle insulators/disc insulators shall be erected on the cross arms, as
specified in the BOQ or as directed by the Engineer.
3.6.6
3.7
Shackle insulators shall be erected on cross arms at intermediate support in case of
long lines, deviation from straight line, terminal positions, junction poles etc.
ACSR Conductors
3.7.1 All conductors shall conform to IS: 398/pt. II/1996. Conductors shall be strung with
permissible sag and the profile shall be got approved from the Engineer.
Dated 29.Jan 2015
Page 50 of 429
RVNL
3.7.2 Jumpers
3.7.2.1 Sufficient length of conductor shall be kept at shackle termination and Parallel Groove
(PG) clamp shall be used for making jumper connections.
3.7.2.2 Jumpers used shall be of the same material as the line conductor and be of adequate
current carrying capacity.
3.7.3
Binding of Conductors
3.7.3.1 The binding of conductor to insulator shall be sufficiently firm and tight to ensure
that no intermittent contacts develop.
3.7.3.2 The ends of binding wire shall be tightly twisted in a closely spaced spiral around the
conductor to ensure good electrical contact and to strengthen conductors.
3.7.4
3.7.5
Binding Material
The insulators shall be bound with the line conductors with the help of aluminum
binding wire or tape for ACSR/Aluminium conductors. The size of binding wire shall
not be less than 2 mm dia and it shall be of galvanized iron conductors for
galvanized conductors.
Guarding
3.7.5.1 General
At all road crossings, crossing of overhead lines, crossing with other lines ( telephone
lines etc) and between HV and LV/ MV lines carried on the same support, guard shall
be provided.
3.7.5.2 The guard wires shall be bonded to earth wire.
3.7.6
Earth Wire
3.7.6.1 The size of the continuous earth wire shall not be less than 8 SWG GI.
3.7.6.2 All metal supports and all reinforced and pre-stressed cement concrete supports of
overhead and metallic fittings attached there to shall be permanently and efficiently
earthed.
3.7.6.3
The continuous earth wire shall be connected to an earth. There shall be not less
than 3 connections with earth (earth electrode) per kilometer spaced equi-distantly,
as far as possible.
3.7.6.4 Where continuous earth wire cannot be provided, every pole shall be earthed and all
metal parts shall be bonded.
3.7.6.5 Junctions at terminal locations and all special structures shall be connected to earth.
3.7.6.6 The lead from earth electrode shall be suitably bonded to the continuous earth wire.
3.8
Danger Notice Plate and Anti- Climbing Devices
3.8.1
Danger Notice Plate
All supports carrying HV lives shall be fitted with danger notice plates conforming to
IS: 2551-1982 at suitable height from ground indicating the voltage of lines.
Dated 29.Jan 2015
Page 51 of 429
RVNL
3.8.2
Anti Climbing Devices.
For preventing unauthorized persons from ascending any of the supports carrying HV
lines without the aid of a ladder, arrangement for special appliances shall be made as
directed by the Engineer. Barbed wire conforming to IS 278-1978 having 4 point
barbs spaced 75+/-12 mm apart shall be wrapped helically with a pitch of 75 mm
around the limb of the support and tied firmly, commencing from a height of 3.5m
up to a height of 5 meters or as directed by the Engineer.
3.9
Steel/GI Tubular Poles
3.9.1
Steel/GI tubular poles shall be swaged type with single/double bracket/s for
platform/road/level crossing lighting etc. The constructional details shall be as per IS
2713/Pt 1 to 3. The length and designations shall be as per the relevant BOQ item.
The diameter of bracket for mounting of luminary shall match with the inlet diameter
of the luminary. In case of GI pole, the pole with base plate along with the bracket
shall be hot dip Galvanized 80 to 90 microns thickness after the frabrication, as per
I.S 2629. The pole shall be with single/double arm bracket of length 1.0mtr and with
base plate complete. Dimensions of the pole shall be as per IS, reproduced in table
given at 3.9.4. Foundation bolts and base plate sizes shall be:
Base plate of size 300 X 300 X 16 mm
Foundation Bolts: 700x20mm- 4 Nos. with double nut, washer & template.
3.9.2
General
(a) The uncovered platform/road etc. shall be provided with swaged type stee/GI
tubular pole/s and the luminary shall be weather proof, outdoor type as specified in
the relevant BOQ item. Luminary shall be complete with control gear, lamps,
accessories, fixing arrangements etc. The make and type of luminary & lamp shall be
as specified in the BOQ item.
(b) Single core FR, PVC insulated copper conductor cable ( 2 x 1.5 sq mm size for
connections to each luminary and 1 x 1.5 sq.mm for earthing), multi stranded,
conforming to IS 694 (latest), ISI marked shall be supplied and provided for
connections from junction box/overhead/light point as the case may be. Each
luminary and junction box shall be suitably earthed.
(c)
Separate wiring shall be provided for each luminary from junction box.
3.9.3
Steel Tubular pole with Canopy Type Single/Double Bracket/s (7 m for
platform lighting and 9m for Level Crossing/ circulating area
Lighting/Road lighting etc)
3.9.3.1
(a) Steel tubular pole shall be swaged type made from steel of ultimate tensile
strength 410 MPa (42 kg/mm. sq) as per IS: 2713(Pt. I,II and III) 1980 amended
up to date. The pole shall be as per IS designation 410 SP-3 for 7 meter and 410
SP-30 for 9 meter length. The portion to be inserted in the ground shall be about
1/6th of total length as per IS: 2713. Pole shall be supplied with canopy type
brackets, base plate etc. A hole of 25 mm dia and a rubber bush at required height
from the bottom of the pole shall be provided in the lower limb (above the muffing)
for drawing/taking the PVC wire from junction box to inside the pole for the
Dated 29.Jan 2015
Page 52 of 429
RVNL
connection of luminary. Each pole shall be provided with 16 mm dia GI earth
terminals of suitable length for earth connection.
(b) MS square base plate of size 300 x 300 mm and 10 mm thick shall be welded at
the bottom of the pole. The base plate shall have a hole of dia. Approx. 50 mm in
the centre, for draining out of water.
(c) Hot dip galvanised double arm Conicle poles with foundation bolts, base plate and
bracket can also be used in above place. The pole with base plate along with the
bracket shall be hot dip Galvanized 80 to 90 microns thickness after the fabrication,
as per I.S 2629.
3.9.3.2
Bracket
Bracket for accommodating of luminaries shall be canopy type with single/double
G.I. pipe class ”B” 200 mm long (ISI marked), welded at an angle of 15 degree (
horizontal plane). Bracket shall be removable type and adjustable in horizontal
plane. Fixing arrangement with pole shall be with 4 nos. bolts & nuts of dia not less
than 10 mm. Fixing Arrangements shall be suitable to bear the wind pressure. The
dia. Of the bracket pipe shall match with the inlet hole of proposed luminary to be
provided on the pole.
Note:
The drawing of canopy with pipe bracket/s, fixing arrangement and
sample shall be separately got approved from the Engineer.
3.9.3.3
Junction Box
(a) Pole Mounting Type Ms Junction Box of size 300 x 200 x 125 mm deep, shall
be double doors, outdoor type, weather proof with degree of protection no less
than IP54 and conforming to IS:8623 & IS:13032, suitable for operation on
single phase, 230 Volts Ac, 50 Hz supply system. The Junction Board shall be
manufactured with CRCA sheet steel 1.6 mm thick, duly powder coated and
complete with 4 nos. copper bus bars of rating 100 amp (for cable
terminations/ loop-out system ) for looping 4 core 3 nos. LT cables, one no. 16
6 amp 10 kA, SP MCB, earthing studs etc. Outer door shall be hinged on top in
vertical formation, with provision of holding arrangement horizontally. The
front cover of the junction box shall be provided with a lock which can be
opened with a special key.
(b) The junction box shall be earthed as instructed by the Engineer. Junction box
shall be mounted with pole with 2 nos. galvanized Ms flat 40 x 5 mm clamps
and Nut and bolts not less than 10 mm dia.
(c) Detachable gland plate shall be provided on the bottom of the junction box for
entry of incoming and outgoing cables.
(d) The junction box shall be fixed with the pole at a suitable height above ground
level as per instruction of the Engineer.
(e) Holes shall be suitably protected with rubber bushes to prevent entry of rain
water inside the pole.
3.9.3.4
Earthing
Earth electrode shall be provided at approved location as per IE rules. Pole/s shall
be earthed to an earth electrode with 4 mm dia. G. I. Wire/armouring of laid cable
as required.
Dated 29.Jan 2015
Page 53 of 429
RVNL
3.9.3.5
Painting
Steel Poles shall be given 2 coats of red oxide primer and after erection painted as
under:
3.9.3.5.1 The bottom portion of poles up to a height of 1.5 m above the finished muffs shall
be painted with superior quality of black ISI marked paint.
3.9.3.5.2 The remaining portion of poles as well as the clamps shall be painted with 2 coats
of superior quality of Aluminium Paint (ISI marked).
3.9.4
SN
Table below indicates dimensions of swaged type steel tubular pole as per
IS2713/Pt 1 to 3:
Designation
Overall
length
(m)
Length
(m)
of
L
Bott
om
Middl
e
Sections
Outside
diameter
&
thickness of sections(mm)
Top
Plantin
g
depth
(m)
D
Bottom
1
410-SP3(Wt.85 Kg
7.00
4.00
1.50
1.50
1.25
114.3
5.4
2
410-SP-30
(Wt.133 Kg)
9.00
5.00
2.00
2.00
1.50
139.7
x5.4
3.10
3.10.1
x
Middle
Top
88.9
x4.85
76.10
x3.25
114.3
x4.5
88.90x
3.25
HOT DIP GALVANIZED OCTAGONAL POLE
GENERAL:
Octagonal Pole shall be manufactured in single section. Manufacturer shall be ISO:
9001/2000 & ISO: 14001 certified. Drawing of pole and bracket/s shall be got
approved from the RVNL.
3.10.2
DESIGN:
The structure shall confirm to IS: 875-part 3: 1987(latest version) relating to wind load on
structures. Pole shall be designed for wind speed 169Km/hr.
The grade of steel used shall be as per BSEN-10025grade S-355JO. or equivalent standards.
Yield strength shall be minimum 355N/mm. sq and tensile strength 490-630N/mm.sq.
3.10.3
POLE SHAFT:
The pole shaft shall have octagonal cross section & shall be continuously tapered with single
longitudinal welding. There shall not be any circumferential welding. The welding of pole shaft
shall be done by submerged are welding process. The base plate shall be fixed by welding to
the pole shall at two locations i.e. from inside and outside.
Bending of the sheet into polygonal shape shall be done through a CNC controlled. Laser
aligned will be as per IS : 1367.
3.10.4
DOOR OPENING:
The octagonal pole shall have door of aproximate 500mm length at the elevation of 500mm
from the base plate. The door shall be weather proof to ensure safety to inside connections.
The door shall be flush with locking facility. There shall also be suitable arrangements for
earthing. The pole shall be additionally reinforced with a welded steel section so that the
section at door is unaffected and undue bucking of the cut section is prevented.
The base compartment of the built in connector control box shall have provision to have 6
mm thick Bakelite sheet of suitable size to accommodate the required electrical accessories
Dated 29.Jan 2015
Page 54 of 429
RVNL
with compression gland for termination of incoming & out going supply cables. The connector
box shall be provided with 2 Nos. 32 Amp heavy duty connectors (3way) for loop in and loop
out of cables, 6 Amp C-Series DP MCB for individual fitting with din channel, earth stud and
other required accessories.
3.10.5
GALVANIZING:
Internal and external surface of the octagonal pole shall be single dip, hot galvanized as per
IS: 2629 / IS: 2633 / IS: 4759 standards with minimum coating thickness of 65 microns.
3.10.6
BASE PLATE:
Material of base plate shall be Fe 410 conforming to IS: 226/IS: 2062
3.10.7
Standard Dimensions of pole shall be as under:STANDARD DIMENSIONS OF Hot Dip Galvanized POLE
Height
(Meter)
Top Dia Bottom Sheet
Base Plate
(mm)
Dia (A/F) Thicknes Dimensions
s (A/F) (LxBxT)
(mm)
(mm)
5.00
70
130
3
200X200X1
2
FOUNDATION BOLT
Bolt
Size
(no.xdi
a)
(mm)
4X1
6
Pitch
Circle
Dia.
(mm)
Bolt
Lengt
h
(mm)
200 600
Anchor
Foundati
Plate
on
Project
Thicknes
ed
s
Length
(mm) (mm)
80
3
500x500
x1000
(depth)
7.00
70
130
3
220X220X1
2
4X2
0
205 700
100
3
500x50
0x1250
(depth)
3.10.8
BRACKETS:
Bracket for accommodating of luminaries shall be canopy type with Galvanized single /
double arm 200mm long to suit the inlet dia of luminary as per requirement of BOQ, welded
at an angle of 15 degree (horizontal plane). Bracket shall be removable type and adjustable
in horizontal plane. Fixing arrangement with pole shall be with 4 nos. bolts & nuts of dia not
less than 10 mm. Fixing arrangements shall be suitable to bear the wind pressure. The dia. of
the bracket pipe shall match with the inlet hole of proposed luminary to be provided on the
pole.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 55 of 429
Dated 29.Jan 2015
RVNL
Page 56 of 429
RVNL
Tech. Spec. No. –RVNL/Elect/GS/04
CABLE LAYING
Dated 29.Jan 2015
Page 57 of 429
Dated 29.Jan 2015
RVNL
Page 58 of 429
RVNL
CHAPTER:A-4
CABLE LAYING
4.0
General
(a) LT XLPE cables shall be of 1/2/3/3.5/4 core/s (as specified in the relevant BOQ Item).
With aluminium conductor, armoured/unarmoured (as specified in the relevant BOQ
item). PVC outer sheathed, conforming to IS: 7098 Pt.1(ISI Marked).
(b) HT XLPE (earthed) cable shall be of 3 core, aluminum conductor, screened, armoured
shielded and PVC sheathed, conforming to IS: 7098/Pt 2 (latest version)(ISI Marked).
(c) IS 1255-1983 shall be followed in general for laying of cables.
4.1
The minimum safe bending radius for all types of cables shall be at least 15 times the
diameter of the cable up to 11 kV grade and 20 times the diameter for cables above 11 KV
grade.
4.2
Route
The route of the cable shall be decided before the work of cable laying is undertaken. The
drawing indicating the route of the cable shall be prepared by the contractor and got
approved from the Engineer. Cable runs/routes shall generally follow the fixed development
such as roads, pathways, track etc.
4.3
Cables of different voltage grading shall be generally laid in different trenches. In case it is
not possible to lay them in separate trenches, due to site constraint, the same trench may
be used, but adequate separation within the trench shall be ensured. Specific approval shall
be obtained from the Engineer.
4.4
There shall be adequate distance between HT & LT cables. In case it is unavoidable to
separate HT &LT cables, the high tension Ht cable shall be laid below LT cable.
4.5
Wherever the power and telecom cables are to cross each other the same shall be laid at
right angles to avoid interference. Wherever it is unavoidable to lay them in proximity,
horizontal and vertical clearance between the two shall not normally be less than 600 mm
4.6
Laying of Cable
The cable shall be laid in ground, in pipes, under road/railway track, recess in wall/on
surface/clamping with erected pole etc. depending upon the requirement and site conditions.
4.6.1
Laying in Ground
The cable shall be laid in ground, wherever it is passing through open country/along
road/lanes etc.
4.6.2
Laying of Cables under road/ Railway track/Bridge etc.
a) Wherever the cable is to cross road/railway track/ Bridge, Nalla etc. the cable shall be
laid through suitable size of pipes as per instructions of the Engineer.
b) GI/CI/RCC/HDPE pipe etc as specified in the BOQ item shall be used for the purpose.
Pipes shall be continuous with couplers etc. and clear of any debris. Before drawing of
cables, sharp edges at ends shall be smoothened to prevent injury to cable insulation
and/or sheathing.
Dated 29.Jan 2015
Page 59 of 429
RVNL
c)
All the road crossings to be done by UG cables with spare cable provision. One spare
duct with same size dia HDPE/GI/CI/RCC pipe also to be made along with crossing for
future use.
4.6.3
Laying of Cables under Passage/Wall etc.
Passage/wall used for the laying of cables, shall be cut as required and repaired to match
with the original finish. In case cable is being laid on the wall, cable should be well supported
by J clamp/hooks.
4.6.4
Erection along Erected Pole
For erection of cable along the pole, the cable shall be held vertically with protective G. I.
pipe. The diameter of the pipe shall be adequate for the cable size and length of pipe shall be
3 meters. Cable & G. I. pipe shall be clamped with the erected pole with 40 x 6 mm Ms flat
clamps, not more than 2m apart. End of the pipe should be sealed with suitable putty to avoid
entry of moisture and rodents.
4.6.5
Width of Trench
(a) The width of cable trench shall be approx. 350 mm. Wherever one additional cable is laid
in the same trench in horizontal formation, the width shall be increased such that inter
axial distance between the cables shall be at least 200 mm. There shall be clearance of
150mm between the end cables and sides of the trench.
(b) In addition to the protective cover over the cables laid in the underground trench, a brick
on edge shall be laid in between the two juxtaposed cables along the direction of lay of
the cables for providing separation.
(c) Minimum width of cable trench for laying of LT/ HT cable at various locations shall be as
indicated here under:
Location
Under-ground
On platform
Under Railway
Track/road
In wall/floor
Other
above
than
Location
Under-ground
On platform
Under Railway
Track/road
Other
than
above
Width of Trench for LT Cables
Width of cable trench
Width of cable trench for one additional
cable
Width
Remarks
350mm approx.
550 mm approx.
Additional
bricks
on
edge shall be laid in
350 mm approx.
550 mm approx.
between
the
two
juxtaposed cables.
350 mm approx.
-Through pipe
To be recessed as per
instructions of the Engineer
As per instructions of the
Engineer
-
-
As per instructions of
the Engineer
As per instructions of
the Engineer
Width of Trench for HT Cables.
Width of cable trench
Remarks
Additional cable not permitted in trench
350mm approx.
350 mm approx.
Through pipe.
With trenchless method/or digging method as
decided by engineer
As per instructions of the As per instructions of the Engineer
Engineer
Dated 29.Jan 2015
Page 60 of 429
RVNL
4.6.6
Depth of Trench
Normally cables shall be laid in single tier formation and the minimum depth of top of laid
cable/pipe at various locations from the ground surface/bottom of sleeper shall not be less
than as indicated here under:
Location
Under road
Under-ground
On platform
Under Railway Track
In wall/floor
Other than above
Location
Under-ground
Under road
Under Railway Track
Other than above
Dated 29.Jan 2015
Depth of Trench for LT Cable
Minimum Depth of top of laid cable/pipe from
the ground surface/bottom of sleeper
1000 mm from ground surface
750 mm from platform level
Not less than 1200 mm from bottom of laid sleeper at
locations where ground & track formation are in
same level (with manual digging)
Not less than 3000 mm from ground level at
locations where track formation level is above
ground surface. ( with trenchless method)
Not less than 1200 mm (with manual digging) and
3000 mm ( with trenchless method) from bottom of
laid sleeper at locations where ground & track
formation are in same level.
3000 mm (with trenchless method from ground level
at locations where track formation level is above
ground surface.
To be recessed
As per instructions of the Engineer
Remarks
Cables to be laid
in
single
tier
formation
--do---do-New Lines
Locations
other
than New Lines
(as approved by
Engineer)
---do----do--
Depth of Trench for HT Cable (above than 440 V)
Minimum Depth of top of laid cable/pipe Remarks
from the ground surface/bottom of sleeper
Cables to be laid
in
single
tier
formation
--do-Not less than 1200 mm from bottom of laid New Lines
sleeper at locations where ground & track
formation are in same level (with manual
digging)
Not less than 3000 mm from ground level at
locations where track formation level is above
ground surface. (with trenchless method)
Not less than 1200 mm (with manual digging) and Locations
other
3000 mm (with trenchless method) from bottom than New Lines
of laid sleeper at locations where ground & (as approved by
track formation are in same level.
Employer)
3000 mm (with trenchless method from ground
level at locations where track formation level
is above ground surface.
As per instructions of the Engineer
--do--
Page 61 of 429
RVNL
4.6.7
Excavation of Trench
a) To the extent possible, the trenches shall be excavated in straight lines. Wherever a change in
line is required, due to site conditions, suitable curvature shall be provided. As far as possible,
mechanical means shall be employed for undertaking excavation. Manual excavation method
shall be used if adequate working area is not available. The soil shall be stacked on the side of
the trench in such a manner that it does not fall back into the trench.
b) Due care shall be taken to avoid damage to any existing cables, pipes or other such
installations in the proposed route during execution. While excavating, if route markers,
bricks, tiles, bare or protective covers are encountered, further excavation shall not be carried
out without the approval of Engineer.
c)
4.6.8
In case existing property gets exposed during trenching, the same shall be temporarily
supported or propped adequately as directed by the Engineer. The trenching in such case shall
be limited to short lengths. Protective pipes shall be laid for passing the existing cables
therein, and the trench shall be refilled, in case there is a danger of collapse, or the trench is
endangering existing structure the same shall be sufficiently supported before proceeding with
the excavation work. The bottom of the trench shall be level, free from brick bats and gravel
etc.
Laying of Cable
Before and after the cable is laid, the individual cores shall be tested for continuity and
insulation resistance and ends of cables shall be sealed suitably to avoid ingress of moisture.
Surplus length of approx. 3.0 meters shall be left in the shape of a loop at each
termination/joint etc. unless otherwise approved by Engineer.
4.6.9
Protection and Sand Cushioning
a)
The cable shall be protected to provide warning to future excavators and also for avoiding any
accidental mechanical damage by pickaxe blows etc.
b)
The cable shall be protected with well-burnt bricks. The bricks on face shall be so provided
that the width of the brick is in the direction of lay of cable. The bricks shall be provided
throughout the length of the cable to the satisfaction of Engineer. Wherever more than one
cable is laid I n the same trench, the protection cover for cable shall protect at least 50 mm
on the side of end cables.
c)
Protective covering, sand cushioning of LT/ HT Cable & making good surface at various
locations shall be as indicated here under:
Location
Underground
Protection and Sand Cushioning
Protective Covering
2nd
class Bricks 225 x
100x60 mm (nominal size)
width wise on top
On platform
Under Road
Under Rly Track
In wall/floor
Other than above
Dated 29.Jan 2015
-do-Through laid pipe
--do-Plastering
As per instructions of the
Engineer
for LT Cable
Sand cushioning
Base cushion 80 mm
under cable & 100 mm
above laid cable
-do----do---do---do-As per instructions of the
Engineer
Surface
Making
good
damages
and
finishing
as
per
original
--do---do---do---do-As per instructions of
the Engineer
Page 62 of 429
RVNL
Protection and Sand Cushioning for HT Cable
Location
Underground
Protective Covering
2nd class Bricks 225x 100x60 mm
(nominal size) width wise on top &
length wise on both sides
Sand cushioning
Base cushion 80 mm
under cable & 100 mm
above laid cable
Under Road
Under Rly Track
Other than above
Through RCC/HDPE/GI pipe
--do-As per instructions of the Engineer
---do----do-As per instructions of
the Engineer
Surface
Making
good
damages
and
finishing as per
original
--do---do---do--
4.6.10 Back Filling of Trench
a) After excavation and laying of cables, the trench shall be back filled with the excavated earth,
free from stone or other sharp-edge debris and shall be watered if necessary. A 100 mm
crown of earth shall be left in the center, tapering towards the sides of the trench to allow for
subsidence. The trench shall be inspected at regular intervals particularly during wet weather
and any settlement of soil shall be made good by the contractor by further filling, if required.
b) Due to cable laying work, if any disturbance to existing equipments in the area, like roads,
pavements and garden takes place, the same shall be made good to original standard /finish
after the cable laying work is over.
4.6.11
4.6.11.1
Cable Route Marker and Joint Indication Marker
Route markers shall be provided along straight runs of the cables at locations approved by
the Engineer and generally at intervals not exceeding 50 meters. Wherever the cable route
is changing or it is entering a fixed installation, route marker must be provided. Route
markers shall be properly grouted in concrete or laid along with the cable securily to avoid
theft as per directions of the engineer.
4.6.11.2
Joint indication marker shall also be provided at joints of cable.
4.6.11.3 The word cables, the level of voltage, size of cable, depth shall be inscribed on the route
marker and joints.
4.6.12
Normally no joints are permitted. Under the circumstances, if joints can not be avoided,
specific approval shall be obtained from the Engineer.
4.6.13
Cable Testing
All cable shall be tested jointly at site by the contractor with the engineer, before laying, to
ensure that the insulation values of the cable are within limits. The insulation test on the
cable shall be conducted with 500 V megger up to and including 1.1 kV grade and with
5000 V megger for cables of higher voltage. The cable cores shall be tested for continuity,
insulation resistance etc. All cables shall be again tested after laying and before covering.
4.7
GI Cable trays:
GI Trays of size of suitable size as per BOQ may be used for neatly laying cables where it is not
feasible to make them underground.
4.7.1 DESIGN REQUIREMENTS:
The hot dip galvanized steel perforated cable trays having rectangular channel section
with
appropriate depth shall be designed for a uniform load of at least 400N per 1000 mm ladder
length tray. The trays shall be fabricated in a length of 2.5 m to 3m.
The perforated cable trays shall be manufactured from good commercial, high grade strength
sheet steel having minimum thickness of 2mm and shall be hot dip galvanized according to IS2629 and IS-4759 suitable for indoor/out door use having moderate humidity and air pollution.
Dated 29.Jan 2015
Page 63 of 429
RVNL
The zinc coating thickness shall works out by applying a 610 gm of zinc per square meter
surface with approximate thickness of 80 micron. The zinc coating shall be smooth, clean and
uniform thickness and free from defects like ash and dross inclusions, bare patches, black
spots, pimples, lumpiness, rust stains, blisters etc. The galvanizing shall not adversely affect
the mechanical properties of the coated materials; the quality of the coating will be established
by tests as per IS-2633. All manufacturing process including punching, cutting, bending and
welding of perforated cable trays shall be completed and burrs shall be removed before the
application of galvanization process is applied. Zinc conforming to at least Grade Zn 98 as
specified in IS-209-1966 shall be used for the purpose of galvanizing.
The joints of two trays shall be butt construction and shall be made with the help of
coupler plates by nuts and bolts. The coupler plate and nuts and bolts shall also be properly
hot dip galvanized, where the bends of the trays are required at site the same shall be supplied
by the bidder without any extra cost.
While adopting the modules at site if cutting of any length is required the same shall
be cut at site and joined by nuts and bolts with the help of coupler plates.
The perforated cable trays shall be supported on the solid supporting arrangement
made from channel of minimum size 100x50mm and angle iron of size 50x50x6mm thick angle
approximately at a distance of 0.1 to 1.2m center to center either from ground/wall or ceiling.
However, the supporting system shall be designed by bidder suitable to bear the uniform load
of 400N per 1000mm ladder length for 300mm wide tray. The calculations in respect of this
design shall be supplied by the successful bidder during design stage. M.S. angle iron brackets
shall be further supported/anchored either to wall or ceiling/ground as per the site
requirement. The brackets and supporting system shall be painted with two coats of zinc
chromate primer followed by two coats of synthetic enamel paint of approved colour
conforming to relevant Indian standard.
Bends, tees and cross connections shall also be designed properly as per site
requirement.
The free vertical distance between parallel perforated trays/racks/ladder shall be at
least 250mm and the perforated trays shall be 50mm away from the walls. The trays shall be
fixed to the brackets with proper nuts and bolts system.
The perforated trays shall be free from sharp edges and burns etc. so that joint
between two trays shall be without any clearance and matched in proper shape.
At the bends the curvature in all axis of perforated trays/racks shall be 20R or
maximum size of cable. The supporting brackets/fixing bolts size shall be so calculated that the
design load as specified in Design Requirements does not exceed. The perforated trays shall be
installed in such a way that as far as possible the cables can be laid directly in place rather
than be pulled through.
The current carrying cables as HT cables, LT cables; and DC cables shall be laid in
different tray. The cables shall be fixed in the perforated trays by means of plastic ties or
plastic coated wires etc.
The number of perforated tray shall be sufficient in order to accommodate all the
power cables indicated in the specification for cables. However, the approximate quantity of
different trays have been given under clause 2.21, which can be ensured by the bidder by
visiting the site before filling the tender.
4.7.2
EARTHING:
The perforated cable trays along with their supporting arrangements shall be properly earthed
by the contractor with nut and bolts from the earthing risers generally in the vicinity of the tray
routing. The earthing shall be as per latest I.E. rules and IS/IEC recommendation. The size of
Dated 29.Jan 2015
Page 64 of 429
RVNL
earth connection shall be such that its conductance should be more than the conductance of 14
sq. mm. Copper conductor.
4.7.3
FABRICATION OF TRAYS
All fabrication of trays shall be in accordance with IS: 800 and as per the approved drawings
unless otherwise specified.
The trays should have min 2mm thickness with all connected accessories viz. vertical
bends, reducers, tees, cross members etc. as required according to the site conditions
including painting besides clamping firmly to support the tray with MS angular legs fabricated
with 40x40x6mm angular of 1 1/2' length, fixed in CC bed blocks (including casting) for
holding the angular, on the RCC / Cover Over Platforms including painting etc. The trays
should be fixed with suitable Clamps/ GI angles/ GI flats and with necessary connected
hardware to the Trusses or Columns. The running/ arranging of the cables in these trays
should be done by duly clamping at regular intervals and undertaking numbering by sticker to
the cables for easy identification.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 65 of 429
Dated 29.Jan 2015
RVNL
Page 66 of 429
RVNL
Tech. Spec. No: RVNL/ Elect/GS/05
HIGH MAST LIGHTING
SYSTEM
Dated 29.Jan 2015
Page 67 of 429
Dated 29.Jan 2015
RVNL
Page 68 of 429
RVNL
CHAPTER: A-5
HIGH MAST LIGHTING SYSTEM
5.0
Scope
The scope covers supply and erection of the high mast lighting system of specified height
including foundation and other civil works. High Mast System includes all components and
accessories, foundation bolts with nuts, washers, anchor plates, templates, Metal Halide
luminaries (degree of protection IP65), etc. and provision of luminaries on the head frame of
high mast with manual/electrical operation arrangements to lower/raise for maintenance
purposes.
5.1
Codes and Standards
Design, manufacture and performance of the High Mast lighting system shall comply with all
currently applicable statutory regulations and safety codes and standards in the locality where
the equipment is being installed and generally in accordance with the following standards for
the loading of the High Mast.
S. No.
1
2.
3.
4.
5.
6.
CODE
IS 875 (Part III) 1987
BSEN 10025/DIN 17100
BS5135/AWS
BS ISO 1461
TR. No. 7 1996 of ILE UK
BS 5135/AWS
TITLE
Code of practice for design loads for structures
Grades of MS plates
Welding
Galvanizing
Specification for masts foundations
Longitudinal weld
5.2
Structure
The High mast shall be of continuously tapered, polygonal cross section, presenting an
standards to give assured performance and reliable service. The structure shall be suitable for
wind loading as per IS 875 Part III of 1987.
5.3
General Constructional Features
The mast shaft shall be made of best steel grade in compliance with BS-EN 10025/DIN 17100
or equivalent, cut and folded to form a polygonal section and shall be telescopically jointed and
welded. The welding shall be in accordance with BS 5135/AWS. The top section shall have a
flange plate bolted to the head frame. The mast shall be fabricated and butt welded
longitudinally to form a tapered section with telescopic friction slip joints. The procedural weld
geometry and workmanship shall be exclusively tested on the completed welds. Mast shall be
delivered at site in multiple sections. Each section shall be hot dip galvanized (single dip) inside
and outside, having uniform coating thickness of 85/65 microns for bottom/top sections
respectively. At site the sections shall be jointed together by slip- stressed-fit method. No site
welding or bolted joint shall be done on the mast.
5.4
The mast shall have fully penetrated flange, which shall be free from any lamination or
incursion. The base plate shall be of single flange and constructed with holes jig- drilled for
anchor bolts passage for fixing the high mast on to the concrete foundation. The base flange
will be provided with supplementary gussets between the bolt holes to ensure elimination of
helical stress concentration of the environmental protection of the mast. The entire fabricated
mast shall be hot dip galvanized, internally and externally, having a uniform thickness of 70
microns for the bottom section and 65 microns for the top section.
Dated 29.Jan 2015
Page 69 of 429
RVNL
5.5
The welded connection of the base plate to the mast section shall fully develop the strength of
the section. Ultrasonic testing procedure shall be considered as the minimum permissible
testing method. The wall thickness of each section shall be designed to withstand the loads to
which the high mast will be subjected but in any case it shall not be less than 3 mm and 4 mm
at top and bottom respectively. Shaft section shall not be jointed by circumferential weld or
bolting.
5.6
All mast components shall be hot dip galvanized, as per British Standard 729/1971 (1986).
Earthing and earthing terminal shall be provided within the access door area of each high mast.
Galvanizing shall be inspected for
(a) Adhesion (b) Mass of zinc coating and (c) Uniformity.
5.7
Mast Design Criteria
(a)
The high mast and the lowering system with the required number of flood lights and lamp
control gears etc. shall be capable of withstanding a sustained basic wind speed the area
as per IS-875.
b)
The design shall be such that the high mast with accessories is capable of withstanding
external forces exerted by wind pressure and shall have a minimum wind load factor of
1.25 and material factor of 1.15.
5.8
Foundations
The mast shall be erected on suitably designed foundation as per high mast manufacturer’s
design with following typical details:
Type of foundation
Size of foundation
Load bearing capacity of soil
Considered wind pressure (Kg per meter
sq)
Considered wind speed (KMPH
as specified by high mast manufacturer.
As per high mast manufacturer’s design
As per soil report of the site at 2 meters depth.
As per IS-875-1987 or latest
As per IS-875-1987 or latest
The rate quoted for the high mast shall include the cost of testing of soil bearing capacityand
laying of foundation. The contractor shall get the foundation designed accordingly from
OEM/other reputeted firm as decided by the RVNL.
5.9
Lantern carriage
5.9.1 The mobile luminaries’ carriage ring shall be of steel tube construction in two segments. The
unit shall be joined by bolted flanges with stainless steel bolts and nyloc type nuts to enable
easy installation or removal from the erected mast. All mobile components of the system shall
be located on the mobile part in order to allow visual inspection during each operation. Proper
luminary carriage ring support arms shall be provided for supporting the luminaries ring when
the latter is lowered for maintenance.
5.9.2 The mobile luminary carriage shall be designed to carry the 9/12 number of luminaries and
control gears as specified in the relevant BOQ item and shall be evenly balanced. Nylon paddle
Guide Ring shall be incorporated as a buffer arrangement between mobile luminaries carriage
and mast shaft. This is to prevent damage to mast Surface during lowering and raising
operation of mobile luminaries’ carriage.
5.10 Winch
(a) For installation and maintenance of luminaries and lamps, it is necessary to lower and raise
the luminary carriage by means of suitable winching arrangement at the base of the mast.
The speed of raising and lowering of lantern carriage ring shall be at least 3.0 meters per
minute.
Dated 29.Jan 2015
Page 70 of 429
RVNL
(b) The winch must be of robust design and fully sustaining type without the need of brake shoe,
springs or clutches. Winching system with the exception of driving unit shall remain
permanently inside the mast with pendant switch control. Each mast shall be provided with a
double drum winch suitable for raising and lowering the luminaries ring, with gear ratio 53:1
self lubricating type. It can be removed from the mast for maintenance if the need arises in
future. The reduction gear of the winch shall be of endless work gear opening in an oil bath
and gear shall be made up of High Carbon steel/ phosphor bronze. The minimum safe working
limit of the winch shall not be less than 750 kg at 200 RPM. The operating speed of the winch
shall be 180 RPM mechanical 0r 1400 RPM electrical motor.
(c) The capacity and the operating speed of the winch shall be clearly marked on each winch on
an indelible label together with the recommended specification of the lubricant. A minimum of
6 turns of wire rope shall be on the grooved drum when the mobile luminaries ring is fully
lowered to rest on the luminaries supporting arms.
(d) The winch shall be entirely sustaining under all normal circumstances and it is not
independent on the brake or restraining device that uncontrolled or dangerous runaway
speeds will occur in the event of total failure of this device. Slip test on winch is to be carried
out by the manufacturer. All manufacturer’s test certificates and reports shall be submitted by
the contractor to the Engineer.
5.11
Head frame
The head frame shall include a pulley system to accommodate three stainless steel hoisting
wire ropes at any one time and separate pulleys for the passage of electrical cables. The
pulleys shall be of non corrosive material and shall run on self-lubricating bearings with
stainless steel axles. The complete head frame chassis shall be hot dip galvanized. The pulley
assembly shall be fully protected by a galvanized (both internally and externally) canopy.
Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do not
get dislodged from their respective positions in the grooves. The head frame shall be provided
with guides & stops with PVC buffer for docking the lantern carriage.
Note: Pulleys made of synthetic material such as plastic or PVC shall not be accepted.
5.12
Hoisting and Suspension Wire Ropes
5.12.1 The high mast shall be fitted with 6 mm dia flexible standard stainless steel hoisting wire
ropes of 7/19 construction, with a minimum breaking strength of 2350 kg. The combined
lifting capacity of the hoisting wire rope shall have a factor of safety of 7 times the Safe
Working Load (SWL) of the winch and shall be entirely suitable for the design application.
Center material shall be conforming to DIN 3060.
5.12.2 A transition plate shall be incorporated to:
a) Connect the three suspension wire ropes to the two stainless winching wire ropes.
b) Allow fixing of electrical wire cables.
c) Ensure even distribution of loads between the two stainless steel winching wires by means
of an equalizer (necessary thimbles and terminals shall be provided for the steel wire ropes).
d) Ensure even distribution of loads between the two stainless steel winching wires by means of
an equalizer (necessary thimbles and terminals shall be provided for the steel wire ropes).
5.13
Electrical Cable
a) Electrical cable shall be copper, anti-twisting, round and multi cored. The cable shall be
suitable to carry the current of the fittings provided. A suitable terminal Board shall be
provided at the base compartment of the high mast for terminating the incoming cable. The
electrical connections from the bottom to the top shall be made by a special trailing cable.
The cable shall be EPR FR PVC insulated and PCP sheathed to get flexibility and endurance.
Size of the copper cable shall not be less than 2.5 sq. mm. At the top there shall be weather
proof junction Board to terminate the trailing cable. Connections from the top junction Board
to the individual luminaries shall be made by using 3 core 1.5 sq. mm flexible PVC cables of
Dated 29.Jan 2015
Page 71 of 429
RVNL
b)
reputed make. The system shall have in-built facilities for testing the luminaries while in
lowered position.
Suitable provision shall be made at the base compartment of the mast to facilitate the
operation of internally mounted, electrically operated power tool for raising and lowering of
the lantern carriage assembly. The trailing cables of the lantern carriage rings shall be
terminated by means of specially designed, metal clad, multi-pin plug and socket provided in
the base compartment to enable easy disconnection when required.
5.14
Winch Driving Power Tool
a) A suitable high powered, electrically driven internally mounted power tool, with normal over
ride, together with an operating stand, shall be provided for the raising and lowering of the
lantern carriage for maintenance purposes. The power tool shall be of single speed to suit
the requirements provided with a motor of required rating, so that vibrations associated with
high speed operation are avoided.
b) The power tool shall be suitable for lifting of the designed load installed on the lantern
carriage and shall also be designed such that it will be not only self supporting, but also align
perfectly with respect to the winch spindle during the operation. The power tool shall be
supplied complete with push button type remote control switch and six meters of additional
power cable, so that the operation can be carried out from a safe distance. In case of failure
of electrical supply, provision for manual operation shall exist and shall incorporate a torque
limiting device. The power tool shall be reversible. Necessary protection against over load,
short circuit, earth fault and single phasing etc. shall be provided.
5.15
Control Panel
5.15.1 Control of raising and lowering operations shall be carried out from the mast base by means
of a portable control panel. The control panel shall be suitable for 3 phases, 415 volts A. C.
supply system and shall consists of:
a)
A power supply and control cable of not less than 5.0 meter length.
b)
A pendant type control panel equipped with push button for raising and lowering of the
mobile part. The push buttons shall operate on the “ dead man” principle i.e. action
shall seize as the button is released.
c)
Steel sheet iron control panel of suitable size and built in type, shall be provided and
fixed in the high mast at a suitable height.
5.15.2 The panel board shall consist the following:
• 1 x 63 A TPN MCB switch for incoming.
• 1 no. of multiple plug socket 16 amps.
• 3x32 A, SPN MCB for outgoing.
• Automatic timer switch with contactor of suitable rating for control of 50 % & 100%
lighting OR as approved.
5.16
Torque Limiter
a. Model
b. Lifting Capacity
c. Adjustable/ Non-adjustable
– Electric TD2
– SWL 750 kg.
- Adjustable.
5.17
Fencing Panel
High mast shall be provided with suitable fencing panel of size 2mX2mX1.5m duly painted for
protection of erected high mast as specified in BOQ and as directed by Engineer.
5.18
Earthing:
Two pipe electrode earthing shall be provided for each High mast system.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 72 of 429
RVNL
PRESTRESSED
CEMENT CONCRETE POLES
FOR
MODIFICATION OF POWER LINE
CROSSINGS
Dated 29.Jan 2015
Page 73 of 429
Dated 29.Jan 2015
RVNL
Page 74 of 429
RVNL
CHAPTER: A-6
Technical Specification No. RVNL/ Elect/GS/06
PRESTRESSED CEMENT CONCRETE POLES
FOR
MODIFICATION OF POWER LINE CROSSINGS
6.0
Scope
This specification covers pre-stressed concrete cement poles for modification of State
Electricity Board’s Power line crossings.
6.1
Application Standards
The pre-stressed concrete cement poles and their erection shall comply with the relevant
provisions of the following BIS Specifications:
a)
IS 1678 of 1998: Specification for pre-stressed concrete poles
traction and telecommunication lines.
for overhead
power,
b)
IS 2905 of 1989: Methods for testing of concrete poles for overhead power and
telecommunication lines.
c)
IS7321 of 1974: Code of Practice for selection, handling and erection of concrete poles
for overhead power and telecommunication lines.
6.2
6.3
Earthing : Suitable arrangement for earthing shall be provided.
Pole
Pole shall be pre-stressed, cement concrete (PSCC), 11 meters long, suitable for 330 kg
working load, with top section 200 mm x 105 mm and bottom section 410 mm x 140 mm
conforming to IS 1678 of 1998.
6.4
Double Pole Structure
Pre-stressed, cement concrete (PSCC) double pole structure shall be 11 meters long suitable
for 330 kg working load with top section 200 mm x 105 mm and bottom section 410 mm x
140 mm and with 4 nos. of channel cross arms & 2 nos. of cross bracing angles, clamps,
bolts, nuts etc. as per SEB’s specifications and site requirement.
6.5
Erection
Erection of pole/double pole structure shall include the excavation of pit 1800 mm deep and
making foundation with cement concrete as per approved drawing of SEB/Railway.
6.6
Inspection at Site
The contractor shall ensure that the manufacturer numbers the poles for identification. The
contractor shall also make arrangements for testing the poles at the manufacturer’s works.
The manufacturer’s test report, indicating the pole identification number, shall be furnished by
the contractor at the time of supply of poles at site. The poles received at site shall be
inspected by the Engineer to ensure that they are free from cracks of breakages of any kind.
In case poles are found having cracks/breakages or are not accompanied by test reports, the
poles shall not be accepted. The contractor shall replace all the defective poles at his own
cost, including transportation charges.
----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 75 of 429
Dated 29.Jan 2015
RVNL
Page 76 of 429
RVNL
MODIFICATION
OF
POWER LINE CROSSINGS
ON
RAILWAY TRACKS
Dated 29.Jan 2015
Page 77 of 429
Dated 29.Jan 2015
RVNL
Page 78 of 429
RVNL
CHAPTER:A-7
MODIFICATION OF POWER LINE CROSSINGS
ON
RAILWAY TRACKS
7.0
General
a) The scope covers modification of existing power line crossings of Railway track as per the
regulations applicable to electrical overhead crossings and/or underground cables crossing the
railway tracks operated by the Indian Railways, Railway companies and port commissioner’s
railways, including assisted and private sidings on which rolling stock of Indian Railway may
work, unless any special section or railway tracks are exempted from these regulations by
specific written orders of the Electrical Inspector.
b)
Detailed drawing of the proposed modification work of crossing shall be prepared and
approval obtained from the Railway and concerned State Electricity Authority.
c) Revised agreement as per the regulations applicable to electrical overhead crossings and/or
underground cables crossing the railway tracks shall be got signed from the concerned State
Electricity Authority.
7.1
Compliance to Rules:
a) All the crossings shall be modified to comply with the latest Regulations for Electrical Crossings
of Railway Track 1987 with up to date amendments issued from time to time thereto.
b) Except where otherwise provided for in the regulations, the contents of relevant sections of
the Indian Electricity Act 2003, Indian Railway Act 1890 and the rules made under these and
as amended from time to time thereto and the relevant provisions of Indian Railway’s
Schedule of Dimensions (IRSOD) for Broad/ Meter / Narrow Gauges together with the latest
amendments shall apply to the modified crossings.
7.2
Standard Specifications
All materials used in the construction of the crossing shall comply with the relevant latest BIS
Specifications.
7.3
Method of crossing – Overhead Line Underground Cables:
All low, medium and high voltages up to and including 11 kV crossings shall normally be by
means of underground cables. While for voltages higher than 11 kV, crossing may be through
overhead lines or underground cables. The use of underground cable to the extent possible
would be advantageous particularly up to and including 33 kV systems.
7.4
7.4.1
Overhead Power Line Crossing
Angle of Crossing
An overhead line crossing shall normally be at right angles to the railway track. In special
cases a deviation of up to 30 degree may be permitted. Deviations larger than 30 degree shall
have to be specifically authorized by the Electrical Inspector of the Railway.
7.4.2 Structures
a)
Steel poles/masts, fabricated steel structures or reinforced/pre-stressed cement concrete
poles either of the self supporting type or guyed type conforming in all respects to the Indian
electricity Rules, 1956 ( as amended till date) and complying with the latest editions of Codes
of Practice, IS: 800-1984 for “Code of Practice for use of Structural steel in General Building
Construction, IS: 1678 of 1998: Specification for ‘Pre-stressed Concrete Poles for Overhead
Power, Traction and Telecommunication Lines’, shall be used on either side of the track to
Dated 29.Jan 2015
Page 79 of 429
RVNL
support the crossing span. These structures shall be of the terminal type. For arriving at the
crippling load, the wind loads as detailed in the latest edition of IS: 802 ( Part I) – 1995 for
“Loads and Permissible Stresses” shall be adopted. The steel structures shall normally be
galvanized in accordance with IS:2629-1985 for “Recommended practice for hot-dip
galvanizing of iron and steel”
b)
The minimum distance of the structures (supporting the crossing span) from the center of the
nearest railway track, including new proposed and considering for future, shall be as per para11(iv) of IRSOD-2004 and given at para 7.5.2(C)
c)
The crossing span shall be restricted to 300 m or to 80% of the normal span for which the
structures are designed, whichever is less.
d)
Wind pressure
The maximum wind pressure for design of the structure shall be as prescribed in IS:
802/Pt.I/1995 for loads and permissible stresses.
7.4.3
Temperature
The maximum and minimum temperatures for design of the conductors and other wires shall
be as prescribed in the latest edition of IS: 802 (pt. 1, Clause-10) with necessary correction
for maximum temperature.
7.4.4
Factor of Safety
The factor of safety of all structures, conductors, guards, guys and ground wires used in the
crossing shall be as stipulated in the Indian Electricity Rules, 1956 as amended and the
relevant code of practice. Ground wires used in the crossing shall be as stipulated in the
Indian Electricity Rules, 1956 ( as amended till date) and the relevant Codes of Practice.
7.5
Clearance between the Overhead Line and Railway Track
An overhead line crossing over electrified railway track shall be located at the middle of
overhead equipment span supported by two adjacent traction masts/structures. The distance
between any of the crossing conductors and the nearest traction mast or structure under the
most adverse conditions shall not be less than 6 m.
Note: If, in unavoidable circumstances, the crossing span cannot be so located, the minimum
clearance between any of the crossing conductors of the crossing and the nearest traction
mast or structure shall not be less than that specified for buildings in Rule 80 of the Indian
Electricity Rules, 1956 (as amended till date). Specific permission in this regard shall be
obtained from the Employer, prior to execution of work.
7.5.1
No overhead line crossing shall be located over a booster transformer, traction switching
station, traction substation or a track cabin in an electrified area.
7.5.2
Clearance for Power Line Crossings including Telephone Line Crossings of Railway
Tracks
Following clearances should be maintained as per ACS-10 of SOD-2004 and Advance
correction slip-18/Jan-2009 to ACTM circulated vide Railway Board’s letter no.
2000/Elect.(G)/161/1 Part-III dated 19.01.2009.
Dated 29.Jan 2015
Page 80 of 429
RVNL
(a) Clearance for Power Line Crossings in Non-Electrified & Electrified Territory:
Sr
No
Over
Head
Crossing Voltage
(1)
1
(2)
Upto and including 11
KV
Above 11 KV and
upto 33 KV
Above 33 KV and
upto 66 KV
Above 66 KV and
upto 132 KV
Above 132 KV and
upto 220 KV
Above 220 KV and
upto 400 KV
Above 400 KV and
upto 500 KV
Above 500 KV and
upto 800 KV
2
3
4
5
6
7
8
Minimum Clearances from Rail Level
Existing
Power New Power line
line Crossing for Crossing
or
Non-Electrified
Crossing Planned
Territory
for
Alteration
(mm)
(mm)
(3)
(4)
Normally by underground cable
Minimum
Clearance
between
Highest
Traction Conductor and
Lowest
Transmission
line Crossing Conductor
(mm)
(5)
10860
14660
2440
11160
14960
2440
11760
15560
3050
12660
16460
4580
14460
18260
5490
15360
19160
7940
18060
21860
7940
Note:
i)
ii)
All heights/clearances are in mm and under maximum sag conditions.
If the crossing is provided with guarding, a minimum clearance of 2000 mm shall be
maintained between the bottom of the guard wire and highest traction conductor.
iii) Power line crossings in yard and station area shall be avoided.
iv) For new electrification works, existing crossings can continue, if dimensions are as per
Column (5) above.
7.5.2 (b) Minimum Clearance between any conductor not adequately insulated and any
railway structure under most adverse conditionsSN
1
1.
2.
3
4
5
6
7
8
9.
Voltage
2
Upto and including 650 V
Above 650 V and upto and including 33 kV
Above 33 KV and upto and including 66 kV
Dated 29.Jan 2015
Minimum clearance
(mm)
3
2500
3700
4000
4600
4900
5500
7300
8200
10900
Page 81 of 429
RVNL
7.5.2 (c)
Minimum Horizontal Distance of Structures:
The minimum horizontal distance measured at right angles from the centre of the nearest
track to any part of a structure (all structures shall be rigid and well founded), carrying
electrical conductors crossing a railway shall be:
(i) For new structure
: (H+6) meters
(ii) For existing structure
: (H+2.135) meters (as per A&c-13)
{where H is height of the post/structure from nearest ground level }
The working of railway crane under an overhead line crossing shall normally be avoided.
If it becomes absolutely essential for a crane to work under such a crossing, the
minimum clearance required to be maintained between the highest working point of the
jib and the lower crossing conductor shall be as under:
Nominal System Voltage (kV)
33
66
110
132
220
400
500
800
Min. Safe Clearance (in mm)
1500
2000
2250
2500
3500
6000
7250
11500
7.5.3
Clearance between Power Line & Communication Line:
The minimum clearance to be maintained between a power line and a communication line
shall be as prescribed in the “ Code of Practice for the Protection of Telecommunication Lines
at Crossings with Overhead Power Lines other than Electrical Traction Circuits” (latest edition)
issued by Central Electricity Authority (CEA), Telecommunication Directorate, Power and
Telecommunication Co-ordination Committee (PTCC Unit), Govt. of India.
7.6
Insulators
A double set of strain insulator strings shall be used in crossing span in conjunction with a
yoke plate where necessary. Each string of such strain insulators shall have one insulator
more than the number used in a normal span of the overhead line. The factor of safety of
each string of insulators under the worst conditions shall be not less than 2.
7.7
a)
Guarding
All overhead power line crossings upto and including 33 kV shall be provided with guarding
under the power line. Guarding need not be provided for overhead power line crossings of
voltages above 33 kV if the transmission/ distribution line is protected by circuit breakers of
modern design with total tripping times of 0.20 seconds for voltage below 220 kV and 0.10
seconds for voltages of 220 kV and above, from the time of occurrence of the fault to its
clearance. Wherever, guarding is adopted for the crossing span, cradle guards shall be
provided.
Minimum height above rail level to the lowest level of cradle guard or guard wires under
condition of maximum sag shall not be less than the values specified in the clause 7.3.1.8
above.
The minimum height between any guard wire and a live crossing conductor under the most
adverse conditions shall not be less than 1.5 meters.
b)
c)
Dated 29.Jan 2015
Page 82 of 429
7.8
RVNL
Anti-climbing Devices and Warning Notices:
Where the voltage exceeds 650 V, the supporting structures (of the overhead line crossing) on
railway land shall be provided with anti-climbing devices. Besides, suitable caution/warning
notices shall be erected on all such structures, in the regional language and in English, as may
be prescribed for the purpose. The anti-climbing devices and the caution/warning notices shall
be got approved from the Railway by the Engineer.
7.9
Earthing
(a) Each structure on either side of the crossing span supporting the transmission line conductors
shall be earthed effectively by two separate and distinct earths and connections. At least one
separate earth electrode shall be provided for each earth connection. Earth resistance of the
independent electrode shall be less than 5 ohms.
(b) All guard and stay wires shall be properly clamped to the structures connected to earth so as
to maintain proper electrical continuity to earth.
(c) Where struts are provided, they shall also be effectively connected to earth separately as well
as to the main structure earths.
(d) Where the earth resistance of the independent tower/structure is higher, the owner shall take
necessary steps to improve the earth resistance either by providing multiple earth electrodes
or by suitably treating the soil surrounding the earth electrode or by resorting to counterpoise
earthing. The method of earthing the transmission/distribution line structures etc., for the
crossing span shall be got approved from the Railway by the Engineer.
(e) The cross section of the earth conductor/ connections for the earthing system shall be
adequate for the application. They shall not be liable to be damaged or overheated or melted
while carrying the short circuit current.
7.10
Cable Crossing
7.10.1 General
As for as possible, cable crossings shall make use of any existing culverts, sub-ways etc.
In case of electrified track(s), the crossing shall be provided at locations at least 5 meters
away from any traction substation or switching station or mast or structure erected or
proposed to be erected by the railway for the purpose of supply and distribution of power to
the traction overhead equipment. The exact locations of such traction substation or switching
station or mast or structure in any particular area shall be obtained by the Engineer/
Employer from the Railway.
7.10.2 Cathodic Protection
Cathodic protection of the cables shall normally not be adopted, unless specifically required by
the Railway or any other organization having assets nearby to which interference is likely to
be caused by currents flowing through the crossing.
7.10.3 Method of Laying cable under Railway Track(s)
(a) Cable shall be laid through cast iron or spun concrete pipes/ HDPE pipe etc. as per BOQ item,
of suitable diameter and strength. Long lengths of pipe shall be laid with a gradient to
facilitate drainage of water. The pipe shall be laid up to the Railway boundary at both ends or
up to the point as approved by the Railway/ Engineer. The laying of the cable shall be in
accordance with the latest edition of IS: 1255-1983”Code of practice for Installation and
Maintenance of Power Cables up to and including 33 kV”
b) The armouring and sheathing of the underground cable laid across or near any electrified
railway track shall be earthed by independent earths at the two sealing ends of the cable.
c) No further earthing of the armouring and sheathing of the cable shall be done within 500m of
the electrified track. The scheme and method of earthing shall specifically be approved by the
Railway.
Dated 29.Jan 2015
Page 83 of 429
RVNL
7.10.4 Termination of cable with structure
a) Where the ends of a cable of an underground crossing are terminated on structures for
connection to an overhead line, such structures shall comply with the Regulations in so far as
they are applicable to overhead line crossings in respect of structures.
b) The pole on which the cable is terminated shall be provided with strut/stays to take the load
of over head mains. The crossing cable shall be inserted in a GI pipe of suitable diameter. The
GI pipe shall be supported to the termination pole with proper clamps, bolts and nuts. The
clamps shall be provided to support the GI pipe at an interval of not more than 2.0 meter. The
supporting GI pipe shall be provided along the structure up to a height of 2 m above the
ground level. The open ends of the GI pipe shall be sealed to prevent extraneous matter
causing damage to the cable. The exposed portion of the cable above the GI pipe shall be
clamped to the pole at an interval of not more than 2 m.
c) The cable end shall be provided with termination kits on either ends of the crossing. Suitable
jumper connections shall be provided between the overhead mains and the
cable end terminations.
7.10.5 Marking of Crossings
Each cable crossing shall be indicated by at least two cable route markers, one at each end of
the crossing within the railway boundaries. The cable route marker shall be fixed at both ends
of the underground crossings. The following information shall be clearly displayed on the
markers.
7.11
Electrical Cable
Number of Cables
Danger Notice Plate
-- kV
-- Nos.
-- In English, Hindi and the Vernacular language of the
District
Depth of Cable
Depth of Cable
-- mm below track level.
-- mm below ground level between the toe of bank and
railway fencing
Coordination with SEBs and standards:
The contractor shall coordinate with State Electricity Board authorities for smooth working and
shall arrange required approvals if any. Contractor shall also follow standards and
specifications, approved list of concerned SEB for proper energisation.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 84 of 429
RVNL
Tech. Spec. No. - RVNL/Elect/GS/08
MEDIUM VOLTAGE
SWITCH BOARD
(for Sub Stations)
Dated 29.Jan 2015
Page 85 of 429
Dated 29.Jan 2015
RVNL
Page 86 of 429
RVNL
CHAPTER:A-8
MEDIUM VOLTAGE SWITCH BOARD
(for sub stations)
8.1
General
(a) Medium voltage switch board shall be cubicle type, floor mounted, free standing type,
dust and vermin proof, totally enclosed & compartmentalized design of uniform height
and of multi-tier construction for indoor utilization and suitable for 3 phase, 4 wire, 415
V, 50 Hz AC, solidly earthed neutral, electric supply system complete with accessories,
inter connections, continuous GI earth strip, bus bar chamber with copper/aluminium bus
bar ( as specified I n the relevant BOQ item), ON/OFF & trip indication, all instruments,
CT’s energy meters, switchgears etc. (as specified in the relevant BOQ item) in position,
duly wired up with copper conductor cable with colour coding, code numbering etc. and
other accessories though not mentioned here but necessary to complete the work in all
respects.
(b) LT panel shall conform to IS: 8623/Pt-I/1993
(c) The panel manufacturer shall have ISO: 9001 certification with testing arrangement as
per IS: 8623 and power coating facilities in the works.
8.2
8.2.1
Construction
The panels shall be fabricated from 2.0 mm thick CRCA sheet steel. The shroud & partitions
shall be minimum 1.6 mm thick CRCA sheet steel. The panels shall be powder coated in
approved shade. The degree of protection shall not be less than IP42 as per IS: 13942/Pt. 1.
8.2.2
Height of panel shall not be more than 2200 mm and operating height of switchgears shall be
between 300 to 1900 mm. Depth of panel shall not be less than 1200 mm. Continuous GI
earth bus bar shall be of size not less than 50 x 6 mm.
8.2.3
The following minimum clearances shall be maintained:
i)
Between Phases
-32 mm
ii)
Between Phases & Neutral
-26mm
iii)
Between Phases & Earth
-26 mm
iv)
Between Neutral & Earth
-26 mm
8.2.4
All functional units shall be arranged in a multi-tier formation & each such unit shall be fully
compartmentalized. Vertical cable alley shall be provided. Cable alley shall have hinged doors
& suitable cable clamping arrangement. Vertical bus bars shall be housed in between two
feeder compartments in a separate bus chamber. The openings between the bus chambers &
feeder compartments shall be covered with Bakelite/hylem sheet of minimum 4.0 mm
thickness. All the interconnecting links to the feeders shall be shrouded by means of phenolic
barriers to avoid accidental contact. Each compartment shall have its own individual door with
concealed hinges & the door shall have interlocking so door can only be opened after
switching off the module.
Bus Bars
The bus bars shall be made of high conductivity aluminium/copper (as specified in BOQ)
conforming to the requirement of IS 5082/1998 for aluminium and IS: 1897/1983 for copper.
The bus bars shall have uniform cross section ( basis of bus bar cross section will be
maximum of 1000 A/sq. inch for copper and 630A/sq. inch for aluminium). The cross-section
of the neutral bus bar shall be same as that of the phase bus bar for bus bars of capacity up
8.3
8.3.1
Dated 29.Jan 2015
Page 87 of 429
RVNL
to 200 Amp. For higher capacities, the neutral bus bar shall not be less than half (50 %) the
cross-section of that of the phase bus bars.
8.3.2
Bus bars are to be provided in sections as per requirement for feeding essential/non-essential
load and domestic/commercial load as per the approved drawing.
8.3.3
Provision shall be made in the switch board to take in main bus bar trunking from
top for LT panels to be provided with transformers of capacity above 750 KVA.
8.3.4
Bus bars shall be supported on suitable non-hygroscopic,, non-combustible, material such as
DMC/SMC. The joints in the bus bars shall be provided with fish plates on either side of the
bus bars to provide adequate contact area. Bus supports shall be provided on either side of
the joints.
8.3.5 All bus bars shall be insulated with PVC tapes/tubes (heat shrink type) with colour coding
(Red/Yellow/Blue/Black) to withstand the test voltage of 2.5 kV for one minute.
8.4
8.4.1
Molded Case Circuit Breakers (MCCB)
MCCBs shall conform to IS13947/Pt-2/1993 (Ics = 100%Icu) with thermal release setting
70/80%-100% and shall have ON, OFF & TRIP indications with breaking capacity as specified
in the relevant BOQ item. MCCBs shall be 3 pole/4 pole (as specified in the relevant BOQ
item) and suitable for three phase, 415 Volt, AC supply. MCCB shall overall conform to
IS13947/Pt.II/1993.
8.4.2
Tripping unit shall be of thermal-magnetic type provided in each pole and connected by a
common trip bar such that tripping of any one pole operates all the poles to open
simultaneously.
8.5
Air Circuit Breaker (ACB)
Air circuit breaker of rating as specified in the relevant BOQ item, ¾ pole ( as specified in the
relevant BOQ item), 415V, 3 phase, 50 Hz AC Manual/ Electrical draw out type (as specified in
the relevant BOQ item), trip free, front operated, with ON/OFF indications. The breaker shall
have Ics – Icw – Icu minimum breaking capacity of 45/50 KA (as specified in the relevant BOQ
item). The circuit breaker shall be fitted with CT operated micro-processor based trip unit for
over load, short circuit and ground fault trip and shall be independently adjustable. ACB shall
overall conform to IS: 13947/Pt. II/1993.
8.6
Fuse Switch/ Switch Fuse Unit
Fuse switch/switch fuse unit shallbe heavy duty, TPN double break of rating as specified in the
relevant BOQ item, utilization category AC 23, conforming to IS: 13947/Pt. III/1993 with HRC
fuses conforming to relevant IS and one neutral link.
8.7
On load change over Switch 4 pole
On load changeover switch shall be 4 pole, heavy duty of rating (as specified in the relevant
BOQ item), utilization category AC 23, conforming to IS:13947/Pt.III/1993.
8.8
ACB Bus Coupler
ACB bus coupler shall be 4 pole (fixed type ) of rating as specified in the relevant BOQ item,
overall conforming to IS: 13947/Pt. II/1993. The circuit breaker shall have minimum breaking
capacity of 45/50 kA( as specified in the relevant BOQ item).
8.9
Indication lights
Clustered LED type indication light shall be provided for ON/OFF indication on each incoming
and outgoing module.
8.10
Measurement Instruments for Metering
Dated 29.Jan 2015
Page 88 of 429
RVNL
Measuring instruments shall have accuracy Class I.
8.11 Current Transformers
8.11.1 Current transformers shall be in conformity with IS: 2705 ( Part I, II &III)/1992. Current
transformers shall be rated for 1 kV at rated primary current, rated burden. The rated
secondary current shall be 5 A. The acceptable minimum class of various applications shall be
as given below:
Measuring
: Class 1
Protection
: Class 5 to P10
8.11.2 Separate CT shall be provided for measuring instruments and protection.
8.11.3 The current transformers shall be mounted such that they are easily accessible for inspection,
maintenance and replacement. The wiring for CT’s shall be copper conductor, FR insulated
wires with proper termination lugs and wiring shall be bunched with cable straps and fixed to
the panel structure in neat manner. The VA rating of the CTs shall be 5 VA.
8.12
Miscellaneous
Control switches shall be of the heavy-duty rotary type with plates clearly marked to show the
operating position. They shall be semi-flush mounting with only the front plate and operating
handle projecting.
8.13
Cable/Bus Trunking Termination
8.13.1 Cable entries shall be provided with metallic glands to prevent damage to the insulation of the
cable and terminals shall be provided in the switchboard to suit the number, type and size of
power cables and copper conductor control cables.
8.13.2 Provision shall be made from top for bus trunking terminations/ from bottom for entry of
cables through removable gland plates.
8.13.3 Barriers or shrouds shall be provided to permit safe working at the terminals of one module
without disturbing of other modules.
8.14
Control Wiring
All control wiring shall be carried out with 1100/660 Volt grade, single core FR PVC insulated
cable conforming to IS: 694 having stranded copper conductors of minimum 1.5 sq. mm size
for potential circuits and 2.5 sq. mm for current circuits. Wiring shall be neatly bunched,
adequately supported and properly routed to allow for easy access and maintenance.
Numbering ferrules at each end shall identify wiring. All control fuses shall be mounted in
front of the panel and shall be easily accessible.
8.15
Test at Manufacturer’s Works
8.15.1 All routine tests shall be carried out in the presence of the inspecting Engineer.
8.15.2 Original test certificates of all equipments/instruments shall be submitted along with the
supply of panel board after the Inspecting Officer passes the LT panel board.
8.16
Testing and Commissioning
Following tests shall be carried out prior to commissioning of the panel:
a) Insulation test: When measured with 500 V megger, the insulation
resistance shall not be less than 100 mega ohms.
b) Trip test & protection test.
Note: Each panel shall be displayed with feeder name plate.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 89 of 429
Dated 29.Jan 2015
RVNL
Page 90 of 429
RVNL
Tech. Spec. No. : RVNL/ Elect/GS/09
MEDIUM VOLTAGE
FEEDER PILLAR
&
SWITCH BOARD
(OTHER THAN SUB- STATION WORK)
Dated 29.Jan 2015
Page 91 of 429
Dated 29.Jan 2015
RVNL
Page 92 of 429
RVNL
CHAPTER:A-9
Tech. Spec. No. RVNL/ Elect/GS/09
MEDIUM VOLTAGE FEEDER PILLAR & SWITCH BOARD
(OTHER THAN SUB- STATION WORK)
9.1 Feeder Pillar
9.1.1 General
a) Medium voltage feeder pillar shall be cubicle type, floor mounted, free standing type, dust
and vermin proof, totally enclosed, of uniform height and for outdoor utilization and suitable
for 3–phase, 4 wire, 415 V, 500 Hz AC, solidly earthed neutral, electric supply system
complete with 4 nos. pedestals, accessories, inter-connections, bus bar chamber with
copper/aluminium bus bar (as specified in the relevant BOQ item), ON/OFF indication, CTs,
switchgears ( as specified in the relevant BOQ item), timer etc. in position duly wired up with
copper conductor cable with colour coding, etc. and other accessories though not mentioned
here but necessary to complete the equipment in all respects.
b)
The manufacturer shall have ISO: 9001 certification with testing arrangement and powder
coating facilities in the works.
9.1.2
Digital Time switch (Timer) of suitable rating and contactors (as specified in the relevant
BOQ item) shall be provided in the feeder pillar to operate pump/street lights etc. and this
shall be controlled with independent switchgear/s.
9.1.3 Construction
9.1.3.1 The feeder Pillar shall be fabricated from 2.0 mm thick CRCA sheet steel. The shroud &
partitions shall be of minimum 1.6 mm thickness and shall be fabricated from CRCA sheet
steel. The feeder pillar shall be powder coated in approved shade by seven tank process.
The degree of protection shall not be less than IP 54 as per IS: 13942/Pt.1.
9.1.3.2 Pedestals and base frame shall be of MS angle of 75mm x 75mmx 8 mm (nominal size).
The Feeder Pillar shall have the provision of flush doors on front and back in two equal
parts with hinges and concealed lock openable with special key.
9.1.3.3 The following minimum clearances shall be maintained:
i)
Between Phases
- 32 mm
ii)
Between Phases & Neutral
- 26 mm
iii)
Between Phases & Earth
- 26 mm
iv)
Between Neutral & Earth
- 26 mm
9.1.3.4All functional units shall be arranged in multi-tier formation & each such unit shall be fully
compartmentalized. Vertical cable alley shall be provided. Each compartment shall have its
own individual door with concealed hinges & the door shall have interlocking so that it can
only be opened after switching off the module.
Dated 29.Jan 2015
Page 93 of 429
RVNL
9.1.4 Bus Bars
9.1.4.1The bus bars shall be made of high conductivity aluminium/copper (as specified in BOQ)
conforming to the requirement of IS 5082/1998 for aluminium and IS: 1897/1983 for
copper. The bus bars shall have uniform cross section ( basis of bus bar cross section will be
9.1.4.2 Bus bars shall be supported on suitable non-hygroscopic, noncombustible, material such
as DMC/SMC.
9.1.4.3 Bus bars shall be insulated with PVC tapes/ tubes (heat shrink type ) with colour coding
(Red/Yellow/Blue/ Black) to withstand the test voltage of 2.5 kV for one minute.
9.1.5
9.1.5.1 MCCB shall be TPN of rating as specified in the relevant BOQitem and shall conform to IS13947/Pt-2/1993 (Ics = 100%Icuor as specified in relevant BOQ item) with thermal release
setting 70/80%-100% or fixed type ( as specified in the relevant BOQ item) with breaking
capacity of not less than 25 kA for load currents up to 200 amp. & 35 kA for load currents
above 200 amp rating. MCCBs shall be suitable for three phase, 415 Volt, AC supply.
9.1.5.2 Tripping unit shall be of thermal – magnetic type provided in each pole and connected by a
common trip bar such that tripping of any one pole operates all the poles and they open
simultaneously.
9.1.6
Fuse switch/switch fuse unit shall be heavy duty, TPN double break of rating (as specified in
the relevant BOQ item), utilization category AC 23, conforming to IS: 13947/Pt. III/1993
with 3 HRC fuses conforming to relevant IS and one neutral link
9.1.7
Current Transformers
9.1.7.1Current transformers shall be in conformity with IS: 2705 (Part I, II & III). Current
transformers shall be rated for 1 kV. Current Transformer shall have rated primary current,
rated burden and class of accuracy. The rated secondary current shall be 5 A. The
acceptable minimum class of various applications shall be as given below:
Measuring
: Class 1
Protection
: Class 5 P10.
9.1.7.2The VA rating of the CTs shall be not less than 5 VA.
9.1.8
Cable Termination
9.1.8.1 Cable entries shall be provided with metal glands to prevent damage to the insulation of the
cable and terminals shall be provided to suite the number, type and size of aluminium
conductor power cables.
9.1.8.2 Provision shall be made for bottom entry of cables through removable gland plates.
9.1.9
Tests at Manufacturers’ Works
9.1.9.1 All routine tests shall be carried out in the presence of the inspecting Engineer.
9.1.9.2 Original test certificates of all equipments/ instrument shall be submitted by the contractor
along with the supply of panel board after the Inspecting Officer passes the feeder pillar.
Dated 29.Jan 2015
Page 94 of 429
RVNL
9.1.10 Testing and Commissioning at Site
Following tests shall be carried out prior to Commissioning:
a) Insulation test
b) Trip Tests & Protection Tests
9.1.11 Erection
Brick masonry platform of suitable size with 450 mm height (approximate ) shall be
constructed in the specified location and cement finish. Feeder pillar shall be erected on this
platform by grouting of pedestals as approved by the Engineer.
9.2 SWITCH BOARD
9.2.1 General
a) Medium voltage switch board shall be cubicle type, floor mounted, free standing type, dust
and vermin proof, totally enclosed, of uniform height and for indoor utilization and suitable
for 3- phase, 4 wire, 415 V, 50 Hz Ac, solidly earthed neutral, electric supply system
complete with accessories, inter connections, bus bar chamber with copper/ aluminium bus
bar (as specified in the relevant BOQ item), ON/OFF indication, CTs, switchgears (as
specified in the relevant BOQ item) timer etc. in position duly wired up with copper
conductor cable with colour coding and other accessories though not mentioned here but
necessary to complete the equipment in all respects.
b) The switch board manufacturer shall have ISO: 9001 certification with testing and powder
coating facilities in the works.
9.2.2
Digital time switch (Timer) of suitable rating and contactors (as specified relevant BOQ item)
shall be provided in the panel to operate pump/street lights etc. and shall be controlled with
independent switchgear/s.
9.2.3 Construction
9.2.3.1 The panel shall be fabricated fro 2.0 mm thick CRCA sheet steel. The shroud & partitions
shall be minimum 1.6 mm thickness and shall be fabricated from CRCA sheet steel. The
panel shall be powder coated in approved shade by seven-tank process. The degree of
protection shall not be less than IP 42 as per IS: 13942/Pt.1.
The following minimum clearances shall be maintained:
i)
Between Phases
- 32 mm
ii) Between Phases & Neutral
- 26 mm
iii) Between Phases & Earth
- 26 mm
iv) Between Neutral & Earth
- 26 mm
9.2.3.3 All functional units shall be arranged in multi-tier formation & each such unit shall be fully
compartmentalized. Vertical cable alley shall be provided. Each compartment shall have its
own individual door with concealed hinges & the door shall have interlocking so that it can
only be opened after switching off the module.
9.2.4 Bus Bars
9.2.4.1The bus bars shall be made of high conductivity aluminium/copper (as specified in BOQ)
conforming to the requirement of IS 5082/1998 for aluminium and IS: 1897/1983 for
copper. The bus bars shall have uniform cross section ( basis of bus bar cross section will be
9.2.4.2Bus bars shall be supported on suitable non-hygroscopic, noncombustible, material such as
DMC/SMC.
Dated 29.Jan 2015
Page 95 of 429
RVNL
9.2.4.3 Bus bars shall be insulated with PVC tapes/ tubes (heat shrink type)with colour coding
(Red/Yellow/Blue/ Black) to withstand the test voltage of 2.5 kV for one minute.
9.2.5
9.2.5.1
MCCB shall be TPN of rating as specified in the relevant BOQitem and shall conform to IS13947/Pt-2/1993 (Ics = 100%Icuor as specified in the relevant BOQ item) with thermal
release setting 70/80%-100% or fixed type as specified in the relevant BOQ item) with
breaking capacity of not less than 25 kA for load currents up to 200 amp. & 35 kA for load
currents above 200 amp rating. MCCBs shall be suitable for three phase, 415 Volt, AC
supply.
9.2.5.2 Tripping unit shall be of thermal – magnetic type provided in each pole and connected by a
common trip bar such that tripping of any one pole operates all the poles and they open
simultaneously.
9.2.6
Fuse switch/switch fuse unit shall be heavy duty, TPN double break of rating (as specified
in the relevant BOQ item ), utilization category AC 23, conforming to IS: 13947/Pt.
III/1993 with 3 HRC fuses conforming to relevant IS and one neutral link
9.2.7
9.2.7.1 Current transformers shall be in conformity with IS: 2705 (Part I, II & III). Current
transformers shall be rated for 1 kV. Current Transformer shall have rated primary current,
rated burden and class of accuracy. The rated secondary current shall be 5 A. The
acceptable minimum class of various applications shall be as given below:
Measuring : Class 1
Protection : Class 5 P10.
9.2.7.2 The VA rating of the CTs shall be not less than 5 VA.
9.2.8 Cable Termination
9.2.8.1 Cable entries shall be provided with metal glands to prevent damage to the insulation of
the cable and terminals shall be provided to suite the number, type and size of aluminium
conductor power cables.
9.2.8.2
9.2.9
Provision shall be made from bottom for entry of cables through removable gland plates.
Tests at Manufacturers’ Works
9.2.9.1 All routine tests shall be carried out in the presence of the inspecting Engineer.
9.2.9.2
Original test certificates of all equipments/ instrument shall be submitted by the contractor
along with the supply of panel board after the Inspecting Officer passes the feeder pillar.
9.2.10 Testing and Commissioning at Site
Following tests shall be carried out prior to Commissioning:
a) Insulation test
b) Trip Tests & Protection Tests
---------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 96 of 429
RVNL
Tech. Spec. No- RVNL/ ELECT/GS/10
DISTRIBUTION BOARD
Dated 29.Jan 2015
Page 97 of 429
Dated 29.Jan 2015
RVNL
Page 98 of 429
RVNL
CHAPTER:A-10
DISTRIBUTION BOARD
10.0 GENERAL
a) Distribution boards for power and light circuit distribution shall be pre-wired, factory built, duty
powder coated and complete with copper bus bars, MCB/MCCB/RCBO/RCCB etc. (as specified
in the relevant BOQ item) and shall be suitable for 415 V, 3 – phase or 230 V, single-phase
supply (as per BOQ item). The distribution boards shall conform to IS: 8623 and IS: 13032 as
applicable
b)
However, if none of the types readily available from the approved makes meets the
requirements, alternative makes may be offered with technical literature and test certificates,
for approval of the Engineer.
c) Separate distribution board shall be provided for light and power circuits in quarters
of category Type- IV and above & in service buildings, as approved by the Engineer.
10.1 Type
The Distribution Board shall be single/double door type (as specified in the relevant BOQ item)
suitable for flush installation. The boards shall be of cabinet design, totally enclosed and shall
have a degree of protection not less than IP42 (indoor type) and IP54(outdoor type ) as per IS:
13947/Part1/1993.
10.2 Miniature Circuit Breakers (MCB)
10.2.1 Miniature Circuit Breakers for lighting circuits shall be of “B” series and for inductive
loads shall be of “C” series. Circuits feeding discharge lamps (HPMV/MH/HPSV) halogen lamps,
all power outlet points, equipment/machinery shall be of “C” series (Motor Circuit) type. All
miniature circuit breakers shall be of 10 KA rated rupturing capacity unless otherwise specified.
MCBs shall generally conform to IS: 8828. They shall be suitable for snap fixing on a standard
DIN rail.
10.2.2
Three phase MCBs shall have common trip bar so that all the poles make and break
simultaneously. Miniature circuit breakers shall be quick make & quick break type with trip
free mechanism. They shall have thermal & magnetic short circuit protection.
10.3 Residual Current Circuit Breakers (RCCB), Residual Current Circuit Breaker with
Overload, short circuit & earth leakage Protection (RCBO)
10.3.1
RCCB/RCBO shall be used in distribution boards as per BOQ item. The RCCB/ RCBO shall be
rated for 30/100/300 mA fault circuit tripping as specified in the relevant BOQ item or as per
site requirement. RCCB and RCBO shall conform to relevant IS.
10.4 Molded Case Circuit Breakers (MCCB)
MCCB shall be TPN and of rating as specified in the relevant BOQ item. It shall conform to IS:
13947/Pt-3/1993( Ics-100% Icu) with thermal release (fixed type) and breaking capacity of not
less than 25 KA. MCCBs shall be suitable for 3-phase, 415 V, AC supply.
10.4.1
Tripping unit shall be of thermal-magnetic type provided in each pole and connected by a
common trip bar such that tripping of any one pole results in simultaneous operation of all
the poles.
--------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 99 of 429
Dated 29.Jan 2015
RVNL
Page 100 of 429
RVNL
Tech. Spec. No.-RVNL/Elect/GS/11
EARTHING SYSTEM
Dated 29.Jan 2015
Page 101 of 429
Dated 29.Jan 2015
RVNL
Page 102 of 429
RVNL
CHAPTER-11
Tech. Spec. No.-RVNL/Elect/GS/11
EARTHING SYSTEM
11.0 GENERAL
The earth system shall conform to IS: 3043 and as per approved drawing of the Zonal Railway.
Types of earth systems:
a) Pipe Earth Electrode: Shall be normally provided for earthing of installations other
than
sub-station equipments.
b) Plate Earth Electrode : Shall be normally provided for earthing of sub-station
equipments.
11.1 Pipe Electrode Earth System
11.1.1 The earth electrode shall be made of G.I. pipe of 50 mm dia, medium class (class B)
conforming to relevant IS. It shall be 3.0 meter long and tapered at the lower end. The pipe
shall be drilled with 12 mm dia. holes at intervals of 75 mm from each other, up to 2.0 meter
from the bottom end.
11.1.2 The pipe electrode shall be buried in the ground vertically with its top nearly 200 mm below
the top of the enclosure.
11.1.3 A funnel with mesh shall be provided on top of this pipe for watering. Funnel attachment shall
be housed in the masonry enclosure.
11.1.4 The top of pipe electrode shall be housed in a masonry enclosure (finished) of not less than
400mm x 400 mmx300mm (internal size). The covers of the masonry enclosures shall be of
concrete with handle for lifting.
11.1.5 Normally an earth electrode shall not be situated less than 1.5m from any building. Care shall
be taken that the excavation for the earth electrode may not affect the column footings or
foundations of the building. In such cases, the electrode may be located further away from
building. The location of earth shall be such that the soil has reasonable chances of remaining
moist. Building entrances, pavements, roads etc. shall be avoided for location of earth
electrodes.
11.1.6 Earth resistance shall be reduced by artificial chemical treatment of the soil with sodium
chloride (common salt) mixed with soft coke or charcoal in suitable proportion in layers of
150mm. When this treatment is resorted to, the electrode shall be surrounded by the mixture
of charcoal/coke and salt.
11.1.7 The earth lead from earth electrode to equipment/pole/main switch etc. shall be of GI wire of
size (8 SWG or 25mm X 4mm GI strip). The earth lead for LT panel/feeder pillars shall be of
GI strip of size (25mm X 4mm GI strip). Earthing of internal wiring (point wiring, power plug
wiring, SDB etc) shall be done by means of PVC sheathed copper wire of same size as that of
wire used for relevant point wiring.
11.1.8 Earth lead shall be connected to pipe earth electrode by means of galvanized bolts, nuts,
washers & cable sockets.
11.1.9 All materials used for connecting the earth lead with electrode shall be of GI.
Dated 29.Jan 2015
Page 103 of 429
RVNL
11.1.10 The earth lead shall be securely connected at the other end
board/pole/structure/equipment/feeder pillar etc. with nuts, bolts, washers etc.
i.e.
main
11.1.11 The earth lead from electrode shall be suitably protected from mechanical injury and shall be
buried in ground at minimum 300mm depth when located outdoors. The portion within the
building shall be recessed in walls/floors at adequate depth.
11.1.12 No earth electrode shall have resistance greater than 5 ohms. In rocky soil, the resistance
may be up to 8 ohms.
11.1.13 Locations having more than one electrode shall be connected in parallel to reduce the
resistance.
11.1.14 In locations where the full length of pipe electrode is not possible to be installed due to
meeting a water table, hard soil or rock, the electrode may be of reduced length, provided the
required earth resistance result is achieved with or without additional electrodes, or any
alternative method of earthing may be adopted, with the prior approval of the Engineer-incharge.
11.2
PLATE EARTH ELECTRODE
a)
Substation equipments shall be earthed using Plate Earth Electrode. Metallic frame of all
equipments such as transformers, HT/LT switchgears/DG sets etc. shall be earthed at two
distinct points with GI Plate earth electrodes and neutral points of the transformer/s and DG
set/s shall be earthed at two distinct points with copper plate electrodes.
b)
Electrodes shall be connected in parallel to minimize resistance.
11.2.1 G.I. Plate Earth Electrode
For earthing HT/LT equipments/DG sets, GI plate earth. Electrode shall be 600mmx
600mmx6mm thick and shall be held vertical in ground with its top not less than 3.0 m below
ground level. The earth plate shall be embedded in alternate layers of coke and salt of 150mm
thickness so as to avail earth resistance not greater than 1.0 ohm.
11.2.2 A watering pipe of 20mm dia of medium class GI pipe shall be provided and attached to the
electrode. A funnel with mesh shall be provided on top of this pipe for watering the earth. The
watering funnel attachment shall be housed in masonry enclosure of not less than 40cm x 40
cmx30 cm inner size and shall be provided with hinged MS sheet/CI plate 10 mm thick and
having locking arrangement.
11.2.3 One end of GI earth strip of size 40mmx6mm or as specified in the relevant BOQ item shall be
securely bolted on the GI earth plate with two bolts, nuts, check nuts and washers, all
CADMIUM PLATED. Other end shall be brought above ground level vertically. The portion of
this strip that runs in ground shall be buried 500 mm below ground level to guard against
mechanical damage. The portion within the building shall be recessed in walls/floors at
adequate depth.
11.2.4 The strip shall be connected to the earth terminals of various HT/LT equipments/DG sets etc.
by means of cadmium plated nuts, bolts and washers.
Dated 29.Jan 2015
Page 104 of 429
RVNL
11.3
Copper Plate Earth Electrode
11.3.1 For earthing of neutral of transformers/DG sets, 600mm x600mmx3mm thick copper plate
earth electrode shall be held vertical in ground with its top not less than 3.0 m below ground
level. The earth plate is embedded in alternate layers of coke and salt of 150mm layers each,
to avail earth resistance less not greater than 1.0 ohm.
11.3.2 A watering pipe of 20mm dia of medium class GI pipe shall be provided and attached to the
electrodes. A funnel with mesh shall be provided on top on this pipe for watering the earth.
The watering funnel attachment shall be housed in masonry enclosure of not less than 400
mm x 400mm x300mm inner size and shall be provided with hinged MS sheet/CI plate 10mm
thick and having locking arrangement.
11.3.3 One end of copper strip of size 40x5mm or as specified in the relevant BOQ item shall be
securely bolted on the copper earth plate by means of two nos. of tinned brass bolts, nuts,
check nuts and washers as required. Other end shall be brought above ground level vertically
through GI pipe of 50 mm dia. or as specified in the relevant BOQ item. The portion of this
strip that runs in the ground shall be taken through medium class GI pipe 50 mm dia or as
specified in the relevant BOQ item, buried 500 mm under ground level to guard against
mechanical damage. The portion within the building shall be recessed in walls/floors at
adequate depth.
11.3.4 The strip shall be connected to the neutral terminals of transformer/DG set by means of
tinned brass bolts, nuts and washers, as required. To bring down the earth resistance, every
earth electrode shall be surrounded by charcoal and salt.
11.4
Every individual earth electrode shall be allotted a serial number and an earth plate of size
10x22 cm of 14 SWG sheet steel (painted black) fixed in a conspicuous position near the
earth. The following information shall be displayed with white or yellow paint on the earth
plate.
i)
Earth No……………………………….
ii)
Individual earth resistance…………….ohms.
iii)
Overall earth resistance…………………ohms.
iv)
Date of testing………………………………..
11.5
The following tests shall be carried out before the installation is commissioned.
i)
Earth resistance test.
ii)
Earth continuity test.
11.6
Materials and Sizes of Earth Electrodes
Pipe
Type of Electrode
Material
GI medium class
Size
50 mm dia 3.0 m long (without any joint)
Plate
(i) GI
60 cm x 60 cm x 6 mm thick
Strip
(ii) Copper
(i) GI
(ii) Copper
60 cm x 60 cm x 3 mm thick
40X6 mm section
Conductor
40X5 mm section
4 mm dia (8 SWG)
----------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 105 of 429
Dated 29.Jan 2015
RVNL
Page 106 of 429
RVNL
ELECTRICAL DRIVEN
SUBMERSIBLE PUMPS
Dated 29.Jan 2015
Page 107 of 429
Dated 29.Jan 2015
RVNL
Page 108 of 429
RVNL
CHAPTER:A-12
ELECTRICALLY DRIVEN SUBMERSIBLE PUMPS
12.0 System of Supply
The pump shall be, suitable to operate on single phase, 230V or 3-phase, 415 V, (+/- 10%), 50
Hz, AC supply system depending upon rating.
12.1 General Requirements
Electrically driven submersible pump set shall be ISI marked and star rated multi-stage,
suitable for operation in the specified diameter of bore well and capable of continuously
pumping clear water at specified capacity at the indicated head. Pump set shall be of 2900 rpm
(nominal) submersible electrical motor, suitable to operate on 415 V, 3 –phase, 50 Hz, AC
supply system equipped with integral non-return valve and all necessary accessories for the
application, whether specifically stated or not.
12.2 Pump
The Pump shall be of centrifugal type, fitted with multistage impellers, generally conforming to
IS: 8034/2002, suitable for trouble free operation in the bore well when submerged and
capable of easy installation in bore hole without damage to bore hole lining.
12.2.1 The pump shall be constructed with casing of high-grade cast iron of sufficient strength and
hardness for long lasting. Impellers shall be manufactured from high quality bronze and shall
be dynamically balanced. The shaft of the impeller shall be of hardened stainless steel for long
life. The impeller guide vanes and diffusers shall be of suitable design with special emphasis to
improve the efficiency of the pump.
12.2.2 The material used in all the parts of the pump and casing shall be suitable to withstand
corrosive action of the liquid to be handled by the pump and shall be designed for long
service.
12.2.3 All bearings/bushes used in the pumps shall be of water lubricating, high loading capacity,
synthetic thrust type. The sleeve bearings shall be of special lead bronze having a high
bearing load capacity.
12.2.4 The pump shall be complete with a suitable brass strainer at the suction side to prevent any
hard material from entering the pump.
12.3 Motor
12.3.1 The motor shall be squirrel cage type induction motor, suitable for operation with the pump,
capable of running on 230V, single phase or 415 V, 3 phase, 4 wire, 50 Hz, Ac supply
system(as specified). The motor shall be suitably rated to withstand any overload due to
higher discharge at a lower head and reduction in head up to 25 % of the specified head
without getting over loaded.
12.3.2 The motor shall be of “wet type” according to manufacturer’s standard design and generally
conforming to IS: 325.
Dated 29.Jan 2015
Page 109 of 429
RVNL
12.3.3The casing shall be of stainless steel, tube treated, so as to prevent corrosion and rust during
service. The starter winding shall be provided with one-ageing, waterproof, dense synthetic
molecular insulation so as to resist the environmental chemical influence and shall have
extremely high percussion strength.
12.3.4 The motor shall be assembled on hardened stainless steel shaft and supported on antifriction
thrust bearings of synthetic molecular insulation. The sleeve bearings shall be of special
bronze make. All the end thrust bearings shall be constructed from such material as to
ensured trouble free service and be water lubricated.
12.3.5 The motor shaft shall be fitted with synthetic rubber sealing rings and sand guard to prevent
sand and impurities from entering the motor. The motor shall be directly coupled to the pump
and shall be provided with a suitable device to prevent uncoupling when the motor is started
occasionally in the wrong direction.
12.3.6 The motor shall be equipped with suitable compensative device in order to protect the water
inside the motor from getting mixed up with well water which may contain some quantity of
sand etc. In the event of slight expansion of water inside the motor, the device shall give a
spongy action, to accommodate it and return to normal when the motor is not working.
12.3.7 The electrical cable shall be connected to the motor by means of perfectly watertight sealing
gland, to prevent water from entering the motor. The cable shall be protected by a strong
cable guard plate. Waterproof cable of suitable size and length shall be supplied.
12.4
Control Panel
The control panel shall be wall mounted, cubicle type suitable for outdoor weather proof
application with proper gasketing, complete with incomer TPN MCB 10 KA of suitable capacity,
starter, single phase preventer, accessories, internal connections with copper conductor cable
etc. and fabricated from 16 SWG CRCA sheet steel duly powder coated. Base plate shall be
detachable with cable gland/s. Panel shall be earthed with separate earth suitably.
12.4.1 Starter
The starter for the motor shall be push button operated type with under voltage and over load
release for direct on line starting and conforming to IS: 8544.
12.4.2 Indicator lamps for input supply for each phase, output supply
12.4.3 Suitable ammeter and voltmeter for each phase shall be provided.
12.4.4 Suitable electronic/microcontroller based motor protection relay with over/under voltage
protection, phase sequence, locked rotor, earth fault, over current protection, dry run
protection, single phase preventor, suitable timer control and measurement for running time
of pump.
12.5
Accessories
12.5.1 The submersible pump shall be supplied with the following accessories:
(a) Non-return valve streamlined for minimum friction and integral in each pump set. The
cone of the valve shall be fully quoted on the periphery valve seating shall be renewable
rubber ring type.
(b) Pressure gauge of suitable size and graduated in kg/sq.cm on the delivery side.
Dated 29.Jan 2015
Page 110 of 429
(c)
RVNL
The pump shall be supplied along with the test certificates and catalogue etc. issued by
manufacturer.
12.6 Pump and control panel should be suitably provided with two independent earthing system.
12.7 Foundation/Plinth for Centrifugal pumps
Centrifugal pumps set with motor shall be fixed on the proper designed plinth as specified by
OEM or as per approved drawing.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 111 of 429
Dated 29.Jan 2015
RVNL
Page 112 of 429
RVNL
Tech. Spec. No. –RVNL/Elect/GS/13
POWER DISTRIBUTION
TRANSFORMER
Dated 29.Jan 2015
Page 113 of 429
Dated 29.Jan 2015
RVNL
Page 114 of 429
RVNL
CHAPTER:A-13
Technical Specification No.–RVNL/Elect/GS/13
POWER DISTRIBUTION TRANSFORMER
13.0 General
The transformer shall be suitable for operation in tropical climate and for mixed load and for
continuous operation. It shall be natural cooled, outdoor/indoor type (as specified in the
relevant BOQ item) and star rated. The PF at full load shall not be less than 0.8 lagging. It
Distribution transformers shall conform to IS: 2026 ( Pt. I to Pt. IV)/1997 for more than 100
KVA rating and IS:1180 upto 100 KVA rating. The efficiency of the transformer shall not be less
than 98% at full load. It shall be supplied with first filling of inhibited mineral oil conforming to
IS: 12463-1988 capable of withstanding 50 kV (rms) voltage as per IS: 6792/1972.
13.1 Vector Group
The vector group shall be DYN 11.
13.2 Tapping
An externally operated, off load tap changer with suitable tap indicator and mechanical locking
device shall be provided for giving +/- 5% in steps of 2.5 % each on HT side or as specified in
the BOQ. The rated KVA of the transformer shall not be less than the rated capacity of the
transformer on extreme tapping positions.
13.3
Parallel Operation
The transformers shall be capable of operating in parallel.
13.4 TRANSFORMER CORE:
The transformer core shall be built up of cold rolled grain oriented plain strip laminations fully
processed and stress relieved and annealed having low loss and good ageing characteristics.
The laminations may be bolted together and the whole core fixed through bolts to the steel
frame adequate dimensions or also the construction may be tie rod type but in either case, the
design should be such that it prevents undue vibrations and noise in service. Wooden frame for
core fixing is not acceptable and contractor offer shall be specific about this.
The transformer shall be suitable for ever fluxing due to the combined effect of
voltage and frequency upto 12.5% on any tap without injurious heating. The maximum working
flux density at point shall not exceed 19000 lines per square centimeter on the basis M4 and M6
grade.
13.5 WINDINGS:
The winding shall be with double copper wound delta connected on primary, star with neutral
brought out for earthing purpose on secondary. The copper wires conforming to IS 7404 (Part 1
and 2)/1974 or the latest version for paper covered conductors shall be used for HV and LV
coils. The insulation of the conductors of the HV as well as LV coil shall be double paper
coverage (DPC).The vector group unless other wise stated in the appendix 'A', shall be DY 11.
Class of insulation for winding shall be 'A' class.
The LV wiring shall be circular and concentric with HV winding on the outside. Vertical duct shall
be provided for both HV and LV windings. The arrangements of the windings must be such that
there is no electrical and magnetic balance under conditions of operation. The design shall
permit free circulation of oil to ensure absence of hot posts. All similar coils shall be interchangeable. It is essential that the windings are subjected to a thorough shrinking and
seasoning process during manufacture so that no further shrinkage of windings occur during
early years of service. Adjustable screws shall be provided for taking up possible shrinkage of
Dated 29.Jan 2015
Page 115 of 429
RVNL
windings after a number of years of service. The general design and construction of transformer
and bracings of the windings shall be such that no mechanical movements of the coils will be
possible a dead shot on either sides of the transformer.
The short circuit ratings of the transformer shall be as per relevant clause of IS 2026/1977 or
latest.
The clearance between windings/live parts and nearest earthed parts shall be adequate for
sustained voltage of 110% of the rated operating voltage. The clearance between LT bushing
internal terminal windings and cord shall be adequate so as to facilitate interposing of protective
element if required.
13.6 TERMINAL ARRANGEMENTS:
a)
For out door type transformers: Bushing terminals shall be on HV side and cable end
box on LV side.
b)
For in door type transformers following arrangement shall be provided.
HV side: A trifurcating box for three core XLPE Cable suitable size and voltage. LV
side: A Cable box of suitable size and voltage to take a four core LT Cable.
13.7 TANK:
The transformer tank shall be rectangular and shall be fabricated with tested MS plates of not
less than 5mm thickness at sides top and bottom suitably reinforced and stiffened with ribs etc.
All joints of the transformer tank shall be welded both inside and outside in such a way that
they are fully hot oil type and such that no bulging occurs during service. The tank plates shall
be of such strength that the complete transformer filled with oil can be lifted bodily by means of
lifting lugs provided on the tank and the lifting lugs should be of adequate strength to cater for
this. This tank design shall be such that core and the windings can be lifted together freely out
of the tank with minimum dismantling.
The tank cover shall also be provided with suitable lifting lugs. The tank cover and
bushing joints shall be provided with superior quality oil resistant gaskets to render the tank full
watertight. In case of outdoor transformers, the cover design shall be such that rain water
drains out automatically. The cooling arrangement whether with circular or electrical tubes or
with radiators offered for the transformer shall be indicated in Appendix 'B'.
13.8 CONSERVATOR:
Conservator with its oil gauge filling and drain plugs breather shall be fixed to the transformer
tank cover. Air release device on the tank cover is necessary unless the conservator is so
located has to eliminate the possibility of air being trapped within the main time. Necessary
quantity of transformer oil sufficient for the transformers shall be filled along with the
transformer.
13.9 FINISH
The exterior of transformer tank and outer ferrous fitting shall be thoroughly cleaned, scrapped
and given a primary coat and two finishing coats of durable oil and weather resistance enamel
paint. The colour coats shall be dark admiral gray conforming to No.63 of IS 5/1961 for colours
for ready mixed paints or its latest version.
13.10 Provision of Additional Fittings
The transformers shall be provided with following additional fittings in addition to those
specified in IS-2026:
(a)
Rollers
(b)
Explosion vent.
(c)
Thermometer –dial Type.
(d)
Inspection covers
Dated 29.Jan 2015
Page 116 of 429
2.
RVNL
13.11 Tests
13.11.1 Routine Test
Tests as per Clause 16.1.2 of IS: 2026 (Pt.1)/1977 shall be witnessed at manufacturer’s
works by the nominated Inspecting Officer.
13.11.2 Type Test
Type Test certificates for similar transformer (same voltage class and same rating) as per
IS: 2026 (Pt.I)/1997 shall be furnished. A copy of the short circuit test as per Clause 16.11
of IS: 2026 (Pt.I) /1977, successfully carried out on similar transformers (same voltage class
and same rating, shall be supplied to the Inspecting Officer.
13.12 Earthing
The star point on the low voltage side shall be brought out for solid earthing with copper plate
using copper strip of suitable length as per earthing specifications enclosed.
Transformer body shall also be provided with independent earthing system other
than star point as specified in earthing specification enclosed.
13.13 Installation
Installation of transformers shall be done as per IS 10028 (Pt. II/1981). Suitable concrete
work for foundation or mounting arrangements on pole shall be done as directed by engineer
for erection of transformer.
13.14 Parameters for acceptance/rejection of transformers shall be as under:
ACCEPTANCE/ REJECTION PARAMETERS
SN
1
2
3
4
5
6.
IS Clause No.
4.3.1/2026
(Pt.
I)
(Operation at other than
rated voltage)
3.2/2026(Pt.II)(Temperat
ure rise)
Table 3.2026 (Pt. I) (
Impedance voltage)
Acceptance Limits
Limits within +/- 10 % of rated
voltage of particular tapping.
8.1.6/2026(Pt.I)
(Tap
changing equipment)
9.1.3/2026
(Pt.
I)
(duration of symmetrical
short circuit current)
Table
7/2026(Pt.
I)
(Tolerances)
Limits as specified
3.2/IS:2026 (Pt. II)
2 seconds
Limits as specified in Clause
3.2/IS2026 (Pt II)
i) 4.5% up to 630 kVA
ii) 5% above 630 kVA upto and
including 1000 kVA
in
Clause
As specified in Table-7
Rejection Limits
Limits exceeding +/- 10 % of
rated
voltage
of
particular
tapping
Exceeding Limits as specified in
Clause 3.2 of IS2026(Pt. II)
Exceeding limits
i) 4.5% up to 630 kVA
ii) 5% above 630 kVA up to and
including 1000 kVA
Less than Limits as specified in
Clause 3.2/IS:2026 (Pt. II)
Period less than 2 seconds.
Limits exceeding as specified in
Table- 7
13.15 Technical Specifications of Transformar Summary:
a
Particulars of a specification to
IS 2026 (Part 'A' to IV 1977or its latest version if any
Which the transformer should
confirm
b
No. of transformers required
As per BOQ
C
Type of transformer
Dated 29.Jan 2015
Double wound, core type
Page 117 of 429
RVNL
d
Single or polyphase unit
Polyphase unit
e
No. of phases in system
Three
f
Frequency
50 Hz +/- 3%
g)
Type of insulating and cooling medium
Inhibited Mineral oil to IS 12463:1988 with latest amndts.
h)
Service
Outdoor
i)
Type of cooling
Natural, oil cooled (ON) or as specified by purchase/Supply order
j)
Rated KVA on normal tapping (the
figures given are preferred ratings
Normal HV supply voltage
As per BOQ
No load voltage ratio at normal tap
11000/433 volts
Tapings required
+/- 2 1/2 , 5, 7 1/2 , 10% tapping on HV side
n
Type of tapping switch
OFF 3/4 load type with locking arrangements
o
p
Method of system earthing
Material of winding conductors
Solid earthing of neutral
Copper wire IS 7404 (Part I & II) / 1974
q
Insulation of winding conductors
Double paper covering (DPC)
r
Winding connection
HV delta LV: Star
s
t
Vector reference
Terminal arrangements
i) For indoor type transformers
DY.11
Suitably marked cable boxes with 3 terminals on HV side and 4
on LV side with neutral brought out for earthing
ii) For outdoor type transformers
3 bushings on HV side and 4 bushings on LV side suitably
marked
k)
l
m
11000 volts phase to phase +/- 10%
Note: a) Rods, nuts, washers etc. of all HV and LV bushing must be of brass only.
b) All bushings shall conform to IS 2099/1973 or its latest version.
13.16 Foundation and Fencing
Suitable foundation, fencing for the transformer shall be provided as specified in the BOQ. The
typical details for foundation and fencing (wherever required) shall be as under:
(i) Foundation
M10 type foundation shall be constructed with 20mm coarse aggregate.The size of foundation
shall be as per the approved drawing based on Transformer dimensions but shall not be less
than 2 x1.5mt Length x breadthX 600mm (height above ground level) duly plastered and finished
surface. Curing shall be done as per code applicable. Excavation shall be done complying with
Code of Safety as per IS 3764/1992(Latest Version).
(ii) Fencing
Fabrication of enclosure for housing transformer shall be made in rectangular formation as
required with M.S. angle iron 50x50x8mm spaced at about 2 meters and 12 SWG GI wire. The
design of the fencing panel shall be as approved by RVNL. MS strip not less than 15x3mm size
shall be provided and welded above the GI wire along the angle frame to hold the GI wire
Dated 29.Jan 2015
Page 118 of 429
RVNL
mesh. Height of enclosure shall be 2 meter above ground level. The portion of MS angle to be
grouted in foundation shall be 500mm.
The fencing panels shall be erected on foundation constructed of size 200mmx200mmx500mm
deep with cement concrete M10 grade.
(iii)
Iron gate: Iron gate shall be fabricated with M.S. angle 50x50x8mm iron frame with iron
grill etc as approved. The size of the gate shall be 2.0 m height X 3.5 m width and fabricated
in two parts of aprox size 1.75m each. Gate shall be provided with suitable sliding lock with
padlock. Gate shall be fixed on channels of size not less than 100 X 50 mm (weight 7.90
kg/m). Channels shall be erected on foundation constructed of size 300mm X 500mm deep
with M10 grade cement concrete.
(iv) Painting: MS portions of enclosure (fencing and gate etc) shall be painted with two coats of
red oxide primer and two coats of enamel paint of approved shade.
(vi) Approval of Drawing of Enclosure:
Drawing of the enclosure with gate etc shall be got approved from the Engineer prior to start
of the work.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 119 of 429
Dated 29.Jan 2015
RVNL
Page 120 of 429
RVNL
Tech. Spec. No. RVNL/ Elect./ GS/14
WATER COOLED SILENT DIESEL ENGINE DRIVEN
ALTERNATOR SET
WITH AMF PANEL
(30 KVA AND ABOVE UP TO 500 KVA)
Dated 29.Jan 2015
Page 121 of 429
Dated 29.Jan 2015
RVNL
Page 122 of 429
RVNL
CHAPTER:A-14
Technical Specification No.RVNL/ Elect./ GS/14
WATER COOLED SILENT DIESEL ENGINE DRIVEN
ALTERNATOR SET WITH AMF PANEL
(30 KVA AND ABOVE UP TO 500 KVA)
14
General
14.1 The DG set shall work as a single unit for catering to mixed load comprising electrical power
and for charging battery, average power factor of load being 0.8 (lagging). The set shall be
suitable for operation as per specified site conditions.
14.1 (a) Any equipment/accessory not specifically mentioned herein but essentially required for the
equipment to meet the site requirement shall be deemed to be included in the DG set.
14.1 (b) All the equipments shall conform to the latest version of BIS Specifications including the
following:
•
•
•
•
•
Indian Electricity Act 2003 & Rules framed there under.
BS5514/IS10000- Internal Combustion Engine.
BS2613/IS4722 – Electrical Performance of Rotating Electrical Machines
BS1271- Classification of Insulating Materials.
IS 13947 – Circuit Breakers.
14.2 Rated Power Output
14.2.1 The Diesel Generating Set shall be capable of delivering continuously (on 24 hours basis)
rated power output at 1500 rpm at site conditions and the engine shall conform to
IS:10000/BS5514.
14.2.2 The diesel engine shall be capable for working on 10% over load for one hour in any 12 hours
running.
14.3 Oil Engine
The diesel engine shall be cold starting, vertical direct injection, 4 stroke cycle, water radiator
cooled, turbo-charged, electric battery start, directly coupled to the alternator, mounted on a
combination base plate frame through a flexible coupling. A suitable extension pipe shall be
used with exhaust air chest so that the silencer can be mounted.
14.4 A fuel tank for storing the fuel oil with a capacity corresponding to 12 hrs. consumption of the
DG set shall be provided. The fuel piping shall be free from leakage and air locks. The fuel tank
shall be supplied with a level gauge to indicate the oil level in the tank and the tank shall be
marked to indicate the quantity of diesel oil in the tank.
14.5 Fuel tank shall be in built within an acoustic enclosure OR separately provided at a higher level.
14.6 The engine shall be suitable to run on Diesel Fuel Oil grade ‘ A’ to IS: 1460/2005.
14.7 Governor
The engine shall be supplied with an inbuilt electronic governor to maintain the engine speed at
varying loads. The governor shall conform to Class A-1 or G3 as per relevant BS/ IS
specification.
Dated 29.Jan 2015
Page 123 of 429
RVNL
14.8 The engine shall be complete with standard accessories and protective devices including the
following:
i)
Heavy duty dry type air cleaner.
ii)
Radiator
iii)
Fan for Radiator
iv)
Lubricating Oil Filters.
v)
Fuel Oil Filters.
vi)
Fuel injection equipment with governor to control the engine
speed up to +3%
under varying load conditions.
vii)
Engine speed control unit (manually operated).
viii)
Sump
ix)
Thermostat
x)
Safety control against low lubricating oil pressure, high cooling water temperature and
engine over speed.
xi)
Fly wheel to suite flexible coupling.
xii)
Exhaust silencer.
xiii)
Lube oil cooler and water pump.
xiv)
Fuel tank made of 14 SWG sheet with marking of 50 liter on clear transparent glass
gauge.
xv)
Corrosion Resistor.
xvi)
Self starter for electric start system with battery of adequate capacity with battery
charging alternator. (12V or 24V as per original equipment manufacturer
recommendations).
xvii)
Engine control panel comprising of:
a)
Oil pressure gauge.
b)
Water temperature gauge.
c)
Ammeter
d)
Hour meter with RPM indicator.
e)
Push buttons for starter/key switch starter.
f)
Pilot lamp
g)
Failure indicator.
h)
Battery Charging Indication.
i)
Magnetic pick up fail indication.
j)
HWT trip indication.
k)
LLOP trip indication.
l)
Over speed tripping cum indication.
xviii)
Tool kit complete (as supplied by the engine and alternator manufacturers)
xix)
One set of foundation bolts with nuts.
xx)
O&M manual of diesel engine
xxi)
Spare parts catalogue of diesel engine.
xxii)
Original Test Certificates.
14.9 Silencer Unit
Silencer Unit shall be specially designed, heavy duty, residential type, low noise, meeting the
sound pollution norms of Central Pollution Control Board (CBCB). The exhaust pipe shall be
wrapped with asbestos/ mineral wool and aluminium cladding and exhaust discharge shall be
designed in conformity with extant norms laid down by CPCB and local authority of the area.
14.10 Emission Related Parameters
Emission Related Parameters shall be in accordance with extant norms laid down by CPCB and
local authority of the area.
Dated 29.Jan 2015
Page 124 of 429
RVNL
14.11 Alternator
The alternator shall be self exciting, brush less, copper wound, self regulating with screen
protected enclosure, capable of generating 415 V, 3 phases, 4 wires, 50 Hz Ac supply ( with
neutral point brought out) at 1500 RPM. The alternator shall conform to BS: 5000/IS: 4722
and the winding shall conform to class F insulation. The alternator shall be provided with
Automatic Voltage Regulation (AVR) for regulating the output voltage within +/- 1% of the
rated voltage from no load to full load and permissible over load of 10 % for one hour in 12
hours operation.
14.12 Automatic Main Failure Control Panel (AMF Panel)
14.12.1 General
a) Auto main failure unit shall be capable of starting the Diesel Generating set in the event of
main power supply failure or low voltage below the specified value and changeover to load
from main supply to DG set.
b) The DG set shall start automatically on full load current within 10 seconds of the supply
failure and on restoration of main supply shall stop within 3 minutes after making the
changeover from DG set supply to main supply.
14.12.2 Constructional Features
The AMF panel shall be totally enclosed, made of mild steel of at least 14 SWG thick sheets,
free standing, floor mounted type and totally enclosed with degree of protection not less
than IP54. Front /Rear door of panel shall be hinged and locked. The cubical shall have
powder coating of specified colour to give long lasting finish. Wiring circuit diagram of the
AMF panel shall be affixed inside the cubical so that it is clearly visible when the front hinged
panel is removed. All the switchgears, control devices, push buttons, indication lamps etc.
shall be clearly labeled to indicate their operation. The wiring connections in the control
panel shall be ferruled.
14.12.3 Protection and Control Equipments
The following control devices and equipments shall be suitably housed in the cubical:
a)
Multifunction electronic panel meter with display
1 set
parameters – current, voltage, power factor,
frequency, kW, kWh, maximum demand etc.
b)
Mode Selector Switch for OFF/ AUTO/ MANUALl/TEST
1 Set
c)
Push button for start/stop/acknowledge/reset
1 set
d)
A set of indication lamps for the following indications
1 Set
Load on mains
Load on DG Set.
Low lube-oil pressure.
High coolant temperature.
e)
Battery charger consisting of:
Transformer
Rectifier
DC Voltmeter
Charging rate selector switch for trickle/booster charging.
Pilot lamps to indicate that charger is working.
On/off switch.
f)
Main supply air break contactor, four pole, of rating as under and provided with
suitable HRC fuses for short circuit protection- 1 set.
Dated 29.Jan 2015
Page 125 of 429
RVNL
SN
1
2
3
DG set Capacity
82.5 KVA
160 KVA
250 KVA
g)
h)
i)
j)
k)
l)
SN
1
2
3
m)
Alternator (DG set) Air break contactor of rating as above shall be provided with
separate overload relay for overload protection and provided with suitable HRC fuses
for short circuit protection – 1 set.
Main supply voltage monitor – 1 no.
DG control relays & timer for start/stop/three attempt starting facilities and failure to
start and lock.
Audio alarm hooter in case of low lube-oil pressure, high coolant temperatures, DG set
fails to start - 1 no.
Earth fault relays to cut off the field supply of the alternator.
Copper Bus bar of rating as under for phases and neutral on the basis of 1000
amp./sq. inch:
DG Set Capacity
82.5 KVA
160 KVA
250 KVA
DG Set Capacity
1
2
3
82.5 KVA
160 KVA
250 KVA
SN
1
2
3
Bus bar for Phases
250 amps
400 amps
800 amps
Bus bar for Neutral
200 amps
200 amps
400 amps
Incoming 4 pole MCCB of 50 kA as under:-
SN
n)
o)
Contactor Rating
4 pole contactors 250 amps.
4 pole contactors 400 amps
4 pole contactors 800 amps
4 pole MCCB ( Ics = 100% Icu) with thermal release
setting 70/80%-100%
160 amps
400 amps
800 amps
Provision shall be made to operate the DG set both on auto and manual mode.
Size of Cable
DG Set Capacity
82.5 KVA
160 KVA
250 KVA
Single
1x 120
1 x300
2x 400
core un- armored aluminium conductor cable
sq. mm for phases and neutral
sq. mm for phase and neutral
sq. mm for phase and 1x 400 sq. mm for neutral
14.13 Arrangement
The engine shall be directly coupled to the alternator through flexible coupling and both the
units including the radiator shall be mounted on a rigid fabricated bed plate. Base plate shall
have threaded holes for holding of down bolts for mounting engine and alternator.
14.14 Foundation/Plinth
Complete DG set shall be fixed on the proper designed plinth as specified by OEM or as per
RVNL approved foundation drawing.
14.15 Tests
The generating sets shall be tested at the manufacturer’s works for:
a) Guaranteed fuel –consumption
b) Over load Capacity
c)
Proper operation of protective devices provided for safety of the generating set and AMF
Panel.
Dated 29.Jan 2015
Page 126 of 429
RVNL
14.16 Acoustic Enclosure
The acoustic enclosure shall be conforming to CPCB requirements. In addition, the following
requirements shall also be met:
a) The acoustic enclosure shall be made of 14 SWG CRCA sheet steel.
b) The enclosure shall be of modular construction with the provision toassemble and
dismantle easily at site.
c) The enclosure shall be powder coated (inside as well outside) with a special pure
polyester based powder. All nuts and bolts/ external hardware shall be made from
stainless steel.
d) The doors shall be provided with high quality EPDN gaskets to prevent leakage of sound.
e) Noise Level shall not be more than 75 dBA at 1 meter distance
f)
Temperature of enclosure shall not exceed the ambient temperature by more than 7
deg. C.
g) The door handles shall be lockable type
h) Sound proofing of the enclosure shall be done with high quality rock wool/mineral wool
conforming to IS8183/1993. The rock wool shall be further covered with fiber glass tissue
and perforated sheet
i)
A special residential silencer shall be provided within the enclosure to reduce exhaust
noise.
j)
Adequate ventilation shall be provided to meet total air requirement.
k) There shall be a provision of emergency shutdown from outside the enclosure.
-------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 127 of 429
Dated 29.Jan 2015
RVNL
Page 128 of 429
RVNL
Tech.Spec.No.RVNL/Elect/GS/15
11 kV VCB HT PANEL
Dated 29.Jan 2015
Page 129 of 429
Dated 29.Jan 2015
RVNL
Page 130 of 429
RVNL
CHAPTER:A-15
Technical Spec.No.RVNL/Elect/ GS/15
11 kV Vacuum Circuit Breaker HT Panel
15.1
Scope
This specification covers manually operated, HT switchgear panels, suitable for 11000 volts, 50
Hz, 3- phase, 3-wire, alternating current, solidly earthed, electric supply system, complete with
all accessories. The panel shall be complete with interlocking feature, automatic safety shutters,
internal connections for inter-connections of panels, bus bar chamber, ON&OFF indicators, earth
sockets, with all the instruments and relays in position and duly wired up with copper conductor
cables and any other accessories though not specifically mentioned here but necessary to meet
the site requirements in all respects. HT panel shall be fabricated from CRCA steel sheet, 14
SWG, with anti-corrosive coating and powder coated finish of approved colour.
15.2 Particulars of Electric Supply
a)
Main Supply – 11000 volt 3 phase 50 Hz A. C.
b)
Supply for trip circuit – 110 Volt AC from 11000/110 volt potential transformer &
indicating circuits through Power Pack.
15.3 Details of Panels
15.3.1 HT switchgear shall be suitable for continuous operation at the specified site conditions.
15.3.2 HT panel shall be flush front, metal clad, horizontal draw out type and fully interlocked.
Each circuit breaker shall be housed in a separate compartment enclosed on all sides.
Each withdrawal truck shall have its own circuit breaker. The draw out mechanism shall
be so designed and constructed as to permit smooth withdrawal and insertion, free of
jerks, easy to operate and position.
15.3.3 Mechanical ON/OFF position indication shall be provided on the front of the circuit
breaker. The operating mechanism shall be mounted on the front panel of the truck.
15.3.4 Vacuum circuit breaker shall have an assembly of three vacuum interrupters of proven
design. The vacuum interrupters shall be of same make as that of the circuit breaker.
15.3.5 The operating handle and the mechanical trip push button shall be at the front of and
integral
with the circuit breaker.
15.3.6 The operating mechanism shall provide distinct and separate positions of the circuit
breaker on the cradle for:
•
Service
•
Test
•
Isolated
•
Maintenance
15.3.7 Sheet steel barrier shall be provided between:
•
Instrument panel and potential transformer
•
Instrument panel and current transformer
•
Bus bar chamber and circuit breaker compartment
15.4 Incoming Panel
The panel shall be indoor type, metal clad, extendable on both sides, horizontal draw out type
complete with interlocking features, automatic safety shutters, handle for raising and lowering
the switchgear and rollers for the rolling in /draw out truck etc. and shall consist of:
i)
One-triple pole vacuum circuit breaker, 11000 volt, 630 Amp. Rupturing capacity 350 MVA
at 11 kV (Symmetrical). IS
Dated 29.Jan 2015
Page 131 of 429
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
Xi)
Xii)
xiii)
xiv)
Note:
RVNL
Three- 630 Amps. Rating, air insulated, high conductivity copper bus-bars of uniform
cross-section for electrical purposes, suitably insulated with sleeves and extensible type on
the both ends.
One set- ON and OFF (Red & Green) clustered LED type indicating lamps.
Six- isolating plug contacts.
One- IDMT static relay with two current and one earth fault element with over current
setting range 50%-200%, earth fault setting range 10%-40%, short circuit setting range
200%-800% with flag indication and self reset arrangements.
One -110 Volt AC shunt trip release.
Three- Double wound resin cast current transformers, burden 15 VA, accuracy class 10 P10
for protection & class 1.0 for metering, ratio 60/30/5A (250 KVA and above up to and
including 500 kVA transformers).
One- Digital Ammeter of range suitable for the CT being used.
One- Digital Voltmeter of range 0-15 kV to work in conjunction with the PT offered.
One – 3x 11000/110 Volts, resin cast, potential (voltage) transformer, 100 VA, and
accuracy class 1.0 with protective fuses. The secondary for PT shall have terminals on
terminal block from where 110 Volt power supply can be extended to adjoining panels
through an extra set of kit kat fuses provided for the purpose.
One- Electronic Tri-vector meter (with 30 minutes integration ) for maximum demand
indicator of suitable range, for unbalanced loads.
One- cable box complete with accessories suitably mounted on the rear of the panel for
incoming cable.
One digital power factor meter.
Power Pack for tripping system.
The above mentioned tripping and measuring facilities should be provided in a single multi
function numerical relay cum meter to the extent feasible.
15.5 OUTGOING PANEL
The outgoing panels shall be of indoor type, metal clad, extendable on both ends, horizontal
draw-out type, complete with inter locking features, automatic safety shutters, handle for
raising and lowering the switchgear and rollers for rolling in /draw-out truck etc. and shall
consist of :
i)
One triple pole vacuum circuit breaker- 11000 volt, 630 Amp. Rupturing capacity 350 MVA
at 11 kV (Symmetrical).
ii) Three- 630 Amp, air insulated, high conductivity, copper bus bars of uniform cross section
suitable for electrical purposes, suitably insulated with sleeves and extensible type on both
ends.
iii) One set – ON and OFF( Red and Green), clustered LED type indicating lamps.
iv) Six isolating plug contacts.
v) One – IDMT static relay with two over current and one earth fault element over current
setting range 50%-200%, earth fault setting range 10%-40%, short circuit setting range
200 %-800%, with flag indication and self reset arrangements.
vi) One - 110 Volt shunt trip release.
vii) Three – Double wound, resin cast current transformers burden 15 VA, accuracy class 10
P10 for protection and indication, ratio 30/15/5A (250 KVA and above up to and including
500 kVA transformers).
viii) One- Digital Ammeter range suitable for the CT being used.
ix) One- cable Box complete with accessories suitably mounted on the rear of the panel for out
going cable.
x) Power Pack for tripping system.
Note:
The abovementioned tripping and measuring facilities should be provided in a single multi
function numerical relay cum meter to the extent feasible
Dated 29.Jan 2015
Page 132 of 429
RVNL
15.6 Standard Specifications
The equipments shall conform to latest version of the following BIS specifications:
1
2.
3.
4.
5.
6.
High voltage AC circuit breaker 11000 volt (VCB)
AC metal enclosed switchgear and control gear above 1 kV and
up to and including 52 kV (Switchgear Panel)
Copper strip for electrical purposes (Bus Bar)
Relays for Protection
Potential (voltage) Transformers
IS:13118/1991
IS: 3427/1997
IS: 1897/1983
IS:2705/1992
IS: 3231/1987
IS: 3156/Pt. I to III/1992
15.7 Equipment Specification
15.7.1 Circuit Breaker
The Circuit breaker shall be horizontal draw out type, triple pole, vacuum circuit breaker, for
indoor mounting, conforming to IS: 13118/1991. It shall have the following rating and features:
i)
ii)
iii)
iv)
v)
vi)
vii)
Duty
- General purpose.
Switch voltage
- 11 kV
Normal current
- 630 Amp.
Frequency
- 50 Hz
Phases
-3
Symmetrical Breaking Capacity
- 350 MVA
Tripping device: It shall be shunt release type on 110 V AC control voltage. It shall
trip the circuit breaker automatically in conjunction with the protective relay and also
when intended.
viii) Method of operation: Manual drive with auto closing features.
ix) The breaker shall be housed in a cubical of sheet steel construction (minimum 2 mm
thick) and totally enclosed. It shall be withdrawn horizontally. The breaker cubical
trolley shall be interlocked and of integral design with the main cubical so as to
prevent any mal- operation conditions.
15.7.2 11 KV/110 V Potential (Voltage) Transformer (PT)
The potential transformer shall be resin cast, draw out type, of accuracy class 1 with
protective fuses. These shall be designed for both protection and metering. Construction shall
be matched to suit the switchgear panel. Rated burden of the PT shall be 100 VA. The
secondary for PT shall terminate on terminal block, from where 110 V power supply can be
extended to adjoining panels through an extra set of kit kat fuses.
15.7.3 Current Transformer (CT)
Cast resin, moulded current transformers shall be provided for the panels and shall conform in
all respects to IS2705 (Pt. II & III)/1983. Accuracy shall be of class 1.0 for metering and
10P10 for protective relays. Current transformers shall be double wound and of ratio as per
requirement, based on the capacity of transformers to be installed/existing in the sub-station.
The construction shall be matched to suit the switchgear panel. Rated burden of CTs shall be
15 VA on the secondary side. The CTs design and construction shall withstand system thermal
and dynamic overloads.
15.7.4
Voltmeter
Voltmeter shall be digital type of size not less than 96x 96 mm, square, flush mounted and
shall conform in all respects to the relevant BIS specification. The voltmeter shall be suitable
for use in conjunction with the 11 kV/ 110 V PTs being offered. All meters shall be tested at
2000 V for one minute.
Dated 29.Jan 2015
Page 133 of 429
15.7.5
RVNL
Ammeter
Ammeter shall be digital type, of size not less than 96x96mm, square, flush mounted and
shall conform in all respects to the relevant BIS specification. The voltmeter shall be suitable
for use in conjunction with the CTs being offered.
15.7.6 Over Current And Earth Fault Relays
Static type over current& earth fault relays shall conform to the relevant BIS specification
and shall be suitable for the specified CT ratio. The relays shall have inverse time
characteristic for over current and operate instantaneously on faults. The relays shall be
provided with setting in steps from 50 to 200 % for over current, 200-800% for short circuit
setting and 10 to to 40% for earth faults. The relays shall also be provided with flag
indication as and reset arrangements.
15.7.7
Electronic Tri-vector Meter
The meter is required to be used in conjunction with the PTs and CTs in the main incoming
panel. This meter shall be suitable for recording 3 phase, unbalanced loads. The meter shall
be flush mounted and shall conform in all respects to the latest BIS standards. The
unbalanced load combination cum maximum demand (with 30 minutes interruption).
15.7.8 Construction of Panels
i)
The design, construction, enclosures, ventilation, interlocking, earth marking and testing of
HT 11 kV switchgear panels shall be in accordance with IS: 3427/1997. The degree of
protection shall not be less than IP42.
ii)
iii)
The panels are required to be installed indoors. They shall comprise copper HT bus bars,
VCB, auxiliary equipments and HT cable box etc. The panels shall be fabricated from CRCA
sheet steel not less than 2 mm thick. The panel shall be of self standing type and fixed to
bolts grouted in the foundation.
The cubical shall be finished uniformly with powder coating of specified colour.
iv)
All the equipments viz. VCB, bus bars, PTs, CTs, relays, measuring instruments, auxiliary
terminals blocks, HT cable in let and outlet, earth points etc. Shall be properly arranged
within the cubicles so as to facilitate easy maintenance and replacement. The measuring
instruments and operating switches shall be suitably arranged on the front cover of the
panel.
v)
Suitable interlocking arrangements shall be provided between the front covers and the VCB
switches so that the front cover is openable only when the respective VCB is in OFF
position.
vi)
All the Ht connections shall preferably be arranged at the bottom of the
cubicles.
vii) Proper double earth of the non-current carrying parts of all equipments and unit enclosures
shall be provided with GI strip of not less than 50 mm x 6mm size.
viii) The drawing of the HT panel shall be got prepared by the manufacturer and got approved
from the Engineer, by the contractor.
15.7.9 Space Heaters:
The Switchgear Panel shall have thermostatically controlled space heaters in each panel,
with a controlling 12 Amp, 230 V switch socket outlet, to eliminate condensation.
15.7.10 Power Pack
Suitable capacity power pack shall be provided for tripping circuits.
15.7.11 Type Test Certificates
Copies of type test certificates, successfully carried out on similar type of Vacuum Circuit
Breakers, complying with the relevant Indian Standards, from a recognized Test House/
CPRI shall be furnished.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 134 of 429
RVNL
Tech. Spec. No. RVNL/ Elect/ GS/16
AUTO POWER FACTOR
CORRECTION (APFC)
PANEL
Dated 29.Jan 2015
Page 135 of 429
Dated 29.Jan 2015
RVNL
Page 136 of 429
RVNL
CHAPTER:A-16
AUTO POWER FACTOR CORRECTION (APFC) PANEL
16.0 General
The APFC panel shall be totally enclosed, made of mild steel sheet 14 SWG, free standing, floor
mounting, indoor type, with degree of protection not less than IP42. The panel shall be
compartmentalized, fixed type, manufactured as per IS 8623 Pt. I & II/1993 & powder coated
with specified colour. The panel shall be suitable for operation on 3-phase, 4-wire, 415V, 50 Hz,
AC supply system, with automatic or manual switching arrangement for 10 step power factor
correction, to achieve power factor near unity. The capacitor bank shall be complete with interconnections. A continuous GI earth bus bar shall run at the bottom. It shall comprise of the
following items: (However, any other item, not specifically listed below, but required for
meeting the site requirement, shall also be deemed to be included.)
(1) Incomer shall be double the rating of panel i.e. 250A for 125 kVAR, 50 kA, MCCB 4 pole (Ics
= 100% Icu) conforming to IS 13947/ Part II.
(2) Microprocessor based Automatic Power Factor Control Relay of not less than 12 steps with
display of electrical parameters- i.e. power factor, current, voltage, etc. with following
specifications:
a. 415 V 50 Hz
b. Capacity 5 Amps
c. Intelligent type
d. Built in Automatic and manual control
e. Low current cut out relay,
f. Relay shall function even at low loads
g. It shall have data logging facility and sufficient memory back-up to log the data for 30
days or above.
(3) Indicating Lamp for incoming power supply with suitable back up protection.
(4) ON/ OFF indication lights for each set of capacitor
(5) Configuration of capacitor output – 10 steps x 12.5 kVAR each with switching ratio 1:2:3:4
(6) Knife type HRC fuses with base of suitable capacity for back up protection of capacitor duty
contactor for each capacitor bank.
(7) 3- Pole contactor of suitable rating (capacitor duty).
(8) Capacitor shall be low loss, self-healing type for Ac power system having rated voltage 650
V & conforming to IS13340/1993 & IEC 60831.
(9) TPN copper bus bars of 400 amp rating for phase and 200 amp rating for neutral, fitted on
insulators and PVC sleeves and duly colour coded.
(10) Suitable size cooling fan.
Dated 29.Jan 2015
Page 137 of 429
RVNL
(11) Inter connection of capacitor duty contactors to bus bars with suitable size PVC copper
conductor cable of 1.1 kV grade, with suitable lugs. Lugs, wherever required, for control
wiring of relays, meters, equipments and indicating light etc. Inter connection from MCCB with
suitable size copper bus bars, as required.
(12) LT XLPE armoured cable conforming to IS7098/Pt.1/1988 for connection of control panel to
main bus bar of LT switchboard. The cable shall be connected with suitable size of lugs and
glands.
(13) LT Current Transformer (CT) conforming to IS2705/Part I to IV, of suitable CTR, for
incoming feeder/s complete with four terminal at input side and two terminal at output side
including connection from incoming CTs to summation CT and APFC relay with suitable size
copper conductor cable with proper wiring arrangement.
(14) Suitable metering, indication and other accessories, as per site requirement.
---------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 138 of 429
RVNL
BATTERY CHARGERS
FOR
COACHING APPLICATIONS
Dated 29.Jan 2015
Page 139 of 429
Dated 29.Jan 2015
RVNL
Page 140 of 429
RVNL
CHAPTER: A-17
BATTERY CHARGERS FOR COACHING APPLICATIONS
17.0 General
The battery charging sets shall be natural air cooled type with full wave bridge connected silicon
rectifier stack and chokes for automatic limiting of variation of charging current due to mains
voltage fluctuation. The silicon rectifier diodes shall be of capacity such that when 6 diodes are
used for 3 phase rectification, the normal capacity of the bridge shall not be less than 175% of
rated rectification capacity. The silicon diodes shall be rated for 200 PIV or more. The silicon
rectifier equipment shall conform to IS4540/1968 of rating class-B/air cooled. The maximum
permissible temperature rise on winding shall not be more than 850 C. Battery charger for
following applications shall conform to RDSO specifications listed below:
(a) Static
Battery
charger:
RDSO/PE/SPEC/AC/0008(Rev-2)-2010
RDSO/PE/STR/AC/0013-2004 (Rev ‘0’)
and
STR
No.
(b) Pole mounted battery chargers for train lighting applications- EL/TL/52 (Provisional)
17.1 A maximum of 5% ripple shall be allowed. Surge suppressors and HRC fuses shall be provided
for protection of the rectifier diodes. Chokes shall be wound with copper conductors.
17.2 The rating of transformer provided in the battery charging set shall match the rating of
associated rectifier set. The transformer shall be double wound with copper conductor, naturally
air cooled, as per IS:2026 with class-F insulation, suitably impregnated to withstand moist
tropical climatic conditions. SFU/FSU incorporating HRC fuses and MCCB matching the
characteristics of diodes, shall be provided for the control of incoming AC supply. The SFU/FSU
& knife switch shall be mounted firmly on a steel frame work below panel sheets. Rewirable
fuses shall be provided for pilot lamps and indicating instruments. Two nos. of suitable capacity
knife switches shall be incorporated for the control of outgoing DC supply in addition to diode
protection type HRC fuses of suitable capacity. (2 nos. of knife switches, each of 200 amp.
Capacity, shall be provided for 2 nos. of outgoing cables).
17.3 The silicon rectifier battery charging set shall be capable of giving the rated DC output over the
entire range of 125 to 150 volts. The output voltage shall be capable of adjustment in this
range, for which purpose, coarse, medium and fine control, in not less than 4 steps, shall be
provided through suitable rotary control switches incorporated on the transformers.
17.4 The arrangement of silicon rectifier stacks, transformers and chokes shall be such that each
item can be dismantled independently, without disturbing the other equipments.
17.5 The battery charging sets are required for indoor use and shall be portable with 4 wheels. The
set shall consist of transformers, chokes, silicon rectifier, control switches, ON/OFF switches. DC
Voltmeter, Ammeter of moving coil type, flush pattern, of suitable range and interconnections
etc. Cabinet shall be of 14 SWG CRCA sheet steel and powder coated. The bus bars and inter
connections shall be of copper conductors.
Dated 29.Jan 2015
Page 141 of 429
RVNL
17.6 Over Loading
17.6.1 The rectifier transformer unit capacity shall withstand the following over loading:
i)
ii)
50 % over loading
100% over loading
- Continuously.
- One hour.
17.6.2 The transformer rectifier unit shall be such that on short circuiting the DC side of the rectifier
bridge, the short circuit current does not exceed 300% of the nominal rating of the rectifier
unit.
17.7
Compliance with Specifications
All the equipments shall conform to the following BIS specifications:
Mono-crystalline semi-conductor rectifier cells and
stack
Mono- crystalline semi-conductor rectifier assemblies
and equipment
Direct acting electrical indicating instruments
Heavy duty composite units of air-break switches and
fuses for voltage not exceeding 1000 volts.
MCCB
Rectifier transformer
IS 3895-66
IS4540-68
IS1248-68
IS13947-93
IS 13947-93
Clause 5 of IS4540-68 & IS2026
17.8.0 Tests
17.8.1 Type Tests: The manufacturer shall submit type test certificates for tests successfully carried
out on similar type of sets, to the inspecting authority.
17.8.1.1 The following routine tests shall be carried out by the inspecting authority and results
witnessed:
a)
b)
c)
d)
Insulation Resistance Test- Insulation resistance shall not be less than 2 ohm before
and after the high voltage test. The AC and DC side of rectifier set shall be short
circuited while testing.
Load Characteristic- The battery charger shall give 200 A at 150V Dc.
High Voltage Test- 1 kV shall be applied for 60 sec. and rectifier AC/DC side shall be
short circuited before applying the high voltage.
Load Test-The battery charger shall be connected to variable resistance of water
rheostat and measure the output voltage and current. Check the transformer and
temperature after 2 hours run. Check up the core noise or poor lamination or heating.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 142 of 429
RVNL
Tech. Spec. No.- RVNL/ Elect/GS/18
BATTERY CHARGING
AND
PRE- COOLING POINTS
Dated 29.Jan 2015
Page 143 of 429
Dated 29.Jan 2015
RVNL
Page 144 of 429
RVNL
CHAPTER:A-18
BATTERY CHARGING AND PRE- COOLING POINTS
18.1 Battery Charging Points
18.1.1 Battery charging points shall be constructed in two portions in separate enclosures in vertical
formation. One portion (upper) shall contain bus bars, MCB, provision for accommodating
incoming cable, outgoing looping cable to/from other point and cable connecting to Emergency
Feed Terminal(EFT) etc. and other portion (lower) shall contain EFT terminals for cable
connections to feed supply to batteries for charging. Doors shall be provided with locking
arrangement and open able with special key.
18.1.2 Battery charging points shall be cubicle type, weather proof, out door type, dust & vermin
proof, conforming to IS-8623 with degree of protection not less than IP54. It shall be suitable
for operation on 150V Dc supply system and fabricated with 14 SWG galvanized CRCA sheet
with pedestal of MS channel of size 100 x 50 mm (weight 7.914 kg/m), 1200 mm long, 2 nos.
aluminum bus bars of size 40x10mm, complete with one no. incoming MCB DP 63 Amps (DC
series) 10 KA. Detachable plate shall be provided on bottom for entry of incoming and
outgoing cables with suitably sized gland/s. Channel shall be fixed /welded with the enclosure
on back side in the centre of the enclosure at a specified distance from the top.
18.1.3 EFT (as per RDSO drawing already in use in Train Lighting system) feeding terminals shall be
of galvanized mild steel, suitably mounted on ebonite/Teflon sheet (approx. 12 mm thick),
fixed on the sheet of enclosure.
18.1.4 The feeding terminals shall be marked Red & Black for polarity (“+ve” and “-ve”). Suitable
space shall be provided between terminals.
18.1.5 The incoming connections from bus bars to MCB and from MCB to the feeding terminal (EFT)
shall be done with single core, 10 sq. mm, copper conductor cable, with suitably sized
galvanized Ms bolts, nuts and washers.
18.1.6 Enclosure and channel shall be powder coated and of the specified colour. Enclosure shall have
double earth terminals.
18.1.7 Erection
The channel of the battery charging point shall be grouted vertically in ground 300 mm deep
with cement concrete as per para 13.0 CH-1A. The clearance between the channel and edge
of foundation shall be minimum 200 mm and it shall be duly finished and cured. The muffing
shall be 200 mm above ground level.
18.1.8 All equipments and material used shall conform to the following BIS specifications:
S.N.
1
2.
Dated 29.Jan 2015
Material/Equipment
MCB
PVC copper conductor cable
BIS Specification No.
8828
694
Page 145 of 429
RVNL
18.2 Pre-Cooling Points
18.2.1The pre–cooling points shall be manufactured in two portions, in separate enclosures, in front
and back formation. Bus bar chamber shall be provided on back side of the enclosure and it
shall be capable of opening with special type of key. Front portion shall contain switch gears
and other items. Detachable plate shall be provided at the bottom for entry of incoming and
exit of outgoing cables, with suitably sized cable entry gland/s. Provision for incoming and
looping cables from/to other point shall be from bus bar portion. Connections to switch gear
shall be done with single core unarmoured aluminium conductor cable of size not less than 120
sq mm. Each enclosure shall have independent hinged flushed doors with sliding type lockable
arrangement, as well as concealed lock, open able with special key.
18.2.2 The pre-cooling point shall be manufactured from 3.15 mm CRCA sheet. Pedestals (4 nos. on
corners), shall be of MS angle of size 65x65x8 mm (900 mm long) with base frame of Ms angle
of size 40x40x5mm. MS angle pedestals (grouting portion approx. 150mm) shall be bifurcated.
The enclosure shall have double earth terminals.
18.2.3 The enclosure and pedestals shall be powder coated with specified shade.
18.2.4 (a) Pre-cooling portion shall be provided with
utilization/operation without opening the front door:
the
following,
on
the
front
for
i) One no. 100 A, 4 pole, MCCB 35 kA (Fixed type )
ii) One no. 63A industrial type, iron clad 5 pin (3P +N+E)415 V plug socket with spring
locked cover.
iii) One No. 32 A Industrial type iron clad 3 pin (P+N+E) 250 V plug socket with spring
locked cover.
iv) Batten Holder fixed on Bakelite sheet base plate with suitable lamp and controlled by 5
A piano type switch.
v) 300 A Aluminium bus bar for Phases & 200 A for Neutral, with epoxy coating/ PVC
colour coded sleeves.
vi) Cable entry glands of suitable size
vi) LED indication lights.
b) The connections from bus bars to MCCB and from MCCB to the feeding terminal (Iron Clad
Sockets) shall be done with single core, copper conductor cable of suitable rating with
suitably sized galvanized MS bolts, nuts and washers.
18.2.5 All equipments and material used shall conform to the following BIS specifications:
SN
1.
2
3
4
5
Material/Equipment
MCCB
MCB
LTXLPE Cable
Industrial type plug socket
PVC insulated copper conductor cable
BIS Specification No.
13947
8828
7098/Pt.1/1985
13947
694
18.2.6 Erection
Pedestals shall be grouted vertically 300 mm deep in ground with cement concrete as per para
13.0 CH-1A. They shall be 200 mm in diameter, duly finished and cured muffing 200 mm
above ground level.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 146 of 429
RVNL
SOLAR HOME & STREET LIGHTING SYSTEM
Dated 29.Jan 2015
Page 147 of 429
Dated 29.Jan 2015
RVNL
Page 148 of 429
RVNL
Chapter: A-19
SOLAR HOME and STREET LIGHTING SYSTEM
(Ref: RDSO spec no. RDSO/PE/SPEC/PS/0093-2008 (Rev. 0) Amnd-3)
19.0 Solar Home Lighting:
GENERAL: Solar Home Lighting System shall comprise of lead acid battery, PV module, module
mounting hard-ware, battery box, compact fluorescent lamp complete with
luminaries, Fan, control electronics, interconnecting cables/ wires etc.
19.1 Load: Solar home lighting system shall provide solar electricity for operating 2 lights and 1 fan
for 24 hours continuously.
19.2 COMPONENT DETAILS:
i) PV MODULE
2 X 37Wp or 1 X 74Wp
ii)
Lamp
2 X CFL /LED (11W)
iii)
Fan
1 X DC Fan (with wattage less than 20 W)
iv)
Battery
1 X 12 V, 75 AH minimum
V)
Other
Components
Control electronics, module mounting hardware, and battery box of
thickness not less than 0.71 mm (made up of MS Sheet), interconnecting wires/ cables, switches etc.
NOTE:
a) All the item shall be as per latest MNES specifications (latest) and shall possess satisfactory
test certificate issued by Solar Energy Centre or any other approved testing centre by
MNES.
b) PV Modules manufacturer should be MNES approved.
c) The lamps should be housed in an assembly suitable for indoor use, with a reflector on its
back. While fixing the assembly, the lamp should be held in a base up configuration.
19.3 SPECIFICATIONS OF COMPONENTS:
19.3.1 BATTERY:
a) The battery will be of flooded electrolyte type, positive tubular plate, low, maintenance lead
acid battery.
b) The battery will have a minimum rating of 12V, 75 Ah at C/10 discharge rate.
c) 75% of the rated capacity of the battery should be between fully charged & Load cut off
conditions.
d) The Battery shall be of standard makes of Panasonic, Exide, Amaraja, Hitachi, CSB, and
Tata BP
19.3.2 ELECTRONICS & ELECTRONIC PROTECTIONS:
a) The inverter should be of quasi sine or full sine wave type with frequency in the range of
20-35 KHz. Half wave operation is not acceptable.
b) The total electronic efficiency should be at least 80%.
c) No backening or reduction in the lumen output by more than 10% should be observed after
1000 ON/OFF cycles (two minutes ON followed by four minutes OFF is one cycle.
d) The idle current consumption should not be more than 10 mA.
Dated 29.Jan 2015
Page 149 of 429
RVNL
e) Electronics should operate at 12 V and should have temperature compensation for proper
charging of the battery though out the year.
f) Necessary lengths of wires/cables, switches suitable for DC use and fuses should be
provided.
g) Adequate protection is to be incorporated under no load conditions e.g. when the lamps are
removed and the system is switched ON.
h) The system should have protection against battery overcharge and deep discharge
conditions.
i) Fuses should be provided to protect against short circuit conditions.
19.3.3 PV MODULE(S):
a) The PV module(s) shall contain crystalline silicon solar cells.
b) The power output of the module(s) under STC should be a minimum of 37W or 74W i.e. two
modules of 37 W each or one module of 74W should be used.
c) The operating voltage corresponding to the power output mentioned above
d) Should be 16.4 V
e) The open circuit voltage of the PV modules under STC should be at least 21.0 Volts.
19.3.4 MECHANICAL COMPONENTS:
Metallic frame structure (with corrosion resistance paint) shall be fixed on the roof of the house
to hold the SPV module(s). The frame structure should have provision to adjust its angle of
inclination to the horizontal between 0 and 45, so that it can be installed at the specified tilt
angle.
19.3.5 INDICATIONS :
The system should be provided with 2 LED indicators, a green light to Indicate charging in
progress and a red LED to indicate deep discharge condition of the battery. The green LED
should glow only when the battery is actually being charged.
NOTE:
Components and parts used in solar home systems should conform to the latest BIS
specifications, wherever such specifications are available and applicable.
19.4 Solar LED Street Light system:
19.4.0 Solar Photo Voltaic (SPV) based LED street lighting system shall consists of the following
elements –
(a) SPV Module to convert solar radiation directly into electricity.
(b) 7 m height GI pole with necessary accessories.
(c) Battery bank to store the electrical energy generated by SPV panel during day time.
(d) Charge controller to maintain the battery to the highest possible State of Charge (SOC)
while protecting the battery from deep discharge (by the loads) or extended overcharge
(by the PV array).
(e) Blocking diode, preferably an Schottky diode, connected in series with solar cells and
storage battery to keep the battery from discharging through the cell when there is no
output or low output from the solar cell, if such diode is not provided with the module
itself.
(f)
15 W LED based luminaire as a light source.
(g) Interconnecting wires/cables & hardwares.
The
entire
system
shall
be
in
accordance
with
RDSO
specifications
RDSO/PE/SPEC/PS/0093-2008 (Rev. 0) Amnd-3 except pole shall be 7m GI in place of
6m MS given in RDSO specifications. The salient features of the system are listed below:
19.4.1 GENERAL REQUIREMENTS
Dated 29.Jan 2015
Page 150 of 429
RVNL
The system shall be designed to have 4 days autonomy (i.e. system will run for 4 consecutive
days without charging from the panel).
19.4.2 Battery Bank:
(a) The storage battery Bank shall have enough capacity to keep the system going on
without break down when the weather is not favourable for generation of electricity due
to cloudy days and rains.
(b) Battery shall be Tubular Lead Acid, Low Maintenance type with low antimony lead alloy
plates and ceramic vent plugs and water topping interval of 6months which are specially
designed to be charged & discharged frequently and can handle heavy discharges time
after time with minimum charging efficiency of 90%.
(c) The container material shall be PP
(d) Battery shall have a design life expectancy of >5 years at 50% DOD at 27°C.
(e) The permissible self-discharge rate shall be less than 2% of the rated capacity per month
at 27°C.
(f) The charging instructions shall be provided alongwith the batteries.
(g) Batteries shall be provided with micro porous vent plugs & acid level indicator.
(h) The batteries shall be discharged up to 80% DOD and battery shall be
accordingly sized.
(i) Suitable Battery Box made of Plastic OR M.S fabricated shall be provided to house the
battery.
(j) The minimum capacity of the battery bank shall be 12V/75 Ah @ C10
(k) Alternatively VRLA type battery of proven design for such application may also be
considered provided such battery have been in such application for more than 3 years
satisfactory service.
(l) The Battery shall be of standard makes of Panasonic, Exide, Amaraja, Hitachi, CSB, and
Tata BP
19.4.3 Cables and Hardware
19.4.3.1 Cable shall meet IS:694 Part 1:1988 & shall be of 650 V/ 1.1 kV.
19.4.3.2 A metallic frame structure (with corrosion resistance paint) to be fixed on the pole to hold the
SPV module(s). The frame structure should have provision to adjust its angle of inclination to
the horizontal between 0 and 45 so that the module(s) can be oriented at the specified tilt
angle.
19.4.4 POLE
GI tubular pole shall be swaged type made from steel of ultimate tensile strength 410 MPa (42
kg/mm2) as per IS: 2713 (Pt. I, II and III) 1980 amended up to date. The pole shall be as per
IS designation 410 SP-3. Each pole shall be provided with 16 mm dia GI earth terminals of
suitable length for earth connection. Pole shall be suitable to wind pressure of not less than
150 KMPH. Drawing of pole shall be got approved from the RVNL Engineer.
Dated 29.Jan 2015
Page 151 of 429
RVNL
Outside diameter & Base Plate
thickness of sections Dimen
(mm)
sions
(LxBxT)
Bottom Middle Top
Top
Middle
Length of
Sections (m)
Bottom
Desi
gnat
ion
FOUNDATION BOLT
Bolt Size Pitch
(no.xdia) Circle
(mm)
Dia.
Anchor
Plate
Thickne
ss
Bolt
Length
(mm)
(mm)
(mm)
410- 4.00 1.50 1.50 114.3x
SP-3
5.4
88.9x
4.85
76.10 220X220X
x 3.25 12
4X20
205
700
3
Foundation in mm
STANDARD DIMENSIONS OF POLE
500x5
00x
1250
(dept
h)
19.4.5 FOUNDATION:
Foundation for erection of pole shall be constructed at the approved location.
After excavation of pit of suitable size, cement concrete bed of approx.50mm thickness, using
cement concrete as per para 13.0 Chapter-1A, shall be first provided at the bottom of the pit.
Square foundation shall be made with cement concrete as per para 13.0 Chapter-1A of size as
specified in the above table of standard dimensions of pole up to 150mm above ground
level. Muffing shall be in level, plastered, finished & also cured. After foundation work, the pit
shall be filled with excavated earth. During back filling of earth, ramming and watering shall be
done.
19.4.6 ERECTION OF POLE:
The pole shall be erected in plumb on constructed foundation at the specified location and
bolted on a pre- casted foundation with a set of four bolts. Top of all the poles shall be at the
same level to maintain uniformity.
NOTE:
1.
2.
Components and part used in the solar street lighting systems should conform to the latest
BIS specification. Wherever such specifications are available and applicable.
All the item shall be as per latest MNES specification and manufacturer shall possess
satisfactory test certificate issued by Solar Energy Centre or any other approved testing
centre by MNES and same shall also be furnished at the time of inspection and copies of the
same shall be supplied with supply of material/equipment.
----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 152 of 429
RVNL
Solar Water Heater
Dated 29.Jan 2015
Page 153 of 429
Dated 29.Jan 2015
RVNL
Page 154 of 429
RVNL
CHAPTER: A-20
SOLAR WATER HEATER
(Ref: RDSO spec no.
RDSO/PE/SPEC/PS/0094-2008 (Rev-0) AMDT-1)
20.0 SCOPE
20.1 This specification covers the general and technical requirements of solar based water heating
system both flat plate collector (FPC) or Evacuated Tube collector (ETC) type system. Normally
FPC type water heater shall be installed unless and otherwise specifically mentioned in BOQ.
20.2 Work includes supply, erection testing and commissioning of solar based water heating system
complete with Solar Collectors, Insulated Tank, Supporting Stand, system piping,
instrumentation, electric back up, controls, etc including CONNECTIONS UP TO UTILITY POINTS
of the existing arrangement/system as required.
20.3 REFERENCE STANDARDS
IS: 12933:Pt.1/2003
Solar Plate collector – Specifications Part:1 Requirements
IS: 12933:Pt.2/2003
Solar Plate collector – Specifications Part:2 Components
IS:1570-Pt.5/1985
(Reaffirmed 1998)
IS:12931:1990
Schedule of Wrought steels Pt.5 :stainless & heat resisting steel
IS: 1239:1990 Pt.2
(Reaffirmed 2002)
Mild Steel tubes & other wrought steel pipe fittings
Solar Energy- Thermal applications-Vocabulary
20.4 SYSTEM DESCRIPTION
Solar water heating system shall comprise of following:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
Solar flat plate/Evacuated Tube collector (FPC/ETC type)
Collector stand assembly
Stainless steel insulated hot water storage tank
Heat transfer medium(i.e. water)
Heat Exchanger (where water is hard and more chlorine content)
Inter connecting plumbing
An auxiliary heater
20.5 GENERAL
Solar water Heater device shall be operative on Flat Plate Collector/ETC covered by an insulated
metallic box with glass sheet on top to receive sun rays and suitable for normal, hard water &
pressurized applications for heating capacity per day as specified in BOQ item/s. All systems
shall conform to BIS & MNES standards and specifications. System shall be suitable to heat
water between the ranges 60-80 degree centigrade. System output temperature shall normally
be 60 degree centigrade.
20.6 PIPING & NON RETURN VALVE
Piping from collector to storage tank shall be insulated. Non return valve shall be provided in
the piping system.
Dated 29.Jan 2015
Page 155 of 429
RVNL
20.7 HOT WATER STORAGE TANK
Storage tank shall be double walled. Space between inner and outer walls shall be filled with
insulation to prevent heat losses. Inner tank shall be made with stainless steel and outer tank
shall be made of galvanized sheet steel/aluminium sheet and powder coated of approved shade.
Capacity of tank shall be equal to the capacity of system.
20.8 ELECTRIC BACK UP
Thermostatic controlled, electrical heating element shall be of 2000 watts and shall be
connected with the nearby supply point (power plug point) with 3 x4 sq.mm FRLS PVC insulated
copper conductor cable.
20. 9 WIRING
All control and sensing wiring shall be housed in MS conduit.
20.10 Technical Requirements
(a) Flat Plate Collectors: ISI mark (2 sq. m. absorber area per100 liter tank capacity system.
(b) Evacuated Tube Collectors/ Heat pipes:
Type of tubes
3 layer solar selective (Inner layer of copper coating should be visible).
Detailed specifications of tubes will be as per the guidelines laid down by
MNRE for empanelment of anufacturers of ETC based systems.
No. of tubes in a
system
To have minimum 1 ½ sq. m. of absorber area per 100 litre tank
capacity system. Absorber area will be calculated as follows:
Area in Meter = No. of tubes X Radius in Meter X Length in Meter.
Accordingly, 14 tubes of Dia: 47 mm & length: 1500 mm and 10 tubes
of Dia 58 mm & length: 1800 mm will be required for each 100 lpd
system.
For higher capacity systems, the no. of tubes calculated as per above
could be slightly less. For details, please refer to MNRE Circular no.
25/5/2009-10/ST dated 2nd March, 2010
Procurement
From reputed MNRE approved suppliers.
(c) Storage Tanks, Piping, Support structure etc
Inner tank
material
Inner tank
thickness
SS 304 or 316 grade min/ MS or any other material with
anti-corrosive coating for hard water with chlorine contents.
For SS
minimum thickness will be 0.5 mm when using argon Arc or
metal inert gas for welding & 0.8 mm when using other type of welding.
For MS it will be 1.5 mm. No leakage under any kind of negative or
positive pressure of water will be ensured.
Inner tank
welding
Storage tank
capacity
Thermal
TIG / Seam/ pressurized weld (Open arc weld not permitted).
Dated 29.Jan 2015
Not less than system capacity. In case of ETC based system,
of tubes & manifold not to be included in tank capacity.
Minimum 50 mm thick CFC free PUF having density of
volume
Page 156 of 429
RVNL
insulation of
storage tanks
Thermal
insulation of hot
water pipes
Outer cladding &
Frames
Valves, cold
water tank vent
pipe, heat
exchanger, make
up tank &
instruments.
Support
structure for
Collectors, pipng,
tanks etc.
28-32 kg/ cum for domestic systems and 100mm thick Rockwool of 48
kg per cu. m for other systems. For colder regions, it will be 1½ times
atleast. In case of higher density insulations, the thickness may reduce
proportionately.
Minimum 50 mm thick rock wool or 25 mm thick PUF on GI pipes. For
colder regions, it will be 1½ times at least. For higher density
insulations, the thickness may reduce proportionately.
Al/ FRP or GI powder coated. MS may also be used with Special anticorrosive protective coatings. Thickness of sheets will be strong enough
to avoid any deformation of the cladding.
Of ISI mark
Of non corrosive material or have corrosion resistant Protective
coating. They will be strong enough to sustain their pressure during
the lifetime of system.
20.11
MOUNTING OF SYSTEM
System should be mounted on a rigid structure in such location to allow access all the
equipments for maintenance, repair and replacement and should be firmly fixed in an
approved manner to prevent damage during high winds up to 200 kmph.
NOTE: IT SHALL BE ENSURED THAT THE SYSTEM SHALL NOT BE NEAR ELECTRIC
POWR LINES.
20.12
At places where water is hard and has larger chlorine content, if FPC based system is proposed
for installation, heat exchanger should be installed alongwith to avoid scale deposition in
copper tubes of solar collectors which can block flow of water as well as reduce its thermal
performance.
20.13 INSTALLATION
Solar collector array shall be installed at the proper tilt angle, orientation and the elevation
above roof and shall have proper exposure to sun throughout the day.
------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 157 of 429
,
Dated 29.Jan 2015
RVNL
Page 158 of 429
RVNL
LIGHTENING ARRESTER
Dated 29.Jan 2015
Page 159 of 429
Dated 29.Jan 2015
RVNL
Page 160 of 429
RVNL
CHAPTER:A-21
Lightening Arrester
21.0 Lightening arresters shall be provided on the buildings where large public congregates, essential
public services are concerned, lightening strokes are prevalent, or in structures which are very
tall, isolated, or are historical or cultural importance. The other buildings may also be provided
with lightening arrestors as per risk assessment analysis given in the IEC 62305 chapter-2. The
lightening arresters are governed as per IEC 62305 and BIS 2309.
21.1 Generally lightening protection in installation having nuclear or sensitive electronics are provided
with Level1 Lightening protection whereas buildings housing Data Centre and building taller
than 20 meter height in isolated location are provided level 2 lightening protection, other
buildings having electronics or human occupancy requires level 3 protection and godown having
no electronics will require level 4 lightening protection.
21.2 General Description
Lightening Protection System shall be in accordance with IEC 62305-3, IS:2309 & IS:3043.
21.3 Principle of Protection
The principle for protection of buildings against lightning is to provide a conducting path
between earth and the atmosphere above the building through which the lightning discharge
may enter the earth without causing damage to the building. If adequately earthed metal parts
of proper proportions are provided and spread properly on and around the building, damage
can be largely prevented.
The required conditions of protection are generally met by placing all the air terminals, whether
in the form of vertical finials or horizontal conductors, on the upper most part of the building or
its projections, with lightning conductors connecting the air terminals with each other and to
the earth.
21.4 Zone of Protection
The zone of protection of a lightning conductor defines the space within which Air Terminal
provides protection against a direct lightning strike with probability of protection as per LPL.
21.5 Protective Angle
This cannot be precisely stated, since it depends upon the severity of the stroke and the
presence within the protective zone of conducting objects providing independent paths to the
earth. All that can be stated is that the protection afforded by a lightning conductor increases
as the assumed protective angle decreases.
(a) However, for the practical purpose of providing an "acceptable degree" of protection for an
ordinary structure, the protective angle of any single component part of an air termination
network, namely, either one vertical, or one horizontal conductor is considered to be 45
degrees.
Dated 29.Jan 2015
Page 161 of 429
RVNL
(b) Between three or more vertical conductors, spaced at a distance not exceeding twice their
height, the equivalent protective angle may, as an exception, be taken as 60 degrees to the
vertical.
(c) Protective angles of zones of protection for some forms of air termination are illustrated in IS
2309 : 1989.
21.5.1 Lightning Protection Level(LPL)
LPL is a number associated with a set of lightning current parameters relevant to the probability
that the associated minimum & maximum values do not exceed the normally occurring
lightning. LPL can be determined by Risk analysis as explained in IEC 62305-2.
Sr No
LPL
1.0
2.0
3.0
4.0
LPL
LPL
LPL
LPL
Level
Level
Level
Level
1
2
3
4
Lightening Current Peak
Value Min
3 KA
5 KA
10 KA
16 KA
Lightening Current
Peak Value Maximum
150 KA
150 KA
100 KA
100 KA
Air termination system is to intercept the Lightning current. It consists of vertical air terminal or
Mesh conductor or the combination. No drilling or welding is allowed in the terrace for fixing the
air terminal.
Values of Rolling sphere radius, Mesh size and protection angle as per Class of
LPL/LPS.
Clas of
LPL/LPS
Rolling sphere
radius (m)
Mesh size (m)
Protection angle
Protection angle
1
20
5*5
Refer Graph Below
2
30
10*10
3
45
15*15
4
60
20*20
Dated 29.Jan 2015
Page 162 of 429
RVNL
Class of LPS
80
70
a0
60
50
40
30
IV
I
II
III
20
10
0
10
20
30
40
50
60
H m
If the structure height is more than 60 meters, top 20% of the height of the structure shall be
protected with a lateral air termination system. This is needed because, the probability of flashes to
the side is generally more for structures more than 60 meters in height. For structures of height
more than 120 meters, ring has to be formed for every 20 meters height of the building above 60
meters height.
21.6 Principal Components
The principal components of a lightning protective system are :(a) Air terminations,
(b) Down conductors,
(c) Joint and bonds,
(d) Testing joints,
(e) Earth terminations, and
(f) Earth electrodes.
21.7 Materials
The materials of air terminations, down conductors, earth termination etc. of the protective
system shall be reliably resistant to corrosion, or be adequately protected against corrosion.
The material shall be one of the following, as specified.
(a) Copper: Solid or flat copper strip of at least 98% conductivity conforming to
relevant I.S. Specifications shall be used.
(b) Copper Clad Steel: Copper clad steel with copper covering permanently and
effectively welded to the steel core shall be used. The proportion of copper and steel shall be
such that the conductance of the material is not less than 30% of conductance of the solid
copper of the same total cross-sectional area.
(c) Galvanized Steel: Steel thoroughly protected against corrosion by a zinc coating shall be used.
(d)
Aluminium: Aluminium, 99% pure, and with sufficient mechanical strength, and
protected against corrosion shall be used.
Dated 29.Jan 2015
Page 163 of 429
21.7.1
RVNL
Aluminium should not be used underground, or in direct contact with walls.
21.7.2 All air terminations shall be of GI and all down conductors shall be of GI or aluminium, except where the
atmospheric conditions necessitate the use of copper or copper clad steel for air terminations and down
conductors.
21.7.3 The recommended shape and minimum sizes of conductors for use above and below ground are given in Table1 and 2 respectively.
21.8 Layout
The system design and layout shall be done in accordance with IS 2309: 1989 and specified in the tender
documents.
21.8.1 Air Terminations
(i) Air termination networks may consist of vertical or horizontal conductors, or combinations of both. For the
purpose of lightning protection, the vertical and horizontal conductors are considered equivalent and the use
of pointed air terminations, or vertical finial is, therefore, not regarded as essential.
(ii) A vertical air termination, where provided, need not have more than one point, and shall project at least 30 cm,
above the object, salient point or network on which it is fixed.
(iii) For a flat roof, horizontal air termination along the outer perimeter of the roof shall be used. For a roof of
larger area a network of parallel horizontal conductors shall be installed. No part of the roof should be more than
9 m from the nearest horizontal protective conductor.
(iv) Horizontal air terminations should be carried along the contours such as ridges, parapets and edges of flat
roofs, and, where necessary, over flat surfaces, in such a way as to join each air termination to the rest, and
should themselves form a closed network.
(v) All metallic projections including reinforcement, on or above the main surface of the roof which are
connected to the general mass of the earth, should be bonded and form a part of the air termination network.
(vi) If portions of a structure vary considerably in height, any necessary air terminations or air termination network
for the lower portions should be bonded to the down conductors of the taller portions, in addition to their own
down conductors.
21.8.2 Down Conductors
The function of a down conductor is to provide a low impedance path from the air termination to the earth
electrode so that lightning current can be safely conducted to the earth. In practice, depending upon the form
of a building, it is often necessary to have many down conductors in parallel, some or all of which may be a
part of the building structure itself.
In order to reduce the probability of damage to electronic/electrical equipment, the down conductors shall be
arranged in such a way that from the point of strike to earth, several parallel current paths should exist &
length of the current path should be minimum .Down conductors can be installed separately or more wisely it
can be part of natural components of the building Examples are steel reinforcement in RCC columns, metal
facades, profile rails, metal doors & windows. Down conductors should be installed at each exposed corner of
the structure.
(i) The number and spacing of down conductors shall be as specified, or as directed
by the Engineer-in-charge.
(ii) Routing
Dated 29.Jan 2015
Page 164 of 429
RVNL
(a) A down conductor should follow the most direct path possible between the air terminal network and the
earth termination network. Where more than one down conductor is used, the conductors should be
arranged as evenly as practicable around the outside walls of the structures.
(b) The walls of light wells may be used for fixing down conductors, but lift shafts should not be used for this
purpose.
(c) Metal pipes leading rainwater from the roof to the ground may be connected to the down conductors, but
cannot replace them, such connections should have disconnecting joints.
(d) In deciding on the routing of the down conductor, its accessibility for inspection, testing and maintenance
should be taken into consideration.
(iii) Provision when External Route is Not Available
(e) Where the provision of external routes for down conductors is impracticable, for example, in buildings of
cantilever construction from the first floor upwards, down conductors should not follow the outside
contours of the building. To do so would create a hazard to persons standing under the over hang. In
such cases, the down conductors may be housed in an air space provided by a non-metallic and noncombustible internal duct and taken straight down to the ground.
(f) Any suitable covered recess, not smaller than 76 mm x 13 mm, or any suitable vertical service duct
running the full height of the building may be used for this purpose, provided it does not contain an
unarmoured or a non-metal sheathed cable.
(g) In cases where an unrestricted duct is used, seals at each floor level may be required for fire protection.
As far as possible, access to the interior of the duct should be available.
21.9 Installation
21.9.1 General
(i) The entire lightning protective system should be mechanically strong to withstand the mechanical forces
produced in the event of a lightning strike.
(ii) Conductors shall be securely attached to the building, or other object to be protected by fasteners, which
shall be substantial in construction, not subject to breakage, and shall be of galvanized steel or other suitable
materials, with suitable precautions to avoid corrosion.
(iii) The lightning conductors shall be secured not more than 1.2 m apart for horizontal run, and 1 m for vertical run.
21.9.2 Air Terminations
All air terminals shall be effectively secured against overturning either by attachment to the object to be
protected, or by means of substantial bracings and fixings which shall be permanently and rigidly attached to
the building. The method and nature of the fixings should be simple, solid and permanent, due attention being
given to the climatic conditions and possible corrosion.
21.9.3 Air terminal holder
Conductors shall be securely fixed on the terrace by means of air terminal holder which is fixed
on the roof by adhesive of good quality taking care of varying weather conditions. Air conductor
holder is an insulator & should be of minimum 50 mm height so that even small amount of
water logging on terrace is below the level of conductor holder. Air terminal holder shall not be
more than 0.5 m apart for a flat conductor & 1m for round conductor of atleast 8mm diameter &
1.0 meter apart for vertical run.
Recommended distance between air terminal holders.
Recommended distance For ROUND conductors
Arrangement
Horizontal conductor on horizontal surface.
1000 mm
Horizontal conductor on vertical surface
1000 mm
Vertical conductor from Ground to 20m 1000 mm
height
Dated 29.Jan 2015
Page 165 of 429
RVNL
If antenna, air cooler or any other electrical equipment is present above terrace level, the same
have to be protected by using vertical air terminal after calculating the safety or separation
distance. The vertical air terminal has to have suitable supports to hold it. Vertical air terminal
must be connected to horizontal air terminal by using suitable connectors.
At the crossings of the horizontal air terminals, suitable T or Cross connector has to be used for
secure connection.
21.9.4 Safety or Separation distance.
It is must to calculate safety or separation distance in order to avoid flash over to the electrical
equipment when the lightning current is passing through the vertical air terminal.
Safety/Separation distance (S) in m = ( ki * kc*L) / km
Coefficient ki depends on class of LPL/LPS.
ki = 0.08 for LPL1,
ki = 0.06 for LPL 2,
ki = 0.04 for LPL3 and 4.
Coefficient kc depends on no of down conductors:
kc = 0.66 for 2 down conductors
kc = 0.44 for 3 or more down conductors
Value of coefficient km = 1
Value of L is the total distance between the equipment to be protected ( for e.g. Antenna) to the
equi-potential bonding bar situated just above the ground.
21.9.5 Need for Expansion piece
In order to take care the expansion of the metal in summer and contraction of the metal in
winter, expansion piece with suitable connectors have to be used at every 20m distance of
horizontal air terminal.
21.9.6 Down Conductors
(i) The down conductor system must, where practicable, be directly routed from the air
termination to the earth termination network, and as far as possible, be symmetrically placed
around the outside walls of the structure starting from the corners. In all cases consideration to
side flashing must always be given.
(ii)(a) Practical reasons may not sometimes allow the most direct route to be followed. While
sharp bends, such as arise at the end of roof are inescapable (and hence permissible), re-entrant
loops in a conductor can produce high inductive voltage drops so that the lightning discharge
may jump across the open side of a loop. As a rough guide, this risk may arise when the length
of the conductor forming the loop exceeds 8 times the width of the open side of the loop.
(b) When large re-entrant loops as defined above cannot be avoided, such as in the case of some
cornices or parapets, the conductors should be arranged in such a way that the distance across the
open side of a loop complies with the requirement indicated above. Alternatively, such cornices or
Dated 29.Jan 2015
Page 166 of 429
RVNL
parapets should be provided with holes through which the conductor can pass freely.
(iii) Bonding to Prevent Side Flashing
Any metal in, or forming a part of the structure, or any building services having metallic parts
which are in contact with the general mass of the earth, should be either isolated from, or
bonded to the down conductor. This also applies to all exposed large metal items having any
dimension greater than 2 m whether connected to the earth or not.
Material
Material configuration and Min cross sectional area of
air terminal and down conductors
Min cross section
Type
area
Remarks
Copper
Solid tape
50 sq mm
2mm min thickness
Copper
Solid round
50 sq mm
8mm dia
Aluminum
Solid tape
70 sq mm
3 mm min thickness
Aluminium
Solid round
50 sq mm
8 mm dia
Stainless steel
Solid tape
50 sq mm
2 mm min thickness
Value of distance between down conductors as per Class of LPL / LPS.
Class of LPL/LPS
Typical distance (m)
1
2
3
4
10
10
15
20
21.9.7 Joints and Bonds
(a) Joints:
(i) A lightning protective system should have as few joints as possible. The lightning protective
system shall have as few joints. As far as possible, air terminal & down conductor have to be
straight. Where it is not possible, it should NOT be bent at 90 degree (right angles) & should
have a curved path of 45 degree.
(ii) Joints should be mechanically and electrically effective, for example, clamped, screwed,
bolted, crimped, riveted or welded.
(iii) With overlapping joints, the length of the overlap should not be less than 20 mm for all types of
conductors.
(iv) Contact surfaces should first be cleaned, and then inhibited from oxidation with a suitable
non-corrosive compound.
(v) Joints of dissimilar metals should be protected against corrosion or erosion from the
elements, or the environment and should present an adequate contact area.
(b) Bonds:
(i) Bonds have to join a variety of metallic parts of different shapes and composition, and cannot
Dated 29.Jan 2015
Page 167 of 429
RVNL
therefore be of a standard form.
(ii) There is the constant problem of corrosion and careful attention must be given to the metals
involved, i.e. the metal from which the bond is made, and those of the items being bonded.
(iii) The bond must be mechanically and electrically effective, and protected from corrosion in,
and erosion by the operating environment.
(iv)External metal on, or forming part of a structure, may have to discharge the full lightning
current, and its bond to the lightning protective system should have a cross-sectional area
not less than that employed for the main conductors.
(v) Structures supporting overhead electric supply, telephone and other lines must not be
bonded to a lightning protective system without the permission of the appropriate authority.
(vi) Gas pipe in no case shall be bonded to the lightning protective earth termination system.
21.9.8 Test Joints
Each down conductor should be provided with a test joint in such a position that, while not
inviting unauthorized interference, it is convenient for use when testing.
21.9.9 Earth Termination Network
(i) An earth station comprising one or more earth electrodes as required, should be connected to
each down conductor. This shall be specified.
(ii) Each of the earth stations should have a resistance not exceeding the product given by 10
ohms multiplied by the number of earth electrodes to be provided therein. The whole of the
lightning protective system, including any ring earth, should have a combined resistance to
earth not exceeding 10 ohms without taking account of any bonding [as per 21.9.3(iii)].
(iii) If the value obtained for the whole of the lightning protection system exceeds 10 ohms, a
reduction can be achieved by extending or adding to the electrodes, or by interconnecting the
individual earth terminations of the down conductors by a conductor installed below ground,
sometimes referred to as a ring conductor. Buried ring conductors laid in this manner are
considered to be an integral part of the earth termination network, and should be taken into
account when assessing the overall value of resistance to earth of the installation.
(iv) A reduction of the resistance to the earth to a value below 10 ohms has the advantage of
further reducing the potential gradient around the earth electrode when discharging lightning
current. It also further reduces the risk of side flashing to metal in, or of structure.
(v) Earth electrodes should be capable of being isolated and a reference earth point should be
provided for testing purposes.
For earth termination system, 2 basic types of earth electrode arrangements are applicable:
Type A & Type B arrangement.
Earthing system should meet the requirements according to IS 3043, IEC 60364–5–54, IEC
62561–1 to 7, IEC62305 as well as UL 467. Earthing system should offer resistance less than 1
ohms throughout the year. For this purpose, earthing system vendor should do the soil testing
and provide the necessary recommendation. In places where Soil resistivity is more, multiple
earth electrodes are to be installed to get the required value. In case of multiple earth rods,
vendor should provide possible resistance value of each earth pit. This value remains without
any change for at least one year. Recommended value should be less than 10 ohms. In places
where resistance of each pit is more than 10 ohms, special care needs to be taken. In such
cases, Earth Enhancing compound need to be used for the vertical rods as well as horizontal
conductors.
Dated 29.Jan 2015
Page 168 of 429
RVNL
High-grade solid steel rods of SAE 1035 molecular bonded with 99.9% pure electrolytic copper
with minimum coating thickness of 250 microns should be used as earth electrode. The rods
must be UL listed as well as tested according to IEC62561-2 and comply to the requirements of
IEC 60364-5-54. The rods also should withstand short circuit currents as per the chart below.
All fasteners used should confirm to the requirements of the above standards. Earth enhancing
compound (Soil conductivity improver) should be tested according to IEC62561 – 7 from an
National Test House or at any other laboratory approved by the Engineer-in-charge. Exothermic
welding material used shall be tested as per IEEE 837
A hole of 100 to 125 mm dia. shall be augured / dug to a depth of about 2.8 meters.
Earth electrode shall be placed into this hole.
It will be penetrated into the soil by gently driving on the top of the rod. Here natural soil is
assumed to be available at the bottom of the electrode so that min 150 mm of the electrode
shall be inserted in the natural soil.
Earth Enhancing material (min. approx. 30 to 35 KG) shall be filled in to the augured /dug ole in
slurry form and allowed to set. After the material gets set, the diameter of the composite
structure (earth electrode + Earth Enhancing material) shall be of minimum 100 mm dia.
covering entire length of the hole.
Remaining portion of the hole is filled with backfill soil which is taken out during auguring /
digging
All the joints to the earth electrode shall be exothermically welded
In places where short-circuit level is more than 10 KA, (eg all panel boards, body) a copper
strip of 25 mm * 6 mm with a minimum length of 150 mm need to be exothermically welded to
the solid rod. All further connections need to be done to this copper flat.
For interconnection of earth pits, SOLID copper conductors with a size of 25* 3 mm flat or 10
mm copper bonded round steel conductors are to be used for Lightning Protection/ General
purpose. In places where short circuit currents of more than 10 KA are expected, copper flats of
25 *6mm or 50 * 6 mm need to be used depending upon the expected short circuit level. In
places where short circuit current requirements are more than 10 KA, Exothermic /
Aluminothermic welding are only allowed for jointing earth electrode with round / Flat
conductor. Connections with nut and bolt need to be completely avoided in applications under
ground level, instead exothermic / aluminothermic welding need to be performed.
Dated 29.Jan 2015
Page 169 of 429
RVNL
21.10 Lightening STRIKE recorder with six digit with min current sensitivity of 0.15 KAmps through
to a maximum of 220 KA @ 8/20 Micro Second impulse and operates by means of an inductive
pick up loop. With a polycorbonate IP67 protection. The complete system should have earth
resistance less than less than 10 ohm.
TABLE-1
Shapes and Minimum Sizes of Conductors for Use Above Ground
Sr No
Material and Shape
Minimum size
1
2
Round copper wire or copper clad steel wire
Stranded copper wire
Dated 29.Jan 2015
6 mm diameter
50 sq. mm or (7/3.00 mm dia)
Page 170 of 429
RVNL
3
20 mm x 3 mm
Copper strip
4
20 mm x 3 mm
Galvanized iron strip
5
8 mm diameter
Round aluminium wire
6
25 mm x 3 mm
Aluminium strip
TABLE-2
Shapes and Minimum Sizes of Conductors for Use below Ground
Sr No
1
2
3
4
5
Material and Shape
Round copper wire or copper clad steel wire
Copper strip
Galvanized iron strip
Round Galvanized iron wire
Aluminium strip
Minimum size
8 mm diameter
32 mm x 6 mm
32 mm x 6 mm
10mm X 6 mm
25 mm x 3 mm
--------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 171 of 429
Dated 29.Jan 2015
RVNL
Page 172 of 429
RVNL
CONTROL SWITCH BOARD FOR A.T
Dated 29.Jan 2015
Page 173 of 429
Dated 29.Jan 2015
RVNL
Page 174 of 429
RVNL
Chapter: A-22
CONTROL SWITCH BOARD FOR A.T
22.0 GENERAL
(a) Control switch board shall be cubicle type, mast mounted, dust and vermin proof, totally
enclosed & compartmentalized design of uniform height for outdoor utilization and suitable for
1-phase, 2 wire, 415V, 50Hz AC, solidly earthed neutral, electric supply system complete with
accessories, inter connections, bus bar chamber with copper bus bar, ON/OFF & trip indication,
duly wired up with copper conductor cable with colour coding etc.
(b) Switch board shall conform to IS:8623/Pt.1/1993 (LATEST).
(c) The switch board manufacturer shall have ISO: 9001 certification with testing arrangement as
per IS: 8623 and powder coating facilities in the works.
(d) Drawing shall be got approved from RVNL’s Engineer.
22.1 CONSTRUCTION
a) The panels shall be fabricated from 1.6 mm thick CRCA sheet steel. The shroud & partitions
shall be of minimum 1.6 mm thick CRCA sheet steel. The panels shall be powder coated in
approved shade. The degree of protection shall not be less than IP: 65 as per IS: 13942/Pt.1
(LATEST). The bus bar chamber/s and MCCB chamber shall have double doors. It shall be
possible to operate the MCCB only after opening of the outer door. The Switch board shall be in
vertical formation. Switch board shall be compartmentalized for accommodating bus bars on top
& on bottom and MCCB in centre with individual compartment. Each compartment shall have its
own door with insulated thumb screw. Each compartment/s shall have provision of concealed
lock.
b) Upper side (on top) bus bar compartment shall be for incoming cable from AT to bus bar.
Termination from bus bars to incoming terminals of MCCB shall be with 35 sq.mm copper
conductor single core FRLS PVC insulated cable.
c) Lower side (on bottom) bus bar compartment shall be for outgoing cable for feeding supply to
load. Termination from outgoing terminals of MCCB to bus bars shall be with 35/70 sq.mm (for
10 KVA) & 70 sq.mm (for 25 KVA) copper conductor single core FRLS PVC insulated cable.
d) Cable glands with detachable gland plates shall be provided on Lower side (on bottom) bus bar
compartment for incoming and outgoing cable entry.
e) Earthing terminal as required shall be provided.
22.3
BUS BAR
The bus bars shall be made of high conductivity copper conforming to the requirement of IS:
1897/1983(LATEST) for copper. The bus bars shall have uniform cross section (basis of bus bar
cross section will be 1000 A/sq. inch for copper). The cross-section of the neutral bus bar shall
be same as phase bus bar. Bus bars shall be supported on suitable non-hygroscopic, noncombustible, material such as DMC/SMC. Bus bars shall be insulated with PVC tapes/tubes (heat
shrink type) with colour coding (Red/Yellow/Blue/Black) to withstand the test voltage of 2.5 kV
for one minute
22.4 MCCB
a) MCCBs (Ics=100%Icu) shall conform to IS: 13947/Pt -2/1993(LATEST).Tripping unit shall be of
thermal-magnetic type provided in each pole and connected by a common trip bar such that
tripping of any one pole operates all the poles to open simultaneously.
Dated 29.Jan 2015
Page 175 of 429
RVNL
22.5 INDICATION LIGHTS
a) Clustered LED type Indication light shall be provided for ON/OFF indication on incoming and
outgoing side.
b) Cable entries shall be provided with metallic glands to prevent damage to the insulation of the
cable and terminals shall be provided in the switchboard to suit the number, type and size of
power cables.
22.6 TESTING AND COMMISSIONING
Following tests shall be carried out prior to commissioning of the panel:
a) Insulation test: When measured with 500V meager, the insulation resistance shall not be less
than 100 mega ohms.
b) Trip test & protection test.
22.7 ERECTION
Control switch board shall be fixed with the mast at suitable height /location and arrangement shall
be as approved by the Engineer. Base shall be of Galvanized Mild steel angle of size 50x50x6mm
and holding clamps shall be of Galvanized Mild steel flat of size 50x6mm. Nut & bolt shall not be
less than 12 mm dia.
------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 176 of 429
RVNL
SPECIFICATION FOR LED TYPE LUMINARIES
Dated 29.Jan 2015
Page 177 of 429
Dated 29.Jan 2015
RVNL
Page 178 of 429
RVNL
Chapter: A-23
SPECIFICATION FOR LED TYPE LUMINARIES
23.0 General:
This specification covers for the LED fitted luminaries used for outdoor and indoor applications
for working at 220+/-10% , 50 Hz +/- 3% , Single phase input system. The luminaries are used
at Railway Stations , Circulating Areas, buildings and offices etc. It consist of:
a)
Fixture
b)
LED
c)
Driver and Electronics
For
street
light
and
plateform
applications
RDSO
specification
RDSO/PE/SPEC/PS/0123(Rev ‘0’)-2009, Amendment ‘2’ shall generally be followed.
no:
23.1 Indoor Applications:
The product should be latest state of art and compliant to relevant IEC 60598-1,2,3,
IEC
62031 and IEC 62612 or their latest edition depending on the type of luminaries. In addition to
the above luminaries shall adhere to relevant BIS standards IS 15885, 16101, 16102, 16103,
16104, 16105, 16106, 16107(Part I & II) as per the application. The product shall be of proven
design should possess type test certificate /performance certificate from the accredited
laboratory. The product and its major components shall be state of art and of proven design.
It should be capable to work at Maximum ambient air temperature of 65oC (For outdoor
product) and 45oC (for indoor product) in atmosphere like coastal, humid, salt laden and
corrosive.
Housing, if not used as a heat sink shall be made of 0.5 mm thick CRCA sheet/Extruded
Aluminium(2mm) or pressure die cast(PDC-2 mm) confirming to relevant standards, polyester
powder coated of at least 40 microns) and high U.V. and corrosion resistance.
Luminaries should be covered with suitable Glass or diffuser with High Transitivity. Outdoor
luminaries shall be with clear toughened glass or clear poly carbonate cover.
Lighting fixtures and accessories shall be designed for continuous trouble free operation
under diverse atmospheric conditions without deterioration of materials. Degree of
protection of enclosure shall be at least IP-65 for outdoor fixtures. However, down lighter and
other internal fixture shall be provided with at least IP-55 protection.
To be provided with suitable control optics as per need of application and render glare free
to user.
Test papers for various parameters i.e. flux, power, efficacy, chromaticity, temperature,
protection etc. Issued by certified agency shall be furnished. Estimation on product’s life and
performance shall also be furnished.
(a) Fixture:
The fixture should conform to applicable IS 10322/IEC 60598( All parts & amendments) and
should have the associated LM-79 report(for Electrical and photometric test methodology for
LED lighting) from accredited lab. Test report shall be submitted along with relevant
catalogues. The fixture should have a surge protection of 2 KV.
Dated 29.Jan 2015
Page 179 of 429
RVNL
23.2 LED ( Light Emitting Diode)
LED approved makes are Phillips-Lumileds, Osram, Nichia, Cree/Seoul Semiconductor/Approved
Equivalent on specific approval of project authority on basis of test reports and specification in
comparision of these standard makes. Manufacturer should have IEC (Illuminating Engineering
Society) -LM-80 test report and with projected life as per IEC-LM21. Test report shall be
submitted along with relevant catalogues. All LED to be solid state embedded as light sources,
arrays and modules.
High lumen efficacy LEDs suitable for the application along with following features shall be
used:
(i) LED Efficacy at the chip level shall >120 lumen/watt (For High power LED)
(ii) The efficiency of the LED at 85 Degree C junction temperature shall be more than 85%.
(iii) The system luminous efficacy of LED luminaire’ shall be as under:
a)
Efficacy > 60 lumen/watt for low wattage luminaries (<45W): and
b)
Efficacy > 80 lumen/watt for a high wattage luminaries (>45W).
(iv)
(v)
(vi)
(vii)
Adequate heat sink with proper thermal management shall be provided.
Minimum view angle of the LED shall not be less than 120*.
Power factor of complete fitting shall be more than 0.9
LED shall be surface mounted type duly soldered to PCB by Reflow system of COB Type.
The Solder used shall be ROHS compatible for environment friendliness.
(viii) Colour rendering index CRI >=70 as specified in the item description.
(ix) Correlated colour Temperature shall be in the range of 3000 K-6500 K as specified in
item description.
23.3 LED driver.
LED driver shall be capable to withstand and work with Input voltage Range from 160V (RMS)
to 270 V(RMS) with built in 2KV surge protection. Output voltage of the driver shall be
designed to meet the Power requirement of the system. Output voltage ripple should be within
3%. Output over voltage protection should be up to 125 V DC. Full Load Efficiency shall be
more than 85%.
Total Harmonic Distortion
- For 0-50 W shall be less than 25%
- Above 50 W rating shall be less than 15%
Current waveform should meet EN 61000-3-2. LED Driver shall be able to withstand voltage of
350V for 2 hours and
restore normal working when normal voltage is applied. The driver
should comply to CISPR 15 for limits and methods of measurement of Radio Disturbance
characteristics and it should comply to IEC 61547 for EMC immunity requirement. The
control gear should be compliant to IEC 61347-2-13, IEC 62031 and IEC 62384.
23.4 General
The lumen maintenance of the LED lightings shall not be less than 70% after 50,000 hours i.e.
L70 (B50). The supplier shall provide evidence that the LED chipset manufacturer has the
patent right to produce the supplied LED chipset to avoid infringement of white LED patent.
Free warranty shall commence after delivery and end at 60 months after delivery. The
warranty of replaced item shall re-start from date of attending defect/replaced.
Dated 29.Jan 2015
Page 180 of 429
RVNL
VARIABLE REFRIGERANT FLOW (VRF) SYSTEM FOR
BUILDING
CENTRALISED AIRCONDITIONING
Dated 29.Jan 2015
Page 181 of 429
Dated 29.Jan 2015
RVNL
Page 182 of 429
RVNL
Chapter: A-24
SPECIFICATION FOR VARIABLE REFRIGERANT FLOW (VRF) SYSTEM
FOR BUILDING CENTRALISED AIRCONDITIONING
24.0 General
Scope of work includes design, fabrication, supply, installation, testing and commissioning of
centralized air ventilation with evaporative cooling units. Plant shall be effective to lower the
room temperature with respect to ambient temperature with dust free atmosphere. Scope also
includes supply of materials, fabrication and fixing of GI ducting suitably sized with supporting
MS supporting angles with aluminum powder coated supply air grills with volume control air
dampers, MS stand for AHU, sound attenuator, AHU control panel and related civil works.
Project is turn-key in nature and the contractor’s scope is to ensure proper functioning and
commissioning of the equipment.
24.1
Description
Air conditioning (VRF System): The scope of work includes supply, installation, of all parts
mentioned or not in the schedule as per specification and testing, commissioning of complete
work as turnkey.
24.1.1 The VRF system shall typically consist of an outdoor unit with multiple digital scroll
compressors and different types of indoor units for different zones and electronic
control center / microprocessor.
24.1.2 The Variable Refrigerant Flow (VRF) system shall have Digital/ Inverter Scroll
Compressor to modulate the refrigerant flow to meet the varying cooling loads and to
deliver enormous savings on electricity bills.
24.1.3 The VRF system should be capable of performing cooling during summer / monsoon
season to achieve temperatures of 22°C to 28°C in the conditioned rooms as set by the
occupant.
24.1.4 The VRF system shall be provided with sophisticated electronic control center to enable
zone wise climate control.
24.1.5 The VRF system shall have tropicalized outdoor units, which can operate at ambient
temperatures as high as 520C.
24.1.6 The outdoor unit shall have following features:
(a)
Polyester powder-coated sheet metal housing for longer life.
(b)
Anti-corrosion blue fins in condenser coil for longer life.
(c)
Built-in oil separator, accumulator and liquid receiver for oil, liquid and gas balance of
the entire system.
(d)
Low noise external rotor fan
(e)
Shall operate at high ambient temperatures as high as 520C.
24.2 Compressor:
The compressor(s) shall be combination of highly efficient hermetically sealed fixed scroll and
digital scroll type and should be capable of varying the capacity from 10% to 100% by
modulation technology which allows an external control to switch the compressor rapidly
between its loaded and unloaded states including crank case/oil heaters complete in all respect.
Dated 29.Jan 2015
Page 183 of 429
RVNL
24.3 Heat exchanger / Condenser coil:
The condenser coil shall be constructed with refrigeration grade soft annealed copper tubes
mechanically bonded to aluminum fins to form a cross fin coils. The aluminum fins shall be
given anti-corrosion coating for longer life.
24.4 Refrigeration circuit:
The refrigerant circuit shall include liquid and gas shut off globe valves at outdoor end. All
necessary safety devices for controlling the digital scroll compressor shall be provided to ensure
the safe and efficient operation of the system.
24.5 Safety devices:
24.5.1 All necessary electrical safety devices including single-phase prevention / phase
reversal; overload protection etc to be provided.
24.5.2 All necessary refrigeration safety devices including HP – LP Cut Out Switch etc. to be
provided.
24.5.3 The refrigerant used shall be eco-friendly gas R 410A.
24.6 Indoor unit:
24.6.1 This section deals with type and features of indoor units for the duty selected. The
type, capacity and size of indoor units are as specified in “Schedule of Rates /
Quantity”.
24.6.2 General: Indoor units shall be as specified in “SOR”. Each unit shall have electronic
controller and valve to control the refrigerant flow rate responding to load variations of
the room.
24.6.3 The address of the indoor unit shall be set automatically in case of individual and group
control.
24.6.4 In case of centralized control, it shall be set by liquid crystal remote controller.
24.6.5 The fan / blower shall be aerodynamically designed turbo, multi blade type, statically
and dynamically balanced to ensure low noise and vibration free operation of the system.
The fan shall be directly driven type, mounted directly on motor shaft having support
from housing except for floor standing ducted type in this case the blower shall be belt
driven.
24.6.6 The evaporator coil shall be constructed with refrigeration grade soft annealed copper
tubes mechanically bonded to aluminum fins to form a cross fin coils.
24.6.7 Each unit shall be provided with cleanable air filters.
24.6.8 Each indoor unit shall have computerized PID (Program index) control for maintaining
design room temperature.
24.7
24.6.9 Each unit shall have cordless Remote Controller (RC) as specified in “SOR”.
Controllers:
24.7.1 Salient Features Cordless Remote Controller:
On / Off control on individual unit
Set temperature
Mode settings -Fan / Cool / Heat / Dry
Air flow direction -Auto swing or fixed angle mode for louvers (applicable only
for Cassette Type)
On / off timer.
Dated 29.Jan 2015
Page 184 of 429
(a)
System Controller
The system controller can be located in centralized area and has the following
features:
•
•
•
•
•
•
•
•
•
•
•
•
(b)
RVNL
Can control up to 64 indoor units
Individual setting for operation
Group Stop / Start function
Switch On / Off of individual unit.
Fan speed settings – Auto / High / Medium / Low
Display set temperature
Display room temperature
Self-diagnostic function for all indoor and outdoor units
Air flow direction Auto swing or fixed angle mode for louvers (applicable
only for Hi Wall and Cassette Type)
Long cable connection up to 1000 m between outdoor and indoor units.
Compatible with external BMS (Building management system)
Modbus or compatible– RTU open protocol
Weekly Timer:Features:
•
On / Off timing of individual units
•
Programmable for whole week
•
The units can be set to off mode during holidays.
24.8
Type of Indoor Units:
24.8.1 Cassette Type (Ceiling Mounted):
The cassette type units shall have following features:
(a)
Sleek and low height so as to fit easily into ceiling spaces.
(b)
Fresh Air Intake Provision so as to draw fresh air and maintain good in door air
quality.
(c)
Drain Pump with special drain up mechanism
(d)
No fibrous material to be used on both the panel and the louver.
(e)
Auto-swing louver to ensure uniform airflow.
24.8.2 Ducted type (Concealed Fan coil):
The ceiling suspended type units shall have following features:
(a)
Low height, so that it occupies less space above false ceiling / boxing allowing for
more headroom.
(b)
Fresh Air Intake Provision so as to draw fresh air and maintain good indoor air quality.
(c)
Shall be acoustically lined for low noise.
(d)
The fan panel shall be detachable type by loosening wing nuts. Thereby ensuring easy
access for service of motor and coil.
(e)
The powder coated GI panels shall withstand salt spray test for 1000 hours and shall
be rust proof & maintenance free.
24.9
Refrigerant Piping:
Maximum main branch pipe length should not exceed 150 m
Maximum elevation difference IDU & ODU < 50 m when ODU is higher than IDU
Maximum elevation difference IDU & ODU < 40 m when ODU is lower than IDU
Maximum elevation difference between IDUs fed through same ODU, should be less
than 15 m
(e)
Main Refrigerant Pipe Line:
(i)
Refrigerant piping material should be “hard drawn, super clean quality copper,
18 G” for pipe OD 41.28 mm.
(a)
(b)
(c)
(d)
Dated 29.Jan 2015
Page 185 of 429
RVNL
(ii)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)
18 G” for pipe OD 34.93 mm
(iii)
19 G” for pipe OD less than 38.10 mm.
End Connection of IDU / ODU: Maximum length of soft pipe for flared connection not
to exceed 1.0 m.
Refrigerant piping material should be “soft, super clean quality copper, 18 G” for
pipe OD 19.05 & 22.22 mm.
Refrigerant piping material should be “soft, super clean quality copper, 19 G” for pipe
OD 15.88 mm
Refrigerant piping material should be “soft, super clean quality copper, 21 G” for pipe
OD 6.35, 9.52, 12.7 mm.
The thickness of elbow and socket shall be as per following:
- 0.813 mm
for pipe OD 6.35, 9.52 & 12.7 mm
- 1.000 mm
for pipe OD 15.88 mm to 28.58 mm
- 1.100 mm
for pipe OD 31.75 mm
- 1.350 mm
for pipe OD 34.93 mm to 41.28mm
Bleed nitrogen while brazing the pipes
All the pipes should be insulated with 19 mm thick nitrile insulation. The suction line
insulation shall have at least R-0.35 (R-2) insulation, and exposed insulation to be
protected by aluminum foil, painted canvas, or plastic cover.
Entire piping work and IDUs to be pressure tested for leakages with 450 psig nitrogen
pressure, hold the pressure for 24 hours.
Vacuumise in 2 stages. 2000 micron + Nitrogen 5 psig + 500 micron and hold the
vacuum for minimum 06 hours.
Distribution joint kit: Suitable size factory made Y- joint kits / header to be used for
suction and liquid line.
All refrigerant piping to be laid on cable tray 150 mm wide.
24.10 Control/ Communication wiring: Supply and erection of communication wires of 2 cores x
0.75 mm2 (shielded wire) in conduit of suitable size as per the direction of site engineer.
24.11 Makes: The acceptable make for VRF system shall be Blue Star, Voltas, Mitsubishi, Toshiba and
Daikin. Minor change in standard design shall be acceptable from approved makes only.
24.12 Air Handling Unit:
AHU shall be double skin screw less & sturdy construction for low noise and better thermal
insulation. Double skin panel construction shall allow easy inspection, service and maintenance
and reduce the risk of dirt and bacteria accumulation. Pre-filter provided shall be of synthetic
non-woven type supported with aluminum and HDPE. Filter efficiency shall be 90% for 10%
micron. Control panel shall be provided with powder coated control box to house isolator single
phasing preventer and contactors for starting of the motor. Control panel shall be compatible
with BMS having open protocol. On-off trip indications and luminous push buttons shall be
provided. Provision shall also be made to connect control value, fire dampers, modulating motor
and door switch. Fan and motor shall be mounted on aluminum extruded slide rail base frame
to adjust belt tension without disturbing motor alignment. Fan section shall be provided with an
access door for ease to service, view port shall be provided at fan door panel, which would help
monitoring fan and motor status. Door limit switch shall be provided to automatically trip fan
with the door is open. Every AHU shall be supplying with a factory fitted GI powder coated
volume, control damper to facilitate balancing. All AHU shall be Horizontal/vertical/suspended
type so as to occupy lesser floor space.
Selection of the type of AHU vertical or ceiling
suspended or horizontal shall be based on the rating and the site condition. The fan section
shall be provided with an access door for ease serviceability of fan and motor. Aluminum die
cast powder coated hinges shall be provided. The unit shall be complete in all respect.
Dated 29.Jan 2015
Page 186 of 429
RVNL
24.13 Water Circulation System
Cellulose pad on one side of the air cooling system shall be provided for the purpose of water
circulation to ensure evaporative cooling effect of the system. The ventilated blower used
should be AMCA approved for sound and air. Documentary evidence to this effect shall be made
available along with the tender. Bottom tray shall be of size specified in the technical
specification made of non-corrosive stainless steel grade SS 304. Suitable humidistat shall be
provided to measure humidity level in the room and thereby cutting off pump circulation water.
Make up water required due to the loss of water on account of evaporation shall be provided
through water-cooling system to enable a inflow at required quantity per hour at 30 Degree
Centigrade. Flow of make up water shall be controlled through latest improved mechanism
provided in SS tank other than float valve. The system shall be complete in all respect.
24.14 Details for Ducting :
Ducting will include following itemsItem No. 1 -This work is mainly consisting of Design, Supply, Installation, Testing and
Commissioning of Air cooling system as mentioned in and as per specification enclosed.
Foundation, base frame of the drive & nut bolts are in the scope of contractor.
Item No. 2 - This work is mainly consisting of Design, Installation of fabricated GI sheet
ducting of 18/19/22/24 G along with all material including material required for installation.
Item No. 3- This work is mainly consisting of Design, Fabrication and Installation of Aluminum
powder coated air grills with G.I volume control dampers along with all material including
material required for installation.
Item No. 4 This item work is mainly consisting of Design and Installation of Insulation of latest
improved quality CFC free insulating material in coating form. This should be efficient and good
looking.
24.15 Evaporative cooling system
Description
AHU
Make
Casing
Outer skin
Inner skin
Air quantity
Frame work
Corner joints
Panel thickness
Insulation
PUF density
PUF material
Process
Anti vibration
Pre filter section
Type
Make
Dated 29.Jan 2015
Specification
Voltas, Carrier, Blue Star
Double skin
0.6 mm/23G SS 304 sheet
0.6 mm/23G SS 203 sheet
As per schedule item
SS 203
Welding by MIG technology
25 mm
PUF 55 mm thick / Rock wool 100 mm thick of density 28-32
kg per mt3
CFC Free, improve quality coating type material.
Standard process
Spring isolators to be provided at fan motor
Box type
Spectrum or equivalent imported
Page 187 of 429
RVNL
Media
Thickness
Class/efficiency
Filter area
Humidification section
Casing
Outer skin
Inner skin
Pad
Pad area
Min. pad thickness
Pad efficiency
Sump
Material of construction
Size and material of float
valve
Depth
Pump
Make/model
Rating
Type
Safety against wet run of
pump
Droplet eliminator
Fan section
Fan make
Type
Model
RPM
Rating
Fan efficiency
Fan outlet velocity
Motor
Make
Type
Degree of protection
Insulation
Rating
Supply air damper
Type
Non woven synthetic
48 mm
Eurovent class EU3 as per EN-779 standard/ 90% down to
10 micron
As per suitable for required capacity
Double skin
0.6 mm/23G SS 304
0.6 mm/23G SS 304 grade
Cell deck
As suitable for required capacity
8 inches
90% @ 500 fpm velocity
1.2 mm/18 G stainless steel grade 304
20 mm dia, heavy duty brass
As per standard used by Voltas, Carrier, Blue Star
As suitable for required capacity
Monobloc (IP 65 Protection)
To be provided with water level switch
4 pass PVC
AMCA certified Kruger.
DIDW, Centrifugal forward curve
As per standard model used by Voltas, Carrier, Blue Star
As per standard rating and capacity
As per required capacity
As per relevant IS
As per standard rating and capacity
ABB, CGL, Hindustan motors
4 Pole TEFC
IP 65
Class F
Opposite blade aerofoil aluminum
Note: (1) Minor change in standard design shall be acceptable from approved makes only.
(2) Project is turn-key in nature and the contractor’s scope of work is to ensure proper
functioning and commissioning of the complete system.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 188 of 429
RVNL
MACHINE ROOM TYPE ELECTRIC TRACTION
PASSENGER LIFT FOR BUILDINGS
Dated 29.Jan 2015
Page 189 of 429
Dated 29.Jan 2015
RVNL
Page 190 of 429
RVNL
CHAPTER:A-25
MACHINE ROOM TYPE ELECTRIC TRACTION PASSENGER LIFT FOR
BUILDINGS
25.0
Scope:
The scope includes design, manufacturing, supply at site, erection, testing, commissioning and
handing over in satisfactory working condition of Machine room type motor operated Electric
traction passenger lift to the requirements as given in BOQ as per details of Annexure
‘A’,under the operational and environmental conditions encountered during service, complete
with all accessories. Specifications and other stipulations are given below. The salient points
pertaining to safety shall also be complied by the Supplier/Contractor. All the items mentioned
here are general in nature and any item (s) required for proper and safe functioning of the lift
shall be supplied with the lift without any extra cost even if not specifically mentioned here.
25.1
General.
The Machine Room type Lift shall be governed by relevant International Standards and
International Codes of Practice such as European code of safety EN 81,American National
Standard Safety Code for Elevators (ANSI) A117.1 , IS: 14665 or latest and IEC 60364 for
Electrical Installations of buildings. The traction machine, over speed governor, ropes, brake
gear controls and other safety equipment even though corresponding to specification EN 81 and
ANSI A117.1 should under all conditions of operations at least match with IS code of
specification for passenger Lifts viz. IS: 14665 or latest. This has to be ensured by Lift
manufacturers primarily and the manufacturer should have appropriate Quality Assurance
accreditation ISO 9000 / ISO 14001. The installations shall be to the highest standard as
expected of a fully experienced contractor. The manufacturer shall also comply with the
provision of Indian electricity act and rules in vogue and shall be taken over only if and when
they fully comply with all their requirements. The lift installation shall also be designed to
produce a safe working environment for Engineers and auxiliary workers to work on or around.
Prior APPROVAL OF EMPLOYER shall be obtained for make/detail specifications of the
proposed lift before ordering giving all the relevant details and suiting the site
conditions.
25.2
Intellectual property rights:
If the Supplier/Contractor intends to use the intellectual property rights of another party in
performing the Supplier/Contractor’s obligations under the contract, appropriate licenses shall
be obtained from the relevant beneficial owners.
Where any software is provided in the works, the Supplier/Contractor shall submit
documents showing that appropriate permission or License have been obtained from relevant
beneficial owners of intellectual property rights for the use of the software free of all fees for
the whole operating life of the Works.
Where O&M manuals and as-built drawings are submitted, the Supplier/Contractor shall obtain
appropriate permission or licence from relevant beneficial owners of intellectual property rights
to allow the Supervising Officer, the Employer and the subsequent owners or occupiers of the
Dated 29.Jan 2015
Page 191 of 429
RVNL
Works, and all parties responsible for the operation and maintenance of the Works free from all
fees to make additional copies of the manuals and drawings.
25.3
Environmental service conditions:
All electrical, electronic and mechanical equipment shall suit the tropical climate for use in
service environmental conditions as stated below:Maximum ambient temperature
Minimum ambient temperature
Maximum Relative humidity
Atmosphere
Coastal area
Maximum Ph value
Sulphate
Max. concentration of chlorine
Max. conductivity
Annual Rain fall
Altitude
55º C
-5º C
100%
Extremely dust and desert weather and desert terrain in
certain areas. The dust contents in air may reach as
high values as 1.6 mg/m.cube.
The equipment shall be designed to work in corrosive
atmosphere.
8.5
7mg/litre
6mg/litre
130 micro siemen/cm
Ranging between 1750 to 6250 mm with thunder storm.
Not exceeding 1200m
25.4 Specifications:
25.4.1 Geared Machine:
The lift machine shall be smooth in operation with minimum noise/vibration and of
worm
gear reduction type with traction motor, electromechanical brake, worm gearing, driving
sheaves and suitable to work on 400/440 Volts AC 3 Phase with neutral at 50 cycles per second
supply with VVVF (Variable Voltage Variable Frequency) type of control. The traction motor
shall be energy efficient induction type with minimum of BEE’s three star rating and in
accordance to BS 4999 and BS 5000:part 99.The motor shall be designed to operate for an
unlimited period according to the expected duty of the lift.
25.4.2
Sheaves:
The driving sheave and pulleys should be of hard alloy constructed from fabricated cast steel or
S.G iron or suitable wear resistant material and free from cracks, sand holes and other defects
with truly machined surface in order to ensure perfect alignment of all bearings and prevent
transmission of sound to the building. They shall have machined rope grooves. The traction
sheave shall be grooved to produce proper traction and shall be of sufficient dimension to
provide for wear in the groove. The deflector sheave shall be grooved so as to provide a smooth
bed for the rope. The deflector or secondary sheave assemblies where used shall be mounted in
a proper alignment with the traction sheave. Such deflector sheaves shall have grooves larger
than the rope diameter as specified in clause 8 of IS:14665 (part-4,Sec.3):2000 or latest. The
size of all the sheaves shall be in accordance with clause 8.4 of IS: 14665 (part-4, Sec.3):2001
or latest. Wherever necessary, suitable protective guards may be provided.
Dated 29.Jan 2015
Page 192 of 429
RVNL
25.4.3
Electric Motor duty cycle:
The driving motor shall be designed specially for heavy duty Lifts to run smoothly under load up
to its maximum capacity in either direction with ample power to deal with occasional overloads.
It shall be arranged to develop the requisite, torque, enabling the machine to start easily from
rest.
The motor shall be designed to confirm to S3 duty cycles defined as per IEC duty cycles for non
peak and peak periods of operation. The motor and drive system should be designed for not
less than 150 starts/hour and stops during the peak periods. The peak periods of lift workings
are furnished in Annexure ‘A’.
25.4.4
Brake:
A suitable electro magnetic brake, preferably of the direct acting type integrated with motor
operating on AC/DC shall be provided, with two brake shoes which are automatically applied by
means of a strong compression springs to a brake wheel of large diameter when the circuit is
broken and released by means of an electro-magnet.
The brake mechanism must incorporate provision to allow for minimum wear of brake lining. It
shall also have an emergency quick release device to open the brake without affecting its
adjustment so that the car can be lowered or raised manually in the event of electric supply
failure. The electric solenoid shall be rated to withstand continuous Lift duty.
25.4.5
Car and car frame:
The car enclosure shall be in accordance with clause 4 of IS: 14665 (part-4, Sec.3):2001 or
latest, made up of stainless steel 1.5 mm thickness hairline finish. The Lift car shall have
stainless steel false ceiling adequately illuminated LED luminaries of flush mounted pattern
which shall give illumination of not less than 150 Lux on the lift floor level. The level of
illumination in a power failure shall be a minimum of 50 Lux to floor level throughout to be
maintained by providing Emergency lights. One axial flow fan of quit running type having a
noise level not greater than 30 dBA when measured at a distance of 1 m from the fan and it
shall be capable of handling at least 20 air changes per hour of lift car volume, with car doors
closed. The effective area of ventilation apertures situated in the upper part of the car shall be
at least 1% of the available car area, and the same applies for any apertures in the lower part
of the car. The car ventilation fan shall be switched off within a period which shall be adjustable
from 5 to 15 minutes after the last registered call is answered. One smoked mirror of half
height full width on the rear panel, suitable handrails of 50mm O.D. tubular stainless steel shall
be provided at 86mm height from floor level of the car on three sides of the lift car extending to
within 150mm of all corners and with a 40mm clearance from car walls to facilitate handicapped
passengers. A load plate giving the contract load of the Lift, No. of passenger capacity of the
Lift shall be fitted in the Lift car in a conspicuous position.
Emergency contact number plate should be provided with front transparent acrylic sheet with
flush screw arrangement such that contact numbers can be changed.
Suitable slotting
arrangement should be done accordingly. The Control logic should be used for controlling lights
and fan. The ventilation fan and full lighting shall be switched off by logic and predetermined
period if no button is pressed or call registered.
The lighting except emergency illumination shall also have connection to motion sensor. The
lights and fans supply also should have separate control panel switch to make on/off. The
ventilation fan shall also have one switch for operation in addition to motion sensor control.
For video remote monitoring security web camera to be installed in the lift car having display
with recording arrangement to Control room in addition to self memory of minimum past 72
hours recording.
Dated 29.Jan 2015
Page 193 of 429
RVNL
Floor to be made of 1.5 mm thickness Stainless Steel with 4mm thick antiskid studded rubber
floor to colour and pattern as approved by the employer’s project authority . The switch and
control panel buttons to be made with backlit/letter display by LED with dark background and
the alpha numeric display in English language and also BRAILLE indents. The control activated
voice information of floor level announcement to be provided. The public address system also
to be built in for playing emergency announcement/commercial/ entertainment etc.
Two number LCD display of size of minimum 32 inch diagonal, motion flow 120 Hz live colours
display, HD image on NTSC/PAL/ATSC tuner having VGA/USB/BNC/TV tuner input control to be
provided with connection to public address system. The control supply should be brought to
control room and VGA, Audio/Video output wiring to be done at Control room of lift/machine
room.
Safety instructions in international signages pattern to lift users to be provided inside the car as
approved by the employer’s project authority.
Emergency illumination on LED based luminaries also to be provided in car with adequate SMF
battery to support at least 72 hours back up with control switch in lift car itself. The emergency
battery back also shall be used for operation of interphone and emergency alarm bell.
The roof of the car shall be solid type made of 1.5 mm thickness Stainless Steel capable of
supporting a weight of two persons i.e., at least 138 kg as per IS: 14665 (part-4, Sec.3):2001
or latest and shall withstand to a vertical force of 2000N at any position without causing
permanent deformation.
Lift car, excluding linings, shall be constructed of non-combustible materials.
One lighting socket outlet for hand lamp shall be provided on the top of the Lift car for
inspection. Suitable hand lamp with appropriate size and length of cable shall be supplied to the
maintenance staff by the Supplier/Contractor.
25.4.6
Doors:
Landing doors and car door shall be of 2 panel centre opening sliding closed, stainless steel
powder coated or hairline stainless steel finish panels as approved by the Employer’s project
authority in charge, power operated independent drive with adjustable automatic opening and
closing speeds for door. The clear opening should be 900 mm wide x 2000 mm height. The door
shall have a fire resistance rating of one hour as per EN 81-58 and ground switch/switches at
ground floor level shall be provided on all the lifts to enable the fire service to ground the lifts.
The car doors shall be fitted with a Memco 3D curtain safe edge to detect and open the doors in
the event of obstruction/infringement while the doors are closing.
The door open time to be made programmable for time delay set in the system.
The lift shall be designed to go out of service if the doors are kept open for a long time as
programmed.
A delay to the start the lift after the doors is closed (say 0.2 to 2.0 seconds) also to be
programmable.
The landing doors shall be provided with electro-mechanical inter-locks to prevent operation of
the Lift unless all the doors are closed and positively locked. The inter-lock shall also prevent
the opening of any door until the car has reached the respective landing zone. In the event of
failure of Memco 3D curtain suitable mechanical system should be provided to open the doors in
the case of obstruction.
Any projections on or recesses in the exposed parts of the car doors or landing doors shall be
kept to a minimum in order to avoid finger trapping between sliding parts of the door and any
fixed part of the car or landing entrance.
The clearance between panels or between panels and any fixed part of the car or landing
entrance shall not exceed 6 mm.
Sliding car and landing doors shall be guided on door tracks and sills for the full travel of the
doors. The distance between the car and landing sills shall not exceed 35 mm.
The clear height of all entrances on car and landings shall not be less than 2 m.
Supplier/Contractor shall provide full door sticker of approved quality and design with adhesive
as approved them by employer’s project authority in charge.
Dated 29.Jan 2015
Page 194 of 429
RVNL
Three good quality digitally printed safety and energy saving tips/instructions as per
pictographically international signages pattern of size 2 feet x 3 feet of suitable design to be
supplied and fixed on wall at lift on each floor in Hindi/English/Vernacular language (i.e. one
each).
25.4.7 Electrical device for proving the car doors closed:
Every car door shall be provided with an electrical switch which will prevent the lift car from
being started or kept in motion unless all car doors are closed. A mechanical locking device
shall also be provided such that the car door cannot be opened from the inside while the car is
outside the unlocking zone.
25.4.8 Landing door locking device:
Every landing door shall be provided with an effective locking device so that it shall not
normally be possible to open the door from the landing side unless the lift car door is in that
particular landing zone.
It shall not be possible under normal operation to start the lift car or keep it in motion unless all
landing doors are in the closed position and locked.
25.4.9 Door locking devices to be inaccessible from landing or car:
All door locking devices and door switches, together with any associated actuating rods, levers
or contacts, shall be so situated or protected as to be reasonably inaccessible from the landing
or the car.
25.5
Car Slinging and Safety Gear:
The car body shall be supported in a steel sling so that no strains due to suspensions lifting
action of the safety gear are imposed in it. The sling shall be provided with adjustable shoes on
each side at the top and bottom to engage accurately with the guides to ensure smooth
running. The car and counter weights shall have underneath it an automatic instantaneous type
safety gear operated by an over speed governor designed to ensure positive action for
excessive speed on the down travel of the car. The safety gear shall be equipped with a contact
to cut off power supply/during over load in such event and to bring the car to a stop. Controls
and facilities for inspection shall also be provided at top of the car to facilitate inspection and
testing as per ISS latest and international standard.
25.6
Governor:
The car safety shall be operated by speed governor which shall be in accordance with clause 4
of IS: 14665 (part-4, Sec.3):2001 or latest and shall be adjustable to actuate the safety gears.,
located overhead and driven by governor rope suitably connected to the car and mounted on its
own pulleys. The governor shall be of “V” groove wheel design. The rope shall be maintained in
tension by means of weighted or spring loaded tension sheaves located in the pit. The governor
rope shall not be less than 10mm in dia and shall be made up of steel and as specified in Clause
25.7 of this Specification.
25.7
Suspension Ropes:
The main suspension ropes shall be in accordance with BS 302 part 4 clause B4.1 and clause 7
of IS: 14665 (part-4, Sec.3):2001 or latest and the requirements for steel wire ropes shall be
in accordance with IS: 14665 (part-4, Sec.8):2001 or latest, of the best flexible steel wire
construction conforming to IS: 6594/1981 or latest , with a minimum factor of safety of 12
times ,the number of strands and diameter of the ropes shall also comply with the factor of
safety requirements of the American National Standard Safety code for Elevators (ANSI)
Dated 29.Jan 2015
Page 195 of 429
RVNL
A117.1. The supply of steel wire ropes should be three ropes or more and of minimum 10mm
dia., from the reputed rope manufacturers and shall be guaranteed for a period of two
years. Ends of the ropes shall be properly secured to the car and counter weight hitch plates
with adjustable rope shackles having individual tapers babbit sockets or any other suitable
arrangement. Each rope shall be fitted with a suitable shackle spring, seat washer, shackle nut
& lock and shackle nut split pin.
25.8
Compensation rope:
For travels over 30 m and/or rated speed of the lift exceeds 2.5m/s, the Supplier/Contractor
shall provide compensation ropes with tensioning pulleys. For speeds of 2.5 m/s or below, quiet
operating chains or similar devices may be used as the means of compensation. For speeds
above 3.5 m/s, an anti-rebound arrangement of idler tension pulley shall be provided to prevent
the counterweight jumping with the application of the car safety gear.
25.9 Diverting Pulleys:
Diverting pulleys necessary for suspension of car on counter weight shall be of cast iron,
grooved for wire ropes complete with shaft, bearings and are to be suitably supplied and they
shall incorporate devices to avoid:
▪ The suspension ropes, if slack, leaving the grooves.
▪ The introduction of objects between rope & grooves.
25.10 Guide rails:
The guide rails shall be in accordance with clause 3 of IS:14665 (part-4, Sec.2):2001 or latest
for the car and counterweight and shall be made up of rigid steel ‘T’ sections with machined
working surfaces. These guides shall be erected to plumb and shall be complete with suitable
fixings at such intervals as to prevent deflection. The strength of the guides, their attachments
and joints shall comply with clause 10.1 and 10.2 0f EN 81-1 and BS 5655 : Part 9 Clause B1.2
and be sufficient to withstand the forces imposed due to the operation of the safety gear and
deflection due to uneven loading of the car. The section of weights in kg per meter of rails
should be furnished by the Supplier/Contractor in Annexure`B’. Guide lubricators of approved
design shall be provided.
25.11 Counter Weight:
The counter weight shall be in accordance with clause 6 of IS: 14665 (part-4, Sec.3):2001 or
latest, shall consists of a structural steel frame with loose cast iron filler weights arranged to
balance the full weight of the car plus, approximately 50% of the contract load so as to ensure
low power consumption and economical running of the Lift. The factor of safety of steel frame
members and the tie rods shall not be less than 5. The guide shoes shall be fitted to the top
and bottom of the structural frame on both sides and shall be of replaceable & adjustable type
to ensure smooth and quiet running and long life. Counter weights shall be guarded by means
of a rigid fixed screen extending from a position of 0.3m above the Lift pit floor to a position at
least 2.5m above the Lift pit floor.
25.12 Buffers:
Buffers shall be in accordance with clause 5.15 of IS: 14665 (part-2, Sec.2):2000 or latest.
Hydraulic/spring buffers of tested design shall be installed as a means of stopping the car and
counter weight at the extreme limits of travel. Buffers in the pit shall be mounted on the steel
frame, which shall extend between both the car and counter weight guide rails. Energy
accumulation type buffers shall only be used if the rated speed of the lift does not exceed 1 m/s
Dated 29.Jan 2015
Page 196 of 429
RVNL
and Energy accumulation type buffers with buffered return movement shall only be used if the
rated speed of the lift does not exceed 1.6 m/s.
25.13 Operating System:
The Lift operating system shall be of simplex full collective type with provision for operation
with or without attendant. It should comprise of a call button at each
landing and a set of dispatch buttons together with an emergency stop button in the car. All
components shall be well insulated and mounted in a metal case with suitably finished cover.
25.14(a) Control station in car:
Each lift car shall have a flush mounted control station comprising:1. Call buttons with acceptance signals engraved in Arabic number to correspond with the
landing served;
2. An alarm push button with protection from being operated accidentally; the colour of this
button shall be yellow;
3. "door open" and "door close" push buttons;
4. Audible and visible signals in connection with the overload device;
5. Light switch, alarm reset switch, fan switch and cleaner's "Stop-switch" keeping the car
door open in the form of key switches or housed in a recessed metal box with hinged or
sliding lid which will be key-locked.
6. Two-way intercom speaker - the intercom system shall be as specified in Clause 25.17.
7. Any other control as specified in the specification.
All wordings shall be engraved in both English and Hindi characters. The material for the control
station shall be stainless steel with a thickness of not less than 2.5 mm. The control station
shall be fixed onto the car panel by stainless steel screws of secret-head type.
(b) Additional Control Station:
For passenger lifts of 21 persons capacity or larger, two car control station, one on either side
of the car doors, shall be provided such that one shall have the above functions 1, 2 and 3 only
and one shall have all the functions 1 to 7.
(c) Control station equipped with attendant control:
For lifts equipped with attendant control, the control station shall also incorporate:1. A non-stop button for the purpose of bypassing landing calls, but the calls shall remain
registered until answered. This button shall be inoperative unless the lift is operated by an
attendant.
2. A key-operated attendant control switch to be included in Clause 25.14(a)5.
The additional functions specified in this clause shall be provided in the Control Station in
Clause 25.14 (a).
(d) Car direction and position indicator:
The direction indicators shall be of illuminated directional indicator with an illuminated area not
less than 1125 mm2. The position indicator shall be of digital type display with lamp matrix
actuated by solid state circuitry unless otherwise specified.
The position indicator shall have a minimum height of 50 mm and easy to read even from a
wide angle of view and under an illumination level of 500 lux. LCD display to be provided.
The indicators shall be mounted onto the back of at least 2.5 mm stainless steel
by weld studs and screws flush fit.
Dated 29.Jan 2015
faceplates
Page 197 of 429
RVNL
(e) Push /Electronic touch button:
All push/electronic touch buttons shall be vandal-resistant design and of flush
mounted construction.
The push/electronic touch buttons shall have acknowledgement of the call by illumination. The
halo shall be formed with flame retarding polycarbonate. Shock loads due to pressing of the
pressel must be borne by the body of the unit and not by the contacts.
(f) Lift control buttons:
Essential lift controls buttons such as emergency alarm button, intercom button, door opening
button, call buttons on landings, floor buttons in the lift car shall not be lower than 900mm or
higher than 1200mm above the finished floor level. Braille and tactile markings shall be placed
either on or to the left of the control buttons. Such markings shall be minimum 15mm in height
and 1 mm raised. All lift control buttons shall have a minimum dimension of 20 mm.
25.15
Fire Emergency return:
When the building’s fire or smoke detectors are activated, all calls should be cancelled
automatically and the lift shall travel to the main lobby or a pre-designated floor and park there
with the door fully opened. However the Electrical signal that indicates the actuation of the fire
sensors must be supplied to the lift controller by others or the fire alarm switch provided on the
ground floor is activated. The display to be given in the car with pre-recorded audio message so
that passengers do no panic.
25.16
Car lights & Fan automatically shut off:
The lift shall be installed with an energy saving feature that automatically switches off the car
internal lighting and ventilation fans when there are no calls registered after a predetermined
(Programmable) period of time.
25.17
Interphone:
An interphone for the use in case of emergencies shall be installed in the car for direct
communication with the rescue personnel in the control room/machine room or top of the car.
The interphone shall be such that it is activated by simply pressing the interphone button on the
car operating panel.
25.18 Fault information recording:
The lift shall be provided with an automatically fault recording facility. A minimum of 50 last
fault information’s are recorded to check what happened during a break down.
25.19
Arrival chime:
An electronic chime to provide an audio signal to inform waiting passengers of the arrival of the
lift car at each floor shall be provided. The chime shall be mounted on the top or bottom of the
car. The LED indications for direction of travel and car floor level status to be provided as
current.
25.20
Maximum call registration:
Limit Maximum car calls to be registered at one time to avoid misuse, improve traffic efficiency
and avoid redundant stopping of the car.
Dated 29.Jan 2015
Page 198 of 429
25.21
RVNL
Parking floor:
To improve efficiency and save time the lift car shall be made programmable to return to a
predetermined floor after remaining idle. The idle time shall also be programmed in consultation
with the employer’s project authority.
25.22 Voice anunciator:
All kinds of information that include floor, direction and others shall be spoken out to remind
passenger in three languages i.e. Hindi, English and vernacular.
25.23 Handicap:
It is special for those people who are handicapped, which include Voice anunciator with hand rails,
back mirror and horizontal push button station with Braille buttons.
25.24 Separate landing display:
Big screen dot matrix LCD display shall be provided.
25.25 Duplex indication:
In case call request button is pressed by any passenger from any floor or destination request any
user inside the car the corresponding display button to get lit at respective floor and also in the
car to avoid redundant operation by passengers.
25.26 Control System and Controller Accessories:
The control system shall be of variable voltage variable frequency (VVVF) microprocessor based
simplex full collective. The control system shall include PWM inverter of standard and latest
design so as to achieve maximum energy savings and accurate control. The control system will
limit the starting current of the motor to the rated full load current under all conditions. The
controller shall be enclosed in a
suitable sheet steel wall mounted cubicle with front doors for easy accessibility of various
equipments either on the top landing or inside the Lift shaft as per standard practice.
(a) Construction:
The controller shall be constructed in accordance with IEC 60947 and shall be mounted in a
ventilated steel cubicle with hinged front doors and removable hinged rear panels, in which all
contactors, solenoids, relays, motor starting equipment etc., shall be fitted. All steel sheets shall
be no less than 2.5 mm thick and comply with Clause 25.42 of this Specification.
(b) General requirements:
The controller shall comply with the general requirements as stated in EN 81-1, and in particular,
the following features shall be included: 1. Materials used in the construction of the control equipment shall not support combustion.
2. The components shall be designed and mounted in a manner which will facilitate easy
inspection, maintenance, adjustment and replacement. Wirings shall be terminated in such
a way that the wires are not damaged. Accessible terminals suitably marked, shall be
provided for incoming and outgoing cables.
3. Control circuits at normal mains voltage shall be connected between phase and neutral and
shall be supplied through double wound isolating transformer.
4. Where rectifier is used it shall be of the full wave silicon type fed from a transformer.
5. The control circuit shall be protected by suitably rated over-current circuit breakers or HRC
fuses independently.
6. The brake solenoid and any retiring cam shall operate on direct current.
Dated 29.Jan 2015
Page 199 of 429
RVNL
7. Motors connected to polyphase a.c. power supplies shall incorporate means to prevent the
motor from being energised in the event of phase failure.
(c) Solid state controls:
Microprocessor-based control shall include the following design features:1.
The system hardware shall be capable of supporting fully software based supervisory and
motor control systems.
2.
Interruption of the electrical supply to the lift shall not affect the system memory or
software.
3.
It shall be possible to change the supervisory control algorithm to meet a change in the
use of the building by re-programming the instruction memory.
4. It shall be possible to interrogate, by means of communication access/test points on the
controller, the system operating functions by use of a portable unit using diagnostic
routines.
5.
Visual indicators, e.g. LED'S, shall be provided on the controller to display information on
the operational status of the lift.
6.
Multiplexing techniques may be employed to reduce the number of trailing
cables normally required, if considered cost effective to do so.
(d)
Provisions for future remote monitoring of lift:
The Supplier/Contractor shall provide dry contacts of the following output signals for each lift
installation in a stainless steel cabinet to serve as the interface unit for future connection by
others:
1. Normal/Fault status
2. Duty/Standby status
3. Power Supply Normal/ Fault status
4. Normal/ Essential Power status
5. Passenger trapped alarm
This interface unit shall be located at the management office/caretaker’s room next to the lifts
monitoring panel unless otherwise specified on the Drawing or in the Specification.
(e) Energy consumption and Duty Cycle monitoring:
The lifts shall be provided with energy recording devices and duty cycle reporting system. The
print out port with RS 232/ USB port to be provided to communicate with PC/Laptop to dawn load
energy, duty cycle, fault logs, mode of operation, battery status and other data/information etc.
The down loading software to be supplied along with one Laptop PC and printer independent of
platform as approved by
employer’s project authority.
The down loaded data, reports,
information shall be platform independent in alpha numeric format in English language and shall
have full compatibility and exchange with MS office.
(f) Directional collective control for single lift:
All calls shall be stored in the system and answered in sequence regardless of the order in
which they are registered. When the car is travelling in a given direction it shall travel to the
further-most call, answering any car call or landing call for the corresponding direction of travel.
Landing calls for the direction opposite to that in which the car is travelling shall be by-passed
but shall remain stored in the system to be answered when the car returns in the opposite
direction. When the car stops for the last call in its direction of travel, preference is given to car
Dated 29.Jan 2015
Page 200 of 429
RVNL
call(s) for an adjustable period. When all calls have been answered the car remains with doors
closed at the floor to which it last travelled.
(g) Energy management of lift system:
For each lift car within a lift has been idling for 2 minutes with the lift doors closed, the lift car’s
ventilation shall be shut off automatically until the lift car is activated again by passenger call.
(h) Conduit/Trunking facilities by Supplier/ contractor:
The Supplier/l Contractor or others shall be responsible for the provision of conduit facilities
for the alarm buzzers/bells and the supervisory control panel at the landing of designated point
of entry between the lift shaft and the position of the panel. The Supplier/Contractor shall
furnish sufficient information to the Supervising Officer in good time before the conduit
installation work is commenced on site. The Supplier/Contractor shall be liable for all expenses
incurred due to his failure to comply with the above requirement.
(i) Supervisory control panel:
Where supervisory control panel is specified in the Particular Specification and/or Drawings, the
Supplier/Contractor shall be responsible for the provision of all cablings, visual and audible
signal components, and controls for the supervisory control panel from all lifts to the
supervisory control panel that is located in the caretaker's office at the landing of designated
point of entry unless otherwise specified.
The supervisory control panel shall include at least, but not exclusive, the following basic
facilities :1.
2.
3.
4.
5.
6.
7.
8.
9.
'In service/Out of service' LED lights for each lift.
Floor/position indicators for each lift.
Up/Down direction indicator arrows for each lift.
System fault alarm buzzer / bell and LED indication lights.
Power on indicator.
Mute button for alarm buzzer / bell, and alarm reset button.
Lamp test button
Repeater master unit for intercom system.
'Under Fireman control' LED light for each Fireman's lift.
The conduit/trunking facilities from the lift shaft at the landing of designated point of entry to
the position of the supervisory control panel shall be provided by others as in Clause (h) above.
(j) Closed circuit television:
1.
2.
3.
a CCTV camera mounted on the ceiling of the lift car;
a colour CCTV monitor located at the lift machine room;
separate and independent lift travelling audio/video cable(s) for the CCTV system
connecting between the CCTV camera installed in the lift car (with the corresponding
power supply MCBs in the MCB boards in the lift machine room) and the CCTV monitor(s)
respectively;
4. All the conduit and trunking facilities inside the lift shaft and the machine room (conduit
and trunking facilities outside lift shaft and lift machine room will be provided by others
unless otherwise specified);
Dated 29.Jan 2015
Page 201 of 429
RVNL
5. The Supplier/Contractor shall integrate a set of CCTV video signal and emergency alarm
signal output connection sockets on the lift supervisory control panel for others to connect
the signal output through appropriate plugs to the display monitors of the security control
console based on the following conditions:
i) the CCTV video signal and emergency alarm signal output connection sockets on the lift
supervisory control panel shall be BNC panel sockets.
ii) the Supplier/Contractor shall supply associated connection plugs, which shall suit the
BNC panel sockets on the lift supervisory control panel and shall not be less than the
sockets in quantity, to the security control console specialist contractor who shall then be
responsible for the wiring from the security control console to the plugs.
iii) the BNC connection plugs and sockets shall be of 75 ohm impedance type, service
voltage up to 500 V peak and frequencies up to 4000 MHz, and accept common RF cable.
25.27 Controller Accessories:
An emergency stop switch shall be provided and fitted on the top of the car for use of persons
working thereon. During maintenance suitable limit switch shall be provided for automatically
stopping at the required floor. Limit switches shall be provided to cut off the main supply to the
driving motor and to cut off DC supply to the brake coil causing immediate application of the
brakes in the event of the Lift traveling past the top or bottom terminal limit switches. The limit
switches shall be of approved design and make.
25.28 Leveling Accuracy:
The leveling accuracy shall be ±5 mm or lesser for passenger convenience. This leveling
accuracy shall be maintained under all conditions of loading.
25.29 Reverse Phase Relay:
A reliable reverse phase prevention arrangements shall be provided on the controller, which
shall be designed to protect the Lift equipment against phase reversals and phase failures.
25.30(a) Provision of overload device:
Every lift shall be provided with an overload device which shall operate when the load in the
car is 10% or more in excess of the rated load of the lift.The overload device, when in
operation, shall:1. prevent any movement of the car.
2. prevent the closing of any power operated door whether fitted to
the car or to the
landing at which the car is resting , and
3. give audible and visible signals inside the car.
The lift shall resume normal operation automatically on removal of the excessive load. The
overload device shall be inoperative while the lift car is in motion.
(b) Full load device:
Every lift other than a service lift shall be provided with a full load device having an adjustable
setting range from 80% to 100% of the rated load and when operated, it shall by-pass all
landing calls. When the load in the car is reduced, the car shall stop for landing calls as normal.
Dated 29.Jan 2015
Page 202 of 429
RVNL
25.31 Limit Switches:
Terminal limit switches shall be provided to slow down and stop the car automatically at the
terminal landing and final limit switches shall be provided to automatically cut off the power and
apply the brake should the car travel beyond the terminal landings.
25.32 Top of Car Inspection:
A top of car operating fixture shall be provided on each car, containing continuous pressure
buttons for operating the car in both directions and a toggle switch for making the buttons on
top of the car operative. This toggle switch when switched to inspection operation shall modify
the operation of the car to disconnect it from the normal operation to eliminate all normal
operation devices, automatic leveling and power door operation and the car shall run at
standard speed for the purpose.
25.33 Automatic Rescue Device:
In the event of power failure or failure of control system where the Lift is in operation the
rescue device should take over automatically and bring the Lift to the nearest landing safely.
The rescue device should be operated on rechargeable maintenance free batteries. The battery
charging system to be supplied such that batteries are kept charged always in situ.
25.34 Alarm Bell and Emergency Light:
The alarm bell is to be provided and fitted in an approved position close to the Lift at Ground
floors complete with push button inside the car and with necessary SMF rechargeable Battery.
Battery operated emergency lamp should also be fitted in the car which shall work
automatically in the event of a power failure, providing illumination within the car. The batteries
shall be maintenance free and shall be supplied on board with a battery charging system. The
battery charge status should be displayed in control room/Machine room.
25.35 Machine room installations:
The machine room shall be ventilated such that the motors and equipment as well as electric
cables etc, are protected from dust, harmful dust and humidity. The ambient temperature in the
machine room shall be maintained between +5ºC and+40ºC. The machine room shall be
provided as followingi.
ii.
iii.
iv.
v.
Doors accessing machine room are to be clearly labeled with BS warning signs.
Within the machine room an Electric shock Notice shall be installed.
Within the machine room adequate Rubber Matting shall be installed.
Within the machine room RCD protected 15A socket outlet shall be installed.
The machine room lighting shall be by twin tube 2x28 W T-5 fittings/ adequate LED
luminaries which shall give illumination of 150 Lux. The level of illumination in a power
failure shall be a minimum of 50 Lux to floor level throughout to be maintained by
providing Emergency lights. These lights shall be back up at least 72 hours by
adequate SMF battery and shall be manually operated by a switch located at a
convenient position inside the machine room.
vi. Tool box shall be fitted in the machine room and it shall comprise of the following
minimum equipment:
▪ Release Keys
▪ Winding wheel
▪ Log card
▪ Hand Winding instruction
Dated 29.Jan 2015
Page 203 of 429
RVNL
25.36 Batteries and chargers:
The batteries shall be of sealed , high rate maintenance free nickel-metal hydride type, or a
type of better functions and performance and approved by the Supervising Officer and shall
have a guaranteed life expectancy of at least four (4) years. They shall hot have any memory
effect as to affect their usable life or performance. The nickel-metal hydride battery shall
comply with EN 61436 and EN 61951-2 where appropriate. The battery charger shall be
compatible with the batteries used. The charger shall comply with EN 60335-2-29 and be
capable of fully re-charge the batteries in not more than 12 hours.
25.37
Suppression of Radio and Television interference:
The lift installation shall be adequately suppressed against radio and television interference to
limits as laid down in BS EN 55014 and BS 613. Interference suppression components shall not
be used in any part of the circuit where their failure might cause an unsafe condition.
25.38 Harmonic distortion:
The lift installation shall not, by injection of undesirable waveforms into the electricity supply
distribution system, adversely affect the power company's system and/or the electricity supply
to other users or consumers. The Total Harmonic Distortion (THD) produced by the lift motor
drive system measured at the isolator connecting the lift equipment to the feeder circuit of the
building is limited to the maximum allowable values specified in Table I. The THD shall be
measured at the moment the lift car is moving up with rated load at its rated speed.
The Supplier/Contractor shall be responsible for providing all necessary harmonic filter(s)
should the THD of the installation exceed the maximum allowable values as specified in Table I.
Table – I
Maximum allowable THD for lift motor drive systems.
Circuit Fundamental Current of Motor Drive
Maximum THD (%)
400A < I < 800A
15.0
80A < I < 400A
22.5
I < 80A
35.0
25.39 Maximum allowable Electrical power:
The running active electrical power of the motor drive of traction lift system carrying a rated
load at its rated speed in an upward direction shall be equal to or less than the maximum
allowable values specified in Table II.
Dated 29.Jan 2015
Page 204 of 429
RVNL
Table - II
Rated Load
(Kg)
L< 750
750 <L <
1000
1000 <L <
1350
1350 <L <
1600
1600 <L <
2000
2000 <L <
3000
3000 <L <
4000
4000 <L <
5000
L < 5000
Maximum allowable Electrical power of Traction lifts (Vc < 3)
Maximum allowable Electrical power(kW) of Traction lift
Systems for various ranges of Rated speed (Vc) in m/s
Vc < 1
1 < Vc < 1.5 1.5 < Vc < 2 2 < Vc < 2.5
2.5 < Vc < 3
7
10
10
12
12
17
16
21
18
24
12
17
22
27
32
15
20
27
32
38
17
25
32
39
46
25
37
47
59
70
33
48
63
78
92
42
60
78
97
115
0.0083L+
0.5000
0.0118L+
1.0000
0.0156L+
0.5030
0.0190L+
2.0000
0.0229L+
0.5000
25.40 Sound reducing:
The whole of the lift/ machinery including the opening and closing of the car and landing doors
shall be quiet in operation, and sound reducing rubber pads or other means shall be provided
by the Supplier/Contractor where necessary to eliminate vibration and noise transmission.
25.41 Finish:
All metal work supplied by the Supplier/Contractor in out of the way locations such as the lift
shaft, lift pit, machine room and on the outside of the lift car shall be properly wire-brushed,
cleaned of rust, scale, dirt and grease prior to the application of one coat of rust inhibiting
primer, with particular attention paid to the priming of outer surfaces of car doors, inner
surfaces of landing doors, metal work associated with door assemblies, the underside and the
framework of lift cars. Any part of the equipment, including guide rails, which requires greasing
or oiling and any components that are supplied unpainted by the manufacturers due to
functional reasons shall not be painted.
All normally visible metal surfaces, other than stainless steel and non-ferrous surfaces, shall be
finished with one coat of rust inhibiting primer, one under coat/finishing coat and one finishing
coat of enamel paint to a colour to be selected by the Supervising Officer.
25.42 Stainless steel:
Unless otherwise specified, stainless steel shall be of EN 10029, EN 10048, EN 10095, EN
10258 and EN 10259Grade 316 or equivalent.
Dated 29.Jan 2015
Page 205 of 429
RVNL
25.43 Notice Boards:
The following stainless steel notice boards engraving conpiciously in both English and Hindi
characters shall be provided and rigidly mounted:1. "No Smoking", which shall be in each car,
2. "When there is a fire do not use the lift" in each car and on each landing floor.
25.44 Wiring and Earthing:
The Employer will arrange single phase and three-phase supply with suitable MCCBs / MCBs for
isolation and protection in either on the ground floor or First floor or Second floor as far as
possible near the Lift shaft on request by the Supplier/Contractor. All necessary wiring in heavy
gauge conduits from the MCB to the driving motor, controller, call push buttons, door locks,
limit switches, alarm bell, halfway junction box and wiring inside the car shall be done by the
Supplier/Contractor in accordance to IEC 60364 for Electrical Installations of buildings.
Necessary traveling cables from the car to the halfway junction box in the shaft shall be
provided by the Supplier/Contractor. Equipment earthing required for the machine and in the
Lift well should be carried out by the Supplier/Contractor. The main earthing shall be of 4 SWG
GI wire and subsidiary earthing by 14 SWG tinned copper wire. All electrical equipments in the
Lift including car body shall be provided with two distinct earthing arrangement as per IS
standards and connected to the earth pit provided in stations.
25.45 Departure from Specification:
The Supplier/Contractor should supply standard equipment as far as possible but where it does
not comply with this specification a list of deviation giving full particulars of deviations from this
Specification duly quoting reference to clause No. shall be submitted to the Employer for prior
approval.
25.46 Technical Particulars, Drawings etc.:
The approval application shall be accompanied with:i)
Complete technical illustrated literature for the equipments offered.
ii)
Technical particulars and guaranteed performance of Lifts in the Annexure - `B’.
25.47 Spare parts and tools:
Spares that are considered necessary for continuous satisfactory operation of the equipment for
at least two years shall be advised separately, inclusive of rates for reference. Any special tools
required for the maintenance of the equipment shall be submitted along with the approval.
25.48 Drawing and manuals:
Complete detailed layout drawings showing the structural requirements in the building and
loadings and disposition of various equipments and wiring diagram of various equipments shall
be furnished by the Supplier/Contractor before taking up the work. Six copies in English
language of the manufacturer’s booklet containing description of various equipments of the Lift
shall also be submitted to the employer’s project authority. The operating manual and
maintenance schedule shall also be submitted while handing over the installation. The two
additional manuals and information shall be supplied in Hindi, English and vernacular language
each.
Dated 29.Jan 2015
Page 206 of 429
RVNL
25.49 Tests and Test Certificates:
The Supplier/Contractor shall furnish details of internal tests carried out on all equipment,
components and fittings of the Lift at their works. Suitable test certificates should be submitted
to Employer to establish: (a) The satisfactory operation of the Lift includes protective mechanisms, safety devices, brake
gear, etc. with temperature rise of driving motor not exceeding the guaranteed limits.
(b) That the floor setting of the car at the landings is correct at all loads from no load to full
load.
(c) That the speed of the car is as guaranteed and that the acceleration and
retardation are
satisfactory and smooth.
(d) That the operation of the contactors, interlocks and time lags are satisfactory and
in
correct sequence and the correct functioning of the terminal limit switches.
25.50 General requirements:
All dangerous parts shall be effectively guarded. Where applicable, components shall be
designed to be inherently safe, obviating the need for external or removable guards. Every lift
car body shall be carried in a steel car frame sufficiently rigid to withstand the operation of the
safety-gear without permanent deformation of the car frame. The deflection of the members
carrying the platform shall not exceed 1/1000 of their span under static conditions with the
rated load evenly distributed over the platform. At least four renewable guide shoes, or guide
shoes with renewable linings, or sets of guide rollers shall be provided, two at the top and two
at the bottom of the car frame.
25.51 Training of Staff:
The Supplier/Contractor shall train three staff nominated including one Supervisor nominated
by employer’s project authority, during the erection of the Lift at site. They shall also train the
staff in the maintenance, operation and trouble shooting of the Lift. However the responsibility
of maintenance of Lifts will be with Contractor during the guarantee period.
25.52 Guarantee:
The Supplier/Contractor shall guarantee satisfactory performance of the Lift and allied
equipments over a period of 24 months in actual service from the date of handing over of the
installation to the Railway in normal working conditions. During the guarantee period the
Supplier/Contractor shall rectify free of cost of all defects which may develop due to faulty
design, material failure and bad workmanship inclusive of free replacement of defective parts.
The guarantee will get automatically extended corresponding to the periods during which the
equipment is not in use. On every occasion when the equipment goes out of service, the
duration between the date of intimation of the failure of equipment to the contractor and the
date of handing over of the equipment after repairs in good working condition duly tested and
commissioned in the presence of Purchaser’s representative, will be counted for the extension
of the guarantee period till the equipment completes actual service for a total period of 24
months. During the guarantee period the parts of the equipments requiring repairs or
replacements will be handed over to the contractor at site and the parts after repairs or
replacements shall be fitted in the equipment at site by the contractor. All expenses involved in
fulfilling the above guarantee obligations shall be borne by the contractor.
25.53 Inspection:
The materials will be inspected by purchasers’ nominated representative at manufacturer’s
premises or contractors depot as the case may be. The purchaser or his representative shall have
the right to be present during all the stages of manufacture and shall be afforded free of charge
all reasonable facilities for inspection and testing as well as to examine the stage inspection report
of the manufacturer / inspection in addition to the quality audit which the contractor may institute
Dated 29.Jan 2015
Page 207 of 429
RVNL
as a part of his Programme so as to satisfy himself the materials are in accordance with the
specification, approved drawings and designs and purchasers prescribed Quality Assurance
Standard.
25.54 Civil Engineering:
The contractor should inspect site conditions before ordering. The design of the Lift includes the
design of the support system and guidance which includes the support of the traction machine
and all its accessories. The Lift shaft is either 230 mm brick / concrete. Contractor should give
their design to suit the existing Lift shaft/machine room and well. The design of the Lift should be
compatible with the Lift well and Lift shaft/machine room. The contractor should ensure adequate
design so as the individual load and their distribution of car, counter weight for both normal and
abnormal working (Accident), or with in the structural design limits of Lift well. The anchorage and
guidance of car and counter weight will be designed to suit the Lift shaft under all conditions. This
is considered as primary responsibility of the contractor.
25.55 Preventive Maintenance and Schedules:
The contractor shall service the Lifts thoroughly as per OEM maintenance schedule and attend the
breakdown complaints free of charge during the defect liability period of 24 months including
all spares, materials and replacable parts free of charge.
(a) Important items of Schedule of maintenance during the defect liability period of 24 months is
enclosed herewith however OEM recommended schedule of maintenance shall be followed in
detail.
(b) Maintenance schedule for Electric Lifts:
The following maintenance schedule should be carried out during the maintenance of Lifts and a
record should be maintained in the office as directed by employer. Any abnormality noticed during
the schedule should be attended immediately (within 2 hours) and proper operation ensured. Lifts
should be taken up for schedule of maintenance preferably on Holidays or beyond office hours and
with mutual agreement with user.
I.
Monthly Schedule:
Sl.
No
1.
Nature of Work
Check and attend fittings of Lift (light, fan, emergency light, failure alarm etc.)
2.
Check level of the lubricating oil in the gearbox, any unusual sound in the gearbox.
3.
Check the operation of all the doors, door locks.
4.
Check the brakes and adjust it.
5.
Check the operations of the limit switches.
6.
Clean machine and associated equipments.
7.
Check the main switch contacts and earth connections/continuity.
Dated 29.Jan 2015
Page 208 of 429
RVNL
8.
Check the main switch, fuses etc. (for loose connection, oscillation and ratings etc.).
9.
Check the general condition of the motor.
10.
Control panel:a) Check overhead relays operation
b) Check the interlocks for its proper functioning.
c) Check the relay contacts their operation and chattering.
11.
Check the electrical connections
12.
Check the foundation bolts of the motor any unusual noise, vibration etc.
13.
Check the input voltage & current of the motor and record it.
14.
Check leveling switches, arm pivots and limit switch rollers and lubricate.
15.
Check the performance of the over speed governors and adjust if necessary.
16.
Check the working of the floor selection switch.
17.
Check the floor indicators.
18.
Check all ropes, hinges, shackles etc.
19.
Check the microprocessor control for its proper functioning.
II. Quarterly Shedule of Maintenance:
Sl.
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
Nature of Work
Lubricate the rope pulley bearings in the Machine Room.
Check tightness of the counter weight, fixing clamps, bolts etc.
Check the trailing cables for broken / damaged insulation and loose binding.
Check the condition of the pit clean the car top and clean the gate.
The wire ropes should be cleaned by a stiff brush to remove old lubricant and lubricate it
again by using oil machinery medium or equivalent.
Clean the ropes for broken strands and general condition.
Check the dia. of the rope and record it.
Rope winding drum to be checked for its proper winding in the sheave grooves.
Measure the voltage and current at the various test points in the control system including
microprocessor control and record it.
Check the foundation bolts of the motor for any vibration.
Dated 29.Jan 2015
Page 209 of 429
RVNL
III. Yearly Schedule of maintenance:
Sl.
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
Nature of Work
Overhaul the motor for bearings and alignment.
Check car body supports and steel channels.
Check the condition and wear in the bearings.
Clean and check guide rails.
All break gears to be reconditioned.
Solenoid coils to be tested.
Limit switches to be overhauled and adjusted.
All the interlocking arrangements to be overhauled and checked for proper functioning.
Gearbox to be overhauled completely.
Check the microprocessor units for the proper functioning.
IV. In addition to the above periodical maintenance the firm has to attend the following:a)
b)
c)
d)
e)
f)
The firm has to attend the breakdown failure at any time during the working hours without any
delay.
They have to supply the required consumables, spares, to keep the Lift in good condition.
While attending the quarterly schedules the firm has to carry out the monthly schedules also.
While attending the yearly schedules the firm has to carry out the monthly and quarterly
schedules also.
Maintenance schedule should be carried out in consultation with
If the Lift remains OUT OF SERVICE for more than 48 Hours per month, Employer will have
right to impose penalty to the extent of 10% value of the contract.
Dated 29.Jan 2015
Page 210 of 429
RVNL
ANNEXURE - ‘A’
BRIEF REQUIREMENTS FOR LIFT TO BE SPECIFIED IN BOQ
1.
2.
3.
4.
5.
6.
Capacity
Speed
Car Travel
Stops & Openings
Control
Operation
:
:
:
:
:
:
7.
Controller
8.
9.
Communication
Power Supply
:
:
Loop type serial communication
3 phase AC 415V ±10% Variation, 50 Hz ±5% Variation.
10.
11.
Machine
Hoist way
:
:
12.
13.
14.
:
:
:
15.
Available head room
Available Pit Depth
Position Drive
including Main
machine.
Car Enclosure
Geared type induction machine.
….. mm wide x ….. mm deep (Tenderer to Check the
suitability of the same before tendering).
Tenderer to verify the same at site before tendering.
….. mm (approx.).
Directly at the top of Lift inside the machine room.
16.
Car Safety Gear
:
17.
Landing and Car
Doors.
:
18.
Leveling
:
19.
Human interface
device
a.
Microprocessor based Modular control system
:
b.
c.
d.
e.
Dated 29.Jan 2015
……. Persons.
……. m/Sec.
…. to …. About ….. m (approx.)
…..stops and …… openings. (All openings on same side.)
AC VVVF Variable Frequency with speed encoder
Simplex full collective with/without attendant
Stainless steel car panels of 1.5 mm thickness hairline finish
with stainless steel false ceiling adequately illuminated LED
luminaries of flush mounted pattern, one axial flow fan with grill
of quit running type having a noise level not greater than 30
dBA, one smoked mirror of half height full width on the rear
panel, 4mm thick antiskid studded rubber floor of approved
color. Suitable handrails of 1-1/4” O.D. round stainless steel
provided at 34” height from floor level of the car on three sides
with a 1-1/2” clearance from car walls.
Over speed governor – operated safety.
Landing doors and car door shall be of 2 panel centre opening
sliding closed, stainless steel powder coated or hairline stainless
steel finish panels, power operated independent drive with
adjustable automatic opening and closing speeds for door. The
clear opening should be 900 mm wide x 2000 mm with full
height Memco 3D curtain safe edge to detect and open the
doors in the event of Obstruction /infringement while the doors
are closing.
±5 mm irrespective of load.
Hall button with micro stroke push/touch buttons combined with
16 segment digital LED display position indicator.
Full height car operating panel with micro stroke push/touch
buttons (Located on side panel)
Door Open and Door Close button on the Car operating panel.
2 Way inter communication system.
DOT matrix position indicator display integrated with in the Car
operating panel.
Page 211 of 429
20.
Peak periods of Lift
workings
Dated 29.Jan 2015
RVNL
f.
Over load indicator i.e. device to sense 80% of rated load and
over load. Audio and visual indicator of overload.
g.
h.
i.
j.
:
Battery operated Alarm bell and Emergency Light.
Fireman’s switch.
Manual rescue operation.
Emergency auto rescue device.
Generally between ….. - ….. Hours in morn4mm thick antiskid
studded rubber floor of approved colouring, ….. - ….. Hours in
noon and …... - ….. Hours in the evening.
Page 212 of 429
RVNL
ANNEXURE - ‘B’
TECHNICAL PARTICULARS AND GUARANTEED PERFORMANCE OF THE LIFT
(TO BE FILLED IN WHILE SEEKING RVNL APPROVAL)
1.
Machine:a)
Main driving motor.
:
b)
Current in Amps at rated outputs.
:
c)
Rated make and type.
:
d)
Type of enclosure.
:
e)
Voltage between terminals.
:
f)
Output in HP.
:
g)
Weight.
:
h)
Speed in RPM at rated output.
:
i)
Class of insulation.
:
j)
Temperature rise on full load
:
2.
Brake:a)
Make.
:
b)
Type.
:
c)
Width & diameter of brake wheel.
:
d)
Method of adjustment.
:
e)
Provision for manual release.
:
3.
Car:a)
Dimension (internal).
:
b)
Weight (Approx.).
:
c)
Contract load.
:
d)
Maximum speed.
:
e)
Acceleration.
:
Dated 29.Jan 2015
Page 213 of 429
RVNL
f)
Retardation.
:
g)
Method of suspension.
:
h)
Time for travel between the floors.
Guide Rail:-
:
4.
(i)
For Car:a)
:
b)
Size and weight in kg per linear meter in
Tee sec.
No. of Sections.
:
c)
Spacing of intermediate supports.
:
d)
Method of lubrication.
:
(ii)
For Counter weight:-
a)
Size and weight in kg per linear meter in
Tee sec.
:
b)
No. of Sections.
:
c)
d)
Method of lubrication
:
:
5.
Control Equipments:-
(i)
Control Systems:-
a)
System of control and working DC
voltage for control.
:
b)
Type of VVVF control details.
:
c)
Potential Energy savings.
:
(ii)
Self leveling System:-
a)
Type of car leveling device.
:
b)
Any special features.
:
Limit Switches:Type.
:
b)
:
a)
Suspension Ropes:No. of ropes.
:
(iii)
a)
6.
Dated 29.Jan 2015
Page 214 of 429
RVNL
b)
Size and no. of strands in each rope.
:
c)
Factor of safety.
:
d)
Method of attachment to the car.
:
e)
Method of attachment to the counter
weight.
:
7.
a)
b)
c)
d)
8.
a)
b)
9.
a)
10.
11.
Counter weight:No. of sections.
Weight of each section.
Type of guide shoes.
Method of load equalization of ropes.
Wiring:Specification of wires.
Method of wiring.
Finishing:Full particulars should be given.
Protection devices, details provided in the
Lift:Special inclusions if any:-
:
:
:
:
:
:
:
---------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 215 of 429
Dated 29.Jan 2015
RVNL
Page 216 of 429
RVNL
MACHINE ROOMLESS & GEARLESS VERSION ELECTRIC
PASSENGER LIFT
Dated 29.Jan 2015
Page 217 of 429
Dated 29.Jan 2015
RVNL
Page 218 of 429
RVNL
CHAPTER:A-26
MACHINE ROOMLESS & GEARLESS VERSION ELECTRIC
PASSENGER LIFT
26.1.1 Scope:
The scope includes design, manufacturing, supply at site, erection, testing, commissioning and
handing over in satisfactory working condition of Machine room less & Gear less machine with
permanent magnet motor operated Electric traction passenger lift to the requirements as given
in Annexure 'A', under the operational and environmental conditions encountered during
service, complete with all accessories. Specifications and other stipulations are given below. The
salient points pertaining to safety shall also be complied by the Supplier/Contractor.
26.1.2General
The Machine Room less type Lift shall be governed by relevant International Standards and
International Codes of Practice such as European code of safety EN 81,American National
Standard Safety Code for Elevators (ANSI) A117 .1 , IS: 14665 or latest and IEC 60364 for
Electrical Installations of buildings. The traction machine, over speed governor, ropes, brake
gear controls and other safety equipment even though corresponding to specification EN 81 and
ANSI A117.1 should under all conditions of operations at least match with IS code of
specification for passenger Lifts viz. IS: 14665 or latest. This has to be ensured by Lift
manufacturers primarily and the manufacturer should have appropriate Quality Assurance
accreditation ISO 9000 I ISO 14001. The installations shall be to the highest standard as
expected of a fully experienced contractor. The manufacturer shall also comply with the
provision of Indian electricity act and rules in vogue and shall be taken over only if and when
they fully comply with all their requirements. The lift installation shall also be designed to
produce a safe working environment for Engineers and auxiliary workers to work on or around.
26.1.3Environmental service conditions:
All electrical, electronic and mechanical equipment shall suit the tropical climate for use in
service environmental conditions as stated below :Maximum ambient temperature 55 deg c
Minimum ambient temperature
Maximum Relative humidity
-5 deg c
100%
Atmosphere
Extremely dust and desert weather and desert terrain in
certain areas. The dust contents in air may reach as high
values as 1.6 mg/m.cube
Coastal area
The equipment shall be designed to work in corrosive
atmosphere.
Maximum Ph value
8.5
Sulphate
7 mg/litre
Max. concentration of chlorine
6 mg/litre
Max. conductivity
130 micro siemen/cm
Annual Rain fall
Ranging between 1750 to 6250 mm with thunder storm.
Alltitude
Not exceeding 1200m
Dated 29.Jan 2015
Page 219 of 429
RVNL
26.2.0 Specifications:
26.2.1 Gearless Machine:
The lift machine shall be smooth in operation with mm noise/vibration and of single wrap
traction type gearless machine with permanent magnet motor operated electromechanical brake
suitable to work on 400/440 Volts AC 3 Phase with neutral at 50 cycles per second supply with
VVVF (Variable Voltage Variable Frequency) type of control. The traction motor shall be energy
efficient induction type with a minimum of BEE's three star rating and in accordance to BS 4999
and BS 5OOO: part 99.The motor shall be designed to operate for an unlimited period according
to the expected duty of the lift. The traction machine shall be either induction machine or
synchronous machine. The driving sheave should be integrally coupled with the machine and the
assembly to be completely mounted on guide rail or on suitable rigid frame fixed to the shaft .
The driving sheave should be constructed from fabricated cast steel or S.G iron or suitable wear
resistant material with truly machined surface in order to ensure perfect alignment of all
bearings and prevent transmission of sound to the building. The motor shall be designed to
operate for an unlimited period according to the expected duty of the lift. The
Supplier/Contractor shall furnish detailed drawings showing weights to be tackled and the
disposition of various loads on the Lifts shaft and Lift well for the approval of employer.
26.2.2 Sheaves:
The driving sheave and pulleys should be of hard alloy constructed from fabricated cast steel or
S.G iron or suitable wear resistant material and free from cracks, sand holes and other defects
with truly machined surface in order to ensure perfect alignment of all bearings and prevent
transmission of sound to the building. They shall have machined rope grooves. The traction
sheave shall be grooved to produce proper traction and shall be of sufficient dimension to
provide for wear in the groove .The deflector sheave shall be grooved so as to provide a smooth
bed for the rope . The deflector or secondary sheave assemblies where used shall be mounted
in a proper alignment with the traction sheave. Such deflector sheaves shall have grooves
larger than the rope diameter as specified in clause 8 of IS:14665 (part-4 ,Sec.3):2000 or
latest. The size of all the sheaves shall be in accordance with clause 8.4 of IS: 14665 (part-4,
Sec.3):2001 or latest. Wherever necessary, suitable protective guards may be provided.
26.2.3 Electric Motor duty cycle:
The driving motor shall be designed specially for heavy duty Lifts to run smoothly under load up
to its maximum capacity in either direction with ample power to deal with occasional over loads.
It shall be arranged to develop the requisite, torque, enabling the machine to start easily from t
he rest. The motor shall be designed to confirm to 53 duty cycles defined as per IEC duty cycles
for non peak and peak periods of operation. The motor and drive system should be designed for
not less than 150 starts/ hour a nd stops during the peak periods. The peak periods of lift
workings are furnished in Annexure 'A'.
26.2.4 Brake:
A suitable electro magnetic brake, preferably of the direct acting type integrated with motor
operating on AC/DC shall be provided, with two brake shoes which are automatically applied by
means of a strong compression springs to a brake wheel of large diameter when the circuit is
broken a nd released by means of an electro-magnet.
The brake mechanism must incorporate provision to allow for minimum wear of brake lining. It
shall also have an emergency quick release device to open the brake without affecting its
adjustment so that the car can be lowered or raised manually in the event of electric supply
failure. The electric solenoid shall be rated to withstand continuous Lift duty.
26.2.5 Car and car frame:
The car enclosure shall be in accordance with clause-4
of
IS:14665
(part-4,
Sec.3):2001 or latest, made up of stainless steel 1.5 mm thickness hairline finish. The Lift car
Dated 29.Jan 2015
Page 220 of 429
RVNL
shall have stainless steel false ceiling adequately illuminated LED luminaries of flush mounted
pattern which shall give illumination of not less than 150 Lux on the lift floor level. The level of
illumination in a power failure shall be a minimum of 50 Lux to floor level throughout to be
maintained by providing Emergency lights. One axial flow fan of quit running type having a noise
level not greater than 30 dBA when measured at a distance of 1 m from the fan and it shall be
capable of handling at least 20 air changes per hour of lift car volume, with car doors closed.
The effective area of ventilation apertures situated in the upper part of the car shall be at least
1% of the available car area, and the same applies for any apertures in the lower part of the
car. The car ventilation fan shall be switched off within a period which shall be adjustable from 5
to 15 minutes after the last registered call is answered. One smoked mirror of half height full
width on the rear panel, suitable handrails of 50 mm O.D. tubular stainless steel shall be
provided at 86mm height from floor level of the car on three sides of the lift car extending to
within 150mm of all corners and with a 40mm clearance from car walls to facilitate handicapped
passengers. A load plate giving the contract load of the Lift, No. of passenger capacity of the Lift
shall be fitted in the Lift car in a conspicuous position.
Emergency contact number plate should be provided with front transparent acrylic
sheet with flush screw arrangement such that contact numbers can be changed. Suitable
slotting arrangement shall be done accordingly. The Control logic shall be used for controlling
lights and fans. The ventilation fan and full lighting shall be switched off by logic and
predetermined period if no button is pressed or call registered.
The lighting except emergency illumination shall also have connection to motion
sensor. The lights and fans supply also should have separate control panel switch to make
on/off. The ventilation fan shall also have one switch for operation in addition to motion sensor
control.
For video remote monitoring security web camera to be installed in the lift car having
display with recording arrangement to Control room in addition to self memory of minimum
past 72 hours recording.
Floor shall be made of 1.5 mm thickness Stainless Steel with 4mm thick antiskid
studded rubber floor to color and pattern as approved by the employer or engineer in charge.
The switch and control panel buttons should be made with backlit/letter display by LED with
dark background and the alpha numeric display in English language and also BRAILLE indents.
The control activated voice information of floor level announcement to be provided. The public
address system a lso to be built in for playing emergency announcement/commercial/
entertainment etc.
Two number LCD display of size of minimum 32 inch diagonal, motion flow 120 Hz live
colors display, HD image on NTSC/PAL/ATSC tuner having VGA/USB/BNC/TV tuner input
control to be provided with connection to public address system. The control supply shall be
brought to control room and VGA, Audio/Video output wiring to be done at Control room of lift.
Safety instructions in international signage’s pattern to lift users shall be provided inside the
car as approved by the employer or engineer in charge.
Emergency illumination on LED based luminaries also to be provided in car with
adequate SMF battery to support at least 72 hours back up with control switch in lift car itself.
The emergency battery back also shall be used for operation of interphone and emergency
alarm bell.
The roof of the car shall be solid type made of 1.5 mm thickness Stainless Steel
capable of supporting a weight of two persons i.e., at least 138 kg as per IS: 14665 (part-4,
Sec.3) :2001 or latest ·and shall withstand to a vertical force of 2000N at any position without
causing permanent deformation.
Lift car, excluding linings, shall be constructed of noncombustible materials.
One lighting socket outlet for hand lamp shall be provided on the top of the Lift car for
inspection. Suitable hand lamp with appropriate size and length of cable shall be supplied to
the maintenance staff by the Supplier/Contractor.
26.3.0 Doors:
Landing doors and car door shall be of 2 panel centre opening sliding closed, stainless steel
powder coated or hairline stain less steel finish panels as approved by the employer or engineer
Dated 29.Jan 2015
Page 221 of 429
RVNL
in-charge .power operated independent drive with adjustable automatic opening and closing
speeds for door. The clear opening should be 900 mm wide x 2000 mm height. The door shall
have a fire resistance rating of one hour as per EN 81-58 and ground switch/switches at ground
floor level shall be provided on all the lifts to enable the fire service to ground the lifts.
The car doors shall be fitted with a Memco 3D curtain safe edge to detect and open the doors
in the event of obstruction/infringement while the doors are closing.
The door open time to be made programmable for time delay set in the system.
The lift shall be designed to go out of service if the doors are kept open for a long time as
programmed.
A delay to the start the lift after the doors is closed (say 0.2 to 2.0 seconds) also to be
programmable.
The landing doors shall be provided with electro-mechanical inter-locks to prevent operation of
the Lift unless all the doors are closed and positively locked. The inter-lock shall also prevent
the opening of any door until the car has reached the respective landing zone. I n t h e event
of failure of Memco 3D curtain suitable mechanical system should be provided to open the
doors in the case of obstruction. Any projections on or recesses In the exposed parts of the
car doors or landing doors shall be kept to a minimum in order to avoid finger trapping
between sliding parts of the door and any fixed part of the car or landing entrance. The
clearance between panels or between panels and any fixed part of the car or landing entrance
shall not exceed 6 mm. Sliding car and landing doors shall be guided on door tracks and sills
for the full travel of the doors. The distance between the car and landing sills shall not exceed
35 mm. The clear height of all entrances on ca r and landings shall not be less than 2 m.
Supplier/Contractor shall provide full door sticker of approved quality and design with adhesive
as approved them by employer or engineer in charge.
Three
good
quality
digitally
printed
safety
and
energy
saving tips/
instructions as per pictographically international signage’s pattern of size 2 feet x 3 feet
of
suitable
design to
be supplied
and
fixed
on wall at lift on each floor in
Hindi/English/Vernacular language (i.e. one each).
26.3.1 Electrical device for proving the car doors closed:
Every car door shall be provided with an electrica l switch which will prevent the lift car from
being started or kept in motion unless all car doors are closed. A mechanical locking device
shall also be provided such that the car door cannot be opened from the inside while the car
is outside the unlocking zone.
26.3.2Landing door locking device:
Every landing door shall be provided with an effective locking device so that it shall not
normally be possible to open the door from the landing side unless the lift car door is in that
particular landing zone.
It shall not be possible under normal operation to start the lift car or keep it in motion
unless all landing doors are in the closed position and locked.
26.3.3Door locking devices to be inaccessible from landing or car:
All door locking devices and door switches, together with any associated actuating rods, levers
or contacts, shall be so situated or protected as to be reasonably inaccessible from the landing
or the car.
26.4.0 Car Slinging and Safety Gear:
The car body shall be supported in a steel sling so that no strains due to suspensions lifting
action of the safety gear are imposed in it. The sling shall be provided with adjustable shoes on
each side at the top and bottom to engage accurately with the guides to ensure smooth running.
The car and counter weights shall have underneath it an automatic instantaneous type safety
gear operated by an over speed governor designed to ensure positive action for excessive speed
on the down travel of the car. The safety gear shall be equipped with a contact to cut off power
supply/dur ing over load in such event and to bring the car to a stop. Controls and facilities for
Dated 29.Jan 2015
Page 222 of 429
RVNL
inspection shall also be provided at top of the car to facilitate inspection and testing as per ISS
latest and international standard.
26.5.0 Governor:
The car safety shall be operated by speed governor which shall be in accordance with clause 4
of IS: 14665 (part-4, Sec .3):2001 or latest and shall be adjustable to actuate the safety gears.,
located overhead and driven by governor rope suitably connected to the car and mounted on its
own pulleys. The governor shall be of "V" groove wheel design. The rope shall be maintained in
tension by means of weighted or spring loaded tension sheaves located in the pit. The governor
rope shall not be less than 10mm in dia. shall be made up of steel and as specified in Clause
26.6.0 of this Specification.
26.6.0 Suspension Ropes :
The main suspension ropes shall be in accordance w ith BS 302 part 4 clause B4.1 and clause 7
of IS: 14665 (part-4, Sec.3) :2001 or latest a nd the requirements for steel wire ropes shall be
in accordance with IS: 14665 (part- 4, Sec .8):2001 or latest, of the best flexible steel wire
construction conforming to IS: 6594/1981 or latest , with a minimum factor of safety of 12
times ,the number of strands and diameter of the ropes shall also comply with the factor of
safety requirements of the Ameriican National Standard Safety code for Elevators (ANSI) A117
.1. The supply of steel wire ropes should be three ropes or more and of minimum 10 mm dia.,
from the reputed rope manufacturers and shall be guaranteed for a period of two yea rs .Ends
of the ropes shall be properly secured to the car and counter weight hitch plates with
adjustable rope shackles having individual tapers babbit sockets or any other suitable
arrangement . Each rope shall be fitted with a suitable shackle spring, seat washer, shackle nut
& lock and shack le nut split pin.
26.6.1 Compensation rope:
For travels over 30 m and/or rated speed of the lift exceeds 2.5m/s, the Supplier/Contractor
shall provide compensation ropes with tensioning pulleys. For speeds of 2.5 m/s or below, quiet
operating chains or similar dev ices may be used as the means of compensation. For speeds
above 3.5 m/s, an anti-rebound arrangement of idler tension pulley shall be provided to prevent
the counterweight ht jumping with the application of the car safety gear.
26.7.1 Diverting Pulleys:
Diverting pulleys necessary for suspension of car on counter weight shall be of cast
iron, grooved for wire ropes complete with shaft, bearings and are to be suitably
supplied and they shall incorporate devices to avoid:
•
The suspension ropes, if slack, leaving the grooves.
. The introduction of objects between rope & grooves.
26.8.0 Guide rails:
The guide rails shall be in accordance with clause 3 of IS:14665 (part-4, Sec.2) :2001 or latest
for the car and counterweight and shall be made up of rigid steel 'T' sections with machined
working surfaces. These guides shall be erected to plumb and shall be complete with suitable
fixings at such intervals as to prevent deflection. The strength of the guides, their attachments
and joints shall comply with clause 10.1 and 10.2 of EN 81-1 and BS 5655: Part 9 Clause B1.2
and be sufficient to withstand the forces imposed due to the operation of the safety gear and
deflection due to uneven loading of the car. The section of weights in kg per meter of rails
should be furnished by the Supplier/Contractor in Annexure 'B'. Guide lubricators of approved
design shall be provided.
26.9.0 Counter Weight:
The counter weight shall be in accordance with clause 6 of IS: 14665 (part- 4, Sec.3):2001 or
latest, shall consists of a structural steel frame with loose cast iron filler weights arranged to
Dated 29.Jan 2015
Page 223 of 429
RVNL
balance the full weight of the car plus, approximately 50% of the contract load so as to ensure
low power consumption and economical running of the Lift. The factor of safety of steel frame
members and the tie rods shall not be less than 5. The guide shoes shall be fitted to the top
and bottom of the structural frame on both sides and shall be of replaceable & adjustable type
to ensure smooth and quiet running and long life. Counter weights shall be guarded by means
of a rigid fixed screen extending from a position of 0.3m above the Lift pit floor to a position at
least 2.5m above the Lift pit floor.
26.10.0 Buffers:
Buffers shall be in accordance with clause 5.15 of IS: 14665 (part-2, Sec.2):2000 or latest.
Hydraulic/spring buffers of tested design shall be installed as a means of stopping the car and
counter weight at the extreme limits of travel. Buffers in the pit shall be mounted on the steel
frame, which shall extend between both the car and counter weight guide rails. Energy
accumulation type buffers shall only be used if the rated speed of the lift does not exceed 1 m/s
and Energy accumulation type buffers with buffered return movement shall only be used if the
rated speed of the lift does not exceed 1.6 m/s.
26.11.1 Operating System:
The Lift operating system shall be of simplex full collective type with prov1s1on for operation
with or without attendant. It should comprise of a call button at each landing and a set of
dispatch buttons together with an emergency stop button in the car. All components shall be
well insulated and mounted in a metal case with suitably finished cover.
26.11.2
(a) Control station in car:
Each lift car shall have a flush mounted control station comprising:1. Call buttons with acceptance signals engraved in Arabic number to correspond with the
landing served.
2. An alarm push button with protection from
being operated
accidentally.
The
color of this button shall be yellow.
3. “door open” and “door close” push button.
4. Audible and visible signals in connection with the overload device.
5. Light switch, alarm reset switch, fan switch and cleaner's "Stop switch" keeping the ca r
door open in the form of key switches or housed in a recessed metal box with hinged or
sliding lid which wi ll be key-locked.
6. Two-way intercom speaker - the intercom system shall be as specified in Clause 26.11.4.
7. Any other control as specified in the specification.
All wordings shall be engraved in both English and Hindi characters. The material for the
control station shall be stainless steel with a thickness of not less than 2.5 mm. The control
station shall be fixed onto the car panel by stainless steel screws of secret -head type.
(b) Additional Control station:
For passenger lifts of 21 persons capacity or larger, to control station, one on either side of the
ca r doors, shall be provided such that one shall have the above functions 1, 2 and 3 only and
one shall have all
the functions 1 to 7.
(c) Control station equipped with attendant control:
For lifts equipped with attendant control, the control station shall also incorporate:-
Dated 29.Jan 2015
Page 224 of 429
RVNL
1.
A non-stop button for the purpose of by passing landing calls, but the calls shall remain
registered until answered. This button shall be inoperative unless the lift is operat ed by an
attendant.
2. A key-operated attendant control switch to be included in Clause 26.11.2(a)5.
The additional functions specified in this clause shall be provided in the Control Station in
Clause 26.11.2(a).
(d) Car direction and position indicator:
The direction indicators shall be of illuminated directional indicator with an illuminated area not
less than 1125 mm2. The position indicator shall be of digital type display with lamp matrix
actuated by solid state circuitry unless otherwise specified.
The position indicator shall have a minimum height of 50 mm and easy to read even from a
wide angle of view and under an illumination level of 500 lux. LCD display to be provided.
The indicators shall be mounted onto the back of at least 2.5 mm stainless steel facep lates by
weld studs and screws flush fit.
(e) Push /Electronic touch button:
(f)
All push/electronic touch buttons shall be vandal-resistant design and of flush mounted
construction. The push/electronic touch buttons shall have acknowledgement of the
call by illumination. The halo shall be formed with flame retarding polycarbonate. Shock
loads due to pressing of the pressel must be borne by the body of the unit and not by the
contacts.
Lift control buttons:
Essential lift controls buttons such as emergency alarm button, intercom button, door (opening
button, call buttons on landings, floor buttons in the lift car shall not be lower than 900mm or
higher than 1200mm above the finished floor level. Braille and tactile markings shall be
placed either on or to the left of the control buttons. Such markings shall be minimum 15mm in
height and 1 mm raised. All lift control buttons shall have a minimum dimension of 20 mm.
26.11.2 Fire Emergency return:
When the building's fire or smoke detectors are activated, all calls should be cancelled
automatically and the lift shall travel to the main lobby or a pre- designated floor and park
there with the door fully opened. However the Electrical signal that indicates the actuation of
the fire sensors must be supplied to the lift controller by others or the fire a larm switch
provided on the ground floor is activated. The display to be given in the car with pre-recorded
audio message so that passeng ers do not panic.
26.11.3 Car lights & Fan automatically shut off:
The lift shall be installed with an energy saving feature that automatically switches off
the car internal lighting and ventilation fans when there are no calls registered after a
predetermined (Programmable) period of time.
26.11.4 Interphone:
An interphone for the use in case of emergencies shall be installed in the car for direct
communication with the rescue personnel in the control room or top of the car. The interphone
shall be such that it is activated by simply pressing the interphone button on the car operating
panel.
26.11.5 Fault information recording:
The lift shall be provided with an automatically fault recording facility. A minimum of 50 last
fault information's are reco rded to check what happened during a break down.
26.11.6. Arrival chime:
An electronic chime to provide an audio signal to inform waiting passengers of the arrival of
the lift car at each floor shall be provided. The chime shall be mounted on the top or bottom of
Dated 29.Jan 2015
Page 225 of 429
RVNL
the car. The LED indications for direction of travel and car floor level status to be provided as
current.
26.11.7 Maximum call registration:
Limit Maximum car calls to be registered at one time to avoid misuse, improve traffic efficiency
and avoid redundant stopping of the car.
26.11.8 Parking floor:
To improve efficiency and save· time the lift car sha l be made programmable to return to a
predetermined floor after remaining idle. The idle time shall also be programmed in consultation
with the employer or engineer in charge.
26.11.9 Voice anunciator:
All kinds of information that include floor, direct ion a nd others shall be spoken out to remind
passenger in three languages i.e. Hindi, English and vernacular.
26.11.10 Handicap:
It is special for those people who are handicapped, which include Voice enunciator with hand
rails, back mirror and horizontal push button station with Braille buttons.
26.11.11 Separate landing display:
Big screen dot matrix LCD display shall be provided.
26.11.12 Duplex indication:
In case call request button is pressed by any passenger from any floor or destination request
any user inside the car the corresponding display button to get lit at respective floor and also in
the car to avoid redundant operation by passengers.
26.12.0 Control System and Controller Accessories:
The control system shall be of variable vo ltage variable frequency (VVVF) microprocessor
based simplex full collective. The control system shall include PWM inverter of standard and
latest design so as to achieve maximum energy savings a nd accurate control. The control
system will limit the starting current of the motor to the rated full load current under all
conditions. The controller shall be enclosed in a suitable sheet steel wall mounted cubicle with
front doors for easy accessibility of various equipments either on the top landing or inside the
Lift shaft as per standard practice.
(a) Construction:
The controller shall be constructed in accordance with IEC 60947 and shall be mounted in a
ventilated steel cubicle with hinged front doors and removable hinged rear panels, in which all
contactors, solenoids, relays, motor starting equipment etc., shall be fitted. All steel sheets
shall be not less than 2.5 mm thick and comply with Clause 20.0 of this Specification.
(b) General requirements:
The controller shall comply with the general requirements as stated in EN 81-1, and in
particular, the following features shall be included:
1. Materials used in the construction of the control equipment shall not support combustion.
2. The components shall be designed and mounted in a manner which will facilitate easy
inspection, maintenance, adjustment and replacement. Wirings shall be terminated in
such a way that the wires are not damaged. Accessible terminals suitably marked, shall
be provided for incoming and outgoing cables.
3. Control circuits at normal mains voltage shall be connected between phase and neutral
and shall be supplied through double wound isolating transformer.
4. Where rectifier is used it shall be of the full wave silicon type fed from a
transformer.
Dated 29.Jan 2015
Page 226 of 429
RVNL
5.
The control circuit shall be protected by suitably rated over-current circuit breakers or HRC
fuses independently.
6. The brake solenoid and any retiring cam shall operate on direct current.
7. Motors connected to polyphase a.c. power supplies shall incorporate means to prevent the
motor from being energised in the event of phase failure.
(c) Solid state controls:
Microprocessor-based control shall include the following design features:1.
The system
hardware
shall be
capable of
supporting fully
software
based
supervisory and motor control systems.
2.
Interruption of the electrical supply to the lift shall not affect the system memory or software.
3.
It shall be possible to change the supervisory control algorithm to meet a change in the use
of the building by re-programming the instruction memory.
4.
It shall be possible to interrogate, by means of communication access/test points on the
controller, the system operating functions by use of a portable unit using diagnostic
routines.
5.
Visual indicators, e.g. LED'S, shall be provided on the controller to display information on
the operational status of the lift.
6.
Multiplexing technique s may be employed to reduce the number of trailing cables normally
required, if considered cost effective to do so.
(d) Provisions for future remote monitoring of lift:
The Supplier/Contractor shall provide dry contacts of the following output signals for each lift
installation in a stainless steel cabinet to serve as the interface unit for future connection by
others:
1.
Normal/Fault status
2.
Duty/Standby status
3.
Power Supply Norma l/ Fault status
4.
Normal/ Essential Power status
5.
Passe nger trapped alarm
This interface unit shall be located at the management office/caretaker's room next to the
lifts monitoring panel unless otherwise specified on the Drawing or in the Specification.
(e) Energy consumption and Duty Cycle monitoring:
The lifts shall be provided with energy recording devices and duty cycle reporting system. The
print out port with RS 232/ USB port to be provided to communicate with PC/Laptop to dawn
load energy, duty cycle, fault logs, mode of operation, battery status and other
data/information etc. The down loading software to be supplied along with one Laptop PC and
printer independent of platform as approved by employer or engineer in charge. The down
loaded data, reports, information shall be platform independent in alpha numeric format in
English language and shall have full compatibility and exchange with MS office .
(f) Directiona l collective control for single lift:
All calls shall be stored in the system and answered in sequence regardless of the order in
which they are registered. When the car is traveling in a given direction it shall travel to the
further-most
call, answering any car ca ll or landing call for the corresponding direction of
travel. Landing calls for the direction opposite to that in which the car is traveling shall be bypassed but shall remain stored in the system to be answered when the car returns in the
opposite direction. When the car stops for the last call in its direction of travel, preference is
given to car call(s) for an adjustable period. When all calls have been answered the car remains
with doors closed at the floor to which it last traveled.
Dated 29.Jan 2015
Page 227 of 429
RVNL
(g) Energy management of lift system:
For each lift car within a lift has been idling for 2 minutes with the lift doors closed, the lift car's
ventilation shall be shut off automatically until the lift car is activated again by passenger call.
(h) Conduit/Trunking facilities by Supplier/ contractor:
The Supplier/I Contractor or others shall be responsible for the prov1s1on of conduit facilities
for the alarm buzzers/bells and the supervisory control panel at the landing of designated point
of entry between the lift shaft and the position of the panel. The Supplier/Contractor shall
furnish sufficie nt information to the Supervising Officer in good time before the conduit
installation work is commenced on site. The Supplier/Contractor shall be liable for all expenses
incurred due to his failure to comply with the above requirement.
(i) Supervisory control panel:
Where supervisory control panel
is spec ified
in the Particular Specification
and/or Drawings, the Supplier/Contractor shall be responsible for the provision of all cablings,
visual and audible signal components, and controls for the supervisory control panel from all
lifts to the supervisory control panel that is located in the caretaker's office at the landing
of designated point of entry unless otherwise specified.
The supervisory control panel shall include at least, but not exclusive, the following basic
facilities :-
1.
2.
3.
4.
5.
6.
7.
8.
9.
'In service/Out of service LED lights for each lift.
Floor/position indicators for each lift.
Up/Down direction indicator arrows for each lift.
System fault alarm buzzer I bell and LED indication lights.
Power on indicator
Mute button for alarm buzzer I bell, and alarm reset button.
Lamp test button.
Repeater master unit for intercom system.
'Under Fireman control' LED light for each Fireman's lift.
The conduit/trunking facilities from the lift shaft at the landing of designated point of entry
to the position of the supervisory control panel shall be provided by others as in Clause
26.12.0(h).
(j) Closed circuit television:
1. a CCTV camera mounted on the ceiling of the lift car;
2. a color CCTV monitor located at the lift control room;
3. separate and independent lift travelling audio/video cable(s) for the CCTV system
connecting between the CCTV camera installed in the lift car (with the
corresponding power supply MCBs in the MCB boards in the lift control room) and the
CCTV monitor(s) respectively;
4. All the conduit and trunking facilities inside the lift shaft and the control room (conduit and
trunking facilities outside lift shaft and lift control room will be provided by others unless
otherwise specified) ;
5. The Supplier/Contractor shall integrate a set of CCTV video signal and emergency alarm
signal output connection sockets on the lift supervisory control panel for others to
connect the signal output through appropriate plugs to the display monitors of the security
control console based on the following conditions :
i) the CCTV video signal and emergency alarm signal output connection sockets on the lift
supervisory control panel shall be BNC panel sockets.
ii) the Supplier/Contractor shall supply associated connection plugs, which shall suit the BNC
panel sockets on the lift supervisory control panel and shall not be less than the
sockets in quantity, to the security control console specialist contractor who shall
Dated 29.Jan 2015
Page 228 of 429
RVNL
then
be responsible for the wiring from the security control console to the plugs.
75 ohm impedance type, service
voltage up to 500 V peak and frequencies up to 4000 MHz, and accept common RF
cable.
iii) the BNC connection plugs and sockets shall be of
26.12.1 Controller Accessories:
An emergency stop switch shall be provided and fitted on the top of the car for use of persons
working thereon. During maintenance suitable limit switch shall be provided for automatically
stopping at the required floor. Limit switches shall be provided to cut off the main supply to the
driving motor and to cut off DC supply to the brake coil causing immediate application of the
brakes in the event of the lift travelling past the top or bottom terminal limit switches. The limit
itches shall be of approved designing and make.
26.12.2 Levelling Accuracy:
The leveling accuracy shall be ±5 mm or lesser for passenger convenience. This
leveling accuracy shall be maintained under all conditions of loading.
26.12.3 Reverse Phase Relay:
A reliable reverse phase prevention arrangements shall be provided on the controller, which
shall be designed to protect the Lift equipment against phase reversals and phase failures.
26.12.4(a) Provision of overload device:
Every lift shall be provided with an overload dev ice whic h sha ll operate when the load in
the car is 10% or more in excess of the rated load of the lift. The overload device, when in
operation, shall:-
1. prevent any movement of the car.
2. prevent the closing of any power operated door whether fitted to the car or to the landing
at which the car is resting, and
give audible and visible signals inside the car.
The lift shall resume normal operation automatically on removal of the excessive load. The
overload device shall be inoperative while the lift car is in motion.
(b)
Full load device:
Every lift other than a service lift shall be provided with a full load dev ice having an adjustable
setting range from 80% to 100% of the rated load and when operated, it shall by-pass all
landing calls. When the load in the car is reduced, the car shall stop for landing calls as normal.
3.
26.12.5 Limit Switches:
Terminal limit switches shall be provided to slow down and stop the car automatically at
the terminal landing and final limit switches shall be provided to a utomatically cut off the
power and apply the brake should the car travel beyond the terminal landings.
26.12.6 Top of Car Inspection:
A top of car operating fixture shall be provided on each car, containing continuous pressure
buttons for operating the car in both directions and a toggle switch for making the buttons on
top of the car operative. This toggle switch when switched to inspection operation shall modify
the operation of the car to disconnect it from the normal operation to eliminate all normal
operation devices, automatic leveling and power door operation and the car shall run at
standard speed for the purpose.
26.12.7 Automatic Rescue Device:
In the event of power failure or failure of control system w here the Lift is in operation the
rescue device should take over automatically and bring the Lift to the nearest landing safely.
The rescue device should be operated on rechargeable maintenance of free batteries. The
battery charging system to be supplied such that batteries are kept charged always in situ.
Dated 29.Jan 2015
Page 229 of 429
RVNL
26.13 Alarm Bell and Emergency Light:
The alarm bell is to be provided and fitted in an approved position close to the Lift at Ground
floors complete with push button inside the car and with necessary SMF rechargeable Battery.
Battery operated emergency lamp should also be fitted in the car which shall work
automatically in the event of a power failure, providing illumination within the car. The
batteries shall be maintenance free and shall be supplied on board with a battery charging
system. The battery charge status to be displayed in control room.
26.14 Batteries and chargers:
The batteries shall be of sealed, high rate maintenance free nickel-metal hydride type, or a
type of better functions and performance and approved by the Supervising Officer and shall
have a guaranteed life expectancy of at least four (4) years. They shall hot have any memory
effect as to affect their usable life or performance. The nickel-metal hydride battery shall
comply with EN 61436 a nd EN 61951-2 where ap propriate. The battery cha rger shall be
compatible with the batteries used. The charger shall comply with EN 60335-2-29 and be
capable of fully re-charge the batteries in not more than 12 hours.
26.15 Suppression of Radio and Television interference:
The lift installation shall be adequately suppressed aga inst radio and television interfere nce
to limits as laid down in BS EN 55014 and BS 613. Interference suppression components shall
not be used in any part of the circuit where their failure might cause an unsafe condition.
26.16 Harmonic distortion:
The lift installation shall not, by injection of undesirable waveforms into the electricity supply
distribution system, adversely affect the power company's system and/or the electricity supply
to other users or consumers. The Total Harmonic Distortion (THO) produced by the lift motor
drive system measured at the isolator connect ing the lift equipment to the feeder circuit of
the building is limited to the maximum allowable values specified in Table I. The THO shall
be measured at the moment the lift car is moving up with rated load at its rated speed.
The Supplier/Contractor shall be responsible for providing all necessary harmonic filter(s) should
the THO of the installation exceed the maximum allowable values as specified in Table I.
Table-I max allowable thd for lift Motor Drive Systems
Circuit fundamental current of Motor Drive.
Maximum THD (%)
400A ≤ I< 800A
15.0
80A
22.5
≤ I<400A
I<80A
35.0
26.17 Maximum allowable Electrical power:
The running active electrical l power of the motor drive of traction lift system carrying a rated
load at its rated speed in an upward direction shall be equal to or less than the maximum
allowable values specified in Table II.
Dated 29.Jan 2015
Page 230 of 429
RVNL
Table - II Maximum allowable Electrical power of Traction lifts (Vc < 3 )
Rated Load
{Kg)
Maximum allowable Electrical power{kW) of Traction life Systems for
various ranges of Rated speed {Vc) in m/s
Vc ≤ 1
L< 750
7
1< Vc ≤
1.5
10
1.5 < Vc < ≤
2
12
2 < Vc < ≤
2 .5
16
2.5 < Vc < ≤
3
18
750 <L ≤
1000
1000 <L ≤
1350
1350 <L ≤
1600
1600 <L ≤
2000
2000 <L ≤
3000
3000<L ≤
4000
4000 <L ≤
5000
L < 5000
10
12
17
21
24
12
17
22
27
32
15
20
27
32
38
17
25
32
39
46
25
37
47
59
70
33
48
63
78
92
42
60
78
97
115
0.0083L+
0.5000
0.0118L+
1.0000
0.0156L+
0.5030
0.0190L+
2.0000
0.0229L+
0.5000
26.18 Sound reducing:
The whole of the lift/ machinery including the opening and closing of the car and landing doors
shall be quiet in operation, and sound reducing rubber pads or other means shall be provided
by the Supplier/Contractor where necessary to eliminate vibration and noise transmission.
26.19 Finish:
All metal work supplied by the Supplier/Contractor in out of the way locations such as the lift
shaft, lift pit and on the outside of the lift car shall be properly wire -brushed, cleaned of rust,
scale, dirt and grease prior to the application of one coat of rust inhibiting primer, with
particular attention paid to the priming of outer surfaces of car doors, inner surfaces of
landing doors, metal work associated with door assemblies, the underside and the framework
of lift cars. Any part of the equipment, including guide rails, which requires greasing or oiling
and any components that are supplied unpainted by the manufacturers due to functional
reasons shall not be painted.
All normally visible metal surfaces, other than stainless steel and non-ferrous surfaces, shall
be finished with one coat of rust inhibiting primer, one under coat/finishing coat and one
finishing coat of enamel paint to a colour to be selected by the Supervising Officer.
26.20 Stainless steel:
Unless otherwise specified, stainless steel shell be of EN 10029, EN 10048, EN 10095, EN
10258 and EN 10259Grade 316 or equivalent.
26.21 Notice Boards:
The following stainless steel notice boards engraving conspicuously in both English and Hindi
characters shall be provided and rigidly mounted:-
Dated 29.Jan 2015
Page 231 of 429
RVNL
1. "No Smoking", which shall be in each car,
2. "When there is a fire do not use the lift" in each car and on each landing
floor.
26.22 Wiring and Earthing:
The employer will provide single phase and three-phase supply with suitable MCCBs I MCBs for
isolation and protection in either on the ground floor or First floor or Second floor as far as
possible near .the Lift shaft on request by the Supplier/Contractor. All necessary wiring in
heavy gauge conduits from the MCB to the driving motor, controller, call push buttons, door
locks, limit switches, alarm bell, halfway junction box and wiring inside the car shall be
done by the Supplier/Contractor in accordance to IEC 60364 for Electrical Installations of
buildings. Necessary travelling cables from the car to the halfway junction box in the shaft shall
be provided by the Supplier/Contractor. Equipment earthing required for the machine and in
the Lift well should be carried out by the Supplier/Contractor. The main earthing shall be of 4
SWG GI wire and subsidiary earthing by 14 SWG tinned copper wire. All electrical equipments
in the Lift including car body shall be provided with two distinct earthing arrangement as per IS
standards and connected to the earth pit provided in stations.
26.23 Departure from Specifications:
The Supplier/Contractor should supply standard equipment as far as possible but where it does
not comply with this specification a list of deviation giving full particulars of deviations from
this Specification duly quoting reference to clause No. shall be submitted to the Employer for
prior approval.
26.24 Technical Particulars, Drawings etc.:
The approval applicationr shall be accompanied with:i) Complete technical illustrated literature for the equipments offered.
ii) Technical particulars and guaranteed performance of Lifts in the Annexure- 'B'.
26.25 Spare parts and tools:
Spares that are considered necessary for continuous satisfactory operation of the equipment
for at least two years shall be advised separately, inclusive of rates for reference. Any special
tools required for the maintenance of the equipment shall be submitted along with the tender.
26.26 Drawing and manuals:
Complete detailed layout drawings showing the structural requirements in the building and
loadings and disposition of various equipments and wiring diagram of
various equipments
shall be furnished by the Supplier/Contractor within a month of acceptance of the tender. Six
copies in English language of the manufacturer's booklet containing description of various
equipments of the Lift shall also be submitted to the Engineer in charge nominated by employer
The operating manual and maintenance schedule shall also be submitted while handing over
the installation to the Railways. The two additional manuals and information shall be supplied in
Hindi, English and vernacular language each
26.27 Tests and Test Certificates:
The Supplier/Contractor shall furnish details of internal tests carried out on all equipment,
components and fittings of the Lift at their works. Suitable test certificates should be submitted
to employer and to engineer establish: (a)
The satisfactory operation of the Lift includes protective mechanisms, safety devices,
brake gear, etc. with temperature rise of driving motor not exceeding the guaranteed
limits.
Dated 29.Jan 2015
Page 232 of 429
(b)
(c)
(d)
RVNL
That the floor setting of the car at the landings is correct at all loads from no
load to full load.
That the speed of the ca r is as guaranteed and that the acceleration and
retardation are satisfactory and smooth.
That the operation of the contactors, interlocks and time lags are satisfactory and in
correct sequence and the correct functioning of the terminal limit switches.
26.28 General requirements:
All dangerous parts shall be effectively guarded. W here applicable, components shall be
designed to be inherently safe, obviating the need for external or removable guards.
Every lift car body shall be carried in a steel car frame sufficiently rigid to withstand the
operation of the safety-gear without permanent deformation of the car frame.
The deflection of the members carrying the platform shall not exceed 1/1000 of their span
under static conditions w ith the rated load evenly distributed over the platform.
At least four renewable guide shoes, or guide shoes with renewable linings, or sets of guide
rollers shall be provided, two at the top a nd two at the bottom of the car
frame.
26.29 Training of Staff:
The Supplier/Contractor shall train five staff including two Supervisors nominated by client or
employer in charge, during the erection of the Lift at site. OEM place They shall also train the
staff in the maintenance, operation and trouble shooting of the Lift. However the responsibility
of maintenance of Lifts will be with Contractor during the guarantee period.
26.30 Guarantee:
The Supplier/Contractor shall guarantee satisfactory performance of the Lift and allied
equipments over a period of 24 months in actual service from the date of handing over of the
installation to the Railway in normal working conditions. During the guarantee period the
Supplier/Contractor shall rectify free of cost of all defects which may develop due to any reason
including faulty design, material failure and bad workmanship inclusive of free replacement of
defective parts. The guarantee will get automatically extended corresponding to the periods
during which the equipment is not in use. On every occasion when the equipment goes out of
service, the duration between the date of intimation of the failure of equipment to the
contractor and the date of handing over of the equipment after repairs in good working
condition duly tested and commissioned in the presence of Railway's representative, will be
counted for the extension of the guarantee period till the equipment completes actual service
for a total period of 24 months. During the guarantee period the parts of the equipments
requiring repairs or replacements will be handed over to the contractor at site and the parts
after repairs or replacements shall be fitted in the equipment at site by the contractor. All
expenses involved in fulfilling the above guarantee obligations shall be borne by the contractor.
26.31 Inspection:
The materials will be inspected by purchasers' nominated representative at manufacturer's
premises or contractors depot as the case may be. The purchaser or his representative shall
have the right to be present during all the stages of manufacture and shall be afforded free of
charge all reasonable facilities for inspection and testing as well as to examine the stage
inspection report of the manufacturer/ inspection in addition to the quality audit which the
contractor may institute as a part of his Programme so as to satisfy himself the materials are
in accordance with the specification, approved drawings and designs and purchasers
prescribed Quality Assurance Standard.
Dated 29.Jan 2015
Page 233 of 429
RVNL
26.32 Civil Engineering:
The contractor should inspect site conditions before quoting the tender. The design of the Lift
includes the design of the support system and guidance which includes the support of the
traction machine and all its accessories. The Lift shaft is either 230 mm brick I concrete.
Successful contractor should give their design to suit the existing Lift shaft/control room and
well. The design of the Lift should be compatible with the Lift well and Lift shaft/machine
room. The contractor should ensure adequate design so as the individual load and their
distribution of car, counter weight for both normal and abnormal working (Accident), or within
the structural design limits of Lift well. The anchorage and guidance of car and counter weight
will be designed to suit the Lift shaft under all conditions. This is considered as primary
responsibility of the contractor.
26.33 Preventive Maintenance and Schedules:
The contractor shall service the Lifts thoroughly as per OEM maintenance schedule and attend
the breakdown complaints free of charge during the defedt liability period of 24 months
including all spares, materials and replacable parts free of charge.
(a). Important items of Schedule of maintenance during the defect liability period of
24 months is enclosed herewith however OEM recommended schedule of maintenance shall
be followed in detail.
(b). Maintenance schedule for Electric Lifts:
The following maintenance schedule should be carried out during the maintenance of Lifts and
a record should be maintained in the office as directed by employer. Any abnormality noticed
during the schedule should be attended immediately (within 2 hours) and proper operation
ensured. Lifts should be taken up for schedule of maintenance preferably on Holidays or
beyond office hours and in mutual agreement with the user.
I . Monthly Schedule of maintenance:
S
No.
Nature of Work
1.
Check and attend fittings of Lift (light, fan, emergency light, failure alarm etc.)
2.
Check level of the lubricating oil in the gea rbox, any unusual sound in the gearbox.
3.
Check the operation of all the doors, door locks.
4.
Check the brakes and adjust it.
5.
Check the operations of the limit switches.
6.
Clean machine and associated equipments.
7.
Check the main switch contacts and earth connections/ continuity.
8.
Check the main switch, fuses etc. (for loose connection, oscillation and ratings etc.).
9.
Check the general condition of the motor.
Dated 29.Jan 2015
Page 234 of 429
RVNL
10.
Control panel:a) Check overhead relays operation
b) Check the interlocks for its proper functioning.
c) Check the relay contacts their operation and chattering.
11. Check the electrical connections
12. Check the foundation bolts of the motor any unusual noise, vibration etc.
13. Check the input voltage & current of the motor and record it.
14. Check leveling switches, arm pivots and limit switch roll rs and lubricate.
15. Check the performance of the over speed governors and adjust if necessary.
16. Check the working of the floor selection switch.
17. Check the floor indicators.
18.
Check all ropes, hinges, shackles etc.
19.
Check the microprocessor control for its proper functioning.
Dated 29.Jan 2015
Page 235 of 429
RVNL
II.Quarterly Schedule of maintenance
Sl. No
Nature of Work
1.
Lubricate the rope pulley bearings.
2.
Check tightness of the counter weight, fixing clamps, bolts etc.
3.
Check the trailing cables for broken I damaged insulation and loose bindinq.
4.
Check the condition of the pit clean the car top and clean the gate.
5.
The wire ropes should be cleaned by a stiff brush to remove old lubricant and lubricate
it again by using oil machinery medium or equivalent.
6.
Clean the ropes for broken strands and general condition.
7.
Check the dia. of the rope and record it.
8.
Rope winding drum to be checked for its proper wind ing in the sheave grooves.
9.
Measure the voltage and current at the various test points in the control system
including microprocessor control and record it.
10
Check the fixing bolts of the motor for any vibration.
III. Yearly Schedule of maintenance:
Sr
No.
Nature of work.
1
Overhaul the motor for bearing and alignment.
2
Check car of body supported and steel channels.
3
Check the condition and wear in the bearings.
4
Clean and check guide rails.
5
All break gears to be reconditioned.
6
Solenoid coils to be tested.
7
8
Limit switches to be overhauled and adjusted.
All the interlocking arrangements to be overhauled and checked for proper functioning.
9
Gearbox to be overhauled completely.
10
Check the microprocessor units for the proper functioning.
Dated 29.Jan 2015
Page 236 of 429
RVNL
IV. In addition to the above periodical maintenance the firm has to attend the
following:a)
b)
The firm has to attend the breakdown failure at any time during the working hours without
any delay.
They have to supply the required consumables, spares, to keep the Lift in good condition.
c)
While attending the quarterly schedules the firm has to carry out the monthly schedules also.
d)
While attending the yearly schedules the firm has to carry out the monthly and quarterly
schedules also.
e)
Maintenance schedule should be carried out in consultation with user mostly on Holidays or
beyond office hours.
f)
If the Lift remains OUT OF SERVICE for more than 48 Hours per month, Railways will have
right to impose penalty to the extent of 10% value of the contract .
Dated 29.Jan 2015
Page 237 of 429
RVNL
ANNEXURE”A“
BRIEF REQUIREMENTS FOR LIFT
1
Capacity
:
…..persons.
2
Speed
:
….m/sec.
3
Car Travel
:
.... to
4.
Stop and opening.
:
….stop and …..opening……(all openings on same side)
s.
6.
Control
:
AC VVVF Variable Frequency with speed encoder
Operation
:
Simplex full collective with/w ithout attendant
7.
Controller
:
.... About
..... m (approx.)
Microprocessor based Modular control system
8.
Communication
:
Loop type serial communication
9.
Power Supply
:
3 phase AC 415V ±10% Variation, 50 Hz ±5%
Variation.
10.
Machine
:
Gearless
type
induction/synchronous
permanent magnet motor operated.
11.
Hoist way
:
..... mm wide x ..... mm deep (Tender to Check
the suitability of the same before tendering).
12.
Available head room
:
Renderer to verify the same at site before
tendering.
13.
14.
Available Pit Depth
Position Drive including
Main machine.
:
.....
:
Directly at the top of Lift inside the shaft.
machine
with
mm (approx.).
15.
Car Enclosure
:
Stainless steel car panels of 1.5 mm thickness hairline finish
with stainless steel false ceiling adequately illuminated LED
luminaries of flush mounted pattern, one axial flow fan with
grill of quit running type having a noise level not greater
than 30 dBA, one smoked mirror of half height full width on
the rear panel, 4mm thick antiskid studded rubber floor of
approved color ,suitable handrails of 50mm O.D. tubular
stainless steel shall be provided at 86mm height from floor
level of the car on three sides of the lift car extending to
within 150mm of all corners and with a 40mm clearance
from car walls to facilitate handicapped passengers.
16.
Car Safety Gear
:
Over speed governor- operated safety.
Dated 29.Jan 2015
Page 238 of 429
RVNL
17.
Landing and Car
Doors.
18.
Leveling
19.
Human
device
interface
Landing doors and car door shall be of 2 panel
centre opening sliding closed, stainless steel powder
coated or hairline stainless steel finish panels, power
operated independent drive with adjustable automatic
opening and closing speeds for door. The clear opening
should be 900 mm wide x 2000 mm with full height Memco
3D curtain safe edge to
detect and open the doors in the event of Obstruc- tion I
infringement w hile the doors are closing
:
:
±5 mm irrespective of load.
a.
Hall button with micro stroke push/touch buttons combined
with 16 segment digital LED display positio n indicator.
b.
Full height car operating panel with micro
push/touch buttons (Located on side panel)_
c.
Door Open and Door Close button on the Car
operatinq panel.
d.
Peak periods of
Lift work ings
Dated 29.Jan 2015
2 Way inter communication system.
e.
DOT matrix position indicator display integrated
with in the Car operating panel.
f.
Over load indicator i.e. device to sense 80% of
rated load and over load. Audio and visu l indicator
of overload.
g.
Battery operated Alarm bell and Emergency Light.
h.
Fireman's switch.
i.
Manual rescue operation.
j
20
stroke
:
Emergency auto rescue device.
Generally between..... - ..... Hours in morning,
..... - ..... Hours in noon and ...... - ..... Hours in the eveninq.
Page 239 of 429
RVNL
ANNEXURE - 'B'
TECHNICAL PARTICULARS AND GUARANTEED PERFORMANCE OF THE LIFT
(TO BE FILLED IN AND RETURNED ALONG WITH THE TENDER)
1.
e)
Machine:Acceleration.
:
a)
Main driving motor.
:
b)
Current in Amps at rated output.
:
c)
Make and type.
:
d)
Type of enclosure.
:
e)
Voltage between terminals.
:
Output in HP.
:
g)
Weight.
:
h)
Speed in RPM at rated output.
:
i)
Class of insulation.
:
j)
Temperature rise on full load
:
f)
2.
Brake:-
a)
Make.
:
b)
Type.
:
c)
W idth & diameter of brake wheel.
:
d)
Method of adjustment.
:
e)
Provision for manual release.
:
3.
Car:-
a)
Dimension (internal) .
:
b)
c)
Weight (Approx.).
Contract load.
:
:
d)
Maximum speed.
:
Dated 29.Jan 2015
Page 240 of 429
RVNL
f)
Retardation.
:
g)
Method of suspension.
:
h)
Time for travel between the floors.
:
4.
Guide Rail:-
(i)
For Car:-
a)
Size and weight in kg per linear meter in Tee sec .
:
b)
No. of Sections.
:
c)
:
d)
Method of lubrication .
:
(ii)
a)
b)
For Counter weight:Size and weight in kg per linear meter in Tee
sec.
No. of Sections.
:
:
Spacing of intermediate
supports.
Method of lubrication
:
5.
Control Equipments:-
:
(i)
Control Systems:-
:
c)
d)
a)
b)
System of control and working DC voltage for
control.
Type of VVV F control details.
:
:
:
Potential Energy savings.
:
Self leveling System:-
:
a)
Type of car leveling device.
:
b)
:
Limit Switches:-
:
a)
Type.
:
b)
c)
(ii)
(iii)
Dated 29.Jan 2015
:
Page 241 of 429
RVNL
Suspension Ropes:-
:
a)
No. of ropes.
:
b)
Size and no. of strands in each rope.
:
c)
Factor of safety.
:
d)
Method of attachment to the car.
:
e)
Method of attachment to thecounter weight.
:
Counter weight:-
:
a)
No. of sections.
:
b)
Weight of ea ch section.
:
c)
Type of guide shoes.
:
d)
Method of load equalization of ropes.
:
Wiring:-
:
a)
Specification of wires.
:
b)
Method of wiring.
:
9
FINISHING.
:
Full particulars should be given.
:
6.
7.
8.
a)
10.
Protection devices, details provided in the lift:-
:
11.
Special inclusions if any:-
:
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 242 of 429
RVNL
MISCELLANEOUS SPECIFICATIONS
Dated 29.Jan 2015
Page 243 of 429
Dated 29.Jan 2015
RVNL
Page 244 of 429
RVNL
CHAPTER:A-27
MISCELLANEOUS SPECIFICATIONS
27.1 RDSO SPECIFICATIONS:
RDSO has issued specifications for items which are listed below. These items should be
procured as per RDSO specifications:
SR
No.
1.
2.
3.
4.
5.
7.
8.
9.
10.
11
12
13
14
15
16
17
Item
CENTRALIZED AIR VENTILATION WITH AIR COOLERS
OF WAITING ROOM AND DEPARTURE LOUNGE AT
THE STATIONS
ENERGY SAVER CUM INTELLIGENT MOTOR
CONTROLLER
SPECIFICATION FOR AC INDUCTION MOTORS
STAND-ALONE WIND + SOLAR PHOTOVOLTAIC
HYBRID POWER
GENERATING SYSTEM FOR LEVEL CROSSING GATES
Manufacture & Supply of Solar Cooker
INTEGRATED RENEWABLE ENERGY BASEDPOWER
SUPPLY ARRANGEMENT
TECHNICAL SPECIFICATION FOR FAULT TOLERANT
UNINTERRUPTED POWER SUPPLY (UPS) SYSTEM FOR
PRS, EDP CENTERS AND OTHER SIMILAR
REQUIREMENTS OF ONLINE UPS SYSTEM
INTEGRATED SOLAR PHOTO VOLTAIC BASED POWER
SUPPLY SYSTEM LIGHTING LOADS FOR ELECTRIC
LOCO SHEDS & WORKSHOPS
LED SIGNAGE SYSTEM for stations and circulating
areas
GRID CONNECT SOLAR GENERATING SYSTEM OF
CAPACITY 10 KWp to 100 KWp
STAND-ALONE SOLAR PHOTOVOLTAIC LED BASED
STREET LIGHTING SYSTEM
Solar based water Heating System
PASSENGER ESCALATORS TO BE INSTALLED AT
VARIOUS RAILWAY STATIONS OF INDIAN RAILWAYS
DOUBLE-CAPPED TUBULAR T5 FLUORESCENT LAMPS,
T5 LUMINAIRE & ELECTRONIC BALLAST
MAINTENANCE FREE EARTH FOR ELECTRICAL
INSTALLATION
ENERGY EFFICIENT LED BASED LUMINAIRE UNIT
FOR STREET LIGHT AND PLATFORM LIGHTING
POWER SAVER IN LIGHTING SYSTEM
Dated 29.Jan 2015
RDSO Specification No. & Dt
RDSO/2009/EM/SPEC/0001,
(Rev.‘0’)Amdt.1
RDSO/PE/SPEC/PS/0098(REV ‘0’)-2008,
Amdt. ‘1’
RDSO/PE/SPEC/PS/0124-2009 (Rev. 0)
Amendment ‘1’
RDSO/2009/EM/SPEC/0003, Rev. ‘0’
Amdt. 1
RDSO/2009/EM/SPEC/0004 (Rev. ‘1’) –
2012
RDSO/PE/SPEC/PS/0023– 2001 (Rev-0)
Amdt No. 3
RDSO/2009/EM/SPEC/0005 Rev. ‘0’,
Amdt. ,1,
RDSO/PE/SPEC/PS/0086-2009 (Rev.‘ 0’),
Amdt-1
RDSO/PE/SPEC/PS/0092-2008 (Rev. ‘0’),
Amdt -4
RDSO/PE/SPEC/PS/0093-2008 (Rev. 0)
Amnd. 3
RDSO/PE/SPEC/PS/0094-2008 (Rev-0)
AMDT-1 (Withdrawn)
RDSO/PE/SPEC/TL/0095 (REV ‘1’) -2012
RDSO/PE/SPEC/PS/ 0100 (REV. ‘1’)2011
RDSO/PE/SPEC/PS/0109(REV.0)-2008,
Amendment ‘1’
RDSO/PE/SPEC/PS/0123(Rev ‘0’)-2009,
Amendment ‘2’
DSO/PE/SPEC/PS/0083(REV ‘0’)-2008
Amendment 1
Page 245 of 429
RVNL
18
19
PASSENGER ELEVATOR FOR INDIAN RAILWAYS
Control and distribution panel for CLS supply in 25
KV AC traction system
Manufacture and supply of single/multi core 11/33
KV grade XLPE insulated and PVC sheathed
armoured/ Unarmoured power cables for electric
supply purpose
Static battery chargers
POLE MOUNTED TYPE BATTERY CHARGERS FOR 11V
SG COACHES
20
21
22
RDSO/2013/EM/SPEC/0016 (Rev ’0’)
TI/SPC/PSI/CLS/0020 AMDT-2
RDSO/2009/EM/SPEC/0002, REV-1
RDSO/PE/SPEC/AC/0008 (Rev-2)
EL/TL/52 (Prov)
27.2 Tripping Characteristics of MCBs:
Based on the tripping Characteristics, MCBs are available in B” and ‘C’ Curve to Suit different
types of applications.
‘B” Curve: For Protection of electric circuits with equipment that does not cause surge current
(lighting and socket outlet circuits). Short circuit release is set to 3-5 In
‘C” Curve : For Protection of electric circuits with equipment that cause surge current (inductive and
motor circuits). Short circuit release is set to 5-10 In
‘D” Curve : For Protection of electric circuits which cause high in rush current when they are switched
ON. Typically 15 times the normal running current (Transformers, Heavy Start Motors, 2
Pole Motors). Short circuit release is set to 10-20 In.
27.3
Class of Insulation (For Electric Motors):
Type
Max. Operating
Temp.
Materials Used
Y
90°C
A
105°C
E
B
120°C
130°C
F
155°C
H
180°C
Consists of materials or combination of materials such as mica,
glass fibre Silicon lastomer with suitable winding, impregnating
or coating substances as silicon resins.
C
Above 180°C
Materials such as mica Porcelain, glass quartz and asbestos with
or without inorganic binder.
Dated 29.Jan 2015
Cotton, silk, paper, and similar organic material and
combination of such material which are not (impregnated) nor
immersed in oil.
Above materials impregnated with Varnish or enamel or oil
immersed.
Comprise inorganic materials such as mica, glass fibre asbestos
or combination of these materials in built up form with binding
cement.
Class B materials when built up with suitable cement or binder.
Page 246 of 429
RVNL
27.4 Degrees of Protection as per DIN 40 050 and to IEC 144:
The degree of protection is specified in
accordance with DIN 40 050 and with
Publications
of
the
International
Electro
technical commission (IEC) by means of the
letters IP (International Protection) and two
characteristic numerals.
First characteristic numeral.
Degree of protection against contact with live
parts and the ingress of foreign bodies
First
Degree of Protection.
characte
ristic
Numeral
0
No protection of persons against
contact with live or moving parts
inside the enclosure.
No protection
of equipment
against increase of solid foreign
bodies.
1
Protection
against accidental or
inadvertent contact with live or
moving parts inside the enclosure
body large surface of the human
body as, for example, a hand, but
no protection against deliberate
access to such parts.
Protection against ingress of large
solid foreign bodies of diameters
greater than 50mm.
2
Protection against contact with live
or
moving
parts
inside
the
enclosure by figures.
Protection
against
ingress
of
medium size solid foreign bodies of
diameters greater than 12mm.
3
or
moving
parts
inside
the
enclosure by tools, wires or such
objects of thickness greater than
2.5 mm. Protection against ingress
of small solid foreign bodies of
diameter greater than 2.5 mm.
4
or
moving
parts
inside
the
enclosure by tools , wires or such
objects of thickness greater than 1
mm.
Dated 29.Jan 2015
The first numeral indicates the degree of
protection against contact with live parts and
the ingress of foreign bodies; the second
numeral indicates the degree of protection
against water.
Second characteristic numeral.
Degree of protection against water.
Second
characte
ristic
numeral
0
Degree of Protection.
No protection.
1
Protection
against
drops
of
condensate.
Drops
of
condensate
falling
vertically on the enclosure shall
have no harmful effect.
2
Protection against drops of other
liquids.
Drops of falling liquid shall have no
harmful effect when the enclosure
is tilted any angle up to 15 from
the vertical.
Protection against rain.
Water falling as rain at an angle
equal to or less than 60 with
respect to the vertical shall have no
harmful effect.
3
4
Protection against splashing liquid:
Liquid splashed from any direction
shall have no harmful effect.
Page 247 of 429
RVNL
5
6
Protection against ingress of small
solid foreign bodies of diameter
greater than 1 mm.
Complete Protection against contact
with live or moving parts inside the
enclosure.
Protection against harmful deposits
of dust. The ingress of dust is not
totally prevented, but dust cannot
enter in an amount sufficient to
interfere with the satisfactory
operation
of
the
equipment
enclosed.
Complete Protection against contact
with live or moving parts inside the
enclosure.
Protection against increase of dust.
5
Protection against water –jets:
Water projected by a nozzle from
any
direction
under
slated
conditions shall have no harmful
effect.
6
Protection against conditions on
ships
decks(deck
water
light
equipment):Water due to heavy
seas shall not enter the enclosures
under prescribed conditions’.
Protection against
immersion in
water. It must not be possible for
water to enter the enclosure
understated conditions or pressure
and time’.
Protection
against
indefinite
immersion in water under specified
pressure. It must not be possible
for water to enter the enclosurse’
7.
8.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 248 of 429
RVNL
APPROVED MAKES
OF
EQUIPMENTS & MATERIALS
Dated 29.Jan 2015
Page 249 of 429
Dated 29.Jan 2015
RVNL
Page 250 of 429
RVNL
CHAPTER: A-28
APPROVED MAKES OF EQUIPMENTS & MATERIALS
1.
All Equipments & Materials should conform to latest version of BIS or other indicated
specification as per RVNL Policy guidelines. All energy consuming equipments should have
minimum 3 star rating given by BEE, wherever applicable.
SN
Equipment/ Material
BIS Specification
No.
Name of Manufacturer/Brand Name
1.
PVC Conduit
9537/Pt.3/1983
AKG
Poly cab
Precision
Finolex , CROWN
2.
1.1 kV PVC Insulated,
multi strand Copper
conductor Cable for
wiring (ISI Marked)
694/1990
Presto Plast ,AKU, SUDHAKAR , NANDI
The National Insulated Cable Co.
Grandlay Electricals ( India)Delhi
Cable Corporation of India Ltd.
Fort Gloster Industries Ltd.,
Universal Cable Co.
Asian Cables
Vijay Cables Industrials New Delhi
Sunhome Cables Industries New Delhi
ICL Cable, Rajpura
Incab
Torrent
Skytone
Poly Cab
Arun Manufacturing Delhi
Vishal Brandh of Desmesh Cables
Finolex
Uniflex , PRIMECAB
RPG
Unistar
Indian Cable Co. Kolkata
Havell’s
Frexton Cables(I)
Ajanta cables
Indrani Cables
Fixolite Wires & Cables
Dated 29.Jan 2015
Page 251 of 429
RVNL
Cab com
Galaxy power cables
Victor cables
Tara Cables
Deco Industries
Maxwell New Delhi
Oriental Power cable
Pee Kay Industries
Cab cond, New Delhi
Ajanta Electric Industries.
Insucon cables & cond.
KEI industries Ltd.,
Mid Light Electrical Pvt. Ltd.
Bharat Cab brand of Vardman cables
3.
Metal Box (enclosure
for accessories)
14772/2000
Anchor, PLAZA, RR CABLES, LEADER,
UNI STAR
Anchor , HAVELLS
Cona , GM , C&S ,MDS ,
Legrand , INDOASIAN ,TOYOMA
4(i)
Electrical Accessories
for wiring (ISI Marked)
Relevant
Anchor , GM
Cona
SSK(top Line)
Precision ( Prime)
Vinay ( Clair 30)
4(ii)
Leader
Legrand, Havell’s, HPL, C&S, Ryder,
ABB, Hensel.
Anchor- Roma Woods
Electrical Accessories
for wiring (Modular
switches& Sockets) (ISI
Marked) (NEW ITEM)
Relevant
5
Phenolic Laminated
Sheets(ISI Marked)
2036/1995
Bakelite Hylum Ltd. Calcutta
Formica India Ltd. Motia Khan New
Delhi,
Super Hylan, Pvt Ltd.New Delhi,
Surendra composites Pvt.Ltd. Bhopal
6
Industrial Type Iron
Clad Socket
13947
Havell’s
Indo Asian- Hussman
Havell’s- Crab Tree , GM , MARU ,
LEADER , LEGRAND ,TOYOMA
Crompton
Control & Switchgear
BCH
Dated 29.Jan 2015
Page 252 of 429
RVNL
Standard Electricals
HPL India Ltd.
GE
Siemens
L&T
7
i) MCB
ii) RCBO
iii) RCCB
i) 8828/1996
ii)IEC:61009
iii) IEC: 61008
Indo Asian
Havell’s
Crompton
Control & Switchgear
Legrand
GEC
Jyoti
L&T
MDS
Siemens
GEC
8
Call Bell ( NEW ITEM)
Relevant
Andrew Yule
Indo Asian
Schneider
Standard Electricals
Merlin Gerin
ABB
Moeller
HPL India
BCH
Anchor
Cona , GM
9
MCB Distribution Boards
8623/1993,
13032/1991
MAX.
Leader
SSK
Havell’s
Crompton
Control & Switchgears
GE , GM
Standard
HPL India
L&T , LEGRAND
Siemens
Indo Asian , C&S
BCH
10
Electronic Regulator
(ISI Marked)
Relevant
Anchor
Usha
ERIK
Dated 29.Jan 2015
Page 253 of 429
RVNL
RIDER
CGL , GM
11
Ceiling Fan/Air
Circulating Fan( ISI
Marked
374/1979
Jay Engg.
Matchwell Elect
Roma
Cona
Plaza
Khaitan
Crompton
Usha
Orient
Bajaj
Havell’s
Kedia
Polar
GEC
Almonard
12(i)
Exhaust Fan (ISI
Marked)
2312/1967
Phillips
Anchor
Crompton
GEC
Almonard
Usha
Bajaj
Khaitan
Polar
Orient
Phillips
12(ii)
Exhaust Fan/ Fresh Air
fan with fibre body
Relevant
Usha
Bajaj
Khaitan
Polar , HAVELLS
13
AC Units ( Window &
Split type)* , Cassette
AC, Tower AC ,
Packaged AC , Battery
Operated AC
Relevant
1391/Pt.1/1992
VOLTAS
Carier Air con
Blue Star
Amtrex Appliances
Sidwal Refrigeration
Frick India Ltd.
LG , TROPYCOOL
Samsung , O General
Godrej , PANASONIC
Fedders Lloyd
Hitachi
Dated 29.Jan 2015
Page 254 of 429
RVNL
Shri Ram
Onida
Videocon
Daikan
14
Water Cooler SS Body
1475/Pt.1/2001
Voltas
Blue Star
Sidwal Refrigeration
USHA
Fedders Lloyd
15
Auto Voltage Corrector
Relevant
16
Geyser
2082/1993
Kelvinator
Shriram , Eureka Forbes
As recommended by the OEM of Ac
Unit/Water Cooler
Racold
Bajaj Electricals
Crompton
Venus
Johnson
Superhot
17
Power Distribution
Transformer
2026
USHA
SPHEREHOT,Havells.
Crompton Greaves
NGEF
AREVA T&D India Ltd., New Delhi
Kirloskar Electric Co. Ltd., New Delhi
Andrew Yule and Co., New Delhi
Bharat Bijlee Ltd., New Delhi
Bharat Heavy Electricals Ltd.,
Kanohar Electrical Ltd., Meerut, (UP)
Mirzapur Electrical Industries Ltd.,
Mirzapur, (U.P)
ABB
Siemens
Voltas
Volt Amp. ,
Kerala Electric and Allied Engg. Co. Ltd.,
Rama Krishna Transformers, Hyderabad
Dated 29.Jan 2015
Page 255 of 429
RVNL
ECE Industries
Radhika Electricals
Tesla , SHAKTI
GEC
TELK
Hint Transformers
EMCO
Mahindra Transformers Ghaziabad.
Vijay Electricals
Indo Tech. Transformers Ltd.,
PN Engg.
Power Master Electricals, Kolkata
Automatic Electrogear, Kolkata
Alfa Transformers, Bhubaneshwar
Orissa Transformers, Pvt. Ltd.,
Bhubaneshwar
United Machinery Corporation, Kolkata,
Star Delta Transformers Pvt. Ltd.Bhopal.
18.
11 kV Vacuum Cricuit
Breaker Panel
13118/1991 &
3427/1997
AREVA T&D India Ltd.,
ABB
Crompton
Siemens India
BHEL
Jyoti
Andrew Yule
Kill Burn
Voltas
Biecco Lawrie
ECE Industries
Schneider electric India
GEC
L&T , Denson Yamuna Power
19
HT 11 kV and 33 kV
XLPE (E) Cable (ISI
Marked)
7098/Pt.2/1985
Nicco Corporation Ltd.,
Havell’s
Fort Gloster Industries Ltd.,
Industrial Cable India Ltd.,
Cable Corporation of India
Universal Cable Co.
Asian Cables
Poly Cab Wire (P) Ltd.,
Torrent , Paramount, Sriram , Delton
Incab Industries
Oriental Power cable
Dated 29.Jan 2015
Page 256 of 429
RVNL
Premier cable
Central cables Ltd.
Indian cable
Orient power Cables.
Premier Cables.
Finolex cables.
Sterlite Industries , Prime Cab
20(i)
20(ii)
HT Protection Relays (
Over current, Earth
Fault and other
protective relays for
transformers & Panels
(
Introduction/Static/Nu
mberical type) ( NEW
ITEM)
3231
LT Protection Relays
(NEW ITEM)
3231
AREVA T&D IndiaLtd.
L&T
ABB
Easun Rey Rolle
Alind
BHEL
Jyoti
GE
BCH
Minilac
Enercon
AREVA T&D IndiaLtd.
L&T
ABB
Easun Rey Rolle
Alind
BHEL
Jyoti
21
D.G. Set ( NEW ITEM)
Engine 10000/1980,
Alternator: 4722/2001
GE
BCH
Minilac
Enercon
VXL
Engine:
Kirlosker
Cummins
Ashok Leyland
Greaves Ltd.
Caterpillar
PentaVolvo
Alternator
Kirlosker Electric Co. Hubli
Jyoti
Crompton
Stamford
Kerala
Leroy Somer
Kirlosker Green
Dated 29.Jan 2015
Page 257 of 429
RVNL
22
Cable Jointing/
Terminating Kit for 11
kV to 33 kV HT cables
13573/1992
Yamuna Gases and Chemicals Ltd., New
Delhi
Mohindra Engg.& Chemical Product, New
Delhi
Raychem RPG Ltd.,New Delhi
Hari Consolidated Pvt. Ltd.,New Delhi
XICON
Safe Systems
Shrink Fit
REPL
DENSON Yamuna
Super Seal
Birla 3M
23(i)
Measuring & recording
Instruments( Electrical)
Relevant
Auto Electric
Havell’s
Meco Instruments
Motwani
L&T
National Instruments
Shanti
Toshniwal
Siemens
Sivananda Electronics
JMP
CIE
Electric & Electronic devices.
IMP
Industrial Meters
Rishab
23(ii)
Electric Energy Meter
13779/1999 Cl.1.0
Moeller(HPL)
Havell’s
L&T
HPL
Baroda Electric Meters
VXL India Ltd.
Jaipur Metal Works
Capital Power System
ECE
Meters & Instruments
Industrial Meters
Anchor
Indo Asian
Max Well
IMP
Dated 29.Jan 2015
Page 258 of 429
RVNL
Swecure Meters
ABB
Enercon,BENLO
24
L.T. XLPE armoured
Aluminium Conductor
Cable (ISI Marked)
7098/Pt. 1/1985
NICCO
CCI
ICL
Fort Gloster
Universal Cable
Asian Cables
Havell’s
Orient Power Cables
Preier cables Ltd.
India cables
Polycab
Incab
Finolex
Sterlite Industries
Central Cables Ltd
Sub Cab
SBEE
Fine cab
Bharat Cab brand of Vardhaman cables
Vishal brand cable of Dashmesh cables,
Paramount Communications Ltd,
Sriram Cables Pvt. Ltd.,
Delton cables Ltd,
PRIMECAB
25(i)
APFC Panel
(NEW ITEM)
Relevant
25(ii)
Capacitor
13340/93
L&T
Siemens
ABB ,Neptune
Siemens
ABB
L&T
BHEL
Indian Capacitors
Khatau Junker
Shreem
Unistar
Junkar
W.S. Insulators
Hind Rectifier
Voltas
Schneider
Indian Condensers
Dated 29.Jan 2015
Page 259 of 429
RVNL
26
CLS control Panel for AT
supply ( NEW ITEM)
RDSO Tech. Spec. No.
TI/SPC/PSI/CLS/0023
EPCOS
Universal Cables,
Neptune
JAPS
S&S
Suntron & Matrix &
Other RDSO’s approved makes
27
ACB & ACB Bus coupler
13947/Pt.1&3/1993
Siemens
Control & Switch Gear
ALSTOM
L&T
Crompton
Jyoti
Mysore Electric Industries
GEC(AREVA)
Scheneider Electric India
JSL Industries Ltd.,New Delhi
BCH
MEI
ABB
English Electric
Havell’s , Enercon
NGEF
Legrand
28
MCCB
13947/Pt.1&3/1993
Standard
BHEL
Power Boss
N.N. Planner
Minilac
Andrew Yule ,
Indo Asian
Siemens
Control & Switch Gear
ALSTOM
L&T
Crompton
Jyoti
Mysore Electric Industries
GEC(AREVA)
Scheneider Electric India
JSL Industries Ltd.,New Delhi
BCH
ABB
HAVELLS
Legrand
Standard,Electricals
Dated 29.Jan 2015
Page 260 of 429
RVNL
BHEL
Merlin Gerin
Indo Asian
29
Time switch ( timer)
Solid State
Relevant
General Industrial Control Pvt. Ltd.,
MDS Legrand
Havell’s
Jyoti
BHEL
BCH
GE
ABB,
Indo Asian
L&T
Siemens
Minilac
Legrand
30
Fuse Switch Unit/
Switch Fuse Unit, COS
& HRC fuses
13947/Pt.1&3/1993
L&T
Siemens
Control & Switchgears
Hevell’s
GE
Indo Asian
Crompton
NGEF
ABB
Jyoti
Mysore Electric
HPL
Standard
BCH
Indo Asian
Kenbar
GEC ( Areva)
SHNEIDER Electric
Legrand
Andrewyule
Moeller
Merlin Gerin
31
Cable Jointing/
Terminating Kit for LT
cables
Relevant
DENSON Yamuna
Mohindra Engg. & Chemicals Products,
New Delhi
Raychem RPG Ltd.,New Delhi
Hari Consolidated Pvt. Ltd.,New Delhi
Dated 29.Jan 2015
Page 261 of 429
RVNL
Yaswant Industrial Works (P) Ltd Make:
Super Seal
32
2705/1992
Havell’s
AE
CGL , Risabh
C&S
MECO
Kappa
Siemens
L&T
Schneider
JSL Ind.
33
34
Ferrules, Thimbles/
Lugs
Relevant
Flood Light and street
light Luminaries
10322/Pt.5/sec.3/1987
&
10322/Pt.5/sec.5/1987
Dowells
G.J.Metal Works
Usha Martin
Universal Machines
Kamlesh Industries
KSE Electrical
UML Engg
ASCON
Philips
Bajaj
Crompton
GE
Wipro
Osram
Genlec
Surya
Sylvania ,
Asian
Illumination enterprises
New light industries
ECE Industries Ltd.
Keselec Schreder
Havell’s
35.
Energy Efficient
Luminary & Lamps
10322/pt.5/1987
Asian
Bajaj
Philips
Crompton
Wipro
GE
36
CFL Luminaries
10322
Osram
AREVA
Havells
Keselec
Crompton
Dated 29.Jan 2015
Page 262 of 429
RVNL
Philips
Bajaj
GE
Wipro ,
Asian
Mysore lamps
Shinkolite
Pvt. Ltd.
Twinkle Industries
Tilok Chand & Sons
Surya Roshini
Havell’s
Osram
37
Metal Halide lamps
Relevant IEC
Philips
Bajaj
Crompton
GE
Osram
Arklite
Surya
Sylvania
Wipro
Venture
38
CFL
IEC 901
Phillips
General Electric
Bajaj
Crompton
Osram
Surya
Wipro
Havell’s
Sylvania
39
High Mast Lighting
Tower
Relevant
Bajaj
Phillips
Crompton
General electric
BPP
UTKARSH
40
Tubular Pole
41
GI Pipe (ISI Marked)
Dated 29.Jan 2015
Reputed make with the approval of the
Employer
2713/Pt.1 to 3/1980
1239/Pt.1/2004
TATA
Jindal
Utkarkash
PRAKASH-SURYA Surya
TT Swastik
Page 263 of 429
RVNL
42
Porcelain Insulators
LT-1445/1977 HT731/1971 & fitting IS
486/Pt.2/1989
Bengal Potteries Ltd.
BHEL
W.S. Insulators
Seshasayee Industries Ltd.,
Venkateshwara Ceramics
Jaya Shree Insulators
Insulators and Electricals Company.
Mahalaxmi,
RASTRIYA,
Reputed make ISI mark with the
approval of the Engineer.
43
ACSR Conductor (ISI
Marked)
398/Pt.II/1996
44
RCC Hume /HDPE
pipe/DWC Pipe
Relevant
Reputed make ISI mark with the
approval of the Engineer
45
Battery
Charger for Train
Lighting
2026 & 3895
Hind Rectifier
Usha Rectifier
Suresh Electricals
Pyramid
Automatic Electric
Delta Electric
Universal Industrial products
Trinity Electric
Venus Engg.
R.S. Power
Engineering Services
Equipment control
46
i) H.S. Pump
1520/1980
Maxflow Pumps India Ltd., Gurgaon
Geeta Flow Pumps India Pvt. Ltd.
Kirloskar
Worthington Pumps India Pvt. Ltd.,
Ghaziabad
Beacon Weir Ltd.,Chennai
Mather & Platt Ltd., Pune
Jyoti Ltd., New Delhi
Luxmi Pumps
KSB
Suguna
47.
ii) Control Panel for
Pump
Relevant
Original as supplied with pump by OEM
i) Submersible Pump
8034/2002
KSB Pumps Ltd.
Calama
Dated 29.Jan 2015
Page 264 of 429
RVNL
Mody Industries (FC) Pvt. Ltd., New
Delhi
India Electrical & Engg. Co. Ahemdabad
Jyoti Ltd., New Delhi
Crompton
Kirloskar
KK Pumps
Lix,o Hydraulics
Shroff Engg.
Waterman
SB Pumps
Flow Tech
Suguna
48
ii) Control Panel
Relevant
11 kV Air break Gang
operating Switch with
Drop Out fuse 200 A &
400 A (NEW ITEM)
IS:9921/1993
TEXMO
SABER
Original as supplied with pump by OEM
ABB
ALIND
Crompton Greaves
Jyoti
Mysore Electric
NGEF
Siemens
Trans Electricals
IE Power Gears Pvt. Ltd.,Hyderabad
S&S Power Switch Gears LTd.,
Kiron
49
33 kV Air break Gang
Operating Switch with
Drop Out Fuse 200 A to
1750 A
IS: 9921/1982
Alliance Engg. Pvt. Ltd.
ECE Industries
ECE Industries
ABB
IE Power Gears Pvt. Ltd., Hyderabad
S&S Power Switch Gears Ltd.
Alliance Engg. Pvt. Ltd.
HLM
50
Rotary Switch &
Selector Switch
Relevant
Kay Cee
L&T ,
Slazer
Dated 29.Jan 2015
Page 265 of 429
RVNL
GE
ABB
C&S
Siemens
HPL
Moeller
51
Contactors
13947
L&T
Jyoti
GEC
C&S
Siemens
Crompton
MEI ,
Indo Asian
NGEF
Legrand
BCH
Standard
BHEL
Minilac
Enercon
Andrew Yule
NN Planner
Power Boss
Scheinder
Mysore Electric
52
L.T. Panel
8623
53
Solar lighting system
for Crossing Gate
IS – 12834, 12763,
12761 Part - 1
54
Induction Lamp
Relevant
Bajaj, Philips, LVD Raes, Halonix,
Fortune Art.
55
Remote Energy
Monitoring , Control and
Data Aquisition System
of Power, AMRs ( New
Item)
Relevant
AMI , Analogic , J&J ,VisionTech
56
Elevator , Escalator,
Travelator and lifts(New
Item)
Relevant
57
LED Lamps
Relevant
58
Solar Water Heater
Relevant
Thyssen Krupp ,
Jhonson ,
Schindler ,
OTIS ,
Kone ,
Phillips-Lumileds, Osram, Nichia,
Cree/Seoul Semiconductor
Tata-BP Solar, Racold thermo ltd, Kotak
Urja, Anu solar, Jain Irrigation OR other
Dated 29.Jan 2015
Firm s having ISO:9001 certification &
testing facilities in works as per IS: 8623
TATA BP, BEL, TITAN, SSPL,
ANDROMEDA, SUNWATT, JAIN SOLAR
SYSTEM, CIRA, Nano Bright
Page 266 of 429
RVNL
59
GI Octogonal Poles
60
Battery for solar
systems
MNRE approved sources with prior
approval of RVNL
PHILIPS, BAJAJ, SURYA AND OTHER
REPUTED MAKES WITH PRIOR
APPROVAL OF RVNL
PANASONIC,
EXIDE,
AMARRAJA,
HITACHI, TATA BP
61
Street light controller
energy pack
BAJAJ, PHILIPS, CROMPTON GREAVES,
HAVELLS
62
Air Curtains
63
Cable Fault Locator
APLAP
Thane,
MRPC
ELECTROCON
SYSTEM
AISHWARYA TELECOM LTD
Hyderabad,
Bengaluru,
64
Cable Route Tracer
APLAP
Thane,
MRPC
ELECTROCON
SYSTEM
AISHWARYA TELECOM LTD
Hyderabad,
Bengaluru,
65
Digital Meggar
MOTWANI, KUSUM,
RISHAB, MEGGER
MECO,
METRAVI,
66
Digital Earth Tester
Meggar
MOTWANI, KUSUM,
RISHAB, MEGGER
MECO,
METRAVI,
67
Cable Tray (GI)
Firms having ISO:9001 certification &
testing facilities in works
Relevant
CROMPTON GREAVES, HAVELLS, POLAR
NOTE:
1. If any item/ equipment are not included in the above list, good quality material/equipment shall
be procured, in accordance RVNL policy as stipulated.
2. If any work requires coordination and acceptance of other department of Central/State
government, the contractor shall follow approved vendor list and standards, specifications of
that department and take their approval before ordering the material/equipment.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 267 of 429
Dated 29.Jan 2015
RVNL
Page 268 of 429
RVNL
IMPORTANT
INDIAN STANDARDS
(IS)
Dated 29.Jan 2015
Page 269 of 429
Dated 29.Jan 2015
RVNL
Page 270 of 429
RVNL
CHAPTER: A-29
IMPORTANT INDIAN STANDARDS
Note: The following IS codes (issued by Bureau of Indian Standards) shall be referred with their
latest amendments for supply, erection, testing and commissioning of the equipments and materials.
S.No
1
2.
IS Number
IS/10000/Part
1/1980
IS10000/Part10/1
980
3
IS10000/Part
11/1980
4
IS10000/Part
13/1980
5
IS10000/Part2/19
80
IS10000/Part3/19
80
IS10000/Part5/19
80
IS10000/Part6/19
80
IS10000/Part7/19
80
6
7
8
9
10
14
IS10000/Part8/19
80
IS10000/Part9/19
80
IS10000/Part
IV/1980
IS10000/PartXII/1
980
IS10001/1981
15
IS 10027/2000
16
IS 10118/Part
2/1982
IS10118/Part
3/1982
IS10118/Part
4/1982
IS 10118/Part
I/1982
IS 10322/Part1/
1982
IS10322/Part
2/1982
IS 10322/Part
11
12
13
17
18
19
20
21
22
Dated 29.Jan 2015
Standard Title
Method of tests for internal combustion engines:
Part I Glossary of terms relating to Test methods.
Methods of test for internal combustion engines: Part 10 Tests for Smoke
Levels, Limits and Corrections for Smoke Levels for Variable Speed
Compression Ignition Engines.
Methods of tests for internal combustion engines: Part 11 Information to
be supplied by the purchaser to the manufacturer and information to be
supplied by the manufacturer along with the engine
Methods of tests for internal combustion engines- Part 13:
Recommendations on Nature of Tests Required for Functional changes in
Critical Components
Methods of tests for internal combustion engines: Part 2 Standard
reference conditions
Methods of tests for internal combustion engines: Part 3 Measurements
for testing –units and limits fo accuracy
Methods of tests for internal combustion engines: Part 5 preparation for
tests and measurements for wear
Methods of tests for internal combustion engines: Part 6 Recording of test
results
Methods of tests for internal combustion engines: Part 7 Governing tests
for constant speed engines and selection of engines for use with electrical
generators
Methods of tests for internal combustion engines: Part 8 Performance
tests
Methods of tests for internal combustion engines: Part 9 Endurance tests
Methods of tests for internal combustion Engines Part IV: Declaration of
Power, Efficiency, Fuel Consumption and Lubricating Oil Consumption
Methods of tests for internal combustion Engines- Part XII: Specimen Test
Certificates
Specification for performance requirements for constant speed
compression ignition (diesel ) engines for general purposes( up to 20 kW)
Composite units of Air-break Switches and Rewritable Type Fuses for
Voltages Not Exceeding 650 V Ac- Specification
Code of practice for selection, installation and maintenance of Switchgear
and control gear: Part 2 Selection
Code of practice for selection installation and maintenance of Switchgear
and control gear: Part 3 Installation.
and control gear: Part 4 Maintenance
and control gear: Part I : General
Luminaries: Part 1 General requirements
Specification for Luminaries- Part 2: Constructional Requirements
Specification for Luminaries- Part 3: Screw and Screw less Terminals
Page 271 of 429
32
33
3/1984
IS 10322/Part4/
1984
IS10322/Part5/Se
c1/1985
IS 10322/Part
5/Sec2/1985
IS10322/Part5/Se
c 3/1987
IS 10322/Part 5 /
Sec 4/1987
IS 10322/Part
5/Sec5/1987
IS:15111
IS 10617/Part 1/
1983
IS/10617/Part
2/1983
IS 10617/Part
3/1983
IS 11037/1984
IS 11338/1985
34
IS 12021/1987
35
IS12155/1987
36
IS1239/Part
1/2004
IS 1239/Part
2/1992
IS 1248/Part
1/2003
23
24
25
26
27
28
28A
29
30
31
37
38
39
IS 1248/Part
2/2003
40
IS 1248/Part
3/2003
41
IS 1248/Part
4/2003
IS 1248/Part
5/2003
42
43
IS 1248/Part
6/2003
44
IS 1248/Part
7/2003
45
IS 1248/Part
8/2003
Dated 29.Jan 2015
RVNL
Specification for Luminaries – Part 4: Methods of Tests
Luminaries: Part 5 Particular requirements, sec 1 General purpose
luminaries
Specification for Luminaries – Part 5: Particular Requirements- Section 2:
Recessed Luminaries
Luminaries: Part 5 Particular requirements, Section 3 Luminaries for road
and street lighting ( superseding IS: 2149)
Luminaries: Part 5 Particular requirements, Section 4 portable general
purpose luminaries.
Luminaries: Part 5 particular requirements, Section 5 Flood light
(superseding IS: 1947)
T-5 Fluorescent tubelight
Specific for Hermetic Compressors- Part 1: High Temperature Application
Group
Specification for Hermetic Compressors – Part 2: Medium Temperature
Application group
Specification for Hermetic Compressors- Part 3: Low Temperature
Application group
Electronic type fan regulators
Specification for Thermostats for Use in Refrigerators, Air Conditioners,
Water Coolers and Beverage Coolers
Specification for Control Transformers for Switchgear and Control gear for
Voltages not exceeding 1000V ac.
General and safety requirements for fans and regulators for household
and similar purposes
Steel tubes, tubular and other wrought steel fittings- specification-part 1:
Steel Tubes
Mild steel tubes, tubular and other wrought steel fittings, part 2 mild steel
tubular and other wrought steel pipe fittings
Direct Acting indicating analogue electrical measuring instruments and
their accessories- specification – part:1 Definitions and General
Requirements.
their accessories-Part 2:
Special Requirements for Ammeters and
Voltmeters
their accessories- Part 3: Special Requirements for Watt meters and
Varmeters
their accessories- Part4: Special Requirements for Frequency Meters
their accessories- Pat 5: Special Requirements for Phase Meters, Power
Factors Meters and Synchroscopes
their accessories- Part6: Special Requirements for Ohmmeters (
Impedance Meters) and Conductance Meters
their accessories- Part 7: Special Requirements for Multi- Function
instruments
their accessories- Part 8: Special Requirements for Accessories
Page 272 of 429
46
47
IS 1248/Part
9/2003
IS 1255/1983
48
49
IS 1258/2005
IS12640/Part
1/2000
50
IS 12640/Part
2/2001
51
52
IS 1271/1985
IS 1293/2005
53
54
IS 13010/2002
IS 13032/2002
55
56
IS 13118/1991
IS 13340/1993
57
58
IS 13779/1999
IS13925/Part1/19
98
59
IS 13925/Part
2/2002
IS 13925/Part
3/2002
IS 13947/Part
1/1993
IS 13947/Part
2/1993
IS 13947/ Part
3/1993
60
61
62
63
64
IS 13947/Part
4/Sec 1/1993
65
IS 13947/ Part
Part 5/Sec 1/2004
66
67
IS 13947/Part
5/Sec 2/2004
IS 1445/1977
68
69
IS 1460/2005
IS 14697/1999
70
71
IS 1475/1978
IS 1475/Part
1/2001
IS 1897/1983
IS 14772/2000
72
73
Dated 29.Jan 2015
RVNL
their accessories- Part 9: Test Methods
Code of practice for installation and maintenance of power cables up to
and including 33 kV rating
Bayonet Lamp holders
Residual Current Operated Circuit- Breaking for Household and Similar
Uses- Part 1 Circuit- Breakers with Integral Over current Protection
(RCCBs)
Residual Current Operated Circuit- Breaking for Household and Similar
Uses- Part 2 Circuit- Breakers with Integral Over current Protection
(RCVOs)
Thermal evaluation and classification of electrical insulation
Plugs and Socket- Outlets of Rated Voltage Up to and including 250 Volt
and Rated Current Up to and including 16 Amperes- Specification
AC Watt Hour Meters, Class 0.5, 1 and 2 – Specification
Ac Miniature Circuit- Breaker Boards for Voltages not exceeding 1000VSpecification
Specification for High – Voltage Alternating – Current Circuit-Breakers
Power Capacitors of self-healing Type for Ac Power Systems having Rated
Voltage up to 650 V – Specification.
AC Static Watt- hour Meters, Class 1 and 2- Specification
Shunt capacitors for Ac power systems having a rated voltage above 1000
V Part 1 : General performance, testing and rating safety requirementsGuide for installation and operation
Shunt Capacitors for Ac Power Systems Having a Rated Voltage Above
1000 V – Part 2: Endurance Testing
Shunt Capacitors for Ac Power Systems Having a Rated Voltage Above
1000 V- Part 3: Protection of Shunt Capacitors and Shunt Capacitor Banks
Specification for Low Voltage Switchgear and Control gear- Part 1:
General Rules
Specification for Low- Voltage Switchgear and Control gear- part 2: Circuit
Breakers
Specification for Low Voltage Switchgear and Control gear-Part 3:
Switches, Disconnectors, Switch Disconnectors and Fuse Combination
Units.
Specification for Low-Voltage Switchgear and Control gear- Part 4:
Contractors and Motor-starters- Section 1: Electromechanical Contractors
and Motor Starters
Low Voltage Switchgear and Control gear- specification- Part 5: Control
Circuit Devices and Switching Elements- Section 1: Electromechanical
Control Circuit Devices
Low Voltage Switchgear and Control gear- specification- Part 5: Control
Circuit Devices and Switching Elements- Section 2: Proximity Switches.
Porcelain insulators for overhead power lines with a nominal voltage upto
and including 1000 V
Automotive Diesel Fuels- Specification
AC Static Transformer Operated Watt-hour and VAR Hour Meters, class
0.2 and 0.5 S- Specification
Specification for Self-contained Drinking Water Coolers
Self-Contained Drinking Water Coolers- Specification – Part 1: Energy
Consumption and Performance
Copper Strip for electrical purposes
General Requirements for Enclosures for Accessories for Household and
Similar Fixed Electrical Installations- Specification
Page 273 of 429
RVNL
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
IS 14930/Part
1/2001
IS 14930/Part
2/2001
IS 15111/part
1/2002
IS 15111/Part
2/2002
IS 1678/1998
IS 1777/1978
IS 1897/1983
IS 1944/Part
5/1981
IS 1944/Part
6/1981
IS 1944/Part 7
/1981
IS 1944/Parts I
and II /1970
IS 2026/Part
1/1977
IS 2026/Part
2/1977
IS 2026/Part
3/1981
IS 2026/Part
4/1977
IS 2026/Part
5/1994
IS 2036/1995
IS 2082/1993
IS 2086/1993
IS2121/Part
1/1981
IS 2121/Part
2/1981
IS 2121/Part3/
1992
IS 2121/Part
4/1991
IS 2141/2000
IS 2206/Part
2/1976
IS 2206/Part
3/1976
IS 2206/Part
3/1989
IS 2206/Part
4/1987
IS 2268/1994
IS 2312/1967
IS2418/Part
Dated 29.Jan 2015
Conduit Systems for Electrical Installations- Part 1: General Requirements
Conduit Systems for Electrical Installations- Part 2: Particular
Requirements- Conduit Systems Buried Underground
Self Ballasted Lamps for General Lighting
Services- Part1: Safety
Requirements
Self Ballasted Lamps for General Lighting Services- Part 2: Performance
Requirements
Specification for prestressed concrete poles for overhead power, traction
and telecommunication lines
Industrial luminaries with metal reflectors
Copper strip for electrical purposes
Code of practice for lighting of public thoroughfare: Part 5 Lighting for
grade separated junctions, bridges and elevated roads (Group D)
Code of practice for lighting of public thoroughfare: Part 6 Lighting for
towns and city centres and areas of civic importance (Group E)
Code of practice for lighting of public thoroughfare Part 7 lighting for
roads with special requirement (Group F)
Code of practice for Lighting of public Throughfares
Power transformers: Part 1 General
Power transformers: Part 2 Temperature-rise
Power transformers: Part 3 Insulation level and dielectric tests
Power transformers: Part 4 Terminal marking, tappings and connections
Power Transformer: Part 5 Transformer/Reactor bushings minimum
external clearance in air specification
Phenolic Laminated Sheets- Specification
Stationary storage type electric water heaters
Carriers and bases used in rewirable type electric fuses for voltages up to
650 V
Conductors and earth wire accessories for overhead power lines: Part 1
Armour rods, binding wires and tapes for conductors
Conductors and earth wire accessories for overhead power lines: Part 2
Mid span joints and repair sleeves for conductors
Conductors and earthwire accessories for overhead power lines: part 3
Accessories for earthwire
Conductors and earth wire accessories for overhead power lines: part 4
non tension joints
Hot Dip Galvanized Stay Strand- Specification
Flameproof electric lighting fittings: Part 1 Well-glass and bulkhead types
Flameproof electric lighting fittings: Part 2 Fittings using glass tubes
Flameproof electric lighting fittings: Part 3 Fittings Using Fluorescent
Lamps and Plastic Covers
Specification for Flameproof Electric Lighting Fittings- Part 4: Portable
Flame-proof Hand lamps and Approved Flexible Cables.
Electric call bells and buzzers for indoor use
Propeller type ac ventilating fans
Specification for Tubular Fluorescent Lamps for General Lighting Service-
Page 274 of 429
RVNL
105
106
107
108
109
110
111
112
I/1977
IS2448/Part
1/1963
IS2516/Part 1/Sec
1/1985
IS2516/Part 1/Sec
2/1980
IS 2516/Part
1/Sec 3/1972
IS2516/Part 2/Sec
2/1980
IS2516/Part 3/Sec
2/1980
IS2516/Part 4/Sec
2/1980
IS2516/Part 5/Sec
2/1980
113
114
115
116
IS
IS
IS
IS
117
118
IS 269/1989
IS 2705/Part
1/1992
IS 2705/Part
2/1992
IS 2705/Part
3/1992
IS 2705/Part
4/1992
IS 2713/Parts 1
to 3/1980
IS 278/1978
IS 2905/1989
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
2551/1982
2629/1985
2667/1988
2675/1983
IS 2997 /1964
IS 302/Part
1/1979
IS 302/Part 2/sec
201/1992
IS 302/Part 2/sec
203/1994
IS 302/Part 2/sec
204/1994
IS 302/Part 2/sec
21/1992
IS 302/Part 2/sec
35/1993
IS 302/Part 2 sec
59/1999
IS 302/Part 2/sec
80/2003
Dated 29.Jan 2015
Part I: Requirements and Tests
Adhesive insulating tapes for electrical purposes: Part 1 Tapes with cotton
textile substrates
Circuit breakers: Part 1 &2 Requirements and tests: sec 1 Voltages not
exceeding 1000 V AC or 1200 V DC (Withdrawn)
Circuit-breakers: Part 1 General and definitions, sec 2 For voltages above
1000 V AC (Withdrawn)
Circuit breakers: Part 1 General and definitions, section3 Voltages above
11 kV (Withdrawn)
Circuit Breakers: Part 2 rating, sec 2 for voltages above 1000 V AC
(Withdrawn)
Circuit breakers: Part 3 Design and construction, sec 2 for Voltages above
1000 V AC (Withdrawn)
Circuit Breakers: Part 4 Type Tests and Routine Tests: sec 2 For Voltages
above 1000 V AC (Withdrawn)
Circuit Breakers: Part 5 Information to be given with enquiries Tenders
and Orders and Rules of Transport Erection and Maintenance : sec 2 for
Voltages above 1000 V AC (Withdrawn)
Danger Notice plates
Recommended Practice for Hot-Dip Galvanizing of Iron and Steel
Fittings for rigid steel conduits for electrical wiring
Enclosed distribution fuse boards and cutouts for voltages not exceeding
1000 V Ac and 1200 V DC
Specification for 33 grade ordinary Portland cement
Current transformers: Part 1 General requirements
Current transformers: Part 2 Measuring current transformers
Current transformers: Part 3 Protective current transformers
Current transformers: Part 4 Protective current transformers for special
purpose applications
Specification for Tubular Steel Poles for Overhead Power Lines
Specification for Galvanized Steel Barbed Wire for Fencing
Methods of test for concrete poles for overhead power and
telecommunication lines
Air circulator type electric fans and regulators
General and Safety Requirements for Household and Similar Electrical
Appliances
Safety of household and similar electrical appliances: Part 2 Particular
requirements, Section 201 Electric immersion water heater
Safety of Household and similar Electrical Appliances- Part 2: Particular
Requirements- Section 203 Electric Call Bells and Buzzers for Indoor Use
Safety of household and similar electrical appliances: Part 2 Particular
requirements: Section 204 Electric water boilers
Safety of household and similar electrical appliances Part 2 Particular
requirements, Section 21 Stationary storage type electric water heater
Safety of Household and Similar Electrical Appliances – Part 2: Particular
Requirements- Section 35: Electric Instantaneous Water Heaters
Safety of Household and Similar Electrical Appliances- Part 2: Particular
Requirements- Section 59: Insect Killers
Safety of Household and Similar Electrical Appliances- Part 2 Particular
Requirements- Section: 80 Fans
Page 275 of 429
RVNL
134
135
136
137
138
139
140
141
142
143
144
145
146
147
IS 304/1981
IS 3043/1987
IS 3156/Part
1/1992
IS 3156/Part
2/1992
IS 3156/Part
3/1992
IS 3156/Part
4/1992
IS 3231/Part
0/1986
IS 3231/Part
1/Sec 1/1986
IS 3231/Part
1/Sec 2/1986
IS 3231/Part
1/Sec 3/1986
IS 3231/Part
2/Sec 1/1987
IS 3231/Part
2/Sec 2/1987
IS 3231/Part
2/Sec 3/1987
IS 3231/Part
3/Sec 1/1987
148
IS 3231/Part
3/Sec 2/1987
149
IS 3231/Part
2/Sec 3/1987
150
IS 3231/Part
3/Sec 4/1987
151
IS 3231/Part
3/Sec 5/1987
IS 325/1996
IS 12463/ 1998
IS 3412/1994
IS 3419/1988
IS 3427/1997
152
153
154
155
156
157
158
159
160
161
162
163
IS 3528/1966
IS 3553/1966
IS 371/1999
IS 374/1979
IS 3764/1992
IS 3842/Part
12/1976
IS 3842/Part
IV/1966
Dated 29.Jan 2015
Specification for High Tensile Brass ingots and Castings
Code of Practice for earthing
Voltage transformers: Part 1 General General requirements
Voltage transformers: Part 2 Measuring voltage transformers
Voltage transformers: part 3 Protective voltage transformers
Voltage Transformers: Part 4 Capacitor voltage transformers
Electrical relays for power systems protection: Part 0 General introduction
and list of parts
Specification for Electrical Relays for Power System Protection part 1 :
General Requirements Section 1: Contact Performance
Electrical relays for power system protection: Part 1 General
requirements, section 2 Insulation tests
Electrical relays for power system protection: Part 1 General
requirements, section 3 High frequency disturbance test for static relays
Specification for Electrical Relays for Power System Protection- Part 2 :
Requirements for Principal Families- Section 1 : All –or- Nothing Relays
Specification for Electrical Relays for Power System Protection- Part 2:
Requirements for Principal Families- Section 2: General Requirements for
Measuring Relays
Electrical relays for power system protection: Part 2 requirements for
principal families, section 3 General requirements for thermal relays
Requirements for Particular Group of Relays- Section 1: Non-specified
Time or Independent Specified Time Measuring Relays.
Requirements for Particular Group of Relays- Section 2: dependent
Specified Time Measuring Relays.
Requirements for Particular Group of Relays- Section 3: Biased
(percentage) Differential Relays.
Requirements for Particular Group of Relays- Section 4: Directional Relays
and Power Relays.
Electrical relays for power system Protection: Part 3 Requirements for
particular group of relays, section 5 Impedance measuring relays
Three phase induction motors
New insulating oils
Electric water boilers
Fittings for rigid non-metallic conduits
AC Metal Enclosed Switchgear and Control gear for Rated Voltages Above
1 kV and Up to and including 52 kV
Waterproof electric lighting fittings
Specification for Watertight Electric Lighting Fittings
Ceiling Roses- Specification
Electric Ceiling type fans and regulators
Code of safety for excavation work
Application guide for electrical relays for Ac systems: Part 12 Differential
relays for transformers
Application Guide for Electrical Relays for AC Systems- Part IV: Thermal
Relays
Page 276 of 429
RVNL
164
165
166
167
168
169
IS 3854/1997
IS 3895/1966
IS 398/Part
1/1996
IS 398/Part
2/1996
IS 398/Part
3/1976
IS 398/Part
4/1994
170
IS 398/Part
5/1992
171
IS4064/Part
1/1978
172
IS 4064/Part
2/1978
173
174
IS 4160/2005
IS 418/2004
175
184
IS 4289/Part
1/1984
IS 4289/Part /
2/2000
IS 4347/1967
IS 4540/1968
IS 4615/1968
IS 4648/1968
IS 4722/2001
IS 4770/1991
IS 4794/Part
1/1968
IS 4794/Part
2/1986
IS 4984/1995
185
186
IS 5039/1983
IS 5082/1998
187
IS 5216/Part
I/1982
IS 5216/Part
II/1982
IS 5300/1969
IS 5578/1984
IS 5613/Part
1/Sec 1/1985
IS 5613/Part
1/Sec 2/1985
176
177
178
179
180
183
181
182
183
188
189
190
191
192
Dated 29.Jan 2015
Switches for domestic and similar purposes
Mono crystalline semi-conductor rectifier cells and stacks
Aluminium conductors for overhead transmission purposes: Part 1
Aluminium stranded conductors
Aluminium conductors, galvanized steel reinforced.
Aluminium conductors, aluminized steel reinforced.
Aluminium alloy stranded conductors (aluminium magnesium silicon
type).
Aluminium conductors, galvanized steel reinforced for extra high voltage (
400 kV and above).
Air break switches, air-break disconnectors, air break switch
disconnectors and fuse-combination units for voltages not exceeding 1000
V ac or 1200 V dc: Part 1 General requirements
Air break switches, air-break disconnectors, air break switch
disconnectors and fuse-combination units for voltages not exceeding 1000
V AC or 1200 V dc: Part 2 Specific requirements for the direct switching
of individual motors
Interlocking Switch Socket Outlets- Specification
Tungesten Filament Lamp for Domestic and Similar General Lighting
Purposes
Specification for Flexible Cables for Lifts and Other Flexible ConnectionsPart 1: Elastomer Insulated Cables
Flexible Cables for Lifts and Other Flexible Connections- SpecificationPart 2: PVC Insulated Circular Cables
Code of practice for hospital lighting
Monocrystalline semiconductor rectifier assemblies and equipment
Switch socket outlets (non-interlocking type)
Guide for Electrical Layout in Residential Buildings
Rotating Electrical Machines- specification
Rubber Gloves- electrical Purposes- Specification
Push button switches: Part 1 General requirements and tests
Push buttons switches: Part 2 push button switches, type 1
Specification for high density polyethylene pipes for potable water
supplies
Distribution pillars for voltages not exceeding 1000 V Ac and 1200 V DC
Wrought aluminium and aluminium alloy bars, rods, tubes and sections
for electrical purposes
Recommendations on safety procedures and practices in Electrical WorkPart I: General
Recommendation on Safety procedures and practices in Electrical WorkPart II: Life Saving Techniques
Specification for Porcelain Guy Strain Insulators
Guide for marking of insulated conductors
Code of practice for Design, installation and Maintenance of Overhead
power Lines- Part 1: Lines Up to and Including 11 kV- section 1: Design
power Lines- Part 1: Lines Up to and Including 11 kV- section 2:
Installation and Maintenance
Page 277 of 429
193
IS 5613/Part
2/Sec 1/1985
194
IS 5613/Part
2/Sec 2/1985
195
204
IS 5613/Part
3/Sec 1/1989
IS 5613/Part
3/Sec 2/1989
IS 6236/1971
IS 694/1990
IS 6949/1973
IS 6792/1992
IS 7098/Part
1/1988
IS 7098/Part
2/1985
IS 7098/Part
3/1993
IS 731/1971
205
206
IS 732/1989
IS 7321/1974
207
IS 7935/1975
208
209
IS 800/1984
IS 802/Part 1 Sec
1/1995
210
IS 802/Part 1 /Sec
2/1992
211
IS 802/Part
2/1978
IS 802/Part
3/1978
IS 8034/2002
IS 8041 /1990
IS 8061 /1976
196
197
198
199
200
201
202
203
212
213
214
215
216
217
218
IS8183 /1993
IS 8530/1977
IS 8623 Part
1/1993
219
IS 8623/Part
2/1993
IS 8623/Part
3/1993
220
221
IS 875/Part
1/1987
Dated 29.Jan 2015
RVNL
power Lines- Part 2: Lines above 11 kV Up to and Including 220 kVsection 1: Design
power Lines- Part 2: Lines above 11 kV and Up to and Including 220 k V,
- section 2: Installation and maintenance.
power Lines- Part 3: 400 kV Lines section 1: Design
power Lines- Part 3:400 kV Lines –Section 2 Installation and Maintenance
Direct Recording electrical measuring instruments
PVC insulated cables for working voltages up to and including 1100 V
Summation current transformers
Method for Determination of Electric Strength of Insulating Oils
Cross linked polyethylene insulated PVC sheathed cables: Part 1 For
working voltage up to and including 1 100 V
Cross linked polyethylene insulated PVC sheathed cables: Part 2 for
working voltages from 3.3 kV up to and including 33 kV
Cross –linked polythelene insulated thermoplastic sheathed cables: part 3
for Working voltages from 66 kV upto and including 220 kV
Porcelain insulators for overhead powerlines with a nominal voltage
greater than 1000 V
Code of Practice for Electrical Wiring Installations.
Code of practice for selection, handling and erection of concrete poles for
overhead power and telecommunication lines
Insulator fittings for overhead power lines with a nominal voltage up to
and including 1000 V
Code of practice for general construction in steel
Code of practice for use of structural steel in overhead transmission line
towers, Part 1 Materials and Loads and permissible stresses Section 1
Materials and Loads
towers part 1: Material, loads and permissible stress section 2 Permissible
stress.
Code of Practice for use of structural steel in overhead transmission line
towers- Part II: Fabrication, Galvanizing, Inspection and Packing
towers, part 3 Testing
Submersible Pumpsets-specification
Specification for rapid hardening Portland cement
Code of practice for design, installation and maintenance of service lines
upto and including 650 V
Bonded mineral wool
Maximum demand indicators (class 1)
Specification for Low- Voltage Switchgear and Controlgear AssembliesPart 1: Requirements for Type-Tested and partially type- Tested
Assemblies
Specification for Low- Voltage Switchgear and Controlgear AssembliesPart 2: Particular Requirements for Busbar Trunking Systems ( Busway)
Specification for Low- Voltage Switchgear and Controlgear AssembliesPart 3: Particular Requirements for Equipment where unskilled persons
have Access for their use.
Code of practice for design loads (other than earthquake ) for buildings
and structures Part 1 Dead loads- Unit weights of building material and
Page 278 of 429
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
IS 875/Part
2/1987
IS 875/Part 3
1987
IS 875/Part
4/1987
IS 875/Part
5/1987
IS 8828/1996
IS 8884/1978
IS 9224/Part
1/1979
IS 9224/Part
2/1979
IS 9224/Part
4/1980
IS 9537/Part
1/1980
IS 9537 /Part
2/1981
IS 9537/Part
3/1983
IS 9537/Part
4/1983
IS 9537/Part
5/2000
IS 9537/Part
6/2000
IS 9537/Part
8/2003
IS 9583/1981
IS 9900/Part
1/1981
IS 9974/Part
1/1981
IS 13573: 1992
IS: 1391
Pt.II/1992(Amdnt.
I
IS:1391
Pt.I/1992(
Amendment 1&2
IS 456:2000
RVNL
stored materials ( Incorporating IS1911:1967)
and structures Part 2: imposed loads
and structures Part 3: Wind loads
and structures Part 4 Snow loads
and structures Part 5 Special loads and load combinations
Electrical Accessories- Circuit Breakers for Over Current Protection for
Household and Similar Installations
Code of practice for the installation of electric bells and call system
Low voltage fuses: Part 1 General requirements (Withdrawn)
Low voltage fuses: Part 2 Supplementary requirements for fuses for
industrial applications (Withdrawn)
Low voltage fuses: Part 4 Supplementary requirements for fuse-links for
the protection of semiconductor devices (Withdrawn)
Conduits for electrical installations: Part 1 General requirements
Conduits for electrical installations: Part 2 Rigid steel conduits
(superseding IS: 1653)
Conduits for electrical installations: Part 3 Rigid plain conduits of
insulating materials (superseding IS: 2509)
Specification for Conduits for Electrical Installations – Part 4: Pliable Selfrecovering Conduits of Insulating Materials
Conduits for Electrical Installations- Part 5: Pliable conduits of Insulating
Material
Conduits for Electrical Installations- Specification- Part 6: Pliable Conduits
of Metal or Composite Materials.
Conduits for Electrical Installations- Specification- Part 8: Rigid NonThreadable Conduits of Aluminium Alloy
Emergency lighting units
High pressure mercury vapour lamps: Part 1 Requirements and test
High pressure sodium vapour lamps: Part 1 General requirements and
tests
Joints and Terminations of Polymeric Cables for Working Voltages from
6.6 kV up to and including 33 kV – Performance Requirements and Type
Tests
Split type Air Conditioner.
Window type Air Conditioner
PLAIN AND REINFORCED CONCRETE CODE
OF PRACTICE
------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 279 of 429
Dated 29.Jan 2015
RVNL
Page 280 of 429
RVNL
PART-B
RAILWAY ELECTRIFICATION
WORKS
Dated 29.Jan 2015
Page 281 of 429
Dated 29.Jan 2015
RVNL
Page 282 of 429
RVNL
CHAPTER:B-1
GENERAL REQUIREMENTS FOR 25 kV AC OHE
1.1
INTRODUCTION:
This part contains general, technical and other specifications for design and erection of
complete 25 kV AC 50 Hz single phase traction overhead equipment, switching stations, booster
transformer stations, LT supply transformer stations complete with foundations, structures, return
conductors and 25 kV feeders if any. This part also gives reference to technical specifications of
materials and components, procedure for submission of designs and drawings of basic arrangements,
components and fittings designs and other typical designs relating to overhead equipment, switching
stations and booster transformer stations. A list of the standard drawings is included in the
annexure to these Technical Specifications.
The design and erection of OHE shall conform to standards and specifications, guidelines laid
down in A.C.Traction Manual, IR Schedule Of Dimension-2004, RDSO and Railway Board issued from
time to time with their latest amendments.
The details covered here are for 25 KV conventional OHE. For high rise OHE, para 1.9 may be
referred for relevant specifications of RDSO.
The specifications issued here are meant for guidelines and does not supersede any of the
rules/regulations/codes/instructions issued by Railway Board/RDSO/CORE etc from time to time and
they shall be followed accordingly.
1.2
SYSTEM PARTICULARS:
The nominal voltage of the overhead equipment will be 25 kV AC 50 Hz, single phase. The
supply voltage may, however, rise upto 27.5 kV. One terminal of the 25 kV system will be solidly
earthed at the traction sub-station and also connected to the running rails. The other terminal will be
connected to the overhead equipment through switchgear provided at the traction sub-station and at
the feeding station.
1.3
ROLLING STOCK:
(a)
LOCOMOTIVES
The electric locomotives will generally be equipped with DC motors fed through rectifiers/AC Motors
installed on the locomotives.
(b)
OVERSIZE CONSIGNMENTS
The specific requirement in regard to movement of steam locomotives and over size consignments for
each section, if necessary, are indicated in the Particular Requirements.
1.4 POWER SUPPLY:
(a)SUB-STATIONS
Electric Power will be supplied at 25 kV AC 50 Hz. Single phase from traction sub-stations located
along the track.
(b)SWITCHING STATIONS
Power supply will be controlled to the different sections of traction overhead equipment by switching
stations. At these stations the switching will be effected by means of “Interrupters” which are single
pole, non-automatic circuit breakers capable of repeatedly interrupting normal full load current. There
are three types of switching stations:
(1) Feeding stations(2) Sectioning stations (3) Sub-sectioning stations.
Dated 29.Jan 2015
Page 283 of 429
RVNL
(C) FEEDING STATIONS
Supply will be effected to the overhead equipment through switchgear installed at feeding stations.
All feeding stations will be located normally near the track.
(d) SECTIONING STATIONS
The sub-stations cannot, as a rule be paralleled and consequently a neutral section of overhead
equipment with insulated overlaps on either side will be provided approximately midway between
two consecutive feeding stations. Neutral sections may also be provided at feeding stations. Facilities
to bridge the neutral section between feeding stations will be provided at sectioning stations.
(e)
SUB-SECTIONING STATIONS
In order to facilitate maintenance of overhead equipment and to permit isolation of faulty sections and
expeditious restoration of power supply in healthy sections, sub-sectioning stations with insulated
overlaps will be provided between the feeding stations and the sectioning stations.
(f) RETURN CONDUCTORS
In order to reduce interference to telecommunication circuits arising from A.C. 50 Hz. Single phase
traction current in the overhead equipment, a return conductor may be provided for each main
running track. These return conductors, if provided, shall be connected at intervals to booster
transformers and to the rails.
(g)
BOOSTER STATIONS
Booster transformer stations are provided in conjunction with return conductors to reduce inductive
interference to telecommunication circuits arising from single phase 25 KVAC traction. The Booster
stations are located along the track.
1.5
(a)
(b)
(c)
SAFETY INSTRUCTIONS
EARTHING
Earthing shall be provided as per Indian Electricity(IE) Rules with latest amendments and as
per the railway specifications and site requirements.
INDIAN ELECTRICITY RULES 1956
While the Indian Electricity Rules 1956, as amended up to date, are to be followed in their
entirety, particular attention is drawn to the various clauses indicated in Annexure’I’. Any
installation or portion of installation, which does not comply with these rules, should be got
rectified immediately.
The detailed instructions on safety procedures given in I.S.S. and Indian Electricity Rules,
respective State Electricity Board’s regulation with up to date amendment shall be applicable.
ELECTRICAL LICENCE AND COMPETENCY CERTIFICATE
The Electrical Contractor/Sub-Contractor shall hold a valid Electrical Contractor’s License for
HT/EHT of voltage equal to or more than 25 kV issued by the Statutory Authority of any state.
All work on electrical installations shall be done under the direct supervision of persons
holding valid certificates of competency issued by the appropriate authority.
1.6
APPROVED SUPPLIERS
All equipment, components and fittings shall be procured from RDSO/CORE approved
suppliers/sources with prior approval of RVNL.
1.7
Safety Rules for working on OHE
While working on OHE all the safety rules as per ACTM 20332 to 20348 should be followed
strictly. Salient features of the rules are as under:
(a) Permit to Work
Before commencing work on any part of the dead OHE or within 2m of live OHE, a permit-towork shall be obtained from TPC or other authorized person as detailed in Chapter VI.
Dated 29.Jan 2015
Page 284 of 429
RVNL
(b) Earthing before Commencement of Work
1. All metallic parts within reach (either directly or through tools etc.) shall be earthed, after
they are made dead.
2. Each working party shall be protected by at least two independent earths, one on each
side of a working party.
3. If the distance between the working parties exceeds 100m intermediate earths shall be
provided in such a manner as to ensure that the distance between earths does not
exceed 100m.
4. Even when earthing is provided by isolator switches with earthing heels, additional
temporary earths as above shall also be provided.
(c) Use of safety belts, protective helmets etc.
At the work site staff is advised to wear helmets and use safety belts to protect themselves
against injury. Official incharge of work shall observe relavent provision of G & SR for protection
of trains before and whole time the work is in progress on OHE. Measure laid down shall be
observed by all concerned to prevent accidental energization of the section under power block
on account of electric train movements.
(d) Provision of Special Caution Boards on Vehicles:
Railway board vide their letter No. 2009/RE/161/4 FTS-748 dtd.26-08-14 have advised to provide a special
caution board on all departmental vehicles, track machines, platform shelters. The compliance of the same
should be ensured.
1.8 Compliance to Various Rules and Regulations
The present Book of specification containing part-I( Electrical General specification) and part-II
(TRD Specification) contains only list of important details of specifications. The contractor shall
however follow all the rules, regulations and instructions applicable for the work such as:
1.
2.
3.
4.
AC Traction Manual 1994.
IR Schdule of Dimension 2004.
Standrads, drawings laid down by RDSO/CORE.
Instructions issued by Railway Board/RDSO/CORE/Zonal Railway/RVNL as applicable for the
project.
5 . Indian Electricity Rules 1956.
6 . Indian Electricity Act 2003.
7 . BIS Specifications
8 . Any other rules/standards/instructions etc relevant for the work framed/laid down from time
to time.
Only the latest version of rules/standards/drawings/instructions shall be applicable
unless specifically stated otherwise. In case of any conflict between various instructions,
decision of the Employer shall be final. In case of any conflict/discrepancy between
specifications contained in this book and specifications as per above mentioned authorities, later
shall prevail.
Notwithstanding any approval of drawing or work by RVNL, the contractor shall be finally
responsible for following correct instructions and drawings as per latest amended details. In
case any mistake is found in the work/drawing later on which is not carried out/prepared in
accordance with laid down standards, rules and regulations, the Employer shall be free to reject
it at any stage of the work. The contractor shall be liable to dismantle/modify/redo the rejected
work without any extra cost as per directions of the Employer. The decision of the Employer
shall be final in this regard. In this technical specification, the latest standards/drawings/
instructions /letter/ Code of Practice etc means latest up to the date 28 days prior to the
deadline for submission of bids.
Dated 29.Jan 2015
Page 285 of 429
Dated 29.Jan 2015
RVNL
Page 286 of 429
RVNL
CHAPTER:B-2
OVERHEAD EQUIPMENT
2.1
TRACK
(a) GAUGE AND TRACK CENTRES
The track gauge is 1676 mm (5’-6”). In multiple track zones, the normal distance between
track centres varies between 4720mm and 5500 mm.
(b) SPEED
The overhead equipment which shall be of the simple polygonal type and pre-sag should be
designed for a maximum speed of 160 kmph (approx. 100 miles/h)if unregulated, unless
otherwise specified in any particular section.
(c) CURVES
The minimum radius permissible is 175m (573 ft.) i.e. a 10 deg. Curve. Inside station limits,
the curvature at a 1 in 8.5 turnout is 8 degree i.e. of radius 219m (716 ft.).
(d) SUPER ELEVATION
The maximum super elevation is 165 (6.5”). On curves the minimum setting of structures
shall be decided on the basis of maximum super elevation (see para 4.10). For purposes of
design and erection of overhead equipment, the actual super elevation as existing at site or as
indicated to the contractor shall be adopted.
(e) LOW JOINTS
For low or loosely packed rail joints a difference of 25mm (1”) in the level of opposite rails
may be taken as the basis for estimating the displacement of the pantograph with respect to
its normal position.
(f) FORMATION
Generally sections with more than one track have common formation. In certain lengths,
however the formation for different tracks may be separate (see relevant drawing listed in the
Annexure to these Technical Specifications).
(g) DISPLACEMENT
The general design of overhead equipment shall permit a displacement of +/- 100 mm of
tracks without difficulty and any adjustment of the overhead equipment on this account shall
be of such a nature as could be done conveniently without changing any component of the
overhead equipment.
2.2
SECTIONING
(a) INSULATED OVERLAPS
Insulated overlaps are provided for facility of isolation. Some of the overlaps may be provided
with manually operated isolator switches. In addition, for connecting the overhead equipment
to booster transformers, insulated overlaps are to be indicated in the sectioning diagrams.
(b) YARD SUPPLY
The sectioning diagram/s also indicate the track in stations yards and siding whose
equipments is electrically independent from those of other tracks.
The overhead equipment in yards and sidings may be fed through isolator switch or
interrupter in accordance with arrangement indicated in the sectioning diagram/s.
(c)
SECTION INSULATORS
Dated 29.Jan 2015
Page 287 of 429
RVNL
Section insulators shall be provided as indicated in the sectioning diagrams, on cross-overs
between main tracks and to isolate sections of overhead equipment in yards and sidings.
Section insulators may also be used to form neutral sections at special locations as indicated
in the approved drawings.
Section insulator should be so located that the following conditions are fulfilled:
i) At location of section insulator, the axial distance between the catenary and contact
wire shall not be less than 450 mm in the case of sigle-wire section insulator and 600
mm in the case of double wire section insulator without increasing the encumbrance at
the supports beyond 1.40m.
ii) The section insulator is to be located beyond the point where the centre distance
between the two tracks is equal to or more than 1.65 meter. If the section insulator is
erected with the free ends of the runners away from the centre of the turn outs this
distance may be reduced to 1.45 metre.
iii) The stagger of contact wire at the location of the section insulator should normally
be zero, but in no case should it exceed +/- 100 mm.
iv) As far as possible, on loops the section insulator shall be located close to the first
support of the overhead equipment for the loop.
v) The preferred location of section insulator on main running track is 2 to 10 m from the
support in the direction of the traffic, though its provision on the main line should be
avoided.
vi) In double line section the runner should be in the trailing direction.
(d) PROTECTION OF ISOLATED SECTIONS:
PROTECTION BY SIGNAL OF THE ISOLATED SECTIONS
Normally a stop signal is provided before the insulated overlap, with an isolator so that
approaching train is stopped from entering the isolated section. Although the distance
between the stop signal and the sectioning points has not been specified in the rules it is
desirable to provide 120 m between the stop signal and centre line of the insulated overlap of
the section insulators i.e. the sectioning point.(Para 30.2 ACTM vol-ii)
(e)
FEEDERS & RETURN FEEDERS OF 25 KV ALONG TRACK
25 kV along track feeders may connect sections of overhead equipment to a switching station
or an isolator switch or gantry. Such feeders will be run usually on traction structures and
sometimes on independent masts. A single ‘SPIDER’ conductor shall be used for such feeders.
(f)
RETURN CONDUCTOR
Return conductor may be run on traction structures or masts. A single ‘ SPIDER’ conductor
shall be used for such return conductors.
(g) SCHEMATIC ARRANGEMENTS
The different arrangements of feeders, return feeders, 25 kV along track feeders and return
conductors are shown in the drawing listed in the Annexure to these Technical Specifications.
(h) SHORT NEUTRAL SECTION OF PTFE TYPE
Neutral section shall be located away from stop signals, level crossings and shall be on
tangent track and on level to the possible extent.
(i) If neutral section is provided after a stop signal, the distance * between signal and neutral
section shall be such that after stopping, the train shall be able to pick up enough speed to
coast the neutral section without any risk of stalling.
(ii) If neutral section is provided before a stop signal, the distance* between neutral section
and signal shall be such that the train shall not cross the signals in an effort to cost the
neutral section.
Dated 29.Jan 2015
Page 288 of 429
RVNL
* NOTE: The distance should preferably be 1600 metre away on section with gradient up to 1
in 300 and 2500 metre away in case of higher gradient upto 1in 200, if unavoidable.
(iii) The PTFE type short neutral section shall be located on level tangent track at least 400 m
after the stop signal and 200m before the stop signal. Where, however, modification require
to comply with these guide lines are difficult or entail heavy investment, the Chief Electrical
Engineer of the Railway may direct any other arrangement to be followed consistent with
safety and reliability. For location on graded section guidelines of para2.2 h (i),(ii) shall be
followed.
(iv) PTFE type short neutral section assembly shall be procured as per RDSO specification NO.
TI/SPC/OHE/SNS/0000(01/00) or latest.
2.3
PANTOGRAPHS:
(a) The outline of the pantograph, its dimensions and its current collecting area are shown in a
drawing listed in the Annexure to these Technical Specifications.
(b) NUMBER AND PRESSURE
Each locomotive will be equipped with two pantographs, but any one pantograph generally the
trailing one will be in use at a time. The working pressure of the pantograph on the contact
wire may vary between 5 and 15 kg.
(c)SPACING IN MULTIPLE HEADED TRAINS
The distance between adjacent running pantographs in the case of multiple heading would
normally be 20 metre. This distance may, however, be reduced to 7.9metre between two
pantographs in very exceptional cases.
(d) INSULATION CLEARANCE
The electrical clearances for the pantograph on tangent tracks and on curves for design and
erection of overhead equipment shall be based on the IR schedule of Dimensions 1676mm.
Gauge, 2004 and any other amendments/orders that may be issued by the Railway Board
from time to time.
2.4
(a)
OVERHEAD EQUIPMENT:
BRIEF DESCRIPTION
Essentially the traction overhead equipment shall consist of a standard catenary wire from
which a grooved contact wire is suitably suspended by means of droppers. In order to cater
for a speed of 160 kmph the contact wire is given a pre-sag of about 100 mm or 72m span
and reduced suitably for other spans.
(b) CATENARY
The catenary wire shall be of cadmium copper 19/2.10 mm, 65 mm sq.
(c) CONTACT WIRE
The contact wire shall be grooved and made of hard drawn copper 107/150sq. mm cross
section. 65/150 sq mm OHE with 1200/1200 kgf tension shall be adopted for new
electrification in terms of RDSO L.No. TI/OHE/GA/2013 DT 30th April,2013.
(d)DROPPERS
Droppers shall be made of hard drawn round copper wire, approximately 5 mm dia. Droppers
shall be spaced not more than 9 m apart.
(e) ENCUMBRANCE
As a general rule, the nominal “encumbrance” i.e. the centre distance between the catenary
and the contact wire at the support shall be 1.40m. Deviation from this figure will be
Dated 29.Jan 2015
Page 289 of 429
RVNL
permitted in special cases (e.g. spans near over-bridges, structures with more than one
cantilever etc.).
(f) Jumpers:
All jumpers connected to OHE conductors shall be of copper only. The in –span jumpers
potential equalizer jumpers at insulated overlaps and neutral section shall be of 50 mm sq.
nominal 19/1.8 mm size. Flexible jumper of nominal section 105 mm sq., 19/7/1.06mm size
shall be used at overlaps turnouts, crossings, etc. Provision of long cross type G-jumper on
parallel run side instead of cross-over/turn out side as per RDSO drawing No ETI/OHE/G/02141
Rev ‘C’ or latest.
(g) BRIDDLE WIRE
Bridle wire for supporting contact wire for regulated tramway equipment shall be of cadmium
copper 7/2. 10 mm in size.
(h) ANTI THEFT JUMPER
Anti theft jumper of 50 mm sq. nominal, 19/1.8 mm in size shall be used in out of run wire of
conventional OHE and copper cadmium anti-creep wire as an anti-theft measure.
The jumper connecting the Aluminium Conductors to any other conductors terminal or clamp
shall be made with the aid of suitable bi-metalic clamps. All aluminium jumpers of size
19/7/1.4 mm bare ¾ hard shall be used to connect other aluminium conductors such as
return conductor. The tail ends of feeder wires from the strain clamps at the termination of a
feeder, return feeder or return conductor may be connected directly to a terminal or clamp
where feasible to avoid the use of a separate jumper wire.
(i)
2.5
OHE FITTINGS/COMPONENTS
OHE fittings/ components shall be forged/ compression type instead of malleable cast iron
type wherever these type of fittings are available as per RDSO approved list.
TYPE OF EQUIPMENT:
The overhead equipment used shall normally be either of the regulated or unregulated type.
Unregulated tramway type equipment (contact wire only) may be adopted where specially
indicated by the Engineer.
(a) REGULATED
In the regulated type of overhead equipment, the tension of both the catenary and the
contact wires shall be maintained at a constant value at all temperatures by means of
automatic tensioning devices desired to take up the variation in the length of overhead
equipment due to temperature variation.
An anti creep shall be provided at a point approximately midway between two tensioning
devices and not more than 750 metres from any one of them. The general arrangement of an
anti-creep is shown in a drawing listed in the Annexure to these Technical Specifications. The
arrangement shall generally consist of the galvanized steel wire anchored on the masts
adjacent to the anti creep central mast in accordance with the relevant drawing listed the
Annexure to these Technical Specifications. Alternatively, the arrangement may consist of
anchoring the catenary on either side of the boom of a portal with the contact wire running
through and providing a jumper connection as per general arrangement shown in typical
drawing listed in the Annexure to these technical specifications. The engineer shall indicate
the type of anti-creeps to be adopted in the pegging plans. RDSO drawing No.
TI/DRG/OHE/GENL/RDSO/00001/12/0 REV ‘0’ or latest, Ref.ETI/OHE/G/02111 Rev-A
dt.23.10.2012 or latest is to be followed for use of catenary wire in place of GI wire at ACC
locations in polluted area.
Dated 29.Jan 2015
Page 290 of 429
RVNL
(b) UNREGULATED
The unregulated type of overhead equipment has no provision for automatic regulation of
tension of either the catenary or the contact wire.
(c) TRAMWAY TYPE EQUIPMENT REGULATED CONTACT WIRE ONLY
In tramway type equipment regulated, only a contact wire is provided without a continuous
catenary or droppers. The tension in the contact wire is regulated. At support, bridle wire is
used for supporting the contact wire.
2.6
PLANE OF CONTACT:
(a) REGULATED
The regulated overhead equipment shall be so erected that the contact wire has the designed
sag.
(b) UNREGULATED
In the case of unregulated equipment the contact wire shall have no sag at an ambient
temperature of 35 deg. C.
(c) TRAMWAY TYPE
In tramway type equipment, the contact wire will have its own natural sag when erected.
(d)
2.7
DROPPER
Dropper charts to be used for standard span of regulated and unregulated overhead
equipment would be supplied by the Engineer. Droppers for non-standard spans, span with
section insulators and special locations shall be calculated by the Contractor in accordance
with the method indicated by the Engineer and submitted to the Engineer for approval.
For dropper schedule of OHE having presage of 0.8mm/meter, RDSO drgs
TI/DRG/OHE/DROP/00001/10/1, TI/DRG/OHE/DROP/00002/10/1, TI/DRG/OHE/DROP/00003/
10/1 should be used [RDSO lr No: TI/OHE/SHS/2014 dt 29/9/2014].
TENSIONS:
(a)
REGULATED
(i) In regulated equipment the tension in the catenary and contact wire shall be 1,000 kgf in
each conductor.
(b)
UNREGULATED
In unregulated equipment the tension in the catenary and in the contact wire at 35 degree
C without wind shall be, 1,000 kgf in each conductor.
(C) TRAMWAY TYPE
In regulated type tramway equipment, the tension shall be 1,250 kgf.
2.8 CLEARANCE:
(a) GENERAL
The distance between live parts and parts at earth potential (for parts likely to be earthed) shall
be as large as possible. In all cases the values given in the latest version of the Schedule of
Dimensions shall be observed along with any other supplementary rules, that may be issued by
the Railway Board.
(b) OVER BRIDGES & TUNNELS
The clearances which are to be made available at over bridges, signal, gantries and other
overline structures shall be based on the above rules.
Dated 29.Jan 2015
Page 291 of 429
RVNL
(c) PLATFORM SHEDS AND OTHER STRUCTURES
In the course of checking the overhead equipment pegging plans, the Contractor shall prepare
a list of platform sheds and other structures in the vicinity of track to be wired. The clearances to
these structures shall be in accordance with those shown in the relevant drawings listed in the
Annexure to these Technical Specifications. If these clearances are not available, the Contractor
shall advise the Engineer in time to enable the latter to take up the necessary modifications.
(d)
The electrical clearances to be maintained under the worst conditions of
temperature, wind etc. are as follows:
(As per ACS-10 to IRSOD-2004)
Minimum vertical/lateral distance between any live part of overhead equipment or
pantographs and parts of any fixed structures (earthed or otherwise or moving loads):
a)
Long duration
250 mm
b)
Short duration
200mm
Note:
i) Long Duration means when the conductor is at rest and short Duration means
when the conductor is not at rest.
ii) A minimum vertical distance of 270 mm shall normally be provided between rolling
stock and contact wire to allow for a 20 mm temporary raising of the track during
maintenance. Wherever the allowance required for track maintenance exceeds 20 mm,
the vertical distance between rolling stock and contact wire shall correspondingly be
increased.
iii) Where adoption of above clearances is either not feasible or involves abnormally
high cost, Permanent Bench Mark shall be provided to indicate the level of track to be
maintained.
(e) Working Clearance:
Minimum clearance between live conductor/equipments and such earthed
structure/live parts of different elementary sections where men are required to work shall be 2
m. Where the clearance is not obtained the structure shall be protected by earthed metallic
screens or prescribed warning boards.
(f) The clearance between any part live at 3 kV and any part at earth potential (or part likely to
be earthed) shall be not less than 150 mm under static condition and 70 mm under dynamic
conditions.
2.9
HEIGHT AND GRADIENT OF CONTACT WIRE
Minimum height from rail level to the underside of the contact wire shall be:
(i) Under Bridges and in Tunnels
: 4.80 m
(ii) In the Open
: 5.50 m
(iii) At Level Crossings
: 5.50 m
(iv) In Running and Carriage Sheds
: 5.80 m
(a) STANDARD HEIGHT:
Normally the height of contact wire (under side surface) above the track plane shall not be
less than 5.50m at any point in the span under the worst temperature conditions. To ensure
this, the normal height at the suspension point shall be as under:
Type of OHE Normal Height of contact wire at the support point
i) Regulated: In sections where High speed trains with 160 kmph or higher speed are likely
to be run, contact wire pre-sag shall be planned to be 0.8 mm per meter (precisely rather than
following thumb rule of 50 mm for 72m span as per RDSO letter TI/OHE/SHS/2014 dt 29/9/2014.
Dated 29.Jan 2015
Page 292 of 429
RVNL
However, OHE with 5 cm pre-sag may be provided in long tunnels and through girder bridges to
achieve the minimum electrical clearance of 4.80m.
ii) Unregulated
-
Unregulated OHE designed
5.75 m
For areas with temp. range of
4 deg.C to 65 deg. C
Unregulated OHE designed for
5.65m
Areas with a temp. range of 15
deg. C to 65 deg. C
(b) The height may be reduced under overline structures after a clearance study. The
minimum height shall be 4.92 m for the broad gauge and 4.02 m for the metre gauge to
permit movement of “C” class ODC without physical lifting of wires. In case ”C” class ODC
movement is not required, the height could be reduced to 4.80m (BG). Height may be
further reduced to 4.65 if rolling stock higher than 4.265 m are not allowed on such lines.
(c) At electric locomotive sheds and loco inspection pits, the minimum height shall be 5.80m
for the BG and 5.50m for the MG.
(d) All level crossings, the minimum height shall be 5.50m for both broad and metre gauges.
(e) Necessary provision shall be made in overhead structure and overhead equipment, if
necessary by using longer OHE masts to permit an allowance of 275 mm for raising of
track in connection with introduction of modern track structures in future and for catering
to increased ballast cushion, larger sleeper thickness etc [para 10(f) of ACS-10 of SOD2004]
(f) Erection tolerance:[Para 7.3 of ACTM]
A tolerance of +/- 20mm is permissible on the height of contact wire as measured at a
point of support except on either side of an over bridge where tolerance of +/- 10 mm will
be allowed. But the difference between the heights of contact wire at two adjacent
supports shall not exceed 20mm. In spans with gradient of contact wire, this difference of
20 mm is measured over and above the approved gradient.
(g)
GRADIENT OF CONTACT WIRE
Any change in the height of the contact wire shall be made gradually and the maximum
slope shall not normally exceed 3 mm per metre on main lines and 10 mm per metre on
sidings. In no case shall the relative gradient of the contact wire in two adjacent spans be
greater than 1.5 mm/m on main lines and 3 mm/m on sidings.
In sections where High speed trains with 150 kmph or higher speed are likely to be run,
contact wire gradient of 1mm per meter and difference in contact wire gradient between
two adjoining spans-0.5mm per meter shall be maintained as per RDSO letter
TI/OHE/HS/2003 dt 24/9/2003 and RB letter 2001/RE/170/1 dt 13/3/2007 &
2001/Elect(G)/170/1 Pt 30/6/2009.
2.10 STAGGER:
To ensure uniform wear of contact strips of pantographs, the contact wire shall normally be
staggered in a manner given below.
a) Tangent Track
On tangent track the contact wire is normally given a stagger of 200 mm at each support
alternately on either side of the centre of the track. This is relaxed in special cases for ensuring
requisite clearances in difficult locations such as in the vicinity of signals. Subject to stagger at
midspan not exceeding the permissible values given in Drg. No. ETI/OHE/G/ 00202.
b) On tangent track, the catenary stagger is zero for masts supporting a single equipment.
The catenary is fixed vertically over the contact wire at all supports at which more than one
equipment is supported, at flexible head spans and at supports with reduced encumbrance, on
tangent as well as curved tracks.
Dated 29.Jan 2015
Page 293 of 429
RVNL
c) Curved Track
On curves, the stagger of the contact wire at supports should not exceed 300mm. The stagger
of the catenary on curved track shall be determined with reference to Drg. No.
ETI/OHE/G/00202. The standard values adopted are 0, +200 and -200.
d) Turnouts and Diamond Crossing
At turnouts, the stagger of the contact wire on the main running line shall be in accordance
with Drg. No.ETI/OHE/G/00202. The stagger of contact wire of the branching line shall not
exceed 300 mm at any point in the span. This is achieved by selecting a suitable location for
the mast near the centre of the turnout in the case of overlap type equipment, or by suitably
adjusting the point of crossing of the two contact wires in the case of crossing type equipment.
e) Uninsulated overlap
At uninsulated overlaps, the stagger should conform to drawing No. RE/33/G/0 2121 Sh. 1. On
non uniform curves or at other locations where staggers different from those indicated in these
drawings are adopted, the following points should be observed.
i) The stagger of the in running contact wire does not exceed to 100 mm on tangent track
and 300 mm curved track at any support, at which only one contact wire is in running.
ii) In any span of the centre of which only one of the contact wires is in running ( as in a
4-span overlap), the mid-span stagger of the in-running contact wire does not exceed
the values given in Drg. No. ETI/OHE/G/00202.
iii) The two contact wires run parallel to each other between the intermediate supports at
a distance of 200 mm from each other.
f) Insulated Overlap
At insulated overlaps, stagger should conform to Drg. No. ETI/OHE/G/02131 Sh. 1. On non –
uniform curves and other locations where stagger different from those shown in this drawing
are adopted. The points mentioned against un-insulated overlap spans also apply, with the
difference that between intermediate masts the two contact wires run parallel at a distance of
500 mm from each other.
g) Neutral Section:
The stagger at overlap
Sheet No. 1.
type neutral sections should conform to Drg. No. ETI/OHE/G/02161,
i) The stagger at section insulator type neutral section should be so adopted that the stagger at
the section insulator assembly is within the limit of +/- 100 mm.
ii) PTFE type neutral section shall be erected on tangent track only. The stagger shall be zero at
support.
2.11 SPAN:
Standard spans shall be determined in accordance with following RDSO drawings:
Sr No
1
2
3
4
5
Location
Conventional OHE
Regulated Tramway OHE
Insulated overlaps
Un-Insulated overlaps
Neutral Section
RDSO Dwg Ref
ETI/OHE/G/00202
ETI/OHE/G/00201
ETI/OHE/G/02131/Sheet1
RE/33/G/02121
ETI/OHE/G/02161/Sheet1
The spans should be as large as practicable. The maximum span of the OHE in tangent track is
72 m. Spans may be reduced in interval of 4.5m based on curvature, signal locations etc keeping
in view stagger limits, signal visibility. Maximum span of OHE is also limited based on the wind
Dated 29.Jan 2015
Page 294 of 429
RVNL
zones of the section in the country as per IS-875 (Part-3)-1987. Typical max permissible spans
have been circulated by RDSO vide lr No: TI/OHE/GA/2013 DT 30th April,2013, 8th Aug,2013
and 15 May,2014 which are as under:
Sr
No
Basic
wind
speed (m/sec)
Designed
wind
pressure (kg/m2)
1
2
3
4
5
33
39
44
47
50
73
105
136
155
178
Max permissible
span for 65/107
OHE (1000/1000
kgf
Tension)
(Metres)
67.5
67.5
58.5
54
54
Max
permissible
span for 65/150
OHE
(1200/1200
kgf
Tension)
(Metres)
67.5
67.5
63
58.5
54
Note:
(a)
(b)
(c)
(d)
(e)
On main tracks, the lengths of two consecutive spans shall not normally differ by more than
18m.
The spans in case of unequal encumbrances shall be such that the axial distance between the
catenary and contact wire at the min dropper is not less than 150mm.
With crossed type OHE at facing turnouts, the anchor spans shall be restricted to 54m.
Where earth wire is provided, the max span over level crossings should be 58.5m.
Spans should be restricted when loaded with section insulators.
2.12 TERMINATION
(a)
GENERAL
Traction overhead lines shall be terminated using components as specified in RDSO Drg. The
termination may be carried forward by one or two spans if anchoring facilities so require.
(b)
Terminating wires shall be electrically connected to the conductors with which they
are likely to approach closely or come into contact under normal conditions.
(c)
SUPPLEMENTARY INSULATION
If a terminating wire passes a live conductor to which it should not be connected, i.e. in a
different elementary section, the portion of the terminating wire close to the live conductor shall
be separated by means of insulators. The insulators shall be located in such a manner as to
clear the zone of the pantograph under the worst conditions and as far away as is possible from
live conductors.
(d) Following important points should be kept in mind:
(i) Back to back anchoring of OHE may be done only for fixed type OHE (without counter
weight).
(ii) No live anchor or equipment shall be provided near or over any hut or building. In
such cases cut in insulator should be provided and OHE earthed.
(iii) Masts with counter weights should be avoided on plateforms [para 18.7 ACTM].
Dated 29.Jan 2015
Page 295 of 429
RVNL
2.13 TYPES OF STRUCTURES:
(a) The overhead equipment of main tracks in case of multiple track section shall be electrically
and mechanically independent of one another by provision of independent cantilever masts to the
maximum extent possible (see the Annexure to these Technical Specifications).
(b) HEAD SPANS
Head span construction may be adopted with unregulated overhead equipment. A single head
span shall not normally cover more than six tracks (See the Annexure to this technical
specification for general arrangement drawings of head-span carrying complete overhead
equipment).
(c) PORTALS
In cases where the tracks in a multiple track section do not permit location of independent masts
and where automatic tensioning of overhead equipment is required, rigid portals may be used.
Also in the vicinity of points and crossings, portals may be used, provided it is not possible to
have prescribed setting with independent cantilever masts. These structures shall be equipped
with standard bracket assemblies for supporting individual equipment of different tracks. The use
of such structures is to be avoided as far as possible and for this purpose, the Engineer will
arrange to slew the tracks, if practicable. A single portal shall normally not cover more than five
tracks (See also 4.7). Portal structures shall also be employed at anti-creep central locations and
such portals will have necessary guy arrangement.
(d) FOUNDATIONS
Foundations for all structures shall be designed in an economical manner by following the
methods of design indicated by the Engineer and observing the schedule furnished by him.
2.14 CANTILEVER ASSEMBLY:
The bracket assembly carrying overhead equipment shall be swivel type. The assembly shall be
such that the tubes adopted will permit easy adjustment of the whole equipment after erection to
cater for displacement of the track during maintenance up to the extent of 100 mm on either side
except as otherwise relaxed by the Engineer (see Para 2.1 g). In special locations, pull –off
arrangements may be used with the approval of the Engineer.
In sections where High speed trains with 150 kmph or higher speed are likely to be run, drop
bracket assembly as per drg No ETI/OHE/P/2360 alongwith steady arm drg ET/OHE/P/2390
should be used to give 100mm push up. [RB letter 2001/RE/170/1 dt 13/3/2007 &
2001/Elect(G)/170/1 Pt 30/6/2009].
2.15 OVERLAPS:
Overlaps shall be provided at suitable intervals such that neither the tension length exceeds
1500 m nor the fixed anchor to balance weight anchor exceeds 750m.
(a)
GENERAL
The two contact wires at the overlapping zone shall be parallel to each other in a
plane parallel to the track and run separated from each other.
(b)
INSULATED
In the case of insulated overlaps, the separation between the two contact and the two
catenary wires shall be 0.5m (see the Annexure to these Technical Specifications for
general arrangement drawings).
2.16 POINTS & CROSSINGS:
Arrangements of overhead equipment of different types e.g. regulated, unregulated or tramway
at points and crossings shall be in accordance with the standard drawings.
Dated 29.Jan 2015
Page 296 of 429
RVNL
2.17
ISOLATORS
Manually operated isolators single or double pole type, with or without earth contact assembly
may be required to bridge certain section insulators or insulated overlaps (see para 2.1.11). In
certain large yards, isolators controlling different lines may be grouped together on a gantry
(see the Annexure to these Technical Specifications).
2.18
RETURN CONDUCTORS
At all Booster stations, the return conductor shall be provided with cut-in-insulators. At point
mid way between two booster stations, the return conductor shall be connected to the rail
through suitable terminal lugs which will provide a means of isolation, when required. The
drawings showing the general arrangement of connections to the return conductor are listed in
the Annexure to these Technical Specifications. The connection from the isolating arrangement
to the rail shall be by means of 2 MS. Flats, each of minimum size 40mm x 6 mm and at
feeding stations 4 M.S. flats each of minimum size 40 mm x 6 mm. The flats shall be given two
coats of red oxide zinc chromate primer to IS:2074:1992 or latest CNSL based and finished
with two coats of Bitumen 85/25 blown grade. Return conductors may be taken under ground in
special locations such as under overline structures with the approval of the Engineer. The return
conductor shall also be connected with buried rail on either side of the overlap before the
feeding post. The cut-in-insulator should be provided on the return conductor before the feeding
post within the overlap limits and two independent rail connection links from the mast on either
side on the cut-in-insulator. The same practice is to be adopted for the return conductor, on all
sub-sectioning and sectioning posts.
2.19 BRIDGES AND TUNNELS:
(a) OVERBRIDGES
The complete overhead equipment (i.e. both the catenary and the contact wires) shall
normally pass under over-line structures. Additional intermediate suspension points shall be
provided, if necessary, to ensure the specified minimum height of contact wire being
maintained. In special cases catenary may be anchored on either side of the overline structure
and the contact wire carried underneath using insulated catenary.
Under all over bridges, insulated piece of catenary wire shall be provided as per RDSO’s
specification No. TI/SPC/OHE/INSCAT/0000 (04/00) to avoid cutting of strands.
(b)
TUNNELS AND CUTTINGS
The arrangements proposed for the equipment in tunnels and cuttings shall take into account
the special features of each location and shall be in accordance with general design specified in
part- II.
(b) SAFETY SCREENS
On over-bridges, metallic protective screens shall be provided on both sides of the complete
bridge covering all the tracks in order to prevent any person from coming into contact with the
live overhead equipment. Such screens shall be properly earthed.
2.20
HEIGHT GAUGES AT LEVEL CROSSINGS
Height gauges will be provided at all level crossings in accordance with the following standard
plan drawings:
1.
2.
3.
At National Highway having Class-I road or TVU > 1 lakh)Standard plan- Height
Gauge for level crossing (For Clear span above 7.3 m Upto 12.2 M) details of structure &
foundations Drg. No. TI/DRG//CIV/HGAUGE/RDSO/00002/05/0.
At State Highway having Class-I road or TVU > 1 lakh)Standard plan – Height for
level crossing (For clear span upto 7.3m) details of structure & foundations Drg. No.
TI/DRG/CIV/HGAUGE/RDSO/00001/05/0
At Other roads (Class-II to IV) height gauges at level crossings upto 7.30 m span
Drg. No. RE/CIVIL/S/138-04 (Mod.-R1).
Dated 29.Jan 2015
Page 297 of 429
RVNL
4.
At Other roads (Class-II to IV) and TVU < 1 lakh Standard plan details of height
gauge for span 7.30m to 10.00m with Rail type for Location where TVU less than
1,00,000 Drg No. RE/CIVIL/S-148/2011 ( Mod-R1) with ISMB-225.
In case of non availability of ISMB-225, RDSO dwg with ISMB-250
TI/DRG/CIV/H.GAUG/RDSO/00001/14/0 DT 25/9/2014 may be used.
2.21 BONDING AND EARTHING:
(a) Bonding and earthing shall be done in accordance with the code of practice for bonding and
earthing for power supply installations as per RDSO specification No. ETI/PSI/120(2/91) with
A&C Slip No. 1 (10/93).
(b) LONGITUDINAL AND TRANSVERSE BONDING
Longitudinal and transverse bonding of tracks, bonding of structures including traction
structures to rails and associated earths shall be provided in accordance with the above code.
(c) TRACTION STRUCTURE BONDING
Every traction mast or structure shall be bonded to a non-track circuited rail unless it is
provided with a continuous earth wire or it is individually earthed by means of an earth station.
For general arrangement drawings, see the Annexure to these Technical Specifications.
(d) DOUBLE RAIL TRACK CIRCUIT
Where track circuits are provided on both rails, traction masts/structures shall not be bonded to
rails but shall be provided with an earth wire made of steel reinforced aluminium conductor
consisting of 6 strands of aluminium and one strand of steel each of 4.09 mm dia. ( RACCOON)
( conforming to IS:398 Pt. II/1976 or latest). The earth wire shall be run on traction masts or
structures. They shall be divided into different electrical sections not exceeding 1000m length.
The earth wire in each such section shall be connected at two traction structures, situated at a
distance not exceeding 250 m on either side of the mid-point of the section to two 10 Ohm,
earth stations which will be provided by the Contractor.
(e) STRUCTURE BOND IN AUDIO FREQUENCY TRACK CIRCUIT (AFTC) AREAS
(i) The structure bonds shall continue to be provided. However, earth wire is not required to
be provided.
(ii) The structure bonds shall be painted with ‘high build epoxy paint’ to RDSO Specification
No. M&C/PCN/111/2006.
2.22 LIGHTENING ARRESTORS: No lightening arrestors will be provided on the traction overhead
equipment.
2.23 PTFE TYPE SHORT NEUTRAL SECTION ASSEMBLY:
PTFE type short neutral section assembly shall consist of resin bonded fiber glass or equivalent)
insulators covered with either Teflon (or equivalent) with PTFE spacers (or similar) adequately
dimensioned and rated for the application. The insulators shall have suitable end fitting for
connections to the contact wire through end fitting. For smooth passage of pantograph without
any shock from contact wire to insulator and vice-versa, suitable runners preferably of stainless
steel shall be provided. The central position of the assembly along with arc trap shall be solidly
earthed as the latter with earth clamp is provided to trap any arc current caused by break of
contact between pantograph and live contact wire when it passes from contact wire to insulator.
The distance between arc trap and nearest line position shall be adjustable up to a maximum of
320mm. Suitable means of suspension of the components of the assembly from the catenary
conductor shall be provided. The complete assembly shall be as light as possible and so
constructed that adjustments of components can easily be made during erection and
Dated 29.Jan 2015
Page 298 of 429
RVNL
maintenance for ensuring smooth passage of pantograph. In the catenary conductor, resin
bonded fiber glass insulators with suitable covering shall be provided. The insulators shall have
suitable end fittings for connections to catenary wire through end fittings. The central portion
shall be solidly earthed.
The neutral section assembly shall be suitable for erection symmetrically on either side of the
cantilever bracket support with regulated or unregulated conventional/composite OHE where
one point each for suspension of catenary conductor and contact wire is available as also shown
in GA drawing under the Annexure to these Technical Specifications.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 299 of 429
Dated 29.Jan 2015
RVNL
Page 300 of 429
RVNL
CHAPTER: B-3
FOUNDATIONS
3.0 SCOPE:
This chapter deals with the design of foundations and anchor blocks for traction structures
carrying overhead equipment (including those on bridges), structures at switching stations and
booster stations and other concrete work. It also deals with the specifications for concrete.
3.1 Conformity with IRSOD-2004
While designing and casting the foundation special care should be taken for adhering to all the
latest provisions laid down in IRSOD-2004. Some of the important provisions are as under:
(i) Below and above Rail Level: Miniumum horizontal distance from centre of track to any structre
for Existing works and For New works or alteration to existing works as per Para 11(A),(B) of
A&C-15 of IRSOD-2004.
In case any infringement is detected at any stage of the project execution, such foundations are
liable to be rejected by RVNL not with standing any approval given or supervision done by
RVNL. Final responsibility for the work done lies with the contractor and he shall replace and recast all the rejected foundation and re-erect OHE (if required) free of cost.
3.2
DESIGN OF FOUNDATION:
(a)
SOIL PRESSURE
For design of foundations for traction structures carrying overhead equipment, the Contractor
shall determine the type and allowable bearing pressure of soil at suitable intervals and adopt
the type and size of foundations, suitable for particular locations with the help of the approved
employment schedules. In cases of particularly weak soil, the bearing pressure may have to
be determined for each location where so advised by the Engineer. Soil bearing pressure,
using SPT (falling weight equipment) should be determined generally for every 5 kilometer
interval or less wherever change of soil is encountered. In general, IS code of practice (IS
6403:1981 or latest) should be followed. In addition, at every 250 m the soil bearing pressure
should be determined by dial gauge type penetrometers. Dial gauge type penetrometers shall
also be made available by the Contractor at each foundation site so as to facilitate cross check
at each individual location.
For design of foundations for masts and gantries at switching stations and booster
stations, the Contractor shall determine the type and allowable bearing pressure of soil at the
locations of such stations and shall prepare designs for the foundations suitable for each
location to suite the bearing pressure of the soil in consultation with the Engineer.
(b)
GUIDING INFORMATION
Subject to para 3.2 (a) above, the following allowable bearing pressures may generally be
expected for various kinds of soil. The information is given for general guidance only.
(i)
Average good soil in banks and cutting
11,000kg/sq.m.
(ii)
Moorum soil in cutting
22,000kg/sqm
(iii)
New banks & bad soils in banks and cutting
5,500kg/sqm
(iv)
Poor soil
8000 kg/sqm
(v)
Black cotton soil-pure gravity foundation shall normally be adopted. However, under
reamed pile foundations may be adopted at the option of the Engineer in limited
locations for trial purpose. In the case of dry black cotton soil, the soil should be
subjected to a bearing pressure as close as possible but not exceeding 16,500 kg/sqm
the depth of the foundation block being not less than 2.8m. In case of wet black
Dated 29.Jan 2015
Page 301 of 429
RVNL
cotton soil, the soil should be subjected to a bearing pressure as close as possible but
not exceeding 8,000 kg/sqm.
In the case of hard rock, a hole should be blasted in the rock, or by means of any other
drilling and pneumatic method and the mast sealed into it with concrete.
(c)
STRUCTURES CARRYING OVER-HEAD EQUIPMENT
Foundations for traction structures carrying overhead equipment shall be either of the side
bearing, side gravity or new pure gravity type according to their location, formation of the
sub-grade and bearing pressure of the sol. In new filled up soil or cinder formation, pure
gravity sand-filled core foundations, or foundations with cast-in-site reinforced concrete piles,
or cantilever types foundation with counter-weights or guyed foundations may be adopted.
(d)
SUPPORT FOR OHE IN TUNNELS:
In the lined tunnels, stubs for supporting OHE cantilever assembly should be provided on
boyh sides of the tunnel opposite each other. This would facilitate restoration of OHE in the
event of damage to stubs on one side. [para18.15 ACTM]
(e)
ON BRIDGE PIERS
Complete design of foundations for traction structure on bridges to suit different locations and
local conditions will be furnished by the Contractor. Core holes for erecting masts on bridges
should be provided as per RDSO/RE standard drawing on both sides of all the piers. Holes on
the piers which are not used for foundation should be filled with dry sand covered with
concrete slab [para 18.16 ACTM].
(f)
TYPICAL DESIGN
Typical design and drawings of side bearing and new pure gravity and side gravity type
foundations are included in the drawings listed in the Annexure to these Technical
Specifications. Employment schedules for standard foundations for traction structures for
various locations and types are also included in the drawings listed in the Annexure to these
Technical Specifications.
(g)
SPECIAL FOUNDATIONS
In the case of foundations at locations not covered by the employment schedules furnished by
the Engineer, the Contractor shall prepare special designs and furnish full design calculations
justifying the choice of the type of foundations for such locations. In black cotton soil
especially pile foundations of under reamed type as per RDSO’s standard designs (Reference
RDSO’S Drawings No. ETI/C/0062 MOD. “B”) or any other approved design may have to be
cast at limited locations for trial purpose. The Contractor may furnish the technical details of
alternative design, construction methods proposed to be adopted and their previous
background/experience if any. The decision of the Engineer with regard to feasibility and
suitability of adoption of the alternative design for each type of foundation will be final.
(h)
MASTS & FABRICATED STRUCTURES AT SWITCHING STATIONS
Foundations for the masts of gantries at switching stations shall be of the pure gravity type,
the base of which shall rest on consolidated soil.
(i)
FENCING POSTS
Foundation for fencing posts shall rest on consolidated soil if the depth of unconsolidated soil is
less than 1.5 m below the datum level and shall be rectangular parallel piped in shape. If the
depth of unconsolidated soil is more than 1.5 m the foundation block shall rest on reinforced
concrete piles cast-in-site or reinforced concrete foundation may be adopted as desired by the
Engineer.
Dated 29.Jan 2015
Page 302 of 429
RVNL
(j)
EQUIPMENT PEDESTALS
Pedestals for interrupters and LT supply transformers where required, shall be of mass
concrete with the base resting on consolidated soil.
(k)
CABLE TRENCHES
The cable trench shall rest on original ground if the depth of unconsolidated soil is less than
0.5 m. If the depth of the unconsolidated soil is more than 0.5m, the cable trench shall be
made of reinforced cement concrete of approved design supported at suitable intervals on
concrete pillars.
3.3
CONCRETE:
(a) Concrete for foundations shall be nominal mix of following grade:
Foundation
concrete grade
Grouting and Muff
concrete grade
1
In normal soil- where concrete is
M-10
M-15
2
(a) in contact or buried under nonaggressive soil/ground water
(b) exposed to coastal environment
M-15
M-20
M-15
M-20
M-20
M-20
3
Soft rock with bearing capacity 45000
kg per sqm and Hard rock with bearing
capacity 90000 kg per sqm where
concrete is
(a) buried under
soil/ground water
4
non
aggressive
(b) exposed to coastal environment
(c) For cable trenches at switching stations/TSS, M-15 grade concrete shall be used.
Main Provisions of IS:456-2000 or Latest
TABLE -9: PROPORTIONS FOR NOMINAL MIX CONCRETE
(CLAUSE 9.3 AND 9.3.1)
Grade
of Total Quantity of dry aggregate by Proportion
of
water
mass per 50 kg. of cement, to be fine/coarse
concrete
taken as the sum of the individual aggregate
(by
masses of the fine and coarse mass)
aggregates kg max.
1
2
3
M5
M7.5
M10
M15
M20
Dated 29.Jan 2015
Kg
800
625
480
330
250
Generally 1:2 but
subject
to
an
upper
limit
of
1:1.5 and a lower
limit of 1:2.5
Quantity
of
water per 50
kg. of cement
max.
4
Litres
60
45
34
32
30
Page 303 of 429
RVNL
NOTE: The proportions of the fine to coarse aggregate should be adjusted from upper limit to
lower limit progressively as the grading of the fine aggregates becomes finer and the maximum
size of coarse aggregate becomes larger. Graded coarse aggregate shall be used.
Example:
For an average grading of the fine aggregate (that is zone II of Table 4 of IS: 383-1970* or
latest) the proportions shall be 1:1.5, 1:2 and 1:2.5 for maximum size of aggregate 10mm,
20mm and 40 mm respectively.
* Specification for coarse and fine aggregates from natural sources for concrete (second
revision).
“Volume Batching may be allowed only where weight batching is not practicable and provided
accurate bulk densities of materials to be actually used in concrete have earlier been
established. The quantities of fine and coarse aggregate (not cement) may be determined by
volume. If the fine aggregate is moist and volume batching is adopted. Allowance shall be made
for bulking in accordance with IS: 2386 (Part-III-1963 or latest) the mass volume relationship
should be checked as frequently as necessary, the frequency for the given job being determined
by Engineer to ensure that the grading is maintained”.
In judging the acceptability of the materials, quality of concrete and the method of work, the
Engineer will generally observe the provisions of the “ Indian Standard Code of Practice for Plain
and Reinforced Concrete, IS: 456-2000 or latest. The crushing strength of concrete shall not be
less than the limits given below (as per IS456-2000 or latest Table-2 Grade of Concrete):
Specified Characteristic Compressive Strength of 15 cm Cubes at 28 days
Grade of Concrete
(a) M10
(b) M15
(c) M20
At 28 days age
10 N/mm2
15 N/mm2
20 N/mm2
NOTE: (a) Test specimen of works tests shall be taken at the site of work from mixture
of concrete ready for pouring into the foundation hole. All tests shall be
carried out in accordance with IS: 516-1959 or its latest version. The
sample of concrete from which test specimens are made shall be
representative of the entire batch.
(b) Age is reckoned from the day of casting.
Specified Characteristic Compressive Strength of 15 cm Cubes at 28 days
The indicative Compressive Strength of 15 cm Cubes at 7 days shall normally be 67% of
same value at 28 days.
3.5
3.6
SIZE AND GRADING OF AGGREGATES
The graded coarse aggregate 40 mm nominal size (table 2 of IS: 383-1970) shall be used for
foundation. A coarse aggregate for grouting, muffs, cable trenches and embedding shall be of
20mm graded nominal size as per table of IS: 383-1970 ( specification for coarse and fine
aggregate from natural sources for concrete).
Fine aggregate shall be graded from 10 mm downwards. The maximum size of aggregate for
under reamed pile foundation shall be 20 mm graded nominal size. In case river sand is not
available easily and nearby, quarry dust of appropriate grading may be used without affecting
strength of the concrete and with prior approval of competent authority.
SAND CORED FOUNDATIONS:
Dated 29.Jan 2015
Page 304 of 429
RVNL
After erection of masts in sand-cored foundations, the core hole of the foundation blocks shall
be filled with dried sand and covered with a layer of bitumen of 80 mm thickness below 30
mm from top level of the block. A hemispherical shaped muff shall be provided on such
foundations in lieu of standard type.
3.7
SINKING OF CONCRETE SHELLS:
Where the water-level is high, one or more sections of reinforced concrete shells may have to
be sunk before casting concrete. The size of each of shell shall be 1200 mm outside dia x 50
mm thick x 600 mm high reinforced with 6mm (1/4”) dia rods spaced 150 mm apart, both
longitudinally and circumferentially, the concrete shall be of grade M10 as per provisions of
para 3.3.
3.8
CEMENT:
The cement to be used in the construction of foundations, RCC structures shall be ordinary
Portland cement of 43 grade (conforming to IS-8112) or 53 grade (conforming to IS-12269)
as approved by RVNL based on requirement and availability.
3.9
SELECTION OF FOUNDATIONS(Ref. ACTMVol-II Part-II para 6.5.3 to 6.5.7)
Side bearing foundations are used for masts where the soil bearing capacity is 11000 or
21500 kgf/m sq and 300 mm wide shoulder is available on the banks. However, for overlap
iner masts and masts on the inside of curves, 550 mm wide shoulder is necessary ( Typical
Drg No. ETI/C/0023).
(a) New pure gravity foundations may be used for masts where soil bearing capacity is 5500,
8000 and 11000 kgf/m sq. or where adequate shoulder width as mentioned in above para is
not available. In such cases, it should be ensured that foundation is not exposed.
(b) Side gravity foundations may be used for masts where soil bearing capacity is 8000 and
11000 kgf/m sq or adequate shoulder width is not available. No portion of foundation should
be exposed.
(c) Foundations in black Cotton soil
(i) The foundation of the black cotton should be done preferably in dry season i.e. from
November to May. Excavations should be avoided as far as possible in case of unexpected
rains in dry season also.
(ii) In black cotton soils, WBC and NBC type of foundations are used. Primarily WBC
foundations are to be adopted where swelling/ shrinkage is not expected to take place at the
foundation level and NBC foundations have to be provided where swelling/ shrinkage is
expected to occur.
(iii) The safe bearing capacity should be determined in accordance with IS: 6403 latest.
(iv) When in doubt regarding classification BC soil as to dry or wet, it is preferable to make
NBC type foundation.
3.10 Where foundations are constructed on the slope of banks, the foundations should be so
located that generally no part of it is exposed. The top of foundations may then be brought to
the desired levels (rail level -500 mm ) by providing a super block of length and breadth equal
to the top dimension of foundation. The increase in bending moment due to increased setting
distance should be calculated and the designation of foundation to allow for this BM should be
selected.
Dated 29.Jan 2015
Page 305 of 429
RVNL
3.11 The top of foundation should be 50-100 mm above the surrounding ground level. The
length of mast below rail level should be minimum 1850 mm for regulated OHE and 1750 mm
for un-regulated OHE. A 1350 mm embedment of mast in concrete is necessary. Concrete
cushion of 150 mm below the bottom of mast is also necessary. Where necessary, these may
be achieved by providing a supper block of length and width equal to the top dimension of
foundation. However, portion of existing pure gravity foundations corresponding to a depth of
500 mm of embankment having slope of 1:2 may be exposed.(As per ACTM para no 6.5.9 volII part-II).
Giving due consideration to the above, the most economical type of foundation should be
adopted.
3.12 VOLUME CHARTS:
The foundation bending moment codes (FBM) for each location are obtained from the mast
employment schedules or by actual calculations. Bearing capacity of the soil is determined at
the outer toe of the bottom of foundation at a representative number of locations. Where
foundations are placed on the slope of banks due to increase in setting distance, the bearing
capacity of the soil should be determined on the slope. Bearing capacity of the soil should be
determined thus would be considerably less than those determined on the top of foundation.
Selection of the type and size of foundation is done from volume chart based on shoulder
width and the extent of projection above ground level as detailed below.
3.13 Type of foundations
The following types of foundations are used for OHE mast and portals:
1. For Masts:
(i) a) Side bearing ( Type B)
b) Side gravity ( Type:BG)
c)Pure gravity for black cotton soil
(type: WBC)
(ii) New pure gravity(Type:NG)
(iii) NBC type foundation for dry black
cotton soil (16500 &11000 kgf/m
sq) 3.0 m depth
iv) New pure gravity for different soil
and site conditions( 500 mm
exposed ) (type: NG or SPL)
v) New pure gravity for black cotton
soil (for 8000 kgf/m sq soil
pressure, 2.5 m depth (Type :
NBC)
vi) Foundations in soft rock ( bearing
capacity 45000 kgf/m sq)
vii)
Foundations
in
hard
rock
(bearingcapacity 90,000
kgf/m
sq.)
2. For Portals:
(i) In ordinary soil
(ii) In dry black cotton soil
Dated 29.Jan 2015
Drg. No. TI/DRG/CIV/FND /RDSO/ 00001/04/0
Sheet 1 Mod. B for 2.8 implantation or
TI/DRG/CIV/FND/RDSO/00001/12 /0 for sheet
1 for 2.9 m implantation
-do- sheet 2
-do- sheet 3
-do- sheet 4
-do- sheet 5
Drg. No. ETI/C/0059 Mod C
Drg. No. ETI/C/0060 Mod D
Drg. No. ETI/C/0005/68
Drg. No. ETI/C/0063
Page 306 of 429
RVNL
Note: (i) In the cases of OHE foundations in deep rock cutting, the foundation should be below the
drain.
(ii) For all future construction of pure gravity foundations drawing No. Drg. No.
TI/DRG/CIV/FND/RDSO/00001/04/0 Mod. B or TI/DRG/CIV/FND/RDSO/00001 /12/0 for 2.9 m
implantation only shall be followed.
3.14
(a)
LAYING OF FOUNDATIONS:
The Contractor shall carry out soil pressure tests in accordance with methods approved by the
Engineer to determine permissible bearing pressure of various representative types of soils in
the presence of the Engineer during site pegging. He shall adopt only those values that are
accepted by the Engineer for the design of foundations.
(b)
LOCATION
The location of each foundation or anchor block shall be set out correctly in accordance with
the approved structure/cross-section drawings or foundation layout drawings, as the case may
be, in the presence of the Engineer.
(c)
METHOD OF INSTALLATION
The contractor shall adopt mechanized method (concrete mixer) for installation of foundation
normally. In exceptional circumstances such as mechanical breakdown of mixer, work in
difficult approaches etc, the contractor may adopt manual method of mixing with the
approval of the Engineer subject to adding 10% extra cement in terms of CPWD
specifications for concrete work. When manual mixing is adopted, it shall be carried out on
water tight plateform. The contractor may erect traction masts or structures in the same
operation as casting of foundations or erect them subsequently in core holes left in
foundation blocks and grout them separately. In any case, the method of casting of
foundation blocks and erection of masts or structures shall be subject to the approval of the
Engineer.
(d)
EXCAVATION
Normally, excavation of soil for foundations or anchor blocks along side the tracks may be
done up to the length of 1 to 1.2 m and depth of 0.8 to 1m without shoring, provided the
excavated hole is concreted immediately and not left overnight. Shoring shall otherwise be
done unless the hole is re-villed with soil and tamped. In case the length of excavation is 1 to
1.2 m and depth of excavation for foundations and anchor blocks alongside the tracks is more
than 0.8 to 1m, the excavation may be undertaken only after certification by the Engineer to
be safe and concrete is cast on the same day. Shoring shall be done to the satisfaction of the
Engineer, if the excavated hole is left overnight. All water logged locations will come under the
purview of this para. In poor soil or ash banks, no excavation shall be done without adequate
shoring and piling, For large foundations and water logged locations shoring shall be done in
accordance with drawings submitted by the Contractor and approved by the Engineer. Shoring
/shuttering of the pits should be provided effectively to the satisfaction of the Engineer. Core
hole covers should be provided promptly on casting of foundation (within 48 hours) and their
edges cemented to the foundation blocks. Prior to doing so, water should be filled in the core
hole so as to assist in curing. The date of casting should be inscribed on the foundation block.
In case of platform areas and Level crossings, the core holes should be filled with sand before
provision of core hole covers. So as to prevent any injury to rail users If the core hole cover
gets damaged or is displaced. The track ballast should be restored to its original form
promptly after casting of the foundation block. The excavated earth should be removed well
clear of the area so as to avoid any mixing up with the track ballast or any obstruction to the
track drains. In case of cuttings, the earth should be thrown well away from the shoulders so
that there is no risk of its flowing back to the drain during the rains.
(e)
CONCRETING
All concreting or grouting shall be done in accordance with para 3.3 with coarse aggregate
grade for the purpose specified in para 3.5. The concrete shall be poured and compacted
Dated 29.Jan 2015
Page 307 of 429
RVNL
properly with Vibrator in general. However in rare cases, manual tamping may be adopted
with approval of the Engineer. The contractor shall arrange to provide concrete testing
samples for tests at specified intervals or as and when required by the Engineer, to determine
crushing strength after 7 days and 28 days curing as required. Testing shall be arranged by
the contractor at his own cost. Spare vibrator shall always be kept at site of casting of
foundation for use in emergency.
(f)
MUFFS
All anchor blocks and foundations of structures carrying overhead equipment shall be provided
with concrete muffs. The top of these muffs shall be above the level of ground the track
formation and of adequate height of not less than 15 cm to afford reasonable protection
during rainy weather. Muffs may be installed at the same time masts are grouted or after the
mast/ structure is loaded with equipment. The foundations of structures for switching stations
need not, however, be provided with muffs. The top of such foundations shall be given a slope
of 1 in 50 towards the edge to ensure that water does not collect at the base of the structure
of the frame work of the equipment.
(g)
Suitable grooves or niches shall be provided in the foundation blocks, wherever required, at
the time of casting, to enable embedment of earth strips etc. to avoid the necessity of
chipping of concrete.
(g) Conduits for cables should be embedded in the foundation blocks, wherever required, to avoid
subsequent chipping off and breaking of the foundation blocks.
Shuttering
Suitable iron shuttering of proper dimensions as per type of foundation shall be used while
casting the foundations in the exposed portions or any where required as per the site
conditions so as to get proper shape and finish.
(i)
3.15 MOIST CURING
Exposed surfaces of concrete shall be kept continuously in damp or wet condition by ponding
or by covering with a layer of sacking, canvas, hessian or similar material and kept constantly
wet for atleast seven days from the date of placing concrete in case of ordinary Portland
cement.
3.16
SAMPLING AND TESTING OF CONCRETE:
Sampling and Testing of concrete shall be done generally as per CORE letter No:
EL/CORE/Policy/system Improvement/0272/003 dated 26/2/2003. The provisions are
summarized as under:
(a)
GRADING OF AGGREGATES:
Graded course aggregate should be used in all type of foundation work. Normal size of graded
aggregate 40mm should be used for foundation and 20mm for muffing grouting etc conforming
to the requirements as per table-2 of IS :383-1970 which is reproduced below :-
GRADED COARSE AGGREGATE
Dated 29.Jan 2015
Page 308 of 429
RVNL
IS Sieve Designation
% passing for graded aggregate nominal size
40mm
20mm
100
80 mm
40 mm
20 mm
16 mm
10 mm
-
95 to 100
100
30 to 70
95 to 100
-
-
10 to 35
25 to 55
(b) SAMPLING & TESTING PROCEDURE OF AGGREGATES:
Sieve analysis of representative sample of ballast selected randomly from different parts of stock
e.g. slope, top & inside be done. The sample for sieving shall be prepared from larger sample either
by quartering or by means of a sample divider. The weight of the sample shall be not less than 50
Kg for 40mm or 20mm size aggregate (Table No. II of IS -2386(Pt.I)-1963). The air dry sample shall
be weighted and sieved successively on the appropriate sieves starting with the largest. Care
should be taken to ensure that the sieves are clean before use. A material passing register should
be maintained for the aggregates and necessary test results should be recorded in that in the
Performa given under items 3.0 & 4.0 below.
(c) MECHANICAL TESTING OF COARSE AGGREGATES
The coarse aggregate should be tested for its mechanical properties as per procedures laid
down in IS:2386 Pt.IV, from each source and after getting satisfactory test results only , the source
should be approved by an officers for regular supply of the aggregate. The test results should
conform to IS: 2386 Pt IV. The test record should be maintained in the material passing register as
per the Performa given below:
The record for Mechanical Testing of Coarse aggregate: three samples from every supply source:
Sample
Source of
Crushing
Date of
No.
Supply.
Strength
Testing
Result
Tested
By
Initial of
SuperVisor.
Counter
Signature
of officer.
(d) SIEVE ANALYSIS
Sample as detailed vide Para 2.0 above should be drawn from every supply lot sieve analysis should
be done and recorded as per the format given below. It satisfies the parameters given under Para
1.0 above, then only the same may be allowed for use. The test results should be maintained in the
material passing register.
Record for Sieve Testing of Coarse aggregate: three samples from every supply lot:
Dated 29.Jan 2015
Page 309 of 429
RVNL
Date of
Receipt.
Source of
Supply.
Sample
Location.
Date of
Testing
Result
Tested By
Initial of
Supervisor
Counter
Signature
of officer.
(e) Testing of Compresssive Strength (Cube Testing)
One sample of three cubes should be cast in every two track kilometers or 50 cu meter
of concrete (whichever is early) and they should be subjected to compressive strength test
after a curing period of 7 days and 28 days as approved by the officer. The test should be carried
out in accordance with IS 516-1959 or latest and test results should conform to IS 456-1978
(Table-2 for 28 days). The test results should be maintained in the profarma given below:
Test
cube
No.
Sample
Location
Date of
Casting
Date of
Testing
Test Result
Sample1
Samp 2
Samp 3
Remarks
Tested
by
Initial
of
Sup
Counter
Sig of
officer
(f)
ACCEPTANCE CRITERIA
Acceptance criteria for test sample shall be as per clause 16 of IS: 456:2000 or latest. In case test
results of cube testing do not conform to IS-456 as detailed above, detailed investigation of
foundations including tests like rebound hammer and core cutting shall be done as deemed fit by
RVNL for final acceptance or rejection of the foundations. After detail investigations, foundations
which are finally rejected by the Employer, the contractor shall re-cast all the rejected foundations
free of cost as per directions of the Employer. The core of the rejected foundations shall be filled with
the soil so as to level the surrounding ground properly. OHE masts if erected shall be retrieved free of
cost by the contractor and used elsewhere.
3.17 SUPERVISION:
Constant and strict supervision of all the items of the construction is necessary during the progress of
the work, including the proportioning and mixing of the concrete. Supervision is also of extreme
importance to check the reinforcement and its placing before being covered. Before any important
operation, such as concrete or stripping of the form work is started, adequate notice shall be given to
the construction supervisor.
---------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 310 of 429
RVNL
CHAPTER: B-4
OHE STRUCTURES
4.1
4.2
SCOPE:
This chapter deals with the design of steel structures and steel work for overhead equipment,
switching stations, booster transformer stations and LT supply transformer stations and the
specification for steel and pre-stressed concrete trial mast.
TYPES:
Structures and gantries may consist of any or more of the following types:
(i) Broad flange beams
(ii) Rolled steel joists ( I section).
(iii) Fabricated steel Structures ( Welded/bolted).
Structure/ uprights shall generally be embedded in concrete foundation blocks in special cases
Structures may be secured by means of holding down bolts.
4.3
DESIGN:
(a)
STEEL STRUCTURES
Designs for steel structures shall, except where otherwise provided, comply with the
Indian standard code of practice for use of structural steel in General Building ConstructionIS: 800-1984. The thickness of smallest steel sections used shall be 5 mm for galvanized
members.
(b)
All the steel structures and small part steel for carrying overhead equipment are to be
fully galvanized after drilling and fabrication as per specification No. ETI/OHE/13 (4/84) with
A&C Slip No. 1 to 3.
4.4
CANTILEVER MASTS:
(a) LOAD
For purposes of design the worst possible combination of all loads that may occur shall be
considered.
The load shall include the following (weights to be assumed for design of
structures are shown against important items).
(i)
Weight of overhead equipment (1.60 kg/ meter for each conventional and 1.32
kg/metre fore ach composite OHE).
(ii)
Weight of bracket supporting the overhead equipment ( 60 kg/ normal bracket)
(iii) Weight of a man (60 kg)
(iv) Weight of an earth wire (0.32 kg/metre).
(v)
Weight of feeder, return conductor or other special equipment wherever they occur.
(vi) The effect of eccentricity of vertical and horizontal loads on the bracket due to
variation in temperature.
(vii) Wind loads perpendicular and parallel to the track. The wind pressure adopted shall
be as specified in the Bidding Document.
(viii) Radial forces on the mast, due to stagger, curvature, anchorage etc.
(ix)
Weight of the mast itself.
(x)
Any other load or loads that may occur due to special location of the structure.
(b) REVERSE DEFLECTION
Notwithstanding the provisions contained in IS: 800-1984 or latest referred to in para 4.3
above regarding permissible deflection, the following shall apply.
Dated 29.Jan 2015
Page 311 of 429
RVNL
(i) The deflection at the top of the mast due to permanent loads shall not exceed 8 cm and
the mast shall be so erected that it stays reasonably vertical after application of permanent
loads.
(ii) The additional deflection under maximum wind pressure shall not exceed 8 cm at the level
of the contact wire.
(iii) All traction masts and structures shall be erected with the correct reverse deflection so
that they become reasonably vertical after they are loaded.
(c)
TORSION
The torsional rotation of the mast due to permanent loads shall not exceed 0.1 radian.
(d)
TYPICAL DESIGN
The typical design of a traction mast is included in the set of standard drawings listed in the
Annexure to these Technical Specifications. Employment schedules for standard masts for
various locations and types are included in the standard drawings listed in the Annexure to
these Technical Specifications to enable selection of suitable type for different locations and
local conditions.
4.5
ANCHOR MASTS:
(a) Masts at which overhead equipment will be anchored will be anchored shall also normally be of
the same type as those in other locations. Anchor masts shall normally be provided with
suitable guys but struts may be permitted in special cases.
(b) DWARF MASTS
At certain locations where due to local conditions it is not feasible to anchor the guy rod on a
foundation block in the ground, a dwarf mast shll be used in accordance with approved designs.
4.6 HEAD SPANS ( See paras 2.13 and 5.16)
(a) LOAD
The loads to be considered shall be as detailed in para 4.4 (a) as far as applicable and at their
worst combination.
(b) SAG FOR HEAD SPAN WIRE
The sag of the head span wire shall be approx. on-tenth (1/10) of the span.
(d)
MINIMUM TENSION IN CROSS SPAN & STEADY SPAN WIRES
For purpose of design, a minimum tension of 200 kg, shall be ensured in the span wires for
worst combination of temperature and wind load.
(e)
DEFLECTION OF MAST
Deflection at the top of the mast or structure shall be limited to one eightieth (1/80th) of its
height above foundation.
(e)
TYPICAL DESIGN
Typical design for head span mast carrying overhead equipment for 4 tracks will be furnished
by the contractor.
Dated 29.Jan 2015
Page 312 of 429
4.7
RVNL
PORTALS: (SEE 2.13)
(a) GENERAL
Portals shall be of fabricated steel of standard types of Engineer’s designs. The most
important designs are covered by Drawings listed in the Annexure to these Technical
Specifications.
(b) LOAD
The load shall be as detailed in para 4.4 (a) as applicable.
4.8
a)
STRUCTURES ON BRIDGES:
The structure may be either cantilever masts or portals (hinged or fixed at base) depending
on the type and condition of bridge pier capping. As far as possible cantilever masts grouted
in foundations blocks on pier will be used. Where this is not possible cantilever masts with
holding down bolts or suitable portals (hinged or fixed at the base) may be adopted.
b)
Designs of Structures on bridges to suit different locations and local conditions will be
furnished by the contractor to the Engineer.
4.9
SPECIAL STRUCTURES:
In the case of structures at locations not covered by the employment schedules, the
contractor shall furnish complete design calculations justifying the choice of the type of
structures for such locations.
4.10 SETTING OF STRUCTURES:
a) The setting is the distance from the centre line of the track, on straight or curved track to the
face of the mast/ structure.
b)
On straight track and outside of curve, the standard setting shall be as per the relevant
drawing included in the Annexure to these Technical Specifications. Minimum setting of
structures shall be 2.9 m plus curve allowance as required. Whenever this distance can not be
provided, specific approval of Engineer shall be obtained before erection. The setting of portal
upright, overlap/turn-out structures, anchoring structures and other masts carrying more than
one OHE will be 3.0 m wherever possible.
c)
EXTRA CLEARANCE ON CURVES
The minimum setting of structures on curves shall be determined by adding to the above
minimum figures an extra clearance indicated in the table included in the set of standard
drawings listed in the Annexure to these Technical Specifications.
d)
STRUCTURES WITH COUNTER WIEIGHTS
In case of structures carrying counter-weight assemblies, the term “ setting” shall refer to the
minimum distance of the counter-weight from the track center under the worst conditions of
wind.
e) STRUCTURES ON PLATFORM
The setting of structures on platform shall be not less than 4.75 m.
f)
g)
STRUCTURES NEAR SIGNALS
In the vicinity of signals, structures shall be located in a manner which shall ensure good
visibility where necessary, the setting shall be increased as per the relevant drawing included
in the Annexure to these Technical Specifications.
STRUCTURES NEAR PLATFORM
The setting of structures on platform shall be not less than 4.75m.
Dated 29.Jan 2015
Page 313 of 429
h)
4.11
(a)
RVNL
PAINTING OF SETTING DISTANCE OF STRUCTURES
The value of setting of masts/ structures shall be painted on each mast/ structure. The figure
shall be 25 mm in size in black on yellow background. In addition, the track level shall also be
marked on the mast/structure by a horizontal red painted stroke.
NUMBERING OF STRUCTURES CARRYING OF STRUCTURES CARRYING OVERHEAD
EQUIPMENT:
All structures shall be numbered in accordance with the numbering given in the approved
overhead equipment layout plans. Enameled number plate shall be provided on each mast or
structure as per approved designs. Number plates at specific locatons/all locatiions should be
retro reflective type as per Rly Board/RDSO guidelines.
SIGMA BOARDS FOR EASY IDENTIFICATION OF STOP SIGNALS DURING FOGGY
WEATHER
Sigma Boards for easy identification of stop signals during foggy weather shall be
provided as per RDSO specification No. TI/OHE/ 33A (Revision-8) and Drg. No.
TI/DRG/OHE/PLTBRD/RDSO/00036/12/0
circulated
vide
Railway
Board
letter
No.
2001/Elect.(G)/170/1Pt. dated 07.05.12.
(b) Warning Boards, Danger Boards and other Signages:
All the equipments like isolators, masts, DJ boards, EMU/MEMU boards and panto raise/lower
boards etc shall be numbered and provided as per RDSO standard with enamelled/retro
reflective plates. Similarly separate boards for MEMU shall be provided as per prescribed
standard.
Danger boards at all LC gates, stations, cabins, TSS, switching posts shall be provided at
prominent places cautioning the public. Similarly first aid chart shall also be displayed as per
standard at these places.
4.12
STEEL WORK FOR SWITCHING STATIONS AND GANTRIES:
(a) HORIZONTAL MEMBERS OF GANTRY
The horizontal member of the main as well as the auxiliary gantry carrying isolator switches,
insulators, potential transformers etc. shall be made from steel sections viz. channels, angles
and small joists, single or fabricated. They shall preferably be attached to masts by means of
clamps to avoid drilling of masts sections.
(b)
For purpose of design all possible loads which may occur in the worst combination shall be
considered. The loads shall include the followings:(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
Dated 29.Jan 2015
Weight of insulators, instrument transformers, isolator switches, bus- bars,
and their accessories.
Loads caused by feeders, along and across tracks, return feeders etc.
Loads caused by anchorage due to guying of anchored masts (where
applicable).
Pull or push on the structures due to anchorage and radial tension (where
applicable).
Wind load on the different structures, conductors and equipment.
Weight of men working on the structures.
Weight of structure itself.
Erection loads.
Any other load or loads which may occur due to special equipment wherever
they occur.
Page 314 of 429
(c)
RVNL
TENSION OF CONDUCTORS
For purpose of designs the maximum tension of different conductors, without wind load, shall
normally be as under:(i)
Maximum tension in the cross feeders at switching stations under worst conditions:(1)
(2)
For spans less than 18m……….100 kgf
For spans more than 18m…....200 kgf.
(ii) Maximum tension in longitudinal feeders running parallel to the track at the switching
stations under worst conditions 150 kgf.
(iii) Tension in anchored overhead equipment in case of sectioning and paralleling stations2000 kgf.
(d)
DEFLECTION OF GANTRY MASTS
Deflection under the permanent loads (at an average temperature of 35 deg. C without wind)
at the top of the fabricated structures of mast shall be limited to one eightieth (1/80) of its
(e)
Masts of the gantry at which feeder or overhead equipment will be anchored at the switching
stations shall normally be provided with suitable guys, but struts shall not be permitted.
(f)
CHAIRS AND BRACKENTS
Chairs, brackets and supporting steel work carrying potential transformers, lightning
arrestors, insulators, etc. shall be made of fabricated steel and shall be mounted on the main
auxiliary gantry preferably by means of clamps to avoid drilling of mast sections.
(g)
UPRIGHTS AND FENCING
Uprights carrying operating handles of isolators and fencing posts shall be made from steel
sections, viz. channels, angles or small joists, either single or fabricated.
STEEL
Steel conforming to IS:2062-1992 or latest shall be used for all fabricated steel work.
(h)
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 315 of 429
Dated 29.Jan 2015
RVNL
Page 316 of 429
RVNL
CHAPTER: B-5
EQUIPMENTS, COMPONENTS AND MATERIALS
-OHE & SWITCHING STATIONS
5.1
GENERAL:
This chapter deals with the details and specifications of the equipment, components and
materials to be used for traction overhead equipment, switching stations, booster transformer
stations and LT supply transformer stations.
5.2
COMPLIANCE WITH STANDARD SPECIFICATION:
In the technical specifications of equipments, components and materials, references are made
to the following standard specifications:
(i) International Electro Technical Commission (abbreviated as IEC)
(ii) British Standards ( abbreviated as BS)
(iii) Bureau of Indian Standards ( abbreviated as IS)
5.3
5.4
publications.
QUALITY ASSURANCE:
The provisions of quality assurance will apply, including facilities to be provided by the
manufacturer.
INTER CHANGEABILITY:
All equipments, components and fittings shall be inter-changeable and supplies shall be in
accordance with the Engineer’s designs unless otherwise specifically approved by him.
Components such as fuses, indication lamps etc. should be replaceable with substitutes
available indigenously, as far as possible.
5.5
TECHNICAL SPECIFICATIONS:
The technical specifications included in Annexure-2 to these specifications will govern the supply
and testing of important materials, components and equipments.
5.6
NOMENCLATURE AND MARKING:
(a) All components and fittings shall bear the respective identification number and a mark to
identify the source of supply except in the case of galvanized tubes, bolts and nuts and /or
any other fittings as may be agreed to by the Engineer.
(b) In case of insulators, galvanized steel tubes, stainless steel wire rope and conductors, name of
manufacturer shall be specified in “ As Erected” drawings for identification.
5.7
STEEL WORK AND PROTECTION AGAINST RUST:
(a) GALVANISING
All ferrous materials and fittings shall be hot dip galvanized according to the specification
ETI/OHE/13(4/84) with A&C slip No. 1 to 3
Dated 29.Jan 2015
Page 317 of 429
RVNL
(b) PAINTING
Some components or parts may, with the approval of the Engineer, be protected only by paint
and parts so protected shall be given two coats of composite Aluminium primer and two coats
of Aluminium paint. The second coat of Aluminium paint shall be applied after erection.
(c)
5.8
RECTIFICATION AT SITE
In case of modifications which would damage the protective coat, repairs to such damage would
be allowed only in exceptional circumstances. The part damaged shall be protected in
accordance with the method indicated in specification ETI/OHE/13(4/84) with A&C slip No. 1 to
3 or any other method approved by the Engineer. The Contractor shall in such cases obtain
prior permission from the Engineer before carrying out repairs.
BRACKET ASSEMBLY COMPONENTS: ( See para 2.14)
(a) ARRANGEMENT FOR NORMAL OHE
The arrangement of the different fittings and structural components of bracket assemblies are
shown in drawings listed in the Annexure to these Technical Specifications. The employment
schedule of bracket will be furnished by the Contractor.
(b) BRACKET
The bracket tubes shall be of seamless cold drawn or electr4ic resistance weld steel complying
with ETI/OHE/11 (5/89) with an insulator near the support. The length of the tubes shall be
such that there is a free length of about 200 mm beyond the catenary suspension bracket to
facilitate adjustment during track maintenance (see para 7.9 (b).
Ensure projection of RT at pull off i. e. –ve stagger location to be beyond the vertical plane of
the contact wire as per RDSO drawing No. ETI/OHE/G/02106 Rev ‘C’.
The Raised Register Arm Clamp conforming to RDSO drawings ETI/OHE/P/1370-1, Revision-‘E’
or latest shall only be used.
Gap between mast fitting for hook insulators & top of the mast should be as per drawing no.
RE/33/G/0001.
(c) TUBULAR STAY ARM
Steel tubes with adjustable steel rods shall be used for tubular stay arm of all bracket
assemblies.
(d) REGISTER ARM
The register arm shall be electrical resistance weld or cold drawn steel tubes of proper
dimensions and duly formed. It shall be suspended by a dropper from the catenary suspension
clamp/bracket tube. A hook and eye arrangement shall be used at the bracket end to permit
free movement in every direction.
(e) STEADY ARM
The steady arm shall normally be fitted in all assemblies for overhead equipment in running.
The steady arm shall be of light alloy BFB section arranged to work always in tension in
accordance with ETI/OHE/21(9/74). Steady arms of secondary tracks may be of solid
galvanized steel rodding. The contact wire shall be fixed by a simple swivel clip without
threaded parts. Steady arms shall normally be 1.0m long but for special locations such as
turnouts, diamond crossing etc, the steady arms shall be longer as indicated in the relevant
drawings listed in the Annexure to these Technical specifications.
Bent steady arms of aluminium alloy tube conforming to Spec. ETI/OHE/21 (9/74) shall be used
for neutral section overlap and in the central mast of a 4 span insulated overlap.
Dated 29.Jan 2015
Page 318 of 429
RVNL
(f) BRACKET FOR UNREGULATED TRAMWAY TYPE EQUIPMENT
Brackets provided on cantilever masts for tramway type unregulated equipment shall normally
span two tracks and the contact wires carried on V-type clamps suspended from a san wire. The
span wire shall be provided with a turn buckle at only one end.
5.9
5.10
Use of Forged OHE Fittings:
Wherever applicable, forged fittings shall be used as per RDSO guidelines vide letter No:
TI/OHE/FTGFE/12 dated 03/09/2012, 13/7/2012 including subsequent letters. As on date the
list of these fittings is :Register arm hook top, Register arm hook bottom, Large Register arm
hook top , Large Register arm hook bottom , 25mm drop bracket part, Steady arm hook(BFB),
tubular Stay Sleeve, Register Arm Eye piece 25 mm, Steady Arm Clamp 25 mm, Mast fittings
for Hook Insulators, 9 T eye Turn Buckle, 9 T eye bolt left, 9 T eye bolt right, 9 T Clevis bolt
left, 9 T Clevis bolt right, 18 mm Single Clevis assembly, Clevis and Eye etc. The list may be
enlarged/decreased as per RDSO instructions.
DROPPERS: (SEE PARA 2.4 and 2.6)
(a) GENERAL DESIGNS
The droppers shall generally be designed as shown in standard drawings and made of copper
wire about 5 mm diameter conforming to IS: 282:1982 or latest and shall be attached to the
catenary wire by a copper dropper clip. The contact wire shall be held by a clip of aluminium
bronze as shown in the standard drawings. The distribution of dropper shall be in accordance
with standard designs.
(b) LOADING
The droppers shall be able to withstand a vertical load of 200 kg at the point of attachment to
the contact wire and the clip shall not slide under a horizontal load of 120kgf.
(c) The permissible tolerance in the overall length of a dropper will be +/- 5mm.
5.11
INSULATORS:
(a) All insulators except those on return conductors and earth wires shall be of the solid core type.
Disc insulators shall be used on return conductors and earth wires or other locations as desired
by the Engineer. All solid core insulators shall conform to TI/SPC/INS/0070(04/07).
(b) Use of Insulators:
Normally porcelain insulators with creepage distance of 1050mm shall be used.
Composite/Hybrid insulators shall be used only in polluted, stone pelting areas in terms of RB
policy circular No RB/Elect/TRD/04-12 dt 04/07/2012 with approval of CEE of concerned zonal
Railway. Testing of 25 KV porcelain and composite insulators before installation is to be ensured
as per RDSO guidelines TI/MI/0042 (12/2008) Rev 0.
(c)
INTER-CHANGEABILITY
For free inter-changeability only the following types of insulators shall be used. While the
shapes of the insulators may vary slightly from those shown in the drawings, the essential
dimension of the galvanized malleable cast iron caps as given in standard drawings shall be
adopted.
(i)
(ii)
Stay arm Insulators: These insulators will be used in conjunction with the tubular
stay arm of all bracket assemblies.
Bracket Insulators: These will be used at the base of each bracket assembly in
conjunction with bracket tubes.
Dated 29.Jan 2015
Page 319 of 429
(iii)
(iv)
(v)
(vi)
RVNL
9- tone Insulators: These will be used at all places for cut-in and terminal insulation
including those in return conductors, but excluding those in earth wire.
Solid core post insulators: These will be used at all places for supporting isolator
mechanism, bus-bars, jumpers etc. of 25 kV.
Disc insulators 255 mm: Clevis type 255 mm disc insulators will be used for return
conductor suspension and for earth wire cut-in insulator.
11 kV Post insulators: These will be used at all places for supporting bus-bars,
jumpers etc. in conjunction with return conductor/return feeders.
5.12 ENDING FITTINGS AND SPLICES:
(a) GENERAL DESIGNS
Terminating or ending fittings and splices on copper conductor shall be of cone type clamping
on both the inner and outer strands of conductor except for contact wire ending clamps which
may be of wedge type. The arrangement shall be easy to install and also be such as would
apply the clamping pressure gradually without shock (see ETI/OHE/49(9/95) with AC slip No.
1 of (3/97), No. 2 of (4/2000)-core-1, 3 of (8/2001), core 2&4 of (3/2002) core-3&5. For
aluminium Alloy/ conductor, the end fittings shall be either cone type, strain clamp type or
any other type as approved by the Engineer.
(b)
LOADING
All the parts shall be capable of withstanding without damage, a load greater than the
ultimate strength of the wires to which they are fitted. In case of threads, no damage shall
occur when they are subjected to a load equal to two third of the ultimate strength of the
wires.
(c)
RESTRICTED USE OF SPLICES
The use of splices shall generally be avoided and their use shall be restricted to the minimum
necessary. Over main line tracks, there shall usually be no splice in the contact wire on first
erection. Elsewhere, not more than one splice be used over any tension length (i.e. anchor to
anchor) for which prior approval shall be taken from the Engineer. Additional splices may,
however, be provided on mainline track in station area/yards for introduction/shifting of
overlaps and crossovers for yard modification. Splices may also be permitted for repair of
damage due to thefts or Railway accidents.
(d)
SRENGTH OF ASSEMBLED FITTINGS
The strength of fittings assembled with appropriate conductors or wires shall be not less than
that of the conductor or wire itself.
(e)
ADDITIONAL TERMINATING WIRES
Cadmium copper stranded wire of 65 sq. mm nominal section or 37/2.1 mm ( as used in head
span construction ) may be used as additional terminating wires for extending single and
double conductors respectively, if termination at the nearest structure is not feasible.
(f) PG Clamps:
The Parallel grooved Clamps conforming to following RDSO drawings (or as amended) shall
only be used:
(i) Parallel Clamp (90/50) – RDSO drawing no. ETI/OHE/P/1040-3, Revision ‘B’ or latest
(ii)
Contact Wire Parallel Clamp (Part Small) – RDSO drawing no. ETI/OHE/P/1041-2,
Revision ‘D’ or latest
(iii) Parallel Clamp (150/160) – RDSO drawing no. ETI/OHE/P/1050-3,Revision ‘A’
(iv) Parallel Clamp Part (150 / 105 - 150) – RDSO drawing no. ETI/OHE/P/1051-2,
Revision‘C’.
(v) Parallel clamp (105/240)-RDSO drawing No. ETI /OHE/P/1530-1 Revision” C’
Dated 29.Jan 2015
Page 320 of 429
RVNL
5.13 ELECTRICAL CONNECTIONS FOR OHE:
(a)
GENERAL DESIGNS
All electrical connections between conductors shall be made by parallel clamps. The general
arrangements of connections are shown in the standard drawings, listed in the Annexure to
these Technical Specifications.
(b)
JUMPERS
Copper jumpers shall be of any of the followings:
(i) Large jumpers of annealed copper in accordance with specification ETI/OHE/3(2/94)
with A&C slip No. 1 of 4/95.
(ii) Small jumpers of annealed copper in accordance with the specification IS: 9968
(PT.2) -1981.
(c)
BUS BARS
Bus-bars or rigid jumpers of copper where used shall be of 18 mm dia copper rod in
accordance with RE/30/OHE/5 (11/60). Aluminium bus-bars wherever used shall be of 36/28
mm tubing (see 5.19). Aluminium tubular bus-bars shall be made of Al. alloy grade 63401
(WP condition) to IS: 5082-1981. The tolerance on diameter and thickness shall be as per
Class I, IS: 2673-1979.
(d)
FEEDERS
Feeders shall be of all Aluminium conductor 19/3.99 mm (SPIDER).
(e)
RETURN CONDUCTOR
The return conductor shall be of all Aluminium conductor 19/3.99 mm (SPIDER). The
arrangement of return conductor carried on traction structures is shown in drawings listed in
the Annexure to these Technical Specifications.
(f)
The general characteristics of all wires and conductors shall be as per RDSO/CORE drawings.
(g) Earth wire shall be of steel reinforced Aluminium conductor 7/4.09 mm (RACCOON) conforming
to IS: 398-(Part-II) 1976.
5.14
5.15
(a)
TERMINAL CONNECTORS FOR EQUIPMENTS:
Interruptor, Booster Transformer and LT supply Transformer shall be supplied along with the
terminal connectors suitable for taking jumper/bus-bar as required. However, ALCU strips
shall be provided for bi-metallic connections wherever required.
REGULATING EQUIPMENT:
GENERAL
A general arrangement is shown in the standard drawings of CORE/RDSO. The regulating
equipment should have a minimum adjustment range of 950mm. Stainless steel wire rope in
accordance with TI/SPC/OHE/WR/1060 with A&C slip no. 1 & 2 shall be used in these
equipments and these shall be sufficiently flexible for the purpose.
Fixing arrangement for mast anchor fitting for anti falling device for 3- Pulley modified ATD
should be as per RDSO drg. no TI/DRG/OHE/ATD/RDSO/00009/05/0 or latest and provision
of double eye distant rod as per RDSO MI no TI/MI/0008 Rev 0 (or latest).
The anchor height, X-Y adjustment chart and guide tube will be as per RDSO drawing
No.TI/DRG/OHE/GUYHR/RDSO/00001/13/0(Sheet-1to4),
Dated 29.Jan 2015
Page 321 of 429
RVNL
TI/DRG/OHE/ATD/RDSO/00003/99/0-Three Pulley ATD and drawing No.ETI/OHE/G/01505
respectively.
Anti slipping device assembly (SPACER ANGLES) shall be provided as per RDSO DRAWING NO.
TI/DRG/OHE/ATD/RDSO/00009
(b)
(c)
5.16
COUNTERWEIGHT
Counter weights and arrangements used shall be such that these could be accommodated
within 330 mm (13 inches) measured transverse to the track under the worst wind conditions.
The vertical upward movement shall be limited with a fixed top.
REDUCTION RATIO
Reduction ratio in the arrangement used shall be five for winch type, three in case of three
pulley type and five in case of five pulley type.
HEADSPAN CONSTRUCTION : (see para 2.13 and 4.6)
(a)
SIZE AND FACTOR OF SAFETY
All span wires used in head-span construction shall be of stranded cadmium copper
conductor 65 sq. mm or 130 sq. mm cross section. All the wires shall be designed with a
factor of safety of not less than 4 under the most unfavourable conditions.
(b)
TURN BUCKLES
Each span wire shall be equipped with a turn buckle at each end of the span.
(c)
ADDITIONAL INSULATORS
Additional insulators shall be provided as necessary in head span, cross span and steady span,
wires to ensure electrical independence between the equipment in different elementary
electrical sections.
5.17
ISOLATORS:
25 kV isolator switches shall comply with specifications as indicated in para 5.5.
5.18
INSULATION LEVEL:
Interruptors, potential Transformers line indication type, 42 kV Lightning Arrestors and other
equipments shall be suitable for insulation levels indicated in the relevant specifications.
5.19 BUSBARS:
(a) No splicing will normally be allowed in the tubular bus-bars unless the length of the bus-bar
exceeds 6m.
(b) GENERAL
The bus-bar shall be clean, smooth, mechanically sound and free from surface and other
defects. Provision shall be made where necessary to allow for expansion and contraction of busbars caused by temperature variation. The open ends of bus-bars shall be covered by suitable
tube caps, wherever the tubular bus-bars are required to be bent,
the radius of the bend
shall be not less than 200 mm.
(c) JOINTS
(i) The joints in bus-bars shall be mechanically and electrically sound so that the temperature
rise under normal working condition does not exceed 40 deg. C for an ambient temperature
of 65 deg. C.
(ii) All aluminium joints shall be thoroughly cleaned and smeared with suitable. Oxidation
inhibiting joint compound before and after assembling the joint. Similar procedure shall be
Dated 29.Jan 2015
Page 322 of 429
RVNL
followed for connecting the equipment terminals to the Aluminium bus-bars with bi-metallic
connectors.
5.20 CABLING:
(a) CABLE FOR LT SUPPLY
240 volt AC supply from LT supply transformer at switching stations shall be brought and
terminated on the LTAC distribution board in the remote control cubicles at the switching
stations by 1100 Volt, aluminium conductor, XLPE insulated , PVC sheathed and steel armoured
heavy duty cable conforming to IS7098/Pt.I/1988 of following sizes:
i)
ii)
iii)
iv)
(b)
5kVA AT
10 kVA AT
25 kVA AT
50 KVA AT
-
Cable
Cable
Cable
Cable
size
size
size
size
2x25 sq.mm
2x 70 sq.mm
2x 185 sq. mm
2 x 300 sq. mm
CONTROL AND INDICATION CIRCUITS
All other cables for control and indication at switching stations shall be 1100 –V grade PVC
insulated and sheathed un-armoured (heavy duty ) complying with IS: 1554(Part-I)- 1988. The
cables shall be provided as indicated in the Table below:
PURPOSE
RUN
CIRCUIT
VOLTAGE
COPRE
SIZE
AND MATERIAL
NO. OF
CORES
Control and
indication of
interrupters
Catenary
indication
Heater
supply
for
interruptor
control
mechanism,
From each interruptor to
terminal board
110 V DC
2.5
sq.
copper
mm
7
From line indication type
PT to terminal board
(i) From interruptor to
interruptor
ii) From each interruptor to
fuse box
iii) From fuse box to
distribution board
i) 110 V Battery charger to
battery
ii) 110 V battery to 15
Amp Dc fuse box
iii) 15 A DC fuse vox to
terminal board.
100 V AC
2.5
sq.
mm
copper
4 sq. mm Al
2
4.0
sq.
copper
2
Battery
supply
240V AC
110 V DC
mm
2
Note: (i)In case of feeding stations which are located within the traction sub-station premises, the
cables shall be run from individual equipment and terminated inside the sub-station
control room.
(ii)Notwithstanding the sizes of cables given above, the Bidder shall assure himself that various
cables would suit the ratings of equipments offered by him.
(b) SPECIFICATION
The cables shall be resistant to decay, abrasion, acids, alkalies and other corrosive materials.
All indoor wiring on walls shall be clamped neatly on heavy PVC rigid conduit of nominal
thickness 2 mm fixed to the wall by means of PVC plug rolls. The cable run layout at a typical
switching stations is shown in the relevant drawing already included in the Annexure to these
Dated 29.Jan 2015
Page 323 of 429
RVNL
5.21 LITERATURE FOR EQUIPMENT:
The contractor shall within one month of issue of letter of Acceptance, supply 25 copies of
detailed schedule, catalogues and drawings of all parts of the equipment.
5.22
INSPECTION AND TESTING:
The inspection of all fittings/equipments will be done by RITES or person nominated by the
Employer.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 324 of 429
RVNL
CHAPTER: B-6
DESIGNS AND DRAWINGS
for OHE and switching station
6.1 GENERAL:
(a) This chapter deals with the procedure for approval of designs and drawings.
(b) The type designs shall be as few as possible to cover the largest field of application
consistent
with economic consideration.
(c) In all drawings as far as possible, only internationally accepted symbols shall be used.
6.2
(a)
CONTRACTOR’S DRAWINGS:
The Contractor shall submit to the Engineer for approval, except where otherwise specified, all
detailed designs and drawings which are necessary to ensure correct supply of equipments,
components and materials and to enable correct and complete erection of overhead
equipment, switching stations, booster transformer stations, LT supply transformer stations
and other associated systems, in an expeditious and economic manner.
(b)
RESPONSIBILITY
It is to be clearly understood that all original designs and drawings shall be based on a
thorough study of the project site. General designs and dimensions shall be such that the
Contractor is satisfied about the suitability of the designs for the purpose. The Engineer’s
approval will be based on these considerations and notwithstanding the Engineer’s
acceptance, the ultimate responsibility for the correct design and execution of the work shall
rest with the Contractor.
6.3
STANDARDS FOR DRAWINGS:
All designs, legends notes on drawings and schedules of materials shall be in English and shall
be prepared in the metric system. All designs and drawings shall conform to the specification
RE/OHE/25(3/66) & ETI/PSI/31(5/76).
6.4
(a)
BASIC DESIGNS:
STANDARDS DESIGNS
Where the Contractor adopts designs and drawings conforming to the standard designs,
drawings, and specifications of the Research Designs and Standards Organisation, Manak
Nagar, Lucknow 226011 (RDSO) for basic arrangements, equipments, components and
fittings of traction overhead equipment, switching stations booster transformer stations and
LT supply transformer stations and adopts employment schedules furnished by the Engineer,
he shall verify such designs, drawings and employment schedules and satisfy himself before
use that these are correct. Within two months of the issue of letter of acceptance, the
contractor shall indicate to the Engineer, the list of standard basic arrangements, components
and fittings, drawings and employment schedules, which he will adopted for the purpose of
the work. The proper procedure shall be followed for approval of basic designs. The contractor
for his use and reference shall obtain reproducible transparent film (50 microns) each of such
standard basic arrangement, component and fittings drawings and employment schedules
from Chief Electrical Engineer, Railway Electrification, Allahabad -211001, on payment as per
the prescribed rates.
Dated 29.Jan 2015
Page 325 of 429
RVNL
(b)
DEVIATIONS
Normally, deviations from the standard drawings shall not be made by the Contractor.
However, in exceptional cases where the contractor desires to suggest improvements as a
result of his experience, site requirements or any other reasons, he shall justify his proposals
with supporting explanatory notes.
6.5
(a)
SPECIAL DESIGNS:
In cases where standard designs, drawings or employment schedules do not cover
requirement of special locations or site conditions, the Contractor shall submit his own designs
or drawings along with supporting calculations and notes for scrutiny and approval of the
Engineer.
(b)
Such special designs shall generally be in conformity with the basic designs furnished by the
Contractor and in accordance with the specifications. If the Contractor wishes to adopt
special designs which do not conform to the general basic designs of the CORE/RDSO, he
shall submit alternative designs and drawings justifying his proposals.
6.6
PARTICULAR DESIGNS & WORKING DRAWINGS FOR OHE:
(a)
PEGGING PLANS
The pegging plans for sections to be electrified, indicating the type of overhead equipment,
locations of masts and other general particulars will be prepared on the basis of the latest
survey by the Contractor, if not supplied by the Engineer.
(b)
CONTRACTOR’S PEGGING PLANS
(c)
PRINCIPLES OF LAYOUT
The contractor shall in all cases ensure that the final pegging plans are in conformity with the
latest ‘ Principles of preparation and checking of OHE layout plans and sectioning diagram’
issued by RDSO.
(d)
PROVISIONAL LAYOUT PLANS
The Contractor shall prepare and submit overhead equipment layout plans incorporating the
following information:(i)
(ii)
(iii)
(iv)
(v)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
Deleted
The run of wires in different thickness or colour in special cases and termination.
The run of wires for future wiring indicated to the Contractor in dotted lines.
Exact position of all cut-in-insulators, including section insulators.
Direction and value of stagger at each traction structure location.
Clearance of live conductors to structures in the vicinity including bridges, signals
gantries etc.
(vi)
Layout of feeders.
Jumper connections and connections to switches and switching stations.
List of infringements.
Kilometer numbers and type of Structures.
Location and numbers of switches.
Schematic sectioning diagram drawn to convenient scale showing section insulator,
number of switches, elementary sections and connections to switches and switching
stations.
Table giving references of approved profile drawings, feeder layout plans and other
relevant drawings.
Dated 29.Jan 2015
Page 326 of 429
RVNL
(e)
(f)
OHE PROFILE DRAWINGS
After completion of the overhead equipment layout plans, the Contractor shall prepare
overhead equipment profile drawings showing the actual height of the contact wire under each
over line structure, the gradient and height of the contact wire under each over line structure,
the gradient and height of the contact wire on either side of the structure and the
encumbrances at structures, until normal height of contact wire and encumbrances are
restored.
CROSS SECTION DRAWINGS
While the layout plans are being finalized, the Contractor shall submit for approval, in –so-far
as yards between outer most points and crossings are concerned, cross-section drawings for
each structure showing guy rods, if any, indicating the cross-section of the formation, height
and nature of soil, type of foundation block, structure proposed, reverse deflection of the
structure and all necessary particulars for erection of the foundation and the structures. In the
preparation of drawings, care shall be taken to show all obstructions such as signal wires,
points rods and their correct location in references to track/tracks as well as underground
obstructions like pipes cables, etc. after collecting such information from the site.
In open line sections, cross-sections shall be submitted in the following performa, separately
for each Railway line for special foundation drawings with all necessary details shall be
submitted to the Engineer. In case of side bearing foundation with extra depth, formation
details at such location and necessary details of anchor foundation will be submitted.
CROSS-SECTION
FOR
THE
……………………………to………………………..
OPEN
SN
LOCATION No.
CHAINAGE
SETTING DISTANCE IN ‘m’
STEP DISTANCE IN ‘m’
B.M. CODE
SOIL TYPE & PRESSURE
FOUNDATION TYPE AND SIZE
DETAILS MAST SIZE & LENGTH IN ‘m’
MAST EMBEDDED LENGTH ‘m’
REVERSE DEFLECTION in cm
SUPER MAST LENGTH (m)
CROSS ARM LENGTH (m)
ANY OBSTRUCTION
ROUTE
SECTION…………….KM……
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
(g)
FINAL LAYOUT PLANS
After all the cross section drawings in a section covered by the layout plan are finalized and
foundations are cast, the Contractor shall revise the layout plans to take into account any
modifications to the locations of structures during the process of casting of foundations and
submit the final layout drawings as ’as erected’ drawings.
(h)
STRUCTURE ERECTION DRAWINGS
The contractors shall then submit Structure erection drawings for each structure incorporating
all the details included in the cross section drawing for the structure and as erected at site and
the details or the bracket assembly, mast extensions, isolator mounting frame and anchorage
of overhead equipment, feeder or return conductors proposed for each structure together with
all particulars necessary for the correct erection of overhead equipment at the structure. For
Dated 29.Jan 2015
Page 327 of 429
RVNL
structures with isolators, the details of electrical connections shall also be incorporated. In
open line sections, the Contractor shall submit structure erection particulars in the typical
proforma as given below separately for each main line track in addition to particular details as
indicated in the proforma for cross section drawings. Any modification to this proforma, if
found necessary, will be finalized at time of preparation of structure erection drawings with
the approval of the Engineer.
SN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LOCATION No.
CHAINAGE
1. ENCUMBRANCE
2. CONTACT WIRE HEIGHT
3. STAGGER
(i) CATENARY
ii) CONTACT
4. STAY ARM
i) (a) M
ii) CODE
5. BRACKET
i) (b) M
ii) CODE
6.REGISTER:
i) C/D (M)
ii) CODE
7. STD/BENT CODE
8. IDENTIFICATION MARK (SEE PARA (6.11)
OTHER REFERENCES/CODES FOR MISCELLANEOUS ITEMS LIKE STEEL WORK FOR STAY/BRACKET
ATTACHEMNT, MISC. SINGLE/DOUBLE CAT. ETC. WILL BE INDICATED.
NOTE:
The proforma for SED at individual locations shall be as per standard proforma already
circulated and shall be adopted in consultation with the Engineer.
6.7 PARTICULAR DESIGNS & WORKING DRAWINGS FOR SWITCHING STATIONS
(a)
CONTRACTORS LOCATION PLANS ETC.
The location plans and schematic diagrams of connections for all the switching
stations, booster transformer stations and LT supply transformer stations will be
furnished by the Contractor. These will indicate the following as applicable.
i)
ii)
iii)
iv)
v)
vi)
Overhead equipment layout in the vicinity of switching or other stations.
Location of main masts.
Arrangement of cross feeders and longitudinal feeders to be anchored on the gantry if
any, including jumper connections to the overhead equipment.
Scheme of connections of interrupters.
Position of the remote control cubicle with respect to the switching stations.
Fencing outline at the switching stations.
The Engineer shall satisfy himself about the correctness and applicability of the location plans
given by the Contractor before adopting them for detailed designs.
Dated 29.Jan 2015
Page 328 of 429
RVNL
(b)
DETAILED DRAWINGS
The Contractor shall submit for approval of the Engineer the following drawings:(i)
Cross-section drawings for each switching station indicating the cross section of the
formation transverse to the track at each location of main mast and longitudinal
section parallel to the track along the centre line of the interrupters. These drawings
shall be prepared after an accurate survey at site and shall indicate the nature of the
soil, its bearing capacity, compactness and in case of loose soil, transverse section of
the parent soil. In the preparation of the drawings care shall be taken to show all
obstructions to be removed, such as signal wires, rods and their correct location with
reference to the track/s as well as under-ground constructions like pipes, cables etc.
after collection of such information from the site.
(ii)
GENERAL ARRANGEMENT DRAWINGS
General arrangement drawings shall be prepared for switching stations indicating the
general arrangement of all equipments run of bus bars, position of pedestal insulators,
steel frame work and fencing. The drawings shall also include the schematic
connection/diagram and an isometric view of bus bars and connections. The drawings
shall include an elevation view of the switching stations from behind a transverse
cross section and plan sectional views at the level of feeder anchors, insulator beams,
potential transformer beams and ground. Each drawing shall have a schedule of all
equipments required at the switching station along with drawing references of details
of these equipments.
iii)
STRUCTURAL DRAWINGS
Structural assembly drawings shall be prepared for switching stations indicating the
steel frame work assembly. The drawings shall include one elevation view of the steel
frame work assembly from behind, a transverse cross section and plan views at
various levels such as at the level of feeder anchors, insulator beams/and ground. In
the assembly, each component member shall be marked with its reference number.
The drawing shall also have a schedule of component members along with drawing
reference number. The weight of the component members shall be indicated in a
separate weight schedule. The drawings shall be prepared for the various structural
components. An individual drawing shall be made for each component and this shall
include all fixing bolts, nuts and washers whose sizes will be mentioned on the
drawings. Unit isolator beams, potential transformer beams weight of the component
shall also be given in the drawings.
iv)
FOUNDATION LAYOUT AND CROSS-SECTION DRAWINGS
Foundation layout & cross-section drawings for each switching station indicating
layout of all foundations in plan, transverse cross-section of various foundations
through center line of main masts, interrupters, fencing uprights and LT supply
transformers, if any, and longitudinal sections parallel to track through the center line
of the cable trench. All foundations shall be marked serially on the drawing and listed
in a schedule on the drawing indicating the volume of concrete for each foundation
block.
(v)
FENCING LAYOUT DRAWINGS
Fencing layout drawings shall be prepared for each switching station indicating the
layout of the entire fencing and anti-climbing device in plan. Each upright, fencing
panel and fixture on the upright shall be indicated on the drawing by its reference
number. A schedule of components viz. uprights, panel fixer, and barbed wire shall be
included in the drawings indicating the drawing references of components. An
individual drawing shall be made for each type of panel, fencing post and fixture for
Dated 29.Jan 2015
Page 329 of 429
RVNL
mounting the anti-climbing device. The drawing of each fencing post shall indicate the
unit weight of the fencing post.
vi)
EARTHING LAYOUT DRAWINGS
Earthing layout drawing shall be prepared for each switching station indicating the
layout of full earthing system in plan. The drawing shall show the location of earth
electrodes and mark the runs of earthing strips and connections to each equipment,
mast, fencing post and fencing panel. All components shall be marked with their
reference numbers, for further details of the run of conductors and connections,
separate drawings which may be common to all switching stations may be made and
references to these drawings marked on the layout. A schedule of components shall
be made out in the drawing giving drawing references of components.
(vii)
CABLE RUN LAYOUT.
Cable run layout shall be prepared for each switching station indicating interconnection between various equipments, indoor and outdoor, along with schematic
arrangements and physical disposition of equipments, colour coding or code number
and the index scheme adopted for terminals.The drawings shall also indicate the cable
size and grade s of insulation. The quantity of various cables required shall be
indicated on the drawings.
(viii)
EQUIPMENT DRAWINGS
Equipment drawings shall be prepared for all switching stations. Drawings should be
dimensioned and should indicate:1.
2.
3.
4.
5.
6.
7.
(ix)
MISCELLANEOUS DRAWINGS
This covers miscellaneous drawings applicable to all switching stations. These
drawings shall include drawings or sketches made for study of clearances, isolator
alignment details, scheme of interlocks, number plates of various equipments and “U”
bolts for cable mounting, caution or instruction boards, outriggers for bus bar
supports and non-standard bus bar connectors.
(x)
EMPLOYMENT SCHEDULES AND CHARTS
This covers Employment Schedules and charts applicable to all switching stations.
These will include:
1.
2.
3.
6.8
Fixing or mounting hole dimensions and arrangement;
Net weight of the equipment;
Characteristic and rating of equipment;
Circuit diagrams;
Overall dimensions and other important dimensions;
Height and vertical and horizontal dimensions of all exposed live parts; and
Notes explaining the operation of the equipment
Employment schedule for pure gravity type of foundations for main masts for
various direct loads and bending moments;
Employment schedule for all other foundations for various depths of parent
soil from the datum level.
Sag tension charts for cross feeders for various spans and tensions.
BOOSTER & L.T. SUPPLY TRANSFORMER STATION DRAWINGS:
The Contractor shall submit for approval to the Engineer drawings for booster transformer
stations and LT supply transformer stations, similar to those detailed for switching stations in
6.7 (b). The following drawings may, however, be combined together:
Dated 29.Jan 2015
Page 330 of 429
(i)
(ii)
RVNL
Cross-section and foundation layout drawings;
General arrangement, structural and earthing layout drawings.
6.9
SCHEDULE OF QUANTITIES:
(a)
Within one month of issue of Letter of Acceptance, the Contractor shall assess the quantities
of various items of work including various components and fittings as covered in the Bill of
Quantities and also those required to satisfactorily commission the works, and submit the
same for the approval of the Engineer as Assessment 1. Such an assessment can be revised
at suitable intervals after the first assessment is approved and till the work is completed. Such
reassessments shall be denominated as Assessment 2, Assessment 3 etc., and shall also be
submitted for approval of the Engineer.
On receipt of approval of each final layout plan from the Engineer, the followings Schedules of
quantities relating to each layout plan shall be submitted within a fortnight:
i)
ii)
iii)
iv)
v)
vi)
(b)
SWITCHING/BOOSTER STATIONS
Within a fortnight of receipt of approval of relevant drawings for each switching booster
station, the following schedules of quantities shall be submitted:
i)
ii)
iii)
iv)
6.10
(a)
Schedules of number of masts, types, weight of different masts and total weight of
masts;
Schedules of number of foundations, types, volume of different foundations and total
volume;
Schedule of quantities of various items of work other than masts and foundation
under various Schedules
Schedule of net tension lengths of contact, catenary and feeder wire lengths required
to be ordered;
Schedule of lengths of other wires and conductors required to be ordered and
Schedules of small parts steel work to be supplied by the Contractor.
Schedule of number of foundations, types, volume of different foundations and total
volume. Overlapping foundations will be treated as one foundation;
Schedule of number of masts, types, weight of different masts, and the total weight of
masts of each gantry;
Schedule of steel work, types, weight of each member and total weight and
Schedule of quantities of various items of work not included under (i), (ii), and (iii)
above.
SUBMISSION OF DRAWINGS & SCHEDULES:
The submission of designs and drawings for approval shall be done in the proper manner. In
case, the Contractor wishes to deviate from the standard drawings he should submit to the
Engineer, the revised drawings, with full details of deviation sought explaining the necessity
of deviation, calculations and other supporting documents. The Engineer, if satisfied about
the necessity and adequacy of deviations, shall refer the matter to RDSO for necessary
approval. In case of deviations on working drawings, decision shall be communicated by the
Engineer to the Contractor. The number of copies of drawings which shall be submitted are
indicated in the following sub-paras. The Engineer will return one copy of the drawings either
with approval subject to modification where necessary or with comments. The engineer shall
endeavour to return this copy within a period of fifteen days from the date of receipt and
shall normally return the copy within a month. Where drawings are returned with comments
or approval subject to modifications, the Contractor shall submit to the Engineer within
fifteen days of receipt of such advice, the revised drawings for approval taking into account
the comments or modifications. Also the contractor shall as far as possible avoid
Dated 29.Jan 2015
Page 331 of 429
RVNL
correspondence on such comments and shall endeavor to settle any difference of opinion on
the comments by discussion with the Engineer. No drawings shall be resubmitted without
incorporating the modifications required by the comments of the Engineer, unless the
Engineer has agreed to the deletion of such comments.
(b)
DEVIATION FROM STANDARD DESIGN
In case of deviation from standard designs and drawings, copies of correspondence and
drawings shall be sent in duplicate to the Engineer. In the particular case of deviations in the
design of fittings, the drawings submitted by the Contractor shall be actual manufacturing
drawings complete with tolerances and full specifications of the materials used. In addition,
four samples of the modified fittings shall also be submitted, after the drawings are approved.
(C)
SPECIAL DESIGNS
Special designs to meet the requirement of particular locations and local conditions shall be
submitted in due time in duplicate for approval.
(d)
PEGGING PLANS
Two copies of the Engineer’s pegging plans shall be sent back after verification if found
correct. If modifications are required, fresh pegging plans incorporating the modifications
shall be submitted in two copies for approval (see para6.6).
(e)
CONTRACTOR’S PEGGING PLANS:------DELETED---
(f)
CROSS-SECTION DRAWINGS
Cross-section drawings shall be submitted for approval in two copies for a convenient section
at a time separately for sections within station limits and section outside station limits. Such
drawings shall be submitted progressively and as far as possible without gaps (see para 6.6).
(g)
OHE LAYOUT PLANS AND PROFILE DRAWINGS
Overhead equipment layout plans, provisional and final and profile drawings shall be
submitted for approval in three copies (see para 6.6).
(h)
STRUCTURE ERECTION DRAWINGS
Structure erection drawings shall be submitted for approval in two copies for a section at a
time separately for sections within station limits and sections outside station limits,
progressively and without gaps.
(i)
SCHEDULE OF QUANTITIES
Schedules of quantities for each approved layout plan/switching station shall be submitted for
approval in two copies.
(j)
SUB-SECTION FEEDER DRAWINGS – Deleted.
(k)
SWITCHING/BT/LT SUPPLY TRANSFORMER STATIONS
All drawings for sw3itching stations, booster transformer stations and LT supply transformer
stations shall be submitted for approval in three copies.
(l)
DISTRIBUTION COPIES
On receipt of Engineer’s unqualified approval to the Contractor’s drawings and Schedule of
Quantities, the Contractor shall submit original tracings of those drawings and schedules for
the signature of the Engineer in token of approval within seven days of the receipt of approval
and the Engineer shall as far as possible return the same to the Contractor within 7 working
days thereafter. On receipt of these tracings from the Engineer, the Contractor shall submit
copies for distribution to field officers and other departments as indicated below within 7 days
of receipt of approved tracings:
Dated 29.Jan 2015
Page 332 of 429
RVNL
i
ii
iii
iv
v
vi
vii
viii
ix
Standard designs including fittings drawing as per para 6.10(b)
Special designs
Final pegging plan
Structure Cross- section drawings
OHE layout plans
OHE profile drawings
Structure erection drawings
Schedule of quantities
Drawings for switching stations, booster transformer stations &
LT transformer stations
6
6
2
6
6
6
6
6
6
copies
copies
copies
copies
copies
copies
copies
copies
copies
One soft copy of each drawing (on Autocad) will also be supplied on CD.
6.11
COMPLETION DRAWINGS & SCHEDULES:
After completion of works, all drawings and designs submitted by the contractor and approved
by the Engineer shall be made up to date by incorporating actual supply and erection
particulars, including the name and make of insulators, galvanized steel tubes, stainless steel
wire rope etc. The mark of conductors shall be specified in the “As erected” OHE layout plans,
SEDs and other relevant drawings for identification. Such drawings and schedules shall then be
verified and corrected, if necessary, by the contractor jointly with the Engineer. The verified
and corrected drawings shall be supplied in six sets, one of which shall be transparencies of
linen or film reproduction or any other durable material approved by the Engineer. One soft
copy (on Autocad) will also be supplied on CD.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 333 of 429
Dated 29.Jan 2015
RVNL
Page 334 of 429
RVNL
CHAPTER: B-7
ERECTION AND INSTALLATION OF EQUIPMENT-OHE
PART-1: PRINCIPLES
7.1
SCOPE
This chapter deals with the methods of erection and installation of traction equipment,
including casting of foundations and erection of structures.
7.2
METHODS OF ERECTION:
All work shall be done in accordance with methods of erection and installation of equipment
approved by the Engineer. In the case of switching stations, booster transformer stations, LT
supply transformer stations, standard methods adopted for erection and installation of
electrical equipment shall be adopted.
7.3
SECTIONING:
The entire equipment shall be erected in accordance with the finally adopted sectioning
diagram and in such a way so as to facilitate sectioning which may be required in future and
which will be indicated by the Engineer.
7.4
INSPECTION:
All erection and installation work shall be subject to inspection by the Engineer to ensure that
the work is done in accordance with the specification, approved designs and drawings, is in
line with the best industry practices and of best quality.
7.5
MEASUREMENTS:
All measurements for location of structures and foundations shall be made with the aid of
steel tapes. On curves, these measurements shall be taken on the outer rail of the middle
track in the case of odd number of tracks and on the inner rail of the first outer track from the
centre of the formation in the case of even number of tracks. Structures on curves shall be
located in the radial offset of the location as determined.
7.6
BOLTS, NUTS ETC.:
All bolts, nuts, locknuts, screws, locking plates & split cotter pins etc. shall be properly
tightened and secured and the contractor shall carry out systematic inspection of this aspect
of work after all adjustments to overhead equipment are completed and prior to offering
completed sections to the Engineer for inspection and testing.
7.7
DAMAGE TO GALVANISING/PAINTING:
In loading transport and erection, all galvanized/painted materials shall be handled with care
to avoid damage to galvanized/painting. If galvanizing/painting is damaged in spite of all care
taken, the damaged part of component shall be put up for inspection, to obtain permission
from the Engineer to carry out repairs as per para 5.7 (c ).
7.8
MASTS AND STRUCTURES:
(a)
ERECTION
In case traction masts or structures are erected in cored foundations, till such time they are
grouted, they shall be properly wedged to prevent them leaning towards the track and
endanger safety of moving vehicles. In case traction masts or structures are erected
Dated 29.Jan 2015
Page 335 of 429
RVNL
simultaneously with the casting of the foundations, the Contractor shall provide suitable
temporary supports approved by the Engineer. The masts shall be embedded in the
foundation blocks for the correct length specified in approved drawings.
NOTE: Mast/uprights should be grouted on the same day they are dropped in the
foundations.
(b)
INFRINGEMENT TO STANDARD DIMENSIONS
In erection, care shall be taken to ensure that no part of the traction mast, structure or any
fitting located on such mast or structure infringes the latest version of the Schedule of
Dimensions for 1676 gauge.
(c)
ALIGNMENT OF MAST AT GANTRIES
The main masts of gantries shall be carefully aligned to enable easy and good assembly of
fabricated steel work.
7.9 OVERHEAD EQUIPMENT:
(a)
A suggested method for erection of traction overhead equipment which would ensure good
speed and quality erection, is included in CH-7 part-2-wiring procedure of this chapter. The
Contractor may, however, follow other methods which they consider would speed up and
ensure good quality work, subject to the approval of the Engineer. Any wiring method should
take into consideration appreciable stretch of the catenary and contact wires in the initial days
after they are strung and put under tension.
(b)
BRACKET TUBES
In the erection of bracket assemblies, it shall be ensured that the free length of the bracket
tube beyond the catenary suspension bracket is at least 200 mm to facilitate adjustment
during maintenance.
(c)
STAY ARMS
The choice of stay arms shall be such that their adjuster are capable of adjustments of
minimum of 90 mm in either direction except as otherwise relaxed.
(d)
INSULATORS
Before insulators are used in bracket assemblies or dispatched from the Contractor’s Depot to
work site for erection, they shall be tested as specified for routine mechanical test. NO
chipped or cracked insulators shall be installed. All insulators shall be cleaned before offering
complete wired sections for inspection and testing.
(e)
STRINGING CATENARY
Care shall be taken to avoid kinking or bird caging of the catenary wire in stringing and
subsequent operations. While stringing, the wire shall be suspended from pulley blocks hung
from the suspension clamp eye of bracket assemblies. The pulleys shall be fitted with ball
bearing and shall be of swivel type to permit free movement in all directions to prevent
damage to the strands of the wire. The design shall also be such that it will prevent slipping
off of the wire during stringing operations. The designs of the pulley shall be submitted to the
Engineer for approval. After initial stringing of the catenary, it shall be maintained at the ‘no
load tension’ (see section 2 of this chapter ) for a minimum duration of 48 hours before the
pulley blocks are removed and the catenary is clamped to suspension clamps of bracket
assemblies. Shorter periods may, however, be allowed by the Engineer.
Dated 29.Jan 2015
Page 336 of 429
RVNL
(f)
STRINGING CONTACT WIRE
Care shall be taken to avoid formation of kinks, twists and damage to contact wire in stringing
and subsequent operations. While stringing the contact wire, it shall be suspended from
pulleys hung from droppers and fitted to the catenary in its final position. In curves, the
contact wire shall be run in pulleys located at traction masts or supports, corresponding to the
approximate final position of the wire.
(g)
LOCATION OF DROPPERS
Droppers shall be correctly positioned in each span to ensure correct level of contact wire as
per dropper chart applicable to the particular span.
(h)
CLIPPING DROPPERS
The dropper shall be clipped on the contact wire only after a minimum duration of 48 hours
from the time the automatic tensioning device is brought into action. Shorter periods may,
however, be allowed by the Engineer.
(i)
- NIL-
(j)
AUTO TENSIONING DEVICE
The auto-tensioning device shall be erected with the correct height of the counter-weight
above rail level with corresponding distance between the pulleys of the device for a
temperature of 35 deg. C before it is connected to the overhead equipment and put into
action. The installation of the device shall be such as to permit free, easy and unobstructed
movement of counter-weight.
(k)
CUT-IN-INSULATORS
All insulators in and out of run shall be so positioned that they are away from the zone swept
by the pantograph and will not foul with it. The live parts of these insulators shall also be so
located that they are at least 2 m away from the structures, other than those supporting
traction overhead equipment.
(l)
SECTION INSULATORS
All section insulators shall be so located that they are beyond the zone swept by the
pantograph running on adjacent tracks and there is no unusual sag due to the same. Where
section insulators are installed, the contact plane of the runners of the insulators as well as
those of overhead equipment connected to it shall be parallel to the track plane.
(m)
ANTI-WIND CLAMP
Anti-wind clamp shall be provided as shown in the relevant drawing (refer Annexure to these
Technical Specifications).
(n)
CONNECTIONS
All jumper connections including anti-theft jumpers shall be made properly with parallel
clamps and finished neatly without any loose wire or cables. The length of flexible jumpers
shall be adequate to avoid any disturbance to overhead equipment or restraint in the relative
movement of conductors, but the jumpers should not be excessively long. The ends of
jumpers shall be tinned including the portion inside the first parallel clamp.
(o)
SEPARATION BETWEEN OHE
In erection, the physical separation required between overhead equipments and brackets
assemblies on the same structure at insulated overlaps shall be ensured.
Dated 29.Jan 2015
Page 337 of 429
RVNL
(p)
GRADIENT OF CONTACT WIRE.
The gradient of the contact wire on either side of over line structures with restricted
clearances shall be correctly adjusted and adequate clearance maintained between the over
line structure and the live equipment. Details as per para 2.9(g) shall be followed.
(q)
ADJUSTMENT AT TURNOUTS ETC
Careful adjustment of equipment shall be made on equipments at turnouts, crossovers,
diamond crossings, overlaps and special locations, for position of bracket assemblies, stay
arms and height of contact wire to ensure that pantographs of electric rolling stock will not
foul with any parts of the bracket assemblies and change over of the contact wire is effected
smoothly.
(r)
For wiring in large yards, the Contractor shall, prior to the execution of works, submit to the
Engineer for approval, the sequence of stringing of catenary and contact wires to arrange for
proper crossing of wires. Endeavour will be made by the Engineer to arrange for traffic blocks
to suit approved sequence of wiring.
7.10
ISOLATORS:
Isolator switches shall normally be so mounted that when the switches are being operated, the
operator faces the oncoming direction of train. The operating handles and contact blades shall
be correctly aligned for easy operation.
7.11
BUS BARS AND CONNECTIONS:
Bus bars and connections shall be neatly shaped and bent to give an aesthetic appearance.
7.12 EARTHING:
The copper earth strips or MS flats used for earth shall be bent and shaped neatly before
connection to the structure or frame work of equipment. The connection of MS flats to steel
work shall be made at a height not exceeding 15 cm from the datum level of the switching
station. Before making earth connections, the ends shall be cleaned thoroughly and tinned for
copper strips. All junctions shall be properly secured to avoid loose contact. Portions of copper
earth strips which remain visible above the ground level should be painted with suitable paint to
make them inconspicuous.
7.13
TOLERANCES:
The permissible tolerance in dimensions for erections from those included in the appropriate
drawings or schedules for different items are given below:
(a) MEASUREMENTS
The span length shall not vary more than +/- 50 mm as measured along the appropriate rail
(see para 7.5). The cumulative error of measurement of all spans in a kilometer shall be not
more than 1000mm.
(b)
(c)
SETTING OF STRUCTURES
The setting of structures shall not be less than that included in the appropriate cross section
drawings, specially those with the minimum setting of 2.90m. A tolerance of +/- 20 mm will be
permitted subject to minimum specified value, if the structure is not located in between tracks.
HEIGHT OF CONTACT WIRE
+/- 20 mm will be permitted on the height of contact wire at points of supports as shown in the
relevant structure erection drawings, except under overline structures where no tolerance will
be permitted.
Dated 29.Jan 2015
Page 338 of 429
(d)
Limits and Tolerances in Structure Erection Drawings/Tower wagon Checking:
Following tolerances are recommended hereby for adoption in RE works at field level as per
RDSO letter no: TI/OHE/GA/2013 DT 14th May, 2013:
Sl No
1
Item
Register Arm tube projection
2
3
Bracket tube projection
Dip between Register Arm Tube
& Steady Arm
4
5
Encumbrance
Length of 'A' dropper (1st
dropper from support)
Spacing of 'A' dropper (1st
dropper from support)
Length of other droppers
Spacing of other droppers
Stagger of Catenary wire
Height of Catenary wire
Stagger of Contact wire
Position of compensation plate
Difference in height between
mainline contact wire and the
crossover
contact
wire at
support
6
7
8
9
10
11
12
13
RVNL
Limits/Tolerances
- 150-200 mm in case of push off locations.
- For pull off locations, it shall project over contact
wire plane.
150-200 mm
- 200-250 mm on tangent track (BFB Steady arm).
- 250-320 mm on curves (BFB Steady arm and
bend Tubular Steady arm)
+50 mm
+ 5 mm
+ 30 mm
+ 5 mm
+ 50 mm
+ 30 mm
+ 50 mm
+ 10 mm
It shall be in vertical plane.
50 mm (minimum)
7.14 SUPPLEMENTARY INSTRUCTIONS:
Further working instructions will be issued if considered necessary by the Engineer. These
should be considered to imply that the standard of work of the Contractor requires to be
improved.
7.15
Tree Trimming:
Trimming/cutting of trees in the (to be) electrified section shall be ensured as per RB lr No:
2008/Elect.(G)/1/161/8 pt dt 05/09/2012.
7.16 In pure RE works, wiring train/crane/UTV shall be provided by RVNL but in combined works, the
contractor shall have to make their own arrangement for mast and OHE erection.
In all the works, for final checking adjustment and inspection of OHE, Tower wagon will be
provided free of cost by RVNL. Diesel, lubricant, watering and security of Tower wagon shall be
provided by contractor.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 339 of 429
Dated 29.Jan 2015
RVNL
Page 340 of 429
RVNL
CHAPTER: B-7(b)
ERECTION AND INSTALLATION OF EQUIPMENT-OHE
PART-2: WIRING PROCEDURE-OHE
7.20 WIRING PROCEDURE:
This sections deals with wiring procedure which may be adopted for erections of normal
overhead equipment. The following procedure for erection of overhead equipment has been
formulated with a view to ensure that:
(i) Bracket assemblies (brackets) and regulating are correctly installed in their final position.
(ii) The conductors are correctly tensioned and
(iii) The need for final adjustments of overhead equipment immediately before energisation
and commissioning is virtually eliminated.
7.21 GENERAL
In the case of regulated overhead equipment when the regulating equipments are in action, the
tension in the conductors should remain constant, irrespective of variations in the ambient
temperature. As the regulating equipments are brought into action a few days after the
stringing of conductors the equipment is unregulated in the intervening period. Any of the
following two procedure may be followed for tensioning and clamping of conductors of regulated
overhead equipment during stringing operations i.e. before the regulating equipments are
brought into action:
(i) The catenary is tensioned to 1000kgf, the stipulated tension at the mean temperature of
35 deg. C, whatever may be the ambient temperature during the stringing operations. In
this case, at the time of clamping the catenary to the bracket, the brackets should be
placed at angular positions corresponding to temperature at the time of clamping, and
proportionate to their distance from the anti-creep.
(ii) The catenary is strained to a stringing tension corresponding to the ambient temperature
for the equipment span of the tension length. In this case, the brackets are placed in the
mean position i.e. at right angles to the track, when the catenary is clamped or the
regulating equipment commissioned.
The advantage of the second method is that once the catenary is strung at the proper
tension, there would be no necessity to adjust each bracket separately at the time of
clamping the catenary or commissioning the regulating equipment. The erection work is,
thus considerably simplified and the possibility of errors greatly reduced. This is also
applicable to erection of unregulated overhead equipment.
7.22
7.23
ERECTION OF BRACKETS:
After the brackets are fabricated correctly in the Contractor’s Depot, in accordance with the
approved structure erection drawings, and provided with indelible labels and /or painted
marking indicating the intended locations for each bracket, they are removed to the site of work
and erected on traction masts or supports. The brackets are swiveled to a position at right
angles to the track and secured in that position by means of steel wires tied to similar brackets
located on the opposite side of the track or other suitable means.
ANTICREEP:
The anti-creep of the tension length is then installed in its final positions.
Dated 29.Jan 2015
Page 341 of 429
7.24
RVNL
LOCKING THE REGULATING EQUIPMENT:
In the case of regulated overhead equipment, the regulating equipments are erected on the
terminal masts or structures and their movement locked by suitable means in the middle
position, with the distance between the pulleys of the regulating equipment corresponding to
35deg. C.
7.25 TEMPORARY ARRANGEMENT:
A pulley of approximately 30 cm. in dia. is attached to the overhead equipment and the
regulating equipment by means of temporary accommodation fittings at both ends of the
tension length to be wired. Over this pulley a flexible stranded wire is passed over. At each end
of the wire two ending clamps, one for catenary and one contact wire, are attached. The wire is
also clipped in the middle by’ U’- clamps. The length of this temporary arrangement from the
regulating equipment to the extremities of the stranded wire passing over the temporary pulley
shall be a little longer than the distance between the regulating equipment and the ends of the
catenary and contact wires in their final position, to permit easy clamping of terminal fittings
during the final termination of the wire.
7.26 STRINGING OF CATENARY:
The catenary is initially terminated in the ending clamp of the temporary arrangement at one
end of the tension length. The catenary is then paid out from the reel of the wiring train and
run on pulley blocks hung from the suspension clamp eyes of brackets until the terminating
point at the other end of the tension length in reached.
7.27 TENSIONING OF CATENARY:
The catenary is strained up to the stringing tension’ corresponding to the equivalent span of the
tension length and the ambient temperature at the time of stringing with the aid of a
dynamometer, and terminated at the tension. For this purpose, the ambient temperature shall
be deemed to be the temperature registered by a thermometer tied to a length of catenary
wire 3 to 4 meters long, laid flat on the top platform, on one of the wagons of the wiring train.
Subsequently, the tension in the wire is checked by measurement of sag with the help of
leveling the attached to suspension points and to the catenary at mid span by a ladder working
party. The sag shall be measured in two spans, each preferably greater than 54 metres, and
situated on either side of anti-creep approximately midway between the anti-creep and the
termination points. The value of sag measured by this method should be within +/-5% of the
theoretical value for the corresponding stringing tension, and the temperature at the time of
this measurement. In case the discrepancy is more, the tension should be adjusted again and
sag re-checked as above (see note 1 below). After the sag is checked and the catenary is
terminated at the end fitting of the temporary arrangement at the terminating point.
In order to restrict the duration of traffic blocks to the minimum,in the first block, a catenary is
strained to the stringing tension with the aid of dynamometers and terminated. In the
subsequent block, the sag is checked and the tension readjusted with ladders, if necessary.
7.28 CLAMPING THE CATENARY:
The catenary is clamped on the brackets placed at right angles to the track (see note 2 below).
7.29 DROPPERING:
Droppers are fitted to the catenary at the correct locations. At the contact wire ends these
droppers may be provided with small pulleys or hooks to act as temporary supports when the
contact wire is strung.
Hooks made of scrap contact wire, suspended from the catenary wire, may also be used as
temporary supports.
Dated 29.Jan 2015
Page 342 of 429
RVNL
7.30 STRINGING OF CONTACT WIRE:
The contact wire is initially terminated in the contact wire ending clamp of the temporary
arrangement at one end of the tension length. The wire is then paid out from the reel wagon of
the wiring train and supported on the pulleys hung from droppers or on hooks until the
terminating point at the other end of the tension length is reached (see note 3 below). In
curves, the contact wire shall be registered on pulleys located at traction masts or supports
corresponding to the approximate final position of the wire. The axes of these pulleys should be
more or less vertical.
7.31 TENSIONING OF CONTACT WIRE:
The contact wire is strained to a tension of approximately 1.2 times the tension corresponding
to the ambient temperature and terminated in the ending clamp of the temporary arrangement.
7.32 REGULATING EQUIPMENT IN ACTION:
The regulating equipment is put into action with the counter weight at the correct height above
rail level and with distance between pulleys or the regulating equipment corresponding to a
temperature of 35 deg. C. The regulating equipment is then released and brought into action.
The ‘U’ clamp connecting the flexible stranded wire passing round the temporary pulley is also
removed.
7.33 FINAL ADJUSTMENT:
The entire installation is left in this condition as long as it is possible, preferably for a period not
less than 15 days (see note 4). The temporary pulleys are removed and the conductors
terminated in the permanent end fittings, compensating plates, insulators and turn buckles (see
note 5 below). The equalizer plate is kept vertical or at a slightly inclined position ( the contact
wire being shorter than the catenary by 2 or 3 cm) and the position of the regulating equipment
is checked in relation to the temperature at the time. The contact wire is clipped on to the
droppers (in the vertical position ) and on the steady arms. Contact wire height at the bracket
is adjusted as also the stagger and register arm clearance.
7.34 CONCLUDING REMARKS:
If the above method is followed with care no further adjustment may be needed.
NOTE:
(1) It should be ensured that sagging is done carefully and accurately. The adjustment of
tension in the catenary after checking of sag, if required, would be easy if a temporary turn
buckle is inserted in the temporary termination.
The use
(i)
(ii)
(iii)
of leveling lathes is recommended for the following reasons:
The accuracy of adjustment is greater than that with a dynamometer.
No traffic block is required for this operation.
It obviates the necessity of initial tensioning of the catenary accurately thus
permitting a deduction in the period of traffic block required for the wiring train.
(2) If feasible without offering any hindrance to progress of works, the catenary may be
maintained at stringing tension for a period of 48 hours before checking sag and clamping it
to the brackets. This would ensure equalization of tension in the different spans. Before
clamping the catenary to the brackets, the sag should however, be checked in two spans as
indicated in para 7.27.
(3) If it is difficult to obtain a separate traffic block for stringing contact wire, the wire may be
paid out at the same time as the catenary, with the following precautions:
(i)
The contact wire is run and suspended from independent pulleys hooked on to the
brackets, separately from the catenary pulleys, to avoid twisting together of the two
conductors.
Dated 29.Jan 2015
Page 343 of 429
RVNL
(ii) The contact wire should not be suspended from the catenary until the latter is clamped
on to the brackets.
(iii) The tension in the contact wire before termination should be about 1500 kgf. This will
ensure that sag is not excessive.
(iv) The adjustment of tension and checking of sag of the catenary wire is carried out as if
the contact wire had not been strung. Only after adjustment of tension and checking
of sag is completed, the contact wire is transferred to the pulleys attached to the
droppers or to hooks suspended from the catenary and the tension is adjusted as
indicated in para 7.31.
(4)When the contact wire is under tension, creep takes place which results in an increase in
the length of wire and, consequently, the droppers and the equalizer plates would become
oblique.
Though creep may continue for a long time, may be about a year, the bulk of it would
occur during the days following stringing. If sufficient period of time is allowed, the contact
wire may be clipped to the droppers and the equalizer plates, all in the vertical position,
and the necessity for any further adjustments before energisation and commissioning of
the OHE may be reduced to a great extent. If this precaution is not taken, at the time of
energisation of the OHE, the droppers may not all be vertical and staff would have to be
detailed for shifting the dropper clips which is attendant with risk of damage to the contact
wire.
(5)Before the temporary arrangement is removed, a reference mark should be made on each
conductor. After final termination of the conductors, it should be ensured that two marks
are in the same relative longitudinal position as they were before the removal of the
temporary arrangement.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 344 of 429
RVNL
CHAPTER: B-8
INSPECTION AND TESTING-OHE & Switching Station
8.1
SCOPE:
This chapter deals with the inspection and testing of completely erected overhead equipment,
switching stations, booster transformer stations and LT supply transformer stations.
8.2
OVERALL PERFORMANCE:
The overall performance of the overhead equipment should be
of current by electric rolling stock with full load at speeds up
specified for the design of overhead equipment, smoothly,
prejudicial sparks (see para 2.10) and without undue heating in
8.3
such as would permit collection
to and including the maximum
without mechanical shocks or
the case of other equipments.
RESPONSIBILITY:
The general tests of overall performance stipulated below are only supplementary to other tests
on structures, foundations, equipment, components and fittings as specified. Any testing and
acceptance by the Engineer of overall performance shall be subject to the general terms of
guarantee.
(a)INSPECTION AND TESTING CHARGES:
All inspection and testing charges shall be borne by the Contractor unless otherwise astated.
8.4
TESTS OF OHE:
(a) GENERAL
As soon as a section is ready for inspection and testing, the Contractor shall advise the
Engineer in writing. Tests to be carried out by the Engineer will be done in the presence of the
Contractor’s representative and shall include the following apart from other reasonable tests
that the Engineer may like to conduct with a view to ensure himself of the soundness of the
equipments and their erection in strict compliance with the specifications.
(b) INSULATION
The strength of the insulation and the dielectric strength of the entire equipment as installed
shall be tested with a 2500 V megger.
(C) CONTINUITY
The electrical continuity of the line and the existence of bad contact, if any, will be tested with a
megger.
(d) ELECTRICAL INDEPENDENCE
The electrical independence of individual elementary sections in relation to one another shall
also be tested with a Megger.
(e) SWITCHES
All isolators shall be tested for smooth and trouble free operation.
(f) TENSION DEVICES
All automatic tensioning devices shall be tested for sensitive functioning and adjustment.
(g)STAGGER AND HEIGHT
The stagger and height of contact wire over the entire section of completed overhead
equipment and the clearances available shall be measured and the measurement shall be
checked against approved drawings. These measurements shall be carried out at low speed
with a vehicle or device to be arranged by the Purchaser, the movement of which will follow the
track levels as closely as possible. Tolerance that will be permitted on the dimensions shall be
as per para 7.13 of this specification.
Dated 29.Jan 2015
Page 345 of 429
RVNL
The actual position of the two contact wires, relative to each other, at overlaps and turnouts,
shall also be checked. Special attention shall be paid to smooth movement of pantographs over
section insulators, particularly those which are likely to be frequently traversed.
(h)MECHANICAL BEHAVIOUR
The mechanical behavior of the entire equipment shall be tested at various speeds under
normal pantograph pressure without energizing the overhead equipment.
(i) ENERGISING
If the overhead equipment, after being subjected to the above tests in an un-energised
condition, is found to be satisfactory, it will be energized with the normal 25 kV Ac supply.
(j)Tests shall then be conducted to check if the power collection performance of the overhead
equipment is satisfactory after ensuring that the contact wire is adequately clean. For this
purpose, an observation car shall be attached next to the electric locomotive. The behavior of
the overhead equipment will be watched at various speeds. Power collection shall be considered
unsatisfactory if a long blue flash is observed, indicating that the contact between the contact
wire and the pantograph is not continuous.
8.5
INSPECTION AND TESTING OF SWITCHING STATIONS ETC:
(a)GENERAL
As soon as a switching station, booster transformer station or LT supply transformer station is
ready for inspection and testing, the Contractor shall advise the Engineer in writing. Testing will
be carried out by the contractor at his cost jointly with the Engineer. These shall include the
tests which the Engineer may like to conduct with a view to assure himself of the soundness of
the equipments and their erection in compliance with these specification However, testing
equipments such as those indicated below and staff required for the tests shall be provided by
the Contractor free of charge:
(i)
Oil testing equipment.
(ii)
2500 V & 500 V meggers.
(iii)
Earth megger and accessories.
(iv)
Continuity tests apparatus.
(v)
Avometer;
The Contractor shall take full responsibility for these tests inter-alia his other responsibilities.
(b)VISUAL INSPECTION
Visual inspection which shall include check for satisfactory workmanship shall cover all
connections, painting, plastering, cleanliness of insulators etc. and compliance with Indian
Electricity Rules.
(c) OPERATIONS TEST
This tests will be conducted on every individual item of equipment such as interrupters,
isolators, relays etc. to ensure that the equipment as a whole is functioning properly and
is mechanically sound i.e. in the particular case of isolators the fixed contact and knife
blade have been correctly aligned and operations does not cause undue strain on the
equipment. The operation tests will be carried out with the high tension installation
disconnected from the supply, but by actuating power devices where such are provided.
Continuity tests of high tension connections after setting such interrupter and isolator in
their respective positions shall also be conducted as part of the operation test.
(d) I NSULATION
The strength of insulation of the various items of equipment and of the entire installation as
a whole shall be tested with a 2500 V/500 V megger, as required.
Dated 29.Jan 2015
Page 346 of 429
(e)
RVNL
DIELECTRIC STRENGTH OF OIL
The dielectric strength of the oil of the Booster transformer & LT supply transformer, at each
station, shall be tested before commissioning in accordance with IS 12463-1988 or latest.
Should this not be found correct, the Contractor shall arrange at his own expense, to have it
rectified.
(g) ISOLATORS
All isolators will be tested for smooth and trouble free operation.
(h) INTERRUPTERS
Operation of trip and close coils for interrupters, shall be tested for satisfactory performance
with the respective equipments de-energised.
8.6
EARTHING:
(a)Earth wires will be checked for continuity and electrical isolation after every 1000mapprox.
(b)Clearances between earth wires and out-of –run wires of overhead equipment and signals
shall be checked.
(c)Earth resistance shall be measured separately for each earth electrode. In the case of
interconnected earth electrodes, the net resistance of the Inter-connected electrodes shall also
be measured.
8.7
DETAILED PROCEDURE FOR TESTS:
The detailed procedure for inspection and testing will be furnished to the contractor. The
contractor shall submit the results of tests in the proforma which will be furnished by the
Engineer, in quadruplicate.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 347 of 429
Dated 29.Jan 2015
RVNL
Page 348 of 429
RVNL
CHAPTER: B-9
SWITCHING STATION BUILDING
9.1
GENERAL:
This chapter deals with details and specifications for design and construction of switching
station buildings and associated electrical works.
9.2 EARTH WORK:
(a)Earth work in cutting or embankment in the premises of switching station buildings is included
in the scope of construction of building. The buildings will be adequately leveled with earth duly
consolidated in the premises or as directed by the Engineer.
(b) Mechanical Compaction:
As far as possible, mechanical compaction shall be done for full or part height of embankment,
as decided by the Engineer. If this is not possible, the suitable method for compaction will be
decided by the Engineer.
(c) Excavation:
All cuttings shall be taken down carefully to the precise level and section as shown in the
drawings or as decided by the Engineer. In case the bottom of the cutting is taken down deeper
than is necessary by oversight or neglect of the contractor, the hollow must be filled up to true
depth with selected material and rammed, as approved by Engineer. Cuttings with the
formation in rock will be excavated to 15 cm below the true formation and filled up to true level
with cutting spoil to ensure that no lumps of solid rock project above formation level.
(d) Drainage of cuttings:
In excavating cuttings, special precautions are to be taken to ensure that the excavations drain
themselves automatically. To ensure this, the central block of earth or gullet is to be excavated
first. This will be done in such a manner that the bottom of the excavation shall where possible,
slop downwards from the center of the cutting towards the ends. It will be made in such cuts or
steps as may from time to time, be directed. Generally, in deep cuttings the first cut or step will
approximately follow the surface of the ground where this will secure the necessary slope for
drainage, and will be excavated to a depth not exceeding 3 m or as decided by the Engineer,
with perpendicular sides, leaving pathways for workmen along the sides of the cut parallel to
the central line after about every 15 m. In shallow cuttings, not exceeding 2m in the deepest
part, the gullet may be cut at once to formation level.
(e)Catch Water drains:
Where required, catch water drains shall be constructed on the up hill side leaving a berm of
one metre from the boundary of the railway land. The cross sectional area of the catch water
drain shall normally not exceed 0.75 sq. m. The spoil from the catch water drain will be thrown
up on the side towards the cutting.
(f) Berms and Spoil banks:
No spoil shall be deposited within a distance of 6 m from the top edge of the slop-e of any
cutting.
(g) The spoil heap shall be roughly but neatly dressed off to a slope of 1-1/2:1 and shall form a
continuous bund along the top of the cutting. In country where there is any cross fall sufficient
spoil shall be thrown on the uphill side of the cutting to supplement the catch water drains and
assist in keeping drainage out. This work must be done first.
(h) All material excavated from cutting suitable for pitching, ballast, masonry or any other purpose
whatever, shall be the property of the Railway, and shall be stacked, as also disposed of, as
directed by the Engineer.
Dated 29.Jan 2015
Page 349 of 429
RVNL
(i) Springs or inflow:
Should springs or inflow of water appear in cuttings, or should they be flooded the contractor
must arrange for bailing, pumping or drainage of water, without obstruction to adjacent works.
(j) Blasting:
If any blasting operations are necessary, they shall be carried out by the contractor with all
safety precaution as per purchase directives.
9.3 FOUNDATIONS:
(a) Foundations shall be designed by the contractor in accordance with the tender specification. The
contractor shall get the relevant drawings approved by the Engineer. The foundation work may
involve wet excavation also, for which all due precautions by way of pumping and other
operations, preventing blowing are to be adopted.
(b) Plinth filling:
Plinth filling shall be done with earth in 15 cm layers, duly consolidated, watered & rammed
unless otherwise specified. In black cotton soil, the soil shall be removed for a depth of 60 cm
and top 30 cm filling shall be done with sand.
(c) Wherever it is necessary in case of deep trenches, shoring or timbering for such trenches shall
have to be provided to avoid collapsing of earth.
(d) Apron:
For protection of plinth, an apron as specified in drawing No. RE/Civil/BS -11/95 shall be
provided.
9.4 REINFORCED CEMENT CONCRETE WORK:
(a) RCC of the switching station shall be cast on the controlled concrete technology for M-15 grade
conforming to IS: 456-2000 or latest. The design of all RCC work shall be prepared by the
contractor and got approved from Engineer well in time.
Test concrete specimen shall be cast at the site of work and tested in accordance with the
relevant specification.
(b) If unavoidable due to site conditions, concrete may have to be laid in water as per laid down
procedure.
(c) All RCC works shall be finished smooth.
9.5 SUPER STRUCTURES:
(a) Brick work: Besides following relevant specification, well burnt bricks shall only be used. The
brick work shall be laid in ENGLISH BOND. The brick work below plinth shall be done in Cement
mortal of ratio 1:4(1 cement, 4 sand). The brick work above plinth shall be done in cement
mortal or ratio 1:6. Curing of the brick work shall be done for a minimum period of fourteen
days.
(b) Plastering: Plastering on inside and outside surfaces shall be done with cement mortar of ratio
1:3 and shall have a thickness of 10mm.
(c)Finishing: All external surfaces shall be treated with snowmen over two coats of cement primer
of approved quality and all internal surfaces of wall and ceiling shall be white washed with three
coats.
9.6 FLOORING:
(a)Following pattern of the flooring shall be adopted:
(i)Base concrete- 100 mm thick cement concrete of ratio 1:4:8 with under layer of 100 mm
thick sand filling over well compacted earth.
Dated 29.Jan 2015
Page 350 of 429
RVNL
(ii)Top layer- 40 mm thick cement concrete of ratio 1:2:4, laid in panels with glass dividing
strips of 25 mm x 3mm. Top surface of the flooring shall be finished smooth.
(b) Suitable anti termite treatment, pre and post treatment as approved by the Engineer, shall be
provided.
9.7
ROOFING:
RCC roof, complete in all respects in accordance with RDSO drawing No ETI/C/0067 Mod.-B
shall be provided. Water proofing of roof shall be carried out by the contractor. The type of
water proofing treatment, will be got approved from the Engineer. The contractor shall ensure
at the time of hanging over of the building that roofs are leak proof and water tight. The
contractor shall also provide CI rain water pipes of specified size.
9.8
DOORS, WINDOWS, VENTILATORS:
Pressed steel doors, windows, ventilators and grills etc. shall be provided in accordance with
drawing no. RE/Civil/S-129-2001 Rev-II. All steel work shall be painted with two coats of ready
mixed paint of approved quality and shade with Red Oxide primer coat.
9.9
BUILDING MATERIALS:
Building materials not already specified above, shall be used in accordance with approved
drawing by RVNL or as specified by the Engineer.
9.10 WIRING: Wiring of the substation shall be done as per RVNL standard specifications given in
Part-A.
Electrical fittings, plug points and appliances as indicated in following table shall be provided in
a switching station. The contractor shall get the locations of the electrical fittings/appliances
approved from purchaser.
SN
1
2
3
4
5
6
7
9.11
TABLE
DESCRIPTION OF ITEM
Wiring of Light (3 nos), Fan (1 No.) Ex. Fan (1 No.) &
light plug points (1 No)
Wiring of power plug points (16 Amp.)
1x28 watt Surface type T-5, Energy Efficient Luminary
with Tube
1x150 watt Street light Metal Halide (MH) Luminary
with Lamp 150 watt
230Volt Ac, 450mm, 900 RPM exhaust fan.
AC ceiling fan 1400 mm sweep complete with stepped
type electronic regulator
Double Door MCB Distribution Board complete with
Incoming MCB DP-32 Amp with RCCB 100 mA and O/G--6-16 amps. MCB SP-3 Nos. & 20 amps. MCB SP-3
Nos.
QUANTITY
6 Nos.
2 Nos.
2 Nos. (inside the
building)
1 No. (outside the
building)
1
No.
(battery
room)
1 No.
1 Nos. (Main)
TESTING AND COMMISSIONING:
On completion, all works including wiring, electrical fittings and appliances shall be tested
jointly with the representative of the Engineer in accordance with IS: 732/1989 or latest and
commissioned.
-----------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 351 of 429
Dated 29.Jan 2015
RVNL
Page 352 of 429
RVNL
CHAPTER: B-10
TRACTION SUB-STATIONS/FEEDING POSTS
GENERAL REQUIREMENTS
10.1 INTRODUCTION
This part deals with general information and criteria for design, manufacture, supply, erection
and testing of equipment at 132/25 kV (or any other rating depending on input voltage
availability from grid with output always being 25 kV AC) traction sub-stations, feeding stations
and 25 kV Shunt Capacitor Bank. These traction sub-stations are also referred to as “SUBSTATIONS” in these technical specifications.
10.2 DEFINITIONS
The following definitions shall apply for the purpose of this specification, in addition to
definitions applicable to standard equipments.
(a) ”Grid Sub-station” means the sub-station of a power supply authority which is connected to the
grid network in the area and from which 132 kV (or any other level ) power is supplied to the
Railway for electric traction.
(b) ”Interrupter” means a single pole single phase non-automatic circuit breaker capable of
interrupting normal full load current.
(c) “Return Feeder” means the conductor of the feeder line from a traction sub-station to the
corresponding feeding station which is connected to the earth terminal of the traction
transformer secondary winding.
(d) “Traction overhead equipment” means the overhead conductors and other associated
equipment and structures erected over the track to supply power to the electric locomotives.
(e) “Traction sub-station” means a sub-station that converts the grid supply voltage to 25 kV AC to
supply power to traction overhead equipment installed on the railway track, in accordance with
this specification.
(f) “25 kV Feeder” means the conductor or feeder line from the traction sub-station to the
corresponding feeding station and which is connected to the unearthed terminal of the traction
transformer secondary winding.
(g) ”Feeding station” means the 25 kV interrupters and other associated equipment as also
structures erected near the track, within or outside the sub-station boundary, for feeding
different sections of the traction overhead equipment.
(h) ”Shunt Capacitor Bank” means shunt capacitor equipment, along with control gear, protective
relays, series reactor and accessories erected on 25 kV side of a traction sub-station for the
purpose of maintaining unity power factor and reduction of maximum demand.
10.3 FUNCTIONS
The traction sub-stations covered by this specification will be installed to supply power for
electric traction at 25 kV Ac 50 cycles single phase through the traction overhead equipment.
Dated 29.Jan 2015
Page 353 of 429
RVNL
10.4 LOCATION
The locations of the traction sub-stations are given in the Bidding Documents.
10.5 CLIMATIC DATA
The climatic data pertaining to the area in which the sub-stations will be located are given in
the Bidding Documents.
10.6 WIND PRESSURE
Structures and foundations for the sub-stations shall be designed for a wind pressure as per
wind zone of the area indicated in the IS-875 Part-3 unless otherwise indicated in the Bidding
Documents.
10.7 SYSTEM PARTICULARS
(a) Power will be received at 132 kV ( or any other voltage available in the region) single phase,
50 cycles at the traction sub-stations and stepped down to 25 kV by means of single phase
traction transformer. On the primary side the traction transformers will be connected across two
phases of the 132 kV, 3 phase system, On the secondary side one terminal of the transformer
will be solidly earthed and also connected to the traction rails, the other terminal will be
connected to the traction overhead equipment through 25 kV switchgear.
(a) Adjacent sub-stations will normally be connected across different phases to reduce the
unbalance on the three phase power supply system. In order to keep the supply from two
adjacent sub-stations separate, a neutral section is provided on the traction overhead
equipment approximately midway between them. The neutral section is normally kept dead.
Electric locomotives coast through the neutral section with power off.
(b) The traction sub-stations, will normally be unattended and all switching operations will be
carried out by remote control from a Remote Control Center.
(c) FEEDERS & RETURN FEEDERS 25 KV ALONG TRACK FEEDERS
25 kV along track feeders may connect sections of overhead equipment to a switching station
or an isolator switch or gantry. Such feeders will be run usually on traction structures and
sometimes on independent masts. A single ‘ SPIDER’ conductor shall be used for such feeders.
(e) SCHEMATIC ARRANGEMENTS
The different arrangements of feeders, return feeders, 25 kV along track feeders and return
conductors can be seen from the drawings listed in the Annexure.
(f) JUMPERS
All jumpers connected to OHE conductors shall be of copper only. The in
–span jumpers,
potential equalizer jumpers at insulated overlaps and neutral section, shall be of 50 sq mm
nominal section, 19/1.8mm size. Flexible jumpers of nominal section 105 sq mm, 19/7/1.06
mm size shall be used at overlaps, turnouts, crossings etc.
The jumper connecting the Aluminium conductors to any other conductors, terminals or
clamps shall be made with the aid of suitable bi-metallic clamps. All aluminium jumpers of
size 19/7/1.4 mm bare ¾ hard shall be used to connect other Aluminium conductors such as
return conductor. The tail ends of feeder wires from the strain clamps at the termination of a
feeder, return feeder or return conductor may be connected directly to a terminal or clamp
where feasible to avoid the use of a separate jumper wire.
(g) Capacitor Bank for FP
Dated 29.Jan 2015
Page 354 of 429
RVNL
A capacitor bank may be provided at feeding posts, for power factor correction. This shall be
of outdoor type, mounted on steel racks for connection to the 25 kV bus through single pole
isolator and circuit breaker. The capacitor bank shall consist of groups of individual capacitor
units, connected in series parallel combination to deliver the rated output, at normal rated
system voltage, rated frequency and other rated system conditions.
(h) Series reactor (Harmonic Suppression Reactor)
A series reactor, shall be provided to limit the inrush current and surge voltage at the time of
switching in the capacitor bank. The switching surge voltage shall not exceed 70 kVP. The
series reactor which is also meant to filter a part of the harmonics generated by the traction
loads shall have inductive reactance (XL) equal to or greater than 13% of capacitive reactance
(XC) of the capacitor bank. The series reactor shall be natural air cooled, air cored. The feeder
circuit breakers will from a part of the sub-station and will be covered by this specification.
(i) At the feeding station, the 25 kV supply will be fed to different sections of the traction
overhead equipments by means of interrupters. All interrupters will be remote controlled.
(j) Normally, traction substation will be located alongside the Railway track. The feeding stations
will be located within the sub-station boundary and connected to the traction sub-station
boundary and connected to the traction sub-station by extension of the 25 kv busbars. Where
the traction sub-station is located some distance away from the track, the 25 kV supply will be
extended to the feeding station by means of two overhead feeders carried on tower/masts.
Each feeder line will comprise two conductors one called the 25 kV Feeder and the other
return feeder.
(k) A small masonry building called the control room, will be provided at each sub-station to
house the control and instrument panels, remote control equipment, batteries, battery
chargers, telecommunication terminal equipment, telephones and AC and DC LT distribution
boards, capacitor bank equipment (if required to be indoors) etc. (See relevant drawing
included in Annexure-1).
(l) For Fire protection, baffle wall shall be provided in between the two bays of the power
transformer as per RDSO Drg. No. ETI/C/0214 for wind pressure upto 112.5 kgf/sqm (brick baffle wall)
and RDSO Drg. No. ETI/C/0213 for wind pressure beyond 112.5 kgf/sqm (RCC baffle wall).
(m) The entire traction sub-station and the control room will be protected by a fenced enclosure. A
railway siding from the nearest railway station will be terminated inside each-sub-station,
where feasible, to enable unloading of heavy equipment at site. Road access will also be
provided wherever possible.
10.8 (a) FEEDING STATION
Every feeding station has gantry with two or more main masts (Up-right). The interrupters are
located behind the gantry. Isolators, Potential Transformers, station class lightning arrestors
and pedestal insulators are mounted on the gantry. From the gantry, connections are made to
various sections of overhead equipment by cross feeders and jumper connections. Feeding
stations are unattended and remote controlled from a remote control center (see part-III).
Feeding stations will be located within the traction sub-station premises. Control equipment,
S&T terminal equipments, arrangement for termination of cables from feeding station
equipments will be provided inside the sub-station control room.
10.8(b) SHUNT CAPACITOR BANK
Capacitor Bank, along with associated equipments, will be located inside traction sub-station
premises. Capacitor Bank and series reactor shall be mounted on steel racks for connection 25
kV bus through single pole isolator and circuit breaker. The control panel for the capacitor bank
shall be installed inside the control room of the traction sub-station.
Dated 29.Jan 2015
Page 355 of 429
RVNL
10.9 AUXILIARY SUPPLIES
(a)The following auxiliary supplies shall be provided at each traction sub-station:
(i)110 V, 200 Ah battery for operation of switchgear.
(ii)Single phase 240 V Ac supply.
10.10 SCOPE OF WORK
The traction sub-stations, feeding stations and 25 kV shunt capacitor banks when erected shall
be in accordance with the specification and functionally complete in all respects. All works
required in this connection shall be deemed to be a part of the scope of work of the contract,
whether specifically stated or not.
TRACTION SUB-STATION & SHUNT CAPACITOR BANK
10.11 CLEARANCES
The minimum clearances in mm in air for live equipment shall be as under:
1.
2.
3.
4.
Between phases
Between one phase
and earth for rigid
connection
Between any points
where man may be
required to stand to
the nearest
a)unsecured conductor
in air(mm)
b) Secured condition in
air(mm)
Minimum height of bus
bar.
25 kV
-
66kV
630
100kV
900
132 kV
1300
220 kV
2400
500
630
900
1300
2100
3000
3500
3500
4000
5000
2000
-
-
-
-
3800
4600
4600
4600
5500
10.12 EQUIPMENT AND BUSBAR LAYOUT
The layout of equipment and bus bar arrangement for typical sub-stations is shown
schematically in drawing incorporated in Annexure-1.
10.13 NUMBERING
Each circuit breaker, potential transformer, current transformer, Traction power transformer ,
LT Supply Transformer, Isolator and Lightning Arrestor shall carry a vitreous enameled steel
number plate of approved design (See Annexure-1). The Engineer will furnish the actual
numbers to be allotted to the various switchgear installed at the sub-station.
10.14 BUS BARS
All equipment to equipment connections on the 132 kV side as well as bus bars strung between
gantries/portals to which the HV terminals of the transformers shall be connected, shall
comprise ACSR conductors and aluminium alloy tubes. The bus bars and bus bar connections on
the 25 kV side shall consist of aluminium alloy tubes supported on pedestal insulators wherever
necessary at intervals of not more than 4.5 m.
---------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 356 of 429
RVNL
CHAPTER: B-11
FEEDING STATIONS SWITCHING STATIONS, BOOSTER
TRANSFORMER-STATIONS AND L.T. SUPPLY TRANSFORMER
STATIONS
11.1
DESCRIPTION
(a) Switching Stations
Every switching station has a gantry with two or more main masts (Up-right). The interrupters
are located behind the gantry. Isolators, Potential Transformers, station class lightning arrestors
and pedestal insulators are mounted on a gantry. From the gantry, connections are made to
various sections of overhead equipment by cross feeders and jumper connections. Switching
stations are unattended and remote controlled from a remote control centre. A small masonary
cubicle, called the control cubicle, shall be constructed at each switching station to house
control equipment, batteries, battery charger, S&T terminal equipment, terminal board for
terminating cables from the switching station equipment, a telephone and telephone equipment
and AC 240 V distribution board. The switching station and its control cubicle (other than
feeding posts) shall be enclosed by fencing.
(b) Booster Transformer
Booster stations are provided for each track at the insulated overlap spans. The primary
terminals are connected directly in series with the traction overhead equipment and the
secondary terminals directly in series with the return conductors by means of flexible jumpers.
Normally each booster station will be provided with one booster transformer which will be
mounted on a gantry structure with two masts as indicated in a drawing listed in the Annexure
to these Technical Specifications. Two 7.5 kV lighting arrestors for each booster transformer are
also erected on the gantry and connected to the LT terminals of the booster transformer
Single booster station will be located on either side of the track in a double track section. In
multi-track sections where space does not permit location of a booster station, it may be
provided with cross feeders for connections to the overhead equipment and return conductors
as indicated in the relevant general arrangement drawing listed in the Annexure to these
(c) L.T. Supply transformer stations
The low tension supply required at switching stations will be obtained through L.T. supply
transformers, mounted on steel structures and connected to the 25 kV side through rigid busbars of aluminum. In special cases where the length of connection is small, 50 sq. mm copper
wire may be used for connection, with the approval of the Engineer. At locations other than at
switching stations, wherever low tension supply is required, LT supply transformer stations may
be provided along the track at isolated location.
L.T. supply transformer stations shall essentially comprise of a mast mounted transformer
connected to the traction overhead equipment through dropout fuse switches. The 240 V side
shall be connected to a distribution board located at the remote control cubicle by means of a
two-core, aluminum conductor, XLPE insulated, PVC sheathed and steel armoured heavy duty
cable of requisite size, conforming to IS 7098/Pt. I/1988 or latest (see 5.20 (a). The general
arrangement drawing for LT supply transformer stations for single/double and multi-track
sections is included in the Annexure to these Technical Specifications.
Dated 29.Jan 2015
Page 357 of 429
RVNL
11.2 SCOPE OF WORK:
(a)Switching Staions.
The switching stations shall be complete in all respects in accordance with specifications. The
work may also include, depending on the project requirement and as specified in the Bill of
Quantities of the tender:(i) Filling up and leveling of the ground to the extent necessary.
(ii) Provision of control cubicles for installation of remote control equipment for
switching stations.
(iii) Provision of 240 V AC distribution board.
(iv) Provision of lights, plug points inside the cubicles.
(v) Trench work inside the cubicles.
(vi) Supply and spreading of gravel
(b)
Booster Transformer Stations
The booster transformer stations will be complete in all respects, in accordance with the
specifications. The work may also include the following, depending on the project requirement
and as specified in the Bill of Quantities of the tender:(i) Filling up and leveling the ground to the extent necessary.
(ii) Cable and cable connections in LT side.
(iii) Supply of L.T. supply transformer and other equipment as listed in the Annexure
to these Technical Specifications.
11.3 SETTING OF GANTRIES:
The gantries are normally aligned parallel to the track. The minimum distance of the face of the
gantry from the center line of the nearest track is referred to as the ‘setting’ of the gantry. The
setting shall normally be 3.5m. Setting of the individual gantries of different stations will be
furnished by the Contractor.
11.4 DATUM LEVEL:
The datum level will be the finished level of the gantry mast foundation. All vertical dimensions
shall be stated with respect to this datum level. Datum levels of individual stations will be
indicated on the location and connection diagrams.
11.5 MOUNTING OF EQUIPMENT AND BUSBAR ARRANGEMENT:
(a) The interrupters and isolators shall be mounted in such a way that these can be manually
operated conveniently by a person standing on the ground. The indicators showing the ‘OPEN’
or ‘CLOSED’ position of the equipment shall be so arranged as to be visible from out-side the
fencing enclosure on the side of the main gantry.
(b) The bus-bar arrangement for typical switching stations is schematically indicated in a drawing
included in the Annexure to these Technical Specifications.
11.6 FENCING & ANTICLIMBING DEVICES:
Every switching station, together with its associated control cubicle shall be enclosed by fencing
except at feeding stations that are located within the traction sub-station premises. The fencing
shall have an anti-climbing device also at top.
Transformer and L.T. supply transformer stations, suitable anti-climbing devices
consisting of galvanized steel clamp fixtures shall be mounted on each mast. The device shall
be fitted below the transformer supporting beam or steel work. The general arrangement
Dated 29.Jan 2015
Page 358 of 429
RVNL
drawings indicating the fencing and anti-climbing devices, are indicated in the Annexure to
these Technical Specifications.
11.7 NUMBERING:
Each booster transformer, interrupter, potential transformer, LT supply transformer and isolator
shall carry an enameled number plate of approved design. The Engineer will furnish the actual
numbers to be allocated to the various equipments as per specification No. ETI/OHE/53 (6/88)
with A&C slip No. 1 to 5.
11.8 INTERLOCKING ARRANGEMENTS:
An interlock shall be provided between each interruptor and its associated double pole isolator,
to prevent operation of the isolator from the open to the closed position or vice-versa, unless
the interruptor is locked in the open position and to prevent operation of interruptor either
manually or by remote control unless the isolator is locked in the open or closed position. The
interlocking device shall consist of a lock combined with an electrical contact to make or break
the remote control circuit on the operating mechanism of the interruptor and a lock for the
isolator operating mechanism and interlock key for the two locks.
11.9 CABLE CONNECTIONS:
(a)All PVC cables provided outdoor shall be either laid in the trenches or neatly clamped to the
structures as approved by the Engineer.
(b) Termination of cables
The cables shall be terminated neatly and all the cores arranged and dressed properly. Suitable
indexed terminal lugs or ferrules shall be provided at all terminals to facilitate maintenance.
11.10 CLEARANCES:
No part of the installations which is live at 25 kV shall be erected at a height less than 3 m from
the datum level. Clearance between any part live at 25 kV and any part at earth potential (or
part likely to be earthed ) shall not normally be less than 500 mm. This clearance may be
reduced under special circumstances but in no case static clearance shall be less than 320250
mm and any dynamic vertical and horizontal clearances shall be less than 250 mm and any
dynamic vertical and horizontal clearances 250 mm and 200 mm respectively. The clearance
between any part live at 3 kV and any part at earth potential (or part likely to be earthed) shall
be not less than 150 mm under static condition and 70mm under dynamic conditions.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 359 of 429
Dated 29.Jan 2015
RVNL
Page 360 of 429
RVNL
CHAPTER: B-12
STRUCTURES AND STEEL WORK-TSS
12.1 SCOPE:
This chapter deals with the design of all structural steel work including gantry structures,
supporting structures and small parts steel work including chairs, brackets and other fabricated
steel work for mounting various equipments, bus bars, cables etc. at traction sub-stations,
feeding stations and shunt capacitor banks.
12.2 GENERAL
The steel structures may be of riveted, bolted or welded construction as convenient for
installation. The thickness of smallest steel section used shall not be less than 6 mm (or ¼”).
Legs of gantry structures/portals and supporting steel work and uprights or bus bar supports
shall generally be embedded in concrete foundation blocks and for equipment and in special
cases secured by means of holding down bolts.
12.3 DESIGNS
(a) All the steel structures like gantries/portals, other supporting members, small part steel work
etc. shall be galvanized after fabrication with a minimum value of average mass of zinc coating
being not less than 610 g/m sq as per RDSO’s specification No. ETI/OHE/13 (4/84) with A&C slip
No. 1 to 3.
(b)All designs for special steel work shall be furnished by the contractor for the approval of the
Engineer. Designs for steel structures shall, except where otherwise provided, comply with the “
Indian Standard Code of Practice for use of Structural steel in General Building Construction” –
IS: 800-1984 or latest other relevant IS specifications and statutory regulations.
(c)For purposes of design, all possible loads which may occur in the worst combination shall be
considered.
(d)Steel Structures
For calculation of wind load on structures, conductors and equipment, the basic wind pressure
shall be taken as per wind zone of the area indicated in the IS-875 Part-3 1987.
(e)For purposes of design of gantries, the tension in the 220 kV incoming/outgoing lines shall be
taken as 200 Kg. at 4 degree C ( without wind) in each conductor and 150 Kg. at 4 deg. C (
without wind ) in the earth wire. The tension in the 66 kV strung bus-bars and earth screen wire
at 66/25 kV sub-stations shall not exceed 200 kg. At 4 degree C ( without wind)
(f) Uprights and fencing posts
Uprights carrying equipment such as potential transformers, current transformers, lightning
arrestors, bus bar support insulators, shall be made from standard metric steel sections viz.
channels, angles or small joists, either single or fabricated.
(g) Notwithstanding the provisions contained in I.S. and other regulations referred to in para
12.3(b) above regarding permissible deflection, the following should apply.
• The deflection at the top of the mast or structure shall be limited to one eightieth (1/80) of
its height above foundation.
(h)The torsional rotation of the mast due to permanent loads shall not exceed 0.1 radian.
Dated 29.Jan 2015
Page 361 of 429
RVNL
12.4 STEEL
Steel conforming to IS: 2062-1992 or latest shall be used for all fabricated steel work. Steel
should be to designation ST: 42-S.
12.5 STEEL WORK FOR FEEDING STATIONS AND GANTRIES
(a)HORIZONTAL MEMBERS OF GANTRY
Horizontal member of main as well as auxiliary gantry carrying isolator switches, insulators,
potential transformers etc. shall be made from steel sections viz. channels, angles and small
joists, single or fabricated. They shall preferably be attached to masts by means of clamps to
avoid drilling of masts sections.
(b)For purpose of design, all possible loads which may occur in the worst combination shall be
considered. The loads shall include the following:i) Weight of insulators, instrument transformers, isolator switches, bus- bars, and their
accessories.
ii) Loads caused by feeders, along and across tracks, return feeders etc.
(iii) Loads caused by anchorage due to guying of anchored masts (where applicable).
(iv) Pull or push on the structures due to anchorage and radial tension (where applicable).
(v) Wind load on the different structures, conductors and equipment. The wind pressure shall
be taken as that indicated in the bidding documents.
(vi) Weight of men working on the structures.
(vii) Weight of structure itself.
(viii) Erection loads.
(ix) Any other load or loads which may occur due to special equipment wherever they occur.
(c)TENSION OF CONDUCTORS
For purpose of designs, the maximum tension of different conductors, without wind load, shall
normally be as under:(i) Maximum tension in the cross feeders at switching stations under worst loading conditions:1) For spans less than 18m……..100 kgf.
2) For spans more than 18 m…..200 kgf.
(ii) Maximum tension in longitudinal feeders running parallel to the track at the switching
stations under worst conditions. 1,500 kgf.
(iii)Tension in anchored
stations….2000 kgf.
overhead
equipment
in
case
of
sectioning
and
paralleling
(d) DEFLECTION OF GANTRY MASTS
Deflection under permanent loads (at an average temperature of 35 deg. C (without wind ) at
the top of the fabricated structures or masts shall be limited to one eightieth (1/80th ) of its
Dated 29.Jan 2015
Page 362 of 429
RVNL
(d) Masts of the gantry at which feeder or overhead equipment will be anchored at the switching
station shall normally be provided with suitable guys, but struts shall not be permitted.
(f) CHAIRS AND BRACKETS
Chairs, brackets and supporting steel work carrying potential transformers, lightning arrestors,
insulators, etc. shall be made of fabricated steel and shall be mounted on the main auxiliary
gantry preferably by means of clamps to avoid drilling of mast sections.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 363 of 429
Dated 29.Jan 2015
RVNL
Page 364 of 429
RVNL
CHAPTER: B-13
EQUIPMENT, COMPONENT AND MATERIALS-TSS
13.1 GENERAL
This chapter deals with details and specifications of the equipments, components and materials
to be used at the traction sub-station, feeding station and shunt capacitor bank. It does not
cover foundations and structures which are dealt with in separate Chapters. The detailed
specifications for various items of equipment and materials issued by the Railway may be
bought separately from Research Design and Standards Organisation, Lucknow.
13.2 COMPLIANCE WITH STANDARD SPECIFICATIONS
In the technical specifications of equipments references are made to the following standard
specifications.
i) International Electro-technical Commission (abbreviated as IEC Publications).
ii) British Standards (Abbreviated as BS).
iii) Indian Standards (abbreviated as IS/BIS).
13.3 INSULATION LEVEL
All equipment including insulators to be used at the traction sub-stations, feeding station and
shunt capacitor banks shall be suitable for the insulation level specified below:-
i) Power frequency 1 min. wet with
stand test- in kV(rms)
ii) Impulse (1.2/50 microsecond)
withstand test positive and
negative polarity (crest value)
- in kV (peak).
Service Voltage
-------------------------------------------------------220 kV
132 kV
110 kV 66kV
25 kV
------------------------------------------------------460
275
230
160
95
1050
650
550
350
250
13.4 INSPECTION
All equipment, material etc, shall be inspected by RITES and the inspection charges
shall be borne by the contractor.
13.5 NIL
13.6 ROUTINE TESTS
These comprise inspection and tests conducted at the manufacturer’s works on every
equipment/component /fitting supplied by the Contractor or as specified, for exercising quality
control of manufactured items.
13.7 TEST CERTIFICATES
Three copies of the test certificates of successful prototype tests carried out at the
manufacturer’s works on equipment/component/fitting shall be furnished to the Engineer within
a month after completion of the prototype tests. Three copies of routine tests carried out on
each equipment shall also be furnished, after the equipment is passed by the Engineer’s
representative on inspection.
Dated 29.Jan 2015
Page 365 of 429
RVNL
13.8 BULK MANUFACTURE
Bulk manufacture may be undertaken only after specific written approval of the Engineer or his
representative has been obtained, indicating that tests on the prototypes are satisfactory.
Where prototypes have already been approved in connection with electrification works already
in progress, bulk manufacture may proceed after exemption from prototype tests is received
from the Engineer in writing.
13.9 INTERCHANGEABILITY
Parts and components of similar equipments and all fittings shall be fully interchangeable.
13.10 TECHNICAL SPECIFICATIONS
The following specifications (latest revisions) will govern supply and testing of various items of
equipment and materials except where otherwise specified in the Bidding documents or Railway
specifications, which are listed at Annexure-1.
Standard Specifications
General requirements for the supply of metals and metal
products
Tin bronze castings
All aluminium conductor
Aluminium conductors galvanized steel reinforced
Aluminium conductors galvanized steel reinforced hard
drawn stranded aluminium and steel –code aluminium
conductors for over head power transmission purposes.
Disc Insulators
Aluminium and steel cored Aluminium conductors for
overhead power lines.
Aluminium alloy for clamps and fittings, for connectors
Control cables (PVC insulated)
Structures and steel work
Structural steel ( standard quality).
Code of practice for General Construction of plain &
reinforced concrete.
Method of tests for strength of concrete
Hard-drawn standard aluminium and steel-cored Al
conductors for overhead power transmission purposes
Coarse and fine aggregate from natural sources for
concrete.
IS: 1387-1993
IS:306 -1983 (grade
G-2)
IS: 398 ( Part-I)1996
IS:
398(Part-III)
1976
IS:398(
Part-III)1976
IS:398(Part-I)-1996
IS: 3188-1980
IS: 731-1971
IS:2121-1981(Part I
&II)
IS: 617-1994(A-6-M)
IS:1554(Part-I)-1988
IS:800-1984
IS: 2062-1992
IS: 456-2000
IS:516-1959
IS: 398(Part- I)1996
IS: 383-1970
13.11 STEEL WORK AND PROTECTION AGAINST RUST.
a) Galvanising
All ferrous components and fittings shall be hot-dip galvanized according to specification No.
ETI/OHE/13 (4/84).
b) Rectification at site
If minor modifications, which would damage the protective coat, become necessary at site,
these shall be carried out with the approval of the Engineer and in a manner to be specified by
him in accordance with specification ETI/OHE/13(4/84) with A&C slip No. 1 to 3.
Dated 29.Jan 2015
Page 366 of 429
RVNL
13.12 BUSBARS
a) ACSR Conductors
ACSR conductors used as bus bars or bus bar connectors shall be of ZEBRA ACSR size 61/3.18
mm (28.62 mm dia ) at 220/25 kV traction Sub-station.
b) Aluminium tubes
Aluminium tubes used as bus bars or bus bar connectors shall be of dia 50x39 mm for traction
sub-station and shunt capacitor banks of size 36mm x 28mm for feeding stations. The
aluminium tubes shall be made of alloy 63401 to IS: 5082-1998 or latest and IS: 6051-1970
or latest or its equivalent. The maximum manufacturing tolerance on diameter and thickness
of the tubes shall not exceed the values specified under Class-I of IS: 2673-1979.
c) Busbar junctions and connectors
Busbar junctions and connectors shall be made with aluminium alloy grade 4600 M to IS:6171994 or equivalent.
d) General
The bus bar shall be clean, smooth mechanically sound and free from surface and other
defects. No splices will be allowed in the bus bars unless the length of bus bar exceeds 6 m.
The ends of the tubular bus bars shall be covered with suitable end caps. Provision shall be
made where necessary to allow for expansion and contraction caused by temperature
variation.
e) Joints
The joints in bus bars where unavoidable, shall be mechanically and electrically sound, so that
the temperature rise under normal working conditions does not exceed 40 degree C for a
maximum ambient temperature of 45 degree C.
13.13 TERMINAL CONNECTORS
The equipments such as power transformers, circuit breakers etc. shall be supplied by the
Engineer with suitable terminal connectors of approved design and of bimetallic type wherever
required.
13.14 INSULATORS
The pedestal insulators for service voltage of 132 kV shall be of solid core type conforming to
specification as indicated in Annexure-1. The pedestal insulators for service voltage of 25 kV
shall be of the solid core type conforming to specification as indicated in Annexure-1.
13.15 NOMENCLATURE
All components/fittings supplied by the Contractor to Railway’s standard designs shall bear the
standardized nomenclature and identification numbers, if any.
13.16 CABLES
a) Cables for LT supply
240 V Ac supply from 10 KVA LT supply Transformer shall be brought and terminated on the
LT AC distribution board in the Control room by a 2 core 70 sq.mm. Aluminium conductor
cable. The cables shall be XLPE insulated, PVC sheathed and armored cables of 1100 V grade
complying with IS:7098/Pt.I.1988 or latest.
Dated 29.Jan 2015
Page 367 of 429
RVNL
b) Control Cables
All control cables shall be of copper conductor 1100 V grade and PVC insulated (heavy duty),
complying with IS: 1554(part-I)-1988. The sizes and number of cores of various control cables
required are given in the table below for copper cables.
Requirement
V
No.
of
core/section
(Sq. mm)
7x 2.5
110
DC
V
10x2.5
Five cable to be
used
66/25 kV
to control
110
DC
V
4x4.0
One cable for each
CT to be used
From
each
current
transformer to control
board
110
DC
V
2x4.0
One cable for each
core of CT/ neutral
CT
From
each
potential
transformer to control
board
i) Connection between
battery chargers & DC
distribution board
110
DC
V
2x2.5
One cable to be
used
110
DC
V
4x4.0
ii) Connection between
batteries
&
Dc
distribution board
110
DC
V
4x4.0
iii) Connection from Dc
distribution
board
to
control board
110
DC
V
4x 4.0
From
interrupter
control board.
to
110
DC
V
7 x 2.5
One cable to be
used
with
two
cores connected in
parallel
One cable to be
used
with
two
cores connected in
parallel.
Two cables to be
used with each
circuit
and
one
cable for Dc supply
to control boards.
Two cable to be
used
Connection
from
distribution
board
control board.
Ac
to
240
AC
V
2 x 2.5
Purpose
Run
Circuit
Voltage
1.
Control
&
indication
of
circuit breakers
2.
Transformer
alarm/trip circuits
& tap changer
control
3.
Transformer
protection
(bushing current
transformer
connections)
4.
Current
transformer and
neutral
connections
5.
Potential
transformer
to
connections
6.
110
VDC
supply
From
each
circuit
breaker to control board
110
DC
From each
transformer
board.
66/25 kV
to control
From each
transformer
board
7.
Control
&
indication of bus
coupler
interrupter
8. 240
V Ac
supply
Dated 29.Jan 2015
Three cables to be
used.
One cable to be
used.
Page 368 of 429
RVNL
c) Cables for heater circuits
The 240 V Ac supply to space heaters provided in control cabinets of various equipments shall
be provided by means of 4 sq.mm,2-core aluminium PVC insulated ( heavy duty) cables
complying with IS: 1554 (part-I)-1988 or latest. Three circuits shall be provided on the LT AC.
Distribution board for this purpose, one for the heaters in the control cabinets of 132 kV circuit
breakers the second for the heaters in the control cabinets of 25 kV circuit breakers and
bridging interrupters and the third for heaters in marshalling box of traction transformers. Each
circuit shall be provided with a fuse of approved type and suitable rating in the LT AC
distribution Board.
d) Cables for battery charger
240 V Ac supply to each of the battery chargers in the Control Room shall be provided by means
of 4 sq. mm 2 core PVC insulated, PVC sheathed (heavy duty) copper cables complying with
IS: 1554 (Part-I)-1988 or latest. Two circuits each with a fuse of approved type and suitable
rating in the LT AC. Distribution board shall be provided for the two battery chargers in the
Control Room. The 240 V Ac supply to control board from Ac distribution board shall be
provided by means of 2.5 sq. mm 2-core PVC insulated PVC sheathed (heavy duty ) copper
cable complying with IS: 1554 ( Part-I) -1988 or latest.
Cables for blower fans
240 V Ac supply to blower fans fixed on the traction transformer shall be provided by means of
2 core 25 sq.mm. Aluminium conductor cables. The cables shall be XLPE insulated, PVC
sheathed and armored cables of 1100 V grade complying with IS: 7098/PtI/1988 or latest.
Separate cables shall be laid from the LT AC distribution board in the control room to
marshalling box of each traction transformer. Individual circuits from the LT AC distribution
board shall be provided for this purpose with each circuit protected by a fuse of suitable rating.
f) The cable shall be resistant to decay, mechanical abrasion, acids, alkalis and other corrosive
materials.
e)
13.17 INSTRUCTIONS AND TECHNICAL BOOKLETS
The Contractor shall, within six months of issue of letter of Acceptance, supply 5 copies of
booklets containing manufacturer’s instructions for operation and maintenance of each of the
items of equipments, the supply of which is included in the contract. In addition, 25 copies of
detailed schedule of components, catalogues and drawing of all parts of the equipment shall
also be supplied.
13.18 ELECTRICAL CONNECTIONS FOR OHE AT FEEDING STATIONS
a)GENERAL DESIGNS
All electrical connections between conductors shall be made by parallel clamps. The general
arrangements of connections are shown in the standard drawings listed in Annexulre-1
b) COPPER JUMPERS
Copper jumpers shall be of any of the following type:
i) Large jumpers of annealed copper in accordance with specification ETI/OHE/3(2/94) with
A&C slip
No. 1 (4/95)
ii) Small jumpers of annealed copper in accordance with specification IS: 9968 (Pt.2)- 1981 or
latest
c) ALUMINIUM JUMPERS
Aluminium jumpers wherever used, shall be of all Aluminium stranded conductor 19/7/1.4 mm
bare ¾ H generally conforming to IS: 8130:1984 or latest
d) FEEDERS
Feeders shall be of all aluminium conductor 19/3.99 mm (SPIDER).
-------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 369 of 429
Dated 29.Jan 2015
RVNL
Page 370 of 429
RVNL
CHAPTER: B-14
DESIGNS & DRAWINGS FOR TRACTION SUBSTATION
14.1 GENERAL
a) This chapter deals with the procedure for approval of designs and drawings for traction substations, feeding stations and shunt capacitor banks.
b) The type designs shall be as few as possible to cover the largest field of application consistent
with economic considerations.
c) In all drawings, as far as possible only internationally accepted symbols shall be used.
14.2 CONTRACTOR’S DRAWINGS
a) The Contractor shall submit to the Engineer for approval, except where otherwise specified
below, all detailed designs and drawings which are necessary to ensure correct supply of
equipments, components and materials and to enable correct and complete erection of substations in an expeditious and economic manner.
b) It is to be clearly understood that all original designs and drawings shall be based on a thorough
site study. General designs and dimensions, shall be such that the contractor is satisfied about
the suitability of the designs for the purpose. The Engineer’s approval will be based on these
consideration and notwithstanding the Engineers acceptance, the ultimate responsibility for the
correct design and execution of the work shall rest with the Contractor.
14.3 STANDARDS FOR DRAWINGS
All designs, legends, notes on drawings and schedules of materials shall be in English and shall
be prepared in the metric system. All designs and drawings shall conform to RDSO specification
No. ETI/PSI/31 (5/76).
14.4 BASIC DESIGNS
a) Normally contractor shall adopt latest standard specifications, designs and drawings of the
RDSO and Railway as per broad list enclosed in Annexure-1. Where the Contractor adopts
designs and drawings conforming to standard designs, drawings and specifications of Research
Designs and Standards Organisation (RDSO), Manak Nagar, Lucknow-226011, he shall verify
such designs and drawings and satisfy himself that these are correct and in line with the latest
approved drawings in use. Within two months of issue of letter of Acceptance, the Contractor
shall indicate to the Engineer the list of standard basic arrangement, components and fitting
drawings, equipment drawings, employment schedule etc. which he will adopt for the purpose
of work.
The Contractor for his use and reference shall obtain reproducible transparent film (50 microns)
each of such standard basic arrangement, components and fittings drawings, equipment
drawings, employment schedule etc., from Chief Electrical Engineer, Railway Electrification,
Allahabad on payment as per prescribed rates.
b) Deviations- Normally deviations from the standard drawings of the Railway will not be
accepted. However, in exceptional cases where the contractor desires to suggest improvements
as a result of his experience, specific site conditions or any other developments, he shall justify
his proposals with supporting explanatory notes.
Dated 29.Jan 2015
Page 371 of 429
RVNL
14.5 PARTICULARS AND WORKING DESIGNS
A) Engineer’s location plans
a) FOR TRACTION SUB-STATIONS
The location plans and schematic diagram of connections for each of the traction sub-stations
will be furnished by the Contractor. These will indicate.
i) Position of incoming lines on the gantries to be erected inside the traction sub-station.
ii) Location of switching
terminated.
station gantry showing where the 25 kV outgoing feeders will be
iii) Schematic diagram of connections of Transformers, Circuit breakers, Isolators etc.
iv) Position of the control room with respect to the traction sub-station.
v) Fencing outline with gates.
b) FOR FEEDING STATIONS
The location plans and schematic diagrams of connections for all the feeding stations, will be
furnished by the Contractor. These will indicate the following as applicable:i) Overhead equipment layout in the vicinity of feeding stations.
ii) Location of main masts.
iii) Arrangement of cross feeders and longitudinal feeders to be anchored on the gantry if any,
including jumper connections to the overhead equipment.
iv) Scheme of connections of interrupters.
v) Position of the remote control cubicle with respect to the feeding stations.
c) FOR SHUNT CAPACITOR BANK
a) The location plans and schematic diagram of connections for capacitor bank installation at
each of the traction sub-stations will be furnished by the Contractor. These will indicate.
i) Schematic diagram of connections of circuit breakers, isolators, LAs etc.
ii) Position of the control room with respect of the traction sub-station.
iii) Fencing outline with gates.
B) Contractor’s responsibility- The contractor shall satisfy himself about the correctness and
applicability of the location plans before adopting them for detailed designs.
14.6 DETAILED DRAWINGS
(A) FOR TRACTION SUB-STATION, FEEDING STATIONS AND SHUNT CAPACITOR BANK
The contractor shall submit the following drawings for approval of the Engineer:
a) Cross section drawings
Cross section drawings shall indicate the transverse and longitudinal cross-section of the soil
along the center line of the equipments, bus bar supports and cable trenches. These drawings
shall be prepared after an accurate survey at site and shall indicate the nature of the soil, its
bearing capacity, compactness and in case of loose soil, cross-section of the parent soil. In the
preparation of the drawings, care shall be taken to show all obstructions to be removed, such
as telegraph posts, underground pipes, cables etc. after collection of such information from the
site.
Dated 29.Jan 2015
Page 372 of 429
RVNL
b) General arrangement drawings
General arrangement drawings shall indicate the general arrangement of all equipments, run of
busbars, position of pedestal insulators and steel frame work. The drawings shall also give a
schematic connection diagram and an isometric view of busbars and connections wherever
required. The drawings shall include an elevation view of the traction sub-station, transverse
cross section and plan views. The drawings shall have a schedule of all equipments required at
the traction sub-station along with drawing references of the details of these equipments.
c) Structural drawings
Structural drawings shall be prepared for each supporting steel frame work or pedestal. The
drawing shall include one elevation view of the steel frame work assembly from behind, a
transverse cross section and plan view. In the assembly each component member shall be
marked with its reference number. The drawing shall also have a schedule of components
members along with drawing references of various members. The weight of the component
members shall also be indicated. The drawings shall be made for each component and this
shall include all fixing bolts, nuts and washers whose sizes will be mentioned on the drawing.
Unit weight of the components shall also be given in the drawing.
d) Foundation layout and cross section drawings: Foundation layout and cross section
drawings for each traction sub-station shall indicate layout of all foundations in plan,
longitudinal and transverse cross-sections of various foundations through centre line of
gantry/portal legs, various equipment/bus bar supports, fencing uprights and cable trenches. All
foundations shall be marked serially on the drawing indicating the volume of concrete for each
foundation block.
e) Earthing layout drawings.
Earthing layout drawing shall be prepared for each traction sub-station indicating the layout of
full earthing system in plan, the drawing shall show the location of earth electrodes and mark
the runs of earth leads and connections to equipment, gantry/portal columns, fencing uprights,
structural supports etc. All components shall be marked with their reference numbers. For
further details of the run of conductors and connections, separate drawings which may be
common to all traction sub-stations may be made and references to these drawings marked on
the layout. A schedule of components shall be made out in the drawing giving drawing
references of components. These drawings shall be prepared duly taking into account the actual
soil resistivity of the respective traction sub-station area, measured in the presence of the
Engineer’s representative in accordance with the procedure laid down in IS: 3043-1987 or
latest. The necessary design calculations for the proposed earthing system of the traction substation shall also be submitted by the Contractor for Engineer’s approval.
f) Cabling & Wiring drawings
Cabling and wiring diagrams for each traction sub-station shall indicate the schematic
arrangement and physical disposition of equipment, run of cables and wires for interconnections between various equipments both indoor and outdoor, colour coding and the index
scheme adopted for terminals. The drawings shall also indicate the sizes of wires and grades of
insulation. The quantity of various cables required shall be indicated on the drawings.
g) Fencing layout drawings
Fencing layout drawings for each traction sub-station shall indicate the layout of entire fencing
and anti-climbing device in plan. Each upright, fencing panel and fixture on the upright shall be
indicated on the drawing by its reference number. A schedule of components viz. uprights,
gates, panels fixtures and barbed wires shall be included in the drawing indicating the drawing
reference of the components. Type drawings shall be prepared for the various fencing
components. An individual drawing shall be made for each type of panel, fencing post, gate and
fixture of mounting the anti-climbing device. The drawing of each fencing post shall indicate the
unit weight of the fencing post.
Dated 29.Jan 2015
Page 373 of 429
RVNL
h) Equipment drawings: Equipment drawings shall be applicable to all traction sub-stations
complete with drawings of components/parts. The Contractor shall submit 5 copies for
distribution to field office and one transparent print and soft copy on CD for the equipments to
be supplied by the contractor. Drawings should be dimensioned and should indicate:
1)
2)
3)
4)
5)
6)
Fixing or mounting hole dimensions & arrangement.
Net weight of the equipment.
Characteristics and ratings including those of motors and resistors Etc.
Schematic and detailed circuit diagrams.
Overall dimensions and other important dimensions.
Height and disposition of all exposed live parts, height of the bottom
most point of all bushings and insulators.
7) Notes explaining the operation of the equipment.
i) Miscellaneous Drawings
These drawings shall include the drawings or sketches made for study of clearances, isolator
alignment details, number plates of various equipments, caution or instruction boards, nonstandard bus bar connectors, clamps and U- bolts for cable mounting etc.
j) Schedule of Quantities
On receipt of approval of relevant drawings for each traction sub-station, the following
schedules of quantities relating to each traction sub-station shall be submitted by the
Contractor within a fortnight of receipt of approval.
i. Schedule of foundations, showing volume of each type and total volume.
ii. Schedule of steel work, indicating types, weights of each member and total weight.
iii. Schedule of type and number, weight of different types of masts for each gantry,
iv. Schedule of quantities of those items of Bill of Quantities that are not included in items(i) &
(ii) above.
v. Any other items required to satisfactorily commission the works but not included in the Bill of
Quantities.
14.7 SUBMISSION OF DESIGNS AND DRAWINGS
a) The submission of designs and drawings for approval shall be done in the manner indicated
below . In every case the Contractor shall send all correspondence calculations, explanatory
notes, other documents and drawings, in triplicate to the Design Office of the Engineer. In case
Contractor wishes to deviate from standard drawings he should submit to the Engineer revised
drawings with full details of deviation sought explaining the necessity of deviation, calculations
and other supporting documents. The Engineer, if satisfied about the necessity and adequacy of
deviations, shall refer the matter to RDSO for necessary approval. In case of deviations on
working drawings decision shall be communicated by the Engineer to the Contractor. In respect
of working drawings prepared on the basis of approved typical drawings other special drawings
and schedules, all the three copies shall be submitted to the Design office of the Engineer. The
Engineer will return one copy each of their drawings either with approval, subject to
modification where necessary, or with comments. The Engineer shall endeavor to return this
copy within a period of 15 days from the date of receipt and shall normally return the copy
within a month. Where drawings are returned with comments or approved subject to
modifications, the Contractor shall submit to the Engineer within 15 days of receipt of such
advice, revised drawings for approval taking into account the comments or modifications. Also
the Contractor shall, as far as possible, avoid correspondence on such comments and shall
endeavor, to settle any difference or opinion on the comments by discussions with the
Engineer’s Engineers. No drawings shall be re-submitted without incorporating the modifications
required by the comments of the Engineer, unless the Engineer has agreed to the deletion of
such comments.
Dated 29.Jan 2015
Page 374 of 429
RVNL
b) Distribution copies
On receipt of Engineer’s unqualified approval to the Contractor’s drawings and schedule of
quantities, the Contractor shall submit original tracings of these drawings and schedules for the
signature of the Engineer in token of approval within 7 days of the receipt of the approval. On
receipt of these tracings from the Engineer, the Contractor shall submit 9 copies for distribution
to field officers other departments within 7 days of receipt of approved tracings.
In all the above cases, the Contractor has the option to supply only five copies of the approved
drawings provided one of them is a transparent paper print.
c)
Drawings approved by the Engineer shall not be modified without prior consent in writing from
the Engineer. Drawings incorporating approved modifications shall be resubmitted for formal
approval of the Engineer in the same manner as original drawings.
14.8
COMPLETION DRAWINGS AND SCHEDULES
After completion of works, all drawings and schedules of quantities, submitted by the
Contractor and approved by the Engineer shall be made upto date incorporating actual supply
and erection particulars. Such drawings and schedules shall then be verified and corrected, if
necessary, by the Contractor jointly with the Engineer’s representatives. The verified and
corrected drawings shall be supplied in four sets, two of which shall be transparencies on linen
or any other durable material approved by the Engineer.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 375 of 429
Dated 29.Jan 2015
RVNL
Page 376 of 429
RVNL
CHAPTER: B-15
ERECTION AND INSTALLATION OF EQUIPMENTS-PSI
15.1 SCOPE
This chapter deals with the method of erection and installation of equipments, including casting
of foundation and erection of structures.
15.2 METHOD OF ERECTION
All work shall be done in accordance with standard acceptable methods of erection and
installation of electrical equipment.
15.3 INSPECTION
All erection and installation work shall be subject to inspection by the Engineer to ensure that
the work is done in accordance with specifications, approved designs and drawings and is of the
best quality suitable for the purpose.
15.4 MEASUREMENT
All measurements for location of structures and foundations shall be made with the aid of the
steel tapes.
15.5 BOLTS, NUTS ETC.
All bolts, nuts and locknuts, screws, locking plates, split pins, etc., shall be properly tightened
and secured. No bolt may project more than 10 mm beyond the nut/locknut after full
tightening,. Contractor shall carry out systematic inspection of this aspect of work after the
installation is completed and prior to offering completed traction sub-stations, feeding stations
and shunt capacitors banks to the Engineer for inspection and testing.
15.6 DAMAGE TO GALVANISING/PAINTING
The loading, transport and erection, all galvanized/painted materials shall be handled with care
to avoid damage to galvanizing/painting. If galvanizing/painting is damaged in spite of all care
taken, the damaged part or component shall be put for inspection, to obtain permission from
the Engineer to carry out repairs as per 5.7 (b).
15.7- FOUNDATIONS
a) Soil Sampling
The Contractor shall carry out soil pressure tests in accordance with the method approved by
the Engineer to determine permissible bearing pressure of various representative types of soils
in the presence of the Engineer’s representative during pegging out or site inspection. He shall
adopt only accepted values for the design of foundations.
b) Location
The location of each foundation shall be correctly set out in accordance
with the approved
foundation layout drawings in the presence of the Engineer’s representative.
c) Method of installation
The foundation bolts for erection of gantries, portals and other supporting frames, if any, shall
be grouted into the foundation in cored holes left in foundation blocks. Cored holes shall be left
in foundation blocks for gantry legs or other steel work to be embedded. In any case, the
method of casting foundation blocks and erection of gantries, portals and other supporting
frames shall be subject to the approval the Engineer.
d) Concreting
Dated 29.Jan 2015
Page 377 of 429
e)
f)
g)
h)
i)
RVNL
All concreting or grouting shall be done in accordance with para 3.3 with aggregate graded for
the purpose specified in para 3.5. The concrete shall be poured and compacted properly in
accordance with the method approved by the Engineer. The Contractor shall arrange to provide
concrete testing samples for tests as and when required by the Engineer to determine the
crushing strength after 28 days’ curing. Testing shall be arranged by the Engineer at his own
cost.
Foundation level
The top of all foundations and anchor blocks shall always be above the level of the ground and
of adequate height, not less than 15 cm. to afford reasonable protection during rainy season.
The top of foundation shall be finished to make a smooth surface sloping 1/20 outwards to
drain rain water.
Suitable grooves or niches shall be provided in the foundation blocks at the time of casting, to
enable embodiment of earth strips without calling for chipping of the blocks subsequently.
Conduits of approved size should be embedded in the foundation blocks even in the initial
stages to avoid chipping and breaking of the foundation blocks for embodiment subsequently.
All foundations will be cast in the presence of the Engineer’s representative with regard to fixed
datum level.
Gantry Structures, Mast & fabricated structure at feeding station: Foundations for the
gantry structures/portals, mast of gantries at feeding station shall be as per RDSO drawing
included in Annexure-1 of specification, the base of which shall rest on consolidated soil.
j) Equipment
Pedestals for power transformers shall be made of mass concrete with base resting on
consolidated soil. Foundations for Circuit Breakers supported on steel structures and for other
items of equipment such as isolators, instrument transformers, bus bar support insulators etc.
shall be of the pure gravity type, the base of which shall rest on consolidated soil, and shall be
left with core holes into which the legs of the supporting structures shall be suitably fixed by
grouting.
k) Cable trenches
The reinforced concrete cable trench shall rest on original ground if the depth of unconsolidated
soil is less than 0.5 m. If the depth of the unconsolidated soil is more than0.5 m the cable
trench shall be supported at suitable intervals on concrete pillars. Cable trench details are
shown in a drawing included in Annexure-1 to these technical specifications.
l) Fencing posts
Foundations for fencing posts shall rest on consolidated soil if the depth of unconsolidated soil is
less than 1.5m below the datum level and shall be rectangular parallel-piped in shape. If the
depth of the unconsolidated soil is more than 1.5m the foundation block shall rest on reinforced
concrete piles cast-in-situ or reinforced concrete foundation may be adopted as desired by the
Engineer.
15.8 Structures
a) Erection
The structures shall be embedded in the foundation blocks for the correct length specified in
approved drawings.
b) Alignment
The legs of gantries and other supporting frames shall be carefully aligned to enable easy and
good assembly of top booms and other fabricated steel work.
c) Alignment of Mast at Gantries
The main masts of gantries shall be carefully aligned to enable easy and good assembly of
fabricated steel work.
15.9 Equipment
The installation of the equipment shall be carried out strictly in accordance with the instructions
issued by the Manufacturer. The equipment shall be leveled carefully before being fixed finally
Dated 29.Jan 2015
Page 378 of 429
RVNL
in position. The bushings of equipments shall be protected adequately during erection of
equipment to avoid chipping or damage to the porcelain. The following methods shall be
adopted for mounting the various equipments.
Equipment
i) Main power transformer
ii) 220/110/66 kV Circuit breaker
Method of mounting
On two 90 lb/yd or higher capacity
flat-footed
rails laid on concrete foundations with a spacing
of 1676 mm between the inner face of the rails.
On steel supports mounted on concrete
foundation with operating mechanism kiosk on
concrete pedestal where necessary.
On fabricated steel supports erected on concrete
foundations.
On steel supports mounted on concrete
foundations.
iii)25
kV
Circuit
breakers
&
Interrupters
iv) Isolators, potential transformers,
current
transformer
LT
supply
transformers, 25 kV fuse switches &
lightning arrestors.
v) Shunt capacitor bank & series On steel racks which in turn shall be mounted on
reactor
a concrete plinth with suitable base frame.
(The circuit breakers, interrupters and isolators shall be mounted in such a way that they
can be manually operated conveniently by a person standing on the ground or on a
concrete pedestal of suitable height)
15.10 BUSBARS AND CONNECTIONS
a)The bus bar connections on the incoming side, shall be as tight as possible, all similar
connections in adjacent bays being uniformly shaped and bent to give a good appearance.
The tubular Aluminium busbars shall be supported at a uniform height through out. Wherever
tubular busbars are required to be bent, the radius of the bend shall not be less than 375 mm.
b)All aluminium bus bar joints shall be made carefully, The contact surfaces of the bus-bars and
the connectors shall be cleaned vigorously either by hand with a dry coarse emery cloth or by
power driven wire wheel brush. The surfaces shall be smeared with a suitable corrosion
inhibiting joint compound approved by the Engineer. The joint closed-up as soon as possible
thereafter and a final light application of joint compound shall be made. Similar procedure shall
be followed while connecting the equipment terminals to be bus-bar by means of bi-metallic
connectors.
15.11CABLING
a) Laying of Cables
All cables provided out-door shall be either laid in trenches or neatly clamped to the structures
as approved by the Engineer. If it becomes necessary to take the cable connections along the
steel supports for the equipment, the cables shall be laid through bent or shaped GI pipes
embedded in concrete while the foundations are being cast. All cables in the cable trenches and
along the structures shall neatly secured with proper clamping arrangement at suitable
intervals. Each cable in the cable trench/on the structure shall also be provided at suitable
intervals with identification labels of durable material bearing indelible engraved or punched
markings to facilitate easy identification.
b) Termination of cables
The cables shall be terminated neatly and the cores arranged and dressed properly. Suitable
terminal strips and ferrules made of PVC or other durable materials shall be provided on
terminals and wire ends respectively to facilitate identification. The marking on the terminals
strips and ferrules shall be either engraved or punched so as to be indelible.
Dated 29.Jan 2015
Page 379 of 429
RVNL
c) Indoor wiring
As far as possible all cables shall be laid in the trenches/pipes provided for the purpose in the
Control Room. Wherever necessary indoor wiring on walls shall be clamped neatly on MS flats
fixed to the wall by means of rag bolts grouted in the wall. The typical clamping arrangement is
shown in the relevant drawing listed in Annexure-1.
15.12 EARTHING OF CONTROL ROOM
The earthing of control room shall conform to the guidelines laid down as per para 17.5(i).
15.13 SCADA SYSTEM
RDSO guidelines for increasing SCADA speed from 600/1200 bps to at least 9600 bps issued
vide letter no TI/SPS/RCC/SCADA/0130 dated 04/2014 or latest should be followed.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 380 of 429
RVNL
CHAPTER: B-16
INSPECTION AND TESTING of TRACTION SUB-STATION
16.1 GENERAL
a) This chapter deals with the inspection and testing of completely erected sub-stations.
b) Reasonability
The general tests of overall performance are only supplementary to other tests on structures,
foundations, equipments, components and fittings as specified elsewhere in these specifications
or in standard specifications and are to be complied with. Any testing and acceptance by the
Engineer of overall performance shall be subject to general terms of guarantee, which shall
continue to be valid as provided for in the Bidding Documents.
c) INSPECTION AND TESTING CHARGES:
All inspection and testing charges shall be borne by the Contractor.
16.2 INSPECTION AND TESTS
(A) SUB-STATION
(a) General
As soon as a sub-station is ready for inspection and testing, the Contractor shall advise the
Engineer in writing. Tests will be carried out by the Engineer jointly with the Contractor. These
shall include the tests which the Engineer may like to conduct with a view to assure himself of
the soundness of the equipments and their erection in compliance with these specifications.
Testing equipments such as these indicated below and staff required for the tests shall be
provided by the Contractor free of charge.
1.
2.
3.
4.
5.
6.
7.
Oil testing equipment.
5000 V, 2500 V and 500 V meggers.
Earth megger and accessories.
Continuity test apparatus.
Avometer.
Relay testing kit.
Primary injection test set.
(b) Visual Inspection
connections, painting, plastering, cleanliness of all insulators etc. and compliance with Indian
Electricity Rules.
(c) Correctness of connections
Correctness of connections of relays, alarm circuits, annunciator indications etc., shall be
thoroughly checked.
(d) This test will be conducted on every individual item of equipment such as Circuit Breakers,
Isolators, Relays etc. to ensure that the equipment as whole is functioning properly and is
mechanically sound, e.g. in the particular case of Isolators the fixed contact and knife blade
have been correctly aligned and operation does not cause undue strain on the equipment. The
operation tests will be carried out with the high tension installation disconnected from the
Dated 29.Jan 2015
Page 381 of 429
RVNL
supply, but by actuating power devices where such are provided. Continuity test of high tension
connections after setting each Circuit breaker and Isolator in its respective position shall also be
conducted as part of the operation tests.
(e) Insulation
The strength of insulation of the various items of equipment, cabling and of the entire
installation as a whole shall be tested with 5000/2500/500 V megger, as required.
(f) The di-electric strength of the oil of instrument transformers (except if they are of sealed
construction) auxiliary transformers and Circuit breakers at each sub-station shall be tested
before commissioning.
(g) Isolators
All Isolators will be tested for smooth and trouble-free operation. Correct functioning of interlocking devices shall also be checked.
(h) Instrument transformer
Tests shall be conducted to check the polarity of Current and Potential transformers.
(i) Ammeter and Voltmeter
The Calibration of Ammeters and Voltmeters provided on the control board shall be checked.
(j) Protective relays
The Contractor, shall arrange for all protective relays to be tested and calibrated in a
recognized test laboratory at his own cost, just prior to installation on the control board, and
shall submit six copies of the test certificates to the Engineer.
(k) Secondary injection tests
Operation of all protective relays, auxiliary relays and trip and close coils for circuit breakers
shall be tested for satisfactory performance with the respective equipments de-energised.
Correct functioning of all electrical interlocks inter tripping etc. shall also be checked during
these tests.
(1) Actual fault tests
The performance of the protective equipment for the 25 kV feeder circuits shall be checked
by putting a direct fault on the overhead equipment as below:
i) Close to the feeding posts and
ii) At the farthest point of feed and closing the feeder circuit breaker on the faulty section.
(B) FEEDING STATIONS
a) GENERAL
As soon as a feeding station, is ready for inspection and testing, the Contractor shall advise the
Engineer in writing. Testing will be carried out by the Engineer jointly with the Contractor.
These shall include the tests which the Engineer may like to conduct with a view to assure
himself of the soundness of the equipments and their erection in compliance with these
specification. However, testing equipments such as those indicated below and staff required for
the tests shall be provided by the Contractor free of charge.
i) Oil testing equipment.
ii) 2500 V & 500 v meggers.
iii) Earth megger and accessories.
iv) Continuity test apparatus.
v) Avometer;
Dated 29.Jan 2015
Page 382 of 429
RVNL
(b) VISUAL INSPECTION
Visual inspection which shall include check for
satisfactory workmanship shall cover all
connections, Painting, plastering, Cleanliness of all insulators etc. and compliance with Indian
Electricity Rules.
(c) OPERATIONS TEST
This tests will be conducted on every individual items of equipment such as interrupters,
isolators, relays etc. to ensure that the equipment as a whole is functioning properly and is
mechanically sound, i.e. in the particular case of isolators the fixed contact and knife blade have
been correctly aligned and operations does not cause undue strain on the equipment. The
operation tests will be carried out with the high tension installation dis-connected from the
supply, but by actuating power devices where such are provided. Continuity test of high tension
connections after setting such interrupter and isolator in their respective positions shall also be
conducted as part of the operation test.
(d) INSULATION
The strength of insulation of the various items of equipment and of the entire installation as a
whole shall be tested with a 2500 V/500 V meager, as required.
(e) ISOLATORS
All isolators will be tested for smooth and trouble free operation.
(f) INTERRUPTORS
Operation of trip and close coils for interrupters, shall be tested for satisfactory performance
with the respective equipments de-energised.
(C) SHUNT CAPACITOR BANK
a)General
As soon as a capacitor installation is ready for inspection and testing, the Contractor shall
advise the Engineer in writing. Tests will be carried out by the Engineer jointly with the
Contractor. These shall include the tests which the Engineer may like to conduct with a view to
assure himself of the soundness of the equipments and their erection in compliance with these
specifications. Testing equipments and staff required for the tests shall be provided by the
Contractor free of charge. The Contractor shall take full responsibility for these tests inter-alia
his other responsibilities.
(b)Visual Inspection
connections, painting, plastering, cleanliness of all insulators etc., and compliance with Indian
Electricity Rules.
(c)Correctness of Connections
Correctness of connections of relays, alarm circuits, annunciator indications etc. shall be
thoroughly checked.
(d)Operation test
These test will be conducted on every individual item of equipment such as circuit breakers,
current transformers, potential transformers, isolators, relays etc. to ensure that the equipment
as whole is functioning properly and is mechanically sound, e.g. in the particular case of
isolators the fixed contact and knife blade have been correctly aligned and operation does not
cause undue strain on the equipment. The operation tests will be carried out with the high
tension installation disconnected from the supply, but by actuating power devices where such
Dated 29.Jan 2015
Page 383 of 429
RVNL
are provided. Continuity test of high tension connections after setting each circuit breaker and
isolator in its respective position shall also be conducted as part of the operation tests.
(e)Insulation
The strength of insulation of the various items of equipment, cabling and of the ensure
installation as a whole shall be tested with 5000/2500/500 V megger as required.
(f)The di-electric strength of the oil of instrument transformers (except if they are of seated
construction) shall be tested before commissioning.
(g)Isolators
Isolators will be tested for smooth and trouble free operation. Correct functioning of interlocking devices shall also be checked.
(h)Instrument transformer
Tests shall be conducted to check the polarity of current and potential transformers.
(i) Ammeter and Voltmeter
The calibration of ammeters and voltmeters provided on the control board shall be checked.
(j) Protective relays
The contractor shall arrange for all protective relays to be tested and calibrated in a recognized
test laboratory at his own cost, just prior to installation on the control board, and shall submit
six copies of the test certificates to the Engineer.
(k) Primary & Secondary injection tests.
Operation of all protective relay, auxiliary relays and trip and close coils for circuit breakers shall
be tested for satisfactory performance with the respective equipments de-energised. Correct
functioning of all electrical interlocks inter tripping etc. shall also be checked during these tests.
(l) Performance tests
To verify the performance of the complete capacitor bank, tests as specified vide Clause 13.8
of RDSO specification No TI/SPC/PSI/FC&SR/01100 shall be carried out at site after
installation.
16.3 EARTHING
Earth resistance will be measured separately for each earth electrode and when they are
connected together and to the equipment at each sub-station, feeding station and shunt
capacitor bank.
16.4 PROFORMA FOR TESTS
The contractor shall submit the results of tests at each sub-station feeding station and shunt
capacitor bank in the performa, which will be furnished by the Engineer, in quadruplicate.
16.5
Measurement of contact resistance and opening/closing time of CBs/BMs during commissioning
of TSS/switching post shall be done as per ACTM para 20908 and OEM. This is to be done as
per pre-commissioning test.
Dated 29.Jan 2015
Page 384 of 429
RVNL
CHAPTER: B-17
EARTHING
17.1 EARTHING ARRANGEMENTS:
Earthing of switching stations, booster transformer stations and LT supply transformer stations
shall generally comply with the code of practice for earthing IS: 3043-1987 or latest & RDSO
spec. No. ETI/PSI/120(2/91) with A&C slip /no. 1 (10/93) except where otherwise specified
below.
17.2 Switching Stations
(i) Earthing System
At each switching station, two separate and independent earth circuits shall be provided, one for
earthing the HT equipment and the other for earthing the LT equipment. The general
arrangement of earthing connections at a typical switching station is shown in the relevant
drawing included in the Annexure to these Technical Specifications.
(ii) Earth Circuits
Each earth circuit shall take the form of a closed ring and shall be provided with a minimum of
two earth electrodes. Each earth electrode shall consist of galvanized iron pipe, 40mm nominal
bore at least 3.1 m long provided with a spike at one end and welded lug suitable for taking
minimum size of 50x6 mm mild steel flat, directly at the other. The pipe shall be embedded into
the ground. The earth electrodes of the HT and the LT earth circuits shall be located as far apart
as it is possible. The drawing of typical earth electrode is included in the Annexure to these
(iii)HT earth Circuit
The resistance to earth of the HT earth circuit shall be less than 2 ohms. If this value cannot be
achieved with a maximum of four separate but inter connected earth electrodes then the
additional earth electrodes shall have the surrounding earth treated with charcoal and salt
filling. All masts, structures, fencing uprights and equipment pedestals shall be connected with
two separate and distinct connections to the closed loop of the earth bus. Earth bus and
connections to it shall be of MS flats of a minimum size 50mm x 6 mm. Potential transformers
and lightning arrestors shall be bonded to masts/ structures by 25 mm x 3 mm copper strips.
iv) LT earth circuits
The LT earth circuit shall also comprise of a minimum of two inter-connected earth electrodes as
described in para (iii) above and the total resistance to earth of the earth circuit shall be less
than 2 ohms. All low tension equipment, control boards, one terminal of the secondary of the
potential and LT supply transformers, metal casing of battery chargers, shall be connected with
earth bus through 8 SWG galvanized iron wire. The section of the LT earth bus shall be the
same as that of the HT earth circuit.
(v) Earth strips
The earth bus and connections of Ht earth circuit shall be painted with two coats of red oxide
zinc chromate primer to IS2074:1992 or latest with a minimum thickness of 1.5 mils (40
microns) and with two finishing coats of bitumen 85/25 (blown grade to IS: 702:1988 or latest
with 20% mica to a thickness of about 15 mills (375 microns) either by hot application or by
brushing a solution of it with suitable viscosity to obtain the thickness in minimum number of
coats. It shall be buried at a depth of 300 mm below the ground level.
Dated 29.Jan 2015
Page 385 of 429
RVNL
The earth bus of the LT earth circuit shall run along the wall fixed on PVC plug rolls at a height
of 300 mm from the floor. The connections to equipment will run from the bus along the wall
and in processes in the floor. All recesses will be covered with cement plaster after finishing the
work. The connection of earth strips to each other shall be made by 10 mm dia. Steel rivets or
by welding. The connections to the various items of equipment and structures or fencing posts
shall be made with GI bolts. The earth connection to the structural members shall be made at a
height of about 150mm above the foundation.
(vi) Inter connection
The HT and LT earth systems shall be interconnected. In addition, at all switching stations, the
HT earth shall be connected by two independent mild steel flats each of minimum size 50mm x
6 mm painted with two coats of red oxide zinc chromate primer to IS:2074:1992 or latest and
finished with two coats of bitumen 85/25 blown grade as described above, to the non-track
circuited rail in a single-rail-track-circuited section and to the neutral point of an impedance
bond provided by the Engineer where double-rail-track circuiting is employed so as to limit high
potential gradients developing in the vicinity of switching stations in the event of a fault.
17.3 Booster Transformer Stations
(i) Earthing System
The earthing system shall comprise of a minimum of two inter-connected earth electrodes. The
general arrangement of earthing connections at a typical booster Transformer stations is shown
in the relevant drawing included in the Annexure to these Technical Specifications. Each earth
electrode shall consist of one galvanized iron pipe 40 mm nominal bore at least 3.1 m long
provided with a spike at one end and welded lug suitable for taking a minimum size of 50 mm x
6 mm mild steel flat directly at the other end. The pipe shall be embedded into the ground. The
earth bus interconnecting the two earth electrodes, shall consist of a minimum size of 50 mm x
6 mm mild steel strip. Each mast of the gantry shall be connected at the bottom to this earth
bus by a minimum size of 50 mm x 6 mm M.S. flat. The resistance to earth of the earth circuit
shall be less than 2 ohms as described in para (b) (iii) above. The transformers and the
lightning arrestors shall be bonded to the gantry mast by means of copper strips of size 25mm
x 3 mm. In addition, the earth circuit shall be connected to the non-track circuited rail in the
case of single rail track circuit or to the mid point of impedance bond in case of double rail track
circuit section.
(ii) Earth Strips
The earth strips shall be painted with two coats of red oxide zinc chromate primer to
IS:2074:1992 with a minimum thickness of 1.5 mils (40 microns) and with two finishing coats
of bitumen 85/25 (blown grade to IS:702:1988 or latest) with 20% mica to a thickness of about
15 mils (375 microns) either by hot application or by brushing a solution of it with suitable
viscosity to obtain the thickness in minimum number of coats. They shall be buried at a depth
of 300 mm below the ground level. The connection of earth strips to each other shall be made
by 10mm dia. steel rivets or by welding. The earth connections to the structural members shall
be made at a height of about 150mm above the foundation.
17.4 L.T. supply Transformer Stations.
The earth arrangement of a pole mounted LT supply transformer station shall comprise
interconnected earth electrode/electrodes having a resistance not exceeding 2 ohms. If this
value can not be achieved with two electrodes, additional electrodes shall be provided and
surrounded earth treated with charcoal and salt filling. The transformer and lightning arrestor
shall be connected to the supporting steel structure by means of 2 independent connections at
the top by means of 25mm x 3mm copper strip. At the bottom, the steel structures shall be
connected to the inter-connected earth electrodes and to the nearest traction rail by means of
two independent connections of mild steel flats having a minimum size of 50 mm x 6 mm. In
addition, the earth electrode should be connected to the traction rail by means of a minimum
size of 75 mm x 6mm mild steel flat. The mild steel flat shall be painted with two coats of red
oxide zinc chromate primer to IS:2074:1992 or latest with a minimum thickness of 1.5 mils
Dated 29.Jan 2015
Page 386 of 429
RVNL
(40 microns) and with two finishing coats of bitumen 85/25 (blown grade to IS: 702:1988) or
latest with 20% mica to a thickness of about 15 mils (375 microns) either by hot application or
by brushing a solution of it with suitable viscosity to obtain the thickness in minimum number of
coats.
17.5 EARTHING OF TSS
a) Earthing of traction substation shall generally comply with the code of practice for earthing- IS:
3043-1987 or latest and RDSO’s code of practice No. ETI/PSI/120(2/91) with A&C Slip no. 1
except where otherwise specified. The earthing system shall also conform to Indian Electricity
Rules 1956 with latest amendments.
b) Earthing System
At each substation, two separate earth circuit will be provided, one for earthing the HT
Equipment and the other for earthing the LT Equipment inside the control room.
c) HT earthing grid
A combined resistance of earthing system, in any sub-station shall not be more than 0.5 Ohms.
To ensure this, the Ht earthing grid shall be formed by means of bare mild steel rods of
appropriate size as indicated in Clause (d) below buried at a depth of about 600 mm below the
ground level and connected to earth electrodes by means of two separate and distinct
connections made with 75mmx 8mm Ms flats. The connection between the Ms flat and Ms rod
shall be made by welding, while that between, the earth electrodes and the Ms flats through Ms
links by bolted joints. As far as possible the earthing grid conductor shall not pass through the
foundation block of the equipments. All crossings between longitudinal conductors and
transverse conductors shall be jointed by welding. The transverse and longitudinal conductors
of the earthing grid shall be suitably spaced so as to keep the step and touch potentials within
acceptable limits. The overall length of the earthing grid conductor shall not be less than the
calculated length as per the code of practice. The earth electrodes shall be provided at the outer
periphery of the grid as indicated in the sketch enclosed in Specification No. ETI/PSI/120(9/91)
with A&C slip No.1. The earth electrodes shall be embedded as far away as possible from each
other. Mutual separation between them shall usually be not less than 6 m. The contractor shall
submit detailed design calculation for the earthing system and obtain approval of the
design/drawings.
d) Earthing Grid Conductor
The size of the earthing grid conductor shall be decided based on the incoming system voltage
and fault level. The size of the grid conductor for fault level upto 12000 MVA will be 32 mm dia
and above 12000 upto 160000 MVA 36 mm dia and above 16000 upto 20000 MVA, 40 mm dia
Ms rod respectively.
e) Earth Electrodes
The earth electrodes shall normally be of mild steel galvanized perforated pipe of not less than
40 mm nominal bore of about 3 m length provided with a spike at one end and welded lug
suitable for taking directly Ms flat of required size at other end. The pipe shall be embedded
vertically into the ground as far as possible except in case of hard rock, where it may be buried
inclined, the inclination being limited to 30 degree from the vertical. The connection of Ms flats
to each electrode shall be made through Ms links by bolted joints. A typical drawing number of
one earth electrode installation is included in Annexure-1. If the value of earth resistance
specified may not be achieved with a reasonable number of electrodes connected in parallel
such as in rocky soil or soil of high resistivity, the earth surrounding the electrodes shall be
chemically treated by alternative layers of finely divided coke, crushed coal or charcoal and salt
at least 150mm all around. However, coke treatment shall be used only where absolutely
necessary and such electrodes shall not be situated within 6 m of other metal work. In high
embankments, use of electrodes longer than 3 m shall be considered so as to reach the parent
soil to achieve earth resistance as specified.
Dated 29.Jan 2015
Page 387 of 429
RVNL
f) Buried Rail
A steel rail of section 52 kg/m and length about 13 m shall be buried near the track at the
traction sub-station at a depth of about 1 m to form part of the earthing system. Two separate
and distinct connections shall be made by means of 75mm x 8 mm Ms flats between the
earthing grid and the buried rail. The buried rail shall also be connected by means of two
separate and distinct connections made with 75mm x 8mm Ms flats to the non-track circuited
rail in a single rail track-circuited section and to the neutral point(s) of impedance bond(s) in a
double-rail track circuited section. In case where the feeding post is located separately away
from the traction substation, the buried rail shall be provided at the feeding post (where one
terminal of the secondary winding of the traction power transformer is grounded).
g) System earthing
One terminal of the secondary winding of each traction transformer shall be earthed directly by
connecting it to the earth grid by means of a 75 mm x 8 mm Ms flat and to the buried rail by
means of another 75 mm x 8 mm Ms flat. One designated terminal of the secondary of each
potential, current and Lt supply transformer shall also be connected to earth grid by means of
two separate distinct earth connections made with 50 mm x 6mm MS flat.
h) Equipment earthing
The metallic frame work of all outdoor equipments such as transformers, circuit breakers,
Interrupters & Isolators, as well as steel structures shall be connected to the earth grid by
means of two separate and distinct connections made with MS flat of size 50 mm x 6 mm up to
10000 MVA and by 75 mm x 8 mm MS flats above 10000 MVA upto 20000 MVA. Equipments on
the secondary side of the traction power transformer and steel structures shall be connected to
the earth grid by means of two separate and distinct connections made with Ms flats of size 50
mm x 6 mm. One connection shall be made with the nearest longitudinal conductor while the
other shall be connected with the transverse conductor.
i) Earthing inside the control room
An LT earth circuit shall be provided inside the Control Room by means of 50 mm x 6 mm mild
steel flat and connected to the main earth ring by two independent connections made with 50
mm x 6mm mild steel flat. The metallic frame work of control panels, Lt AC and Dc distribution
boards, battery chargers, remote control equipment, cabinets, etc. shall be connected to the
earth ring by means of 8 SWG galvanized steel wire.
J) Earthing of Lightning arrestors
In addition to the earth electrodes provided for the main earth grid, an independent earth
electrode shall be provided for each lightning arrestor. The earth electrode shall be connected to
the ground terminal of the lightning arrestor as well as the main earth grid by means of two
separate and distinct connections made with 50 mm x 6mm Ms flat for 25 kV side lightning
arrestor. The earth electrode shall be provided as close as possible to the lightning arrestor and
the connection shall be as short and straight as possible avoiding unnecessary bends. For
lightning arrestors provided for the traction transformers, there shall also be a connection as
direct as possible from the ground terminal for the lightning arrestor to the frame of the
transformer being protected by means of two separate and distinct connections made with 50
mm x 6 mm Ms flat for 25 kV side arrestor and with 75mm x 8 mm Ms flat for primary side
arrestor.
k) Earthing of fencing uprights and panels
Each metallic fencing uprights shall be connected to the main by means of two separate and
distinct connection made with 50 mm x 6 mm Ms flat. In addition, all the metallic fencing
panels shall be connected to the uprights by means of two separate and distinct connections
made with 6 SWG GI wire.
Dated 29.Jan 2015
Page 388 of 429
RVNL
l) Method of Jointing
All the joints between the MS flats, Ms rods or between Ms flat and Ms rods shall be made by
welding only. No soldering shall be permitted. For protection against corrosion, all the welded
joints shall be treated with red lead and afterwards thickly coated with bitumen compound.
m) Painting of Ms Flats
For protection against corrosion, all the exposed surfaces of earthing connections (MS flats)
above ground level shall be given all around two coats of painting to colour black of IS: 5/2004
or latest.
n) EARTH SCREEN
The area covered by outdoor sub-station equipment shall be shielded against direct strokes of
lightning by an overhead earth screen comprising 45 tonne quality 7/9 SWG, 19/2/5 mm
galvanized steel stranded wire strung across pinnacles of the metallic structures as indicated in
the drawings included in Annexure-1. The earth screen wires shall be fixed not less than 2.5 m
above the live conductors so as to provide an angle of protection, not exceeding 30 degree to
the equipment/busbar below and shall be solidly connected to the sub-station earth circuit by
means of 50 mm x 6mm Ms flats.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 389 of 429
Dated 29.Jan 2015
RVNL
Page 390 of 429
RVNL
CHAPTER: B-18
High Rise OHE
18.1 HIGH RISE OHE FOR RUNNING DOUBLE STACK CONTAINERS UNDER ELECTRIFIED
ROUTE (WITH SPEED POTENTIAL OF 140 KMPH)
Design, installation and erection of High Rise OHE shall conform as per RDSO’s Design
document No-TI/DESIGNS/OHE/2013/00001 (July 2013). Further RDSO has issued drawings
for 11.4 meter masts, Portals, TTC, Employment Schedule, Foundations, Anchor Arrangement
etc which shall be followed while executing the work.
1.
The type of foundations shall remain same. However, the work to be done as per the
relevant drawings issued by RDSO. Payment shall be made in cum under relevant BOQ.
2.
Structures: RDSO has issued the drawings of 11.4m high masts, which shall be paid under
relevant BOQ items. However, the additional erection rate shall be paid as NS item as per
condition of agreement.
List of Standard Technical Drawings of High Rise OHE
High Rise OHE Drgs
SN
Name of Drawing
Drg No.
1
11.40 m long Standard Traction mast (Fabricated
with Batten Plates) ‘B’ series For High Rise OHE
TI/DRG/CIV/B- Mast/00001/13/0 dtd
18.03.2014
2
Two Track Cantilever structure (TTC) (General
arrangement) For High Rise OHE
TI/DRG/CIV/TTC/00001/13/0 Sh 1dtd
06.05.2014
3
Two Track Cantilever structure (TTC) Details of
upright, For High Rise OHE
TI/DRG/CIV/TTC/00001/13/0 Sh 2 dtd
06.05.2014
4
Anchor arrangement with dwarf
Conventional and High Rise OHE
ETI/OHE/HR/G/01402
5
Volume Charts and Equivalent chart of foundations
(Side Bearing, Side gravity & WBC ) For High Rise
OHE
TI/DRG/CIV/FND/00001/13/0 Sh 1
6
Volume Chart and Equivalent chart of foundations
(N G Type) For High Rise OHE
7
Volume and Equivalent chart of foundations for
Dry Black Cotton Soil Only (NBC type) For 16500
& 11000kgf/ m² 3.0 m DEPTH For High Rise OHE
Volume Charts and Equivalent Chart of New Pure
Gravity (500 mm exposed) For High Rise OHE
8
Dated 29.Jan 2015
mast
for
Page 391 of 429
RVNL
Volume and Equivalent Chart of foundations for
Type Dry Black Cotton Soil Only (8000 Kgf/ m²)
NBC type 2.5 m DEPTH For High Rise OHE
TI/DRG/CIV/FND/00001/13/0 Sh5
10
Standard ‘N’ Type Portal General Arrangements
For High Rise OHE
TI/DRG/CIV/N PORTAL/00001/13/0 Sh
1
11
Standard ‘N’ Type Portal Rod Laced Details of
Upright Part ‘A’ For High Rise OHE
TI/DRG/CIV/N PORTAL/00001/13/0 Sh
2
12
Standard ‘O’ Type Portal General Arrangements
For High Rise OHE
TI/DRG/CIV/O PORTAL/00001/13/0 Sh
1
13
Standard ‘O’ Type Portal Rod Laced Details of
TI/DRG/CIV/O PORTAL/00001/13/0 Sh
2
14
Standard ‘R’ Type Portal General Arrangements
For High Rise OHE
TI/DRG/CIV/R PORTAL/00001/13/0 Sh
1
15
Standard ‘R’ Type Portal Rod Laced Details of
TI/DRG/CIV/R PORTAL/00001/13/0 Sh
2
16
G-Type Portal Special Upright and End Piece For
High Rise OHE
TI/DRG/CIV/G- PORTAL/00001/13/0
dtd 06.05.2014
17
Special BFB portal For 5 tracks
arrangement) For High Rise OHE
(General
TI/DRG/CIV/BFB- PORTAL/00001/13/0
Sh 1 dtd 06.05.2014
18
Special BFB portal Details of Upright Part ‘A’ For
High Rise OHE
TI/DRG/CIV/BFB- PORTAL/00001/13/0
Sh 2 dtd 06.05.2014
19
High Rise OHE Employment Schedule Mast (11.4
m) (Wind pressure 178 Kgf/ m²) (Basic Wind
speed 50 m/s) without return conductor and
without earth wire)
TI/DRG/CIV/ES/00001/13/0 Sh 1 dtd
17.04.2014
without earth wire)
17.04.2014
without earth wire)
17.04.2014
9
20
21
Dated 29.Jan 2015
Page 392 of 429
22
23
RVNL
without earth wire)
17.04.2014
m) (Wind pressure 73 Kgf/ m²) (Basic Wind speed
33 m/s) without return conductor and without
earth wire)
17.04.2014
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 393 of 429
Dated 29.Jan 2015
RVNL
Page 394 of 429
RVNL
Annexure-1
CHAPTER: B-19
List of Standard Technical Drawings/Specifications
For
Traction Sub stations/Feeding Posts
This Annexure contains reference to standard, typical and particular drawings referred to in various
paragraphs of the specification and specifications issued by the Engineer.
S No.
Brief Description
1
2
Drawing
Series
Number
Mod.
No.
3
4
5
1.
Typical location plan and general
arrangement for a feeding station
TI/DRG/PSI/TSSLO/RDSO/
006
E
2.
Typical earthing layout of a feeding station
-do-
203
B
3.
Typical layout of 132 /27kv Traction substation (Type-I)
00001/01
0
4.
Typical layout of 132 /27kv Traction substation (Type-II)
00002/01
0
5.
Typical layout of 132 /27kv Traction substation (Type-III)
00003/02
0
6.
Typical layout of 132/27kv Traction Substation (Type IV) (with outgoing feeders and
metering Facilities)
00004/02
0
7.
Typical layout of 132/27kv Traction Substation (Type V)
TI/DRG/PSI/TSSLO/ RDSO/
00005/02
0
8.
Typical layout of 132/27kV traction substation (Type VI)
00006/02
0
9.
Typical layout of 132/27kV traction substation (Type VII)
00007/02
0
10.
Typical layout of 132/27kV traction substation (Type-VIII)
00008/02
0
11.
Typical layout of 132/27kV traction
substation with single transformer (Type -IX)
00009/02
0
12.
Typical layout of 132/27kv Traction Substation with 132kv Switching Station (Type x)
TI/DRG/PSI/TSSLO/ RDSO/
00010/02
0
Dated 29.Jan 2015
Page 395 of 429
RVNL
S No.
Brief Description
1
2
Drawing
Series
Number
Mod.
No.
3
4
5
13.
Typical layout of 220/27kV traction sub
station (Type -I)
ETI/PSI
0240-1
Nil
14.
Mounting arrangement of 100KVA
25kv/240V LT supply transformer at TSS
ETI/PSI
0312
B
15.
Typical schematic diagram of protection for
double Transformer traction sub station
ETI/PSI
024-1
Nil
16.
Typical layout for 25kv Shunt capacitor
with series reactor to be installed at 132/25kv
TSS
ETI/PSI
223
E
17.
High speed auto reclosing scheme for feeder
circuit breaker at 25kV A.C TSS
ETI/PSI
0231-1
A
18.
Structural layout of 132/25 KV traction substations
ETI/C
0200,
SH.No.-1
H
19.
Structural layouts of 132/25kv traction substations
ETI/C
0200,
SH.No.-2
D
20.
Line Diagram of Structural layouts of
220/25kV Traction sub-station
ETI/C
222
Nil
21.
Typical schematic diagram of protection for
single transformer traction sub-station
ETI/PSI
0228-1
Nil
22.
Scheme of Interlocking arrangement for
25kV circuit breakers at Traction Sub-Station
ETI/PSI
5214
B
23.
Structural layout of 220/27kV traction substation (Type-I)
ETI/C
0222-1
Nil
Typical general arrangement of earth screen
wire termination at Traction substation
ETI/PSI
0225
C
25.
Typical termination arrangement for strung
bus "Spider" (AAC) conductor at TSS.
ETI/PSI
0226
B
26.
General arrangement & terminal connection
for 25kV PT Type-II at TSS
ETI/PSI
0227
A
24.
Dated 29.Jan 2015
Page 396 of 429
RVNL
S No.
Drawing
Brief Description
1
2
Series
Number
Mod.
No.
3
4
5
27.
General arrangement and terminal
connection for 25kV Potential Transformer at
TSS (220kV)
ETI/PSI
0227-1
Nil
28.
Typical return current connection to
buried rail at 220/25kV TSS.
ETI/PSI
0242
A
29.
Typical termination arrangement for strung
bus (ZEBRA ACSR) conductor at TSS
(220kV)
ETI/PSI
0243
A
30.
Typical general arrangement of earth screen
wire termination at 220/25kV traction substation.
ETI/PSI
0244
Nil
31.
Bimetallic terminal connector to suit 'ZEBRA'
ACSR conductor and 30 dia Cu stud of
CT/CB/traction power transformer.
ETI/PSI/P
11010
C
32.
220kV system bimetallic terminal
connector to suit 'ZEBRA' (28.58 Dia ) ACSR
conductor & Al./Cu. pad of Isolator /CT/CB.
ETI/PSI/P
11030
C
33.
220kV system tee connector to suit 'ZEBRA'
(28.58 dia ) ACSR conductor on both ways.
ETI/PSI/P
11040
C
34.
220kV system rigid connector on SI to suit
ZEBRA (28.58 dia) ACSR conductor
ETI/PSI/P
11050
C
35.
Detail of rigid type bimetallic terminal
connector suitable for 50 dia Al. tubular
busbar to 30 dia Cu. Stud of 25kV CT.
ETI/PSI/P
11070
B
36.
Rigid bimetallic terminal connector
suitable for 50 dia Al. tubular busbar to
terminal pad of 25kv Isolator/ CT
ETI/PSI/P
11090
C
37.
Rigid through connector to suit 50 dia Al.
Tubular bus bar and ‘SPIDER’ AAC
conductor for 25kv PT Type-II
ETI/PSI/P
11110
C
38.
25kv system tee connector to suit 50 O/D
Al. Tube and 'SPIDER' 'AAC' conductor
ETI/PSI/P
11140
B
39.
25 K.V system Tee connector to suit 50. O/D
AL. tubular busbar to 50. O/D AL.
tubular busbar
ETI/PSI/P
11150
B
40.
25Kv System Rigid bus splice connector to
suit 50 O/D Al. tube on both ways
ETI/PSI/P
11180
B
41.
25 kV System Sliding clamp for 50mm O/D
Aluminium Bus bar
ETI/PSI/P
11190
C
Dated 29.Jan 2015
Page 397 of 429
RVNL
S No.
Brief Description
1
2
42.
25Kv System Rigid connector on S.I to suit
50 mm O/D Al.Bus bar
Drawing
Series
Number
Mod.
No.
3
4
5
ETI/PSI/P
11200
C
ETI/PSI/P
11210
D
ETI/C
310
G
44.
25kv system expansion bus coupler on SI to
suit 50 O/D Al. tube.
Details of structure for 132kv double pole
Isolator
45.
Details of structure for 132kv support
insulators
ETI/C
320
E
Details of structure for 132kv Current
transformer
ETI/C
330
F
47.
Details of structure for 120kv Lightning
Arrestor
ETI/C
340
F
48.
Details of structure for 25kv Current
transformer
ETI/C
360
F
49.
Typical return current connection to
buried rail at 132 kV/25 kV Traction SubStation.
ETI/PSI
0212-1
NA /Nil
50.
General scheme of supply for 25 kV 50 Hz
Single Phase AC Traction System
ETI/PSI
702-1
D/E
Part Plan for Details of position of feeder
Bus coupling interrupter at TSS
ETI/PSI/SK
272
NA /Nil
Terminal connector for 220kV equipments
(Typical drawing)
ETI/PSI/SK
324
NA/Nil
Expansion type terminal connector for 25 kV,
60mm dia terminal for traction power
transformer.
ETI/PSI/P
11220
D
Details of Beam B/1 for 132/25 KV TSS
ETI/C
201
D
43.
46.
51.
52.
53.
54.
Dated 29.Jan 2015
Page 398 of 429
RVNL
S No.
Brief Description
1
2
Drawing
Series
Number
Mod.
No.
3
4
5
55.
Details of beam B/2 and column C/1 for
132/25kV traction sub-station.
ETI/C
208
E
56.
Details of baffle wall at TSS(WP112.5kg/sq.m) and WP (75kg/sq.m)
ETI/C
213
D
57.
Details of RCC baffle Wall at TSS(WP150kg/sq.m)
ETI/C
214
B
58.
Details of structure and foundation for 25kV
DP Isolator at TSS
ETI/SK/C
0180
B/C
59.
Transformer oil drainage arrangement at
sub-stations
ETI/C
216
B
60.
Drilling schedule for S-1 mast
ETI/C
0030
F
61.
-do-
0031
D
62.
Drilling schedule for S-3 mast (length 11. 4
m)
-do-
0180
C
63.
Drilling schedule for 8” x 6” x 35 1bs. RSJ
mast 8.0 m long for booster transformer
station Type S-4
-do-
0036
E
64.
Drilling schedule for S-5 mast (11.4m long)
-do-
0042
E
65.
Drilling schedule for S-6 mast (length
12.4m)
-do-
0181
C
66.
12.4m)
-do-
0182
C
67.
12.4m)
-do-
0183
C
68.
12.4m)
-do-
0184
C
69.
Typical cable run layout of a feeding station
-do-
303
B
Dated 29.Jan 2015
Page 399 of 429
RVNL
S No.
Brief Description
1
2
Drawing
Series
Number
Mod.
No.
3
4
5
70.
Typical details of cable run at a two
transformer TSS with Shunt Capacitor
ETI/PSI
325
Nil
71.
Typical details of cable run at two
transformers Traction Sub-station with Shunt
capacitor (220kV)
ETI/PSI
326
Nil
72.
Typical details of cable run at a two
transformer TSS
ETI/PSI
323
E
73.
Typical cable trench and foundation lay out
of 132/25kv TSS
ETI/C
210
F
74.
Typical earthing, cable trench & foundation
layout of 132/25kv TSS
ETI/PSI
224
E
75.
Typical earthing cable trench and foundation
layout of 132/25kV traction sub-station with
Shunt Capacitor bay
ETI/PSI
229
Nil
76.
Details of foundation for fencing upright
-do-
0032
B
77.
Typical fencing layout at traction Sub-station
(Details of fencing panel, door, anticlimbing
device etc.)
ETI/PSI
121
F
78.
Typical fencing , door and anticlimbing
device details of traction sub-station
CORE/ALD/PSI
1
D
79.
Typical earthing arrangement for
equipment/structure at TSS
ETI/PSI
228
A
80.
Typical arrangement of an earth electrode.
ETI/PSI
222-1
Nil
81.
Typical number plate for circuit breaker
ETI/PSI/P
7523
Nil
82.
Typical number plate for Auxiliary
Transformer
ETI/PSI/P
7525
Nil
83.
Typical number plate for Power transformer
at TSS
ETI/PSI/P
7526
Nil
84.
Typical number plate for PT at TSS
ETI/PSI/P
7527
A
85.
Typical number plate for CT at TSS
ETI/PSI/P
7528
A
86.
Typical number plate for Isolators at TSS
ETI/PSI/P
7529
A
87.
Typical number plate for interrupter and
double pole isolator
-do-
7520
NA/B
Dated 29.Jan 2015
Page 400 of 429
RVNL
S No.
Brief Description
1
2
Drawing
Series
Number
Mod.
No.
3
4
5
88.
Typical number plate for potential
transformer Type
-do-
7521
B
89.
Gillsans Letters and Figures
RE/33
527
A
90.
Typical number plate for Auxiliary
Transformer
ETI/PSI/P
7525
-
91.
Remote Control Cubicle at Stn, Foundation,
RCC slab, Building plant & Steel door
-do-
0067
B
92.
Typical layout of Control Room at
tractionsub-station.
TI/DRG/PSI/CPROOM/RDS
O/
00001/01
0
93.
Standard plan of control room at traction
sub-station (General arrangement and RCC
details)
RE/Civil/
S-144
6
94.
Control Room for Traction substation
ETI/C
0225
Sheet-1
Nil
95.
Control Room for Traction Sub-station(RCC
details)
ETI/C
0225
Sheet-2
Nil
96.
Typical details of pressed steel door, window
and ventilator
RE/Civil/S
129/
2001
R2
97.
Typical layout of control room at TSS
TI/DRG/PSI/CPROOM/
RDSO
00001/01
0
Details of Tower T 1 for 132/25 KV TSS
ETI/C
202
H
Details of Tower T 2 for 132/25 KV TSS
ETI/C
203
G
100. Details of small part steel for switching
station
ETI/C
0034
Sh.1
K
101. Typical general arrangement of a three
interrupter switching station
ETI/PSI
004
F
Typical location & schematic connection
102. diagram for a three interrupter switching
station
ETI/PSI
003
C
103. Typical earthing layout of sub-sectioning and
paralleling station
-do-
201
B
98.
99.
Dated 29.Jan 2015
Page 401 of 429
RVNL
S No.
Brief Description
1
2
Drawing
Series
Number
Mod.
No.
3
4
5
0038
E
104. Details of pre-cast cable trench for switching
station
-do-
Typical cable run layout of a sub-sectioning
105. & paralleling station
-do-
301
C
Typical cable run layout of a sectioning and
paralleling station
-do-
302
C
General arrangement & details of fencing
panels & gate for switching station
-do-
0186
Sh.1
E
108. Details of fencing uprights and anti-climbing
device for switching station
-do-
0186
Sh.2
E
109. Typical fencing and anti-climbing
arrangement at switching stations
ETI/PSI
104
E
110. Typical location plan & general arrangement
for sectioning & paralleling station
-do-
005
F
111. Typical earthing layout of a sectioning and
paralleling station
-do-
202
B
112. Typical drawing for a terminal board
-do-
501
C
36 mm Aluminum Bus terminal for 25kv
113. Isolator (Rigid type)
ETI/PSI/P
6480
C
114. 36 mm Aluminum Bus splices
-do-
6490
B
115. 36 mm Aluminum Bus Tee connector
-do-
6500
C
116. 36 mm Aluminum Bus Tee terminal
-do-
6510
D
106.
107.
Dated 29.Jan 2015
Page 402 of 429
RVNL
Drawing
Series
Number
Mod.
No.
3
4
5
-do-
6520
B
-do-
6550
B
119. 36 mm Aluminum bus splice cum tee
connector
-do-
6560
B
120. 25kv D.O. Fuse switch assembly
ETI/PSI
032
D
Details of Rigid terminal connector suitable
121. for 20 dia Al. Conductor to terminal pad of
25kv PT Type I & II
ETI/PSI/P
11120
C
122. 25 kV drop out fuse switch details
ETI/PSI
038
C
123. Operating pole for 25kV drop out fuse switch
ETI/PSI
039
B
ETI/PSI/P
6570
F
-do-
204
C
126. Details of anchor beam of SP, SSP, & FP
-do-
0033
D
S-100 fabricated mast for mounting LT
127. supply transformer and drop out fuse switch
at switching station
-do-
0043
B
S-101 details of mast for supporting Isolator
128. inside switching station
ETI/C
0044
A
S-100 Fabricated Mast for mounting
129. LT supply transformer and DO fuse switch
at switching station
ETI/C
0043
B
Standard Post Insulator for clean area
130. (Creepage path 850mm min)
ETI/OHE/P
6090-1
C
Details of structure for 42kv ,10KA LA &
131. 25kv support insulator
ETI/C
0370
Sheet-1
E/J
S No.
Brief Description
1
2
117. 36/15 mm Top connector
118.
36mm Aluminum flexible bus splice
Flexible connector for 25 kV circuit breaker
124. 25kV Interrupter& 25 kV side of 13.5/20
MVA traction transformer.
Earthing details for interrupter L.T. supply
125. transformer 25 KV Lightning Arrestors P.T.
Type- I (S-100 masts, S-101 mast, fencing
upright and main mast)
Dated 29.Jan 2015
Page 403 of 429
RVNL
S No.
Brief Description
1
2
Drawing
Series
Number
Mod.
No.
3
4
5
Black Weight of Structure for 42kv,10KA LA
132. & 25kv support insulator.
ETI/C
0370
Sheet-2
Nil
Details of structure for 25kv Single Pole
133. isolator
ETI/C
0380
F
Details of structure for 25kv
134. transformer
ETI/C
0390
E
Typical schematic diagram for TSS, FP, SSP
135. and SP with 21.6 MVA or 30 MVA
transformers for three lines.
TI/DRG/PSI/3L-TSS/RDSO
00001/07
1
Typical layout of Remote Control cubicle at a
136. switching station
ETI/PSI
0010
E
Typical layout of remote control
137. cubicle at switching stations.
ETI/PSI
0010
E
ETI/PSI
644
C
ETI/PSI
645
C
ETI/PSI
0231-I
A
ETI/PSI/SK
337
Potential
Schematic inter connection diagram for
138. remote control of power gear & supervision
equipments at TSS.
Schematic inter connection diagram for
gear
and
139. remote control of power
supervision equipments at controlled station
(SP & SSP)
High speed Auto reclosing Scheme for
140. feeder Circuit Breaker at 25 kV a.c. Traction
Sub-station.
Control desk arrangement for 2 work stations
141. of SCADA system.
Dated 29.Jan 2015
NA/Nil
Page 404 of 429
RVNL
LIST OF STANDARD RDSO’s SPECIFICATIONS FOR PSI & SCADA
S.No.
DESCRIPTION
SPECIFICATION NO.
LAST
REV.
1
Battery charger for 110 volt battery, 40 Ah.
ETI/PSI/1(6/81)
2
25 kV Dropout fuse switch
ETI/PSI/14(1/86) with A&C slip no 1
of (4/87)
1
3
25kV/240 V Auxiliary Transformer, 5kVA,
10kVA, 25kVA & 50 kVA
ETI/PSI/15(08/2003)
-
4
25kV/240 V Auxiliary Transformers 100
VA.
ETI/PSI/14(1/86) with A&C slip no 1
of (4/87)
1
5
Battery charger for 110V. battery 200 Ah.
ETI/PSI/24(6/81)
-
6
Standards for drawings for power
ETI/PSI/31(5/76)
-
7
Current transformer, 132 kV ( type-II)
ETI/PSI/36(5/75)
-
8
Control & distribution panel for colour light
signaling supply in 25 kV ac traction
systems.
TI/SPC/PSI/CLS/0020(12/02) with
A&C slip No. 1, 2 &3 of 03/07
4
9
Standards for electrical distribution system
in stations & yards where 25 kV ac
traction is to be introduced.
ETI/PSI/44(12/73)
-
10
Control and relay panel for 25 kV ac TSS
including specification for numerical type
protection relays for traction transformer,
25 kV shunt capacitor bank and
transmission line for 25 kV Ac TSS on
Indian Railways.
TI/SPC/PSI/PROTCT/6070(9/08)
with A&C slip No.1
-
11
Shunt Capacitor equipment for Railway
traction sub-stations.
TI/SPC/PSI/FC&SR/0100(01/10)
-
12
Hollow porcelain insulators & Bushing.
ETI/PSI/70 (11/84)
-
13
Metal oxide gapless type lightning arrester
for use on 25 kV. Side of Railway traction
sub-stations and switching stations.
TI/SPC/PSI/MOGTLA/0100(07/10)
-
Dated 29.Jan 2015
Page 405 of 429
RVNL
14
Electric power connectors for AC Traction
power system.
ETI/PSI/72 (9/85)
-
15
25 kV, 50 Hz single phase series
Compensation Equipment.
ETI/PSI/75(10/97)
-
16
25 kV ac 50 Hz single phase oil filled
current transformers with ratio of (i) 1000500/5 A, (for general purposes, (ii) 1500750/5 ( for heavy duty).
ETI/PSI/90 (6/95) with A&C Slip
No.1, 2,3,4,5,6,7 (08/2007) & 8
(April 2009).
8
17
100 KVA, And 150 KVA 25 kV single
phase 50 Hz, oil filled booster transformer.
ETI/PSI/98(8/92)
3
18
Trivector meter and maximum demand
Indicator for Railway ac Traction.
ETI/PSI/99(4/89)
-
19
Specification for 25 kV AC Single pole and
Double pole motorized isolators for
Railway Electric traction
TI/SPC/PSI/ISOLTR/1060(08/06)
-
20
Dynamic reactive power compensation
equipment for Railway traction substations ( for development of prototype
only).
TI/SPC/PSI/DRPC/0050(08/05)
-
21
Gas Chromatograph for use in analuysis
of dissolved gases of transformer oil.
ETI/PSI/105(7/93)
-
22
Capacitance bridge and dissipation factor
bridge for the measurement of solid
insulation of insulating oil.
ETI/PSI/106 (10/87)
-
23
Current transformer
ETI/PSI/117 (7/88) with A&C
Slip No.1 (11/88), 2 (3/89), 3
(12/89), 4 (4/90), 5 (6/90),
6 (9/92), 7 (8/05), 8
(08/2007) & 9 (July 2008).
9
No.1 to 10 (08/12) or latest
10
I) 220 kV, 200-100/5
ii) 132 kV, 400-200/5
iii) 110 kV, 400-200/5
iv) 66 kV, 800-400/5
24
Power transformer 21.6 MVA, single
phase 50 Hz, 220/132/110/66/27 kV for
traction substation.
Dated 29.Jan 2015
Page 406 of 429
RVNL
25
Code of practice for earthing of power
supply installation for 25 kV. AC. 50 Hz
single phase traction system.
ETI/PSI/120 (2/91) with A/c Slip
No1 (10/93)
1
26
Specification for 245/145/123/72.5 kV
double ple and triple pole isolators.
No.1(4/90)
1
27
21.6 MVA, 220/132/110/66 kV/2x27 kV,
single phase, 50 Hz traction power
transformer for AT feeding system
ETI/PSI/123(9/93)
1
28
54 MVA, 220/2x27 kV Scott-connected
power transformer for 2 x 27 kV ‘AT’
feeding system.
ETI/PSI/124(7/95)
-
29
8 or 5 MVA, 2x 27 kV 50 Hz, auto
transformer for 2x27 kV ‘AT’ feeding
system.
ETI/PSI/125(7/97)
-
30
25 kV shunt capacitor equipment for 2x25
kV ‘AT’ feeding system.
ETI/PSI/126(8/89)
2
31
Series capacitor equipment for 225 kV
’AT’ feeding system.
ETI/PSI/127(8/89)
1
32
Resonance suppressing C-R device for
2x25 kV ’AT’ feeding system.
ETI/PSI/128(8/89)
3
33
Control & relay panel including Numerical
TI/SPC/PSI/PROTCT/7100(07/201
2)
-
type protection relays for scott connected
single phase traction transformers, OHE
protection & shunt capacitor bank
protection for 2x25 kV traction sub-station.
34
25 kV ac double pole isolators for 2x 25
kV ’AT’ feeding system.
ETI/PSI/133(8/89)
2
35
‘AT’ Boost up current ratio type fault
locator for OHE for 2x 25 kV;AT’ feeding
system.
ETI/PSI/135(8/89)
1
36
Metal oxide gapless type lightning
arresters for use of 220/132/110/66 kV
side of railway ac traction substation.
No.1 (1/90), 2(2/91), 3(12/91),
4(8/94) 5 & 6 (9/05) &
7(07/2007)
7
Dated 29.Jan 2015
Page 407 of 429
RVNL
37
Technical specification for leakage current
monitor for lightning arrester
TI/SPC/PSI/LCMLA/0030(04/03)
1
38
25 kV ac double pole outdoor Sf6
interrupters for 2 x 25 kv’AT’ feeding
system.
ETI/PSI/139 (12/89)
4
39
Technical specification for Microprocessor
based Numerical integrated feeder
Protection Module comprising DPR, INST,
OCR,PTFE, & Auto Reclosure Relay for
25 kV. AC single phase 50 Hz traction
Sub-station.
-
40
Supervisory control and data acquisition
(SCADA) system for 2x2 5 kV ‘AT’
Traction Power Supply.
ETI/PSI/144(12/91)
-
41
Specification for 11 kV current transformer
with ratio 500/5 for 2x 25 kV ‘AT’ feeding
system.
ETI/PSI/145(3/92)
1
42
Specification for 25 kV current transformer
with CT ratio 100-50/5 for shunt capacitor
banks in 2x 25 kV ‘AT’ feeding system.
ETI/PSI/147(3/92)
1
43
Specification for SF6 gas leakage
detector.
ETI/PSI/148(4/92)
-
44
25 kV ac 50 Hz single pole outdoor pole
mounted vacuum interrupter.
ETI/PSI/159 (10/94)
1
45
21.6 MVA, 100/27 kV OR 22/27 kV single
phase, 50 Hz, ONAN traction power
transformer
ETI/PSI/163 (4/97)
3
46
25 kV, 50 Hz single pole outdoor
interrupter for Railway Traction switching
station.
TI/SPC/PSI/LVCBIN/0120
2
47
Magnetic actuator type 25 kV. AC 50 Hz
single pole outdoor vacuum interrupter for
railway traction switching station.
TI/SPC/PSI/VACINT/0040(05/05)
-
48
Specification for
-
Dated 29.Jan 2015
Page 408 of 429
RVNL
49
Specification for panto flashover
protection relay for 25 kV ac traction
system.
-
50
Control and relay panel for protection
system of Mumbai area for 50 Hz Ac
traction power supply system including
parallel operation on 25 kV side.
-
51
Specification for SCADA, 25 kV single
phase 50 Hz ac traction power supply( not
for general use as validation is yet to be
done.)
TI/SPC/RCC/SCADA/0130(04/2014) 1
52
Specification for 220 kV, Or 132 kV, or
110 kV, or 66 kV or 25 kV potential
transformer.
TI/SPC/PSI/PTS/0990 with A&C
Slip No.1,2,3,4,& 5
5
53
Outdoor circuit breaker for 25 kV, AC
traction sub-station.
TI/SPC/PSI/HVGB/0120
5
54
30 MVA, 22/27 kV single phase traction
power transformer.
TI/SPC/PSI/30TRN/0030(06/03)
-
55
30 MVA, 110 /27 kV single phase traction
power transformer with on load tap
changer ( for use in Mumbai sub-urban
area)
TI/SPC/PSI/30TRN/1050(12/05)
-
56
30 MVA, 220/27 kV, 110/27 kV, & 66/27
kV single phase traction power
transformer ONAN/ONAF with on load tap
changer ( for use in TSSs other than
Mumbai area).
TI/SPC/PSI/30TRN/2070(10/07)
-
57
25 Core Armoured Optic Fibre cable for
use in Indian Railways traction installation
systems.
TI/SPC/PSI/OFC/0050(10/05)
-
58
Technical specification for power quality
analyzer and Recorder with Remote
display.
TI/SPC/PSI/PQAR/0080(09/08)
-
59
Technical specification for Supervisory
control and data acquisition system
(SCADA) for 25 kV single phase 50 Hz ac
traction power supply for Mumbai area.
TI/SPC/RCC/SCADA/1080(9/08)
with Amendment No.1
-
Dated 29.Jan 2015
Page 409 of 429
RVNL
60
Relay testing kit for testing of Static/
Electromagnetic / Micro-processor based
numerical protection relays used for 25 kV
ac, 50 Hz, single phase traction system of
Indian Railways.
TI/SPC/PSI/TESTKIT/1080(12/08)
-
61
Manufacture and supply of 132 kV XLPE
underground cable and accessories.
TI/SPC/PSI/CABLE/0090(02/09)
-
62
Technical specification for 50/75/150
MVA,
TI/SPC/PSI/AUTOTR/0090
-
ONAN/ONAF/OFAR 220/132 kV, 3-Phase
oil immersed type Auto transformer.
1) For structural steel (standard quantity) please refer IS: 2062-1992.
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 410 of 429
RVNL
CHAPTER: B-20
ANNEXURE-2
LIST OF STANDARD DRAWINGS AND SPECIFICATIONS FOR OHE WORKS
All references to drawings charts schedules of specifications given in this Annexure shall be
taken to the latest version of such drawings, charts, and schedules of specifications as issued
by the purchaser.
A)
LIST OF STANDARD DRAWINGS
Sl.
No.
Brief Description
1
2
Extra allowance for setting of structures on curves
(1676 mm Broad gauge)
Standard setting of structure in the vicinity of signals
(broad gauge)
Typical design of bearing foundation.
Deleted
Typical design of cantilever mast.
1.
2
3
4
5
6
7
8
9
10
11
12
13
Standard drilling schedule of OHE masts 9.5 m long
RSJ and BFB respectively.
Span and stagger chart for (conventional ) OHE, Cad.
CU catenary & Cu cont. wire) wind pressure 75,112.5
&150 kgf/sq.m
Employment schedule for Cantilever mast Regulated
OHE cat. 65/Cu and Cont 107/Cu WP 112.5 kgf/sqm
without EW & without RC.
Employment schedule for cantilever mast regulated
OHE cat. 65/Cu & cont. 107/GC, WP 112.5 kgf/sq.m
with EW & without RC.
OHE Cat. 65/Cu & cont 107/Cu, WP 112.2 kgf/sq. m
with EW & with RC
OHE Cat 65/Cu & cont 107/Cu, WP 112.2 kgf/sq.m
with EW & with RC
Employment
schedule
for
cantilever
mast
unregulated OHE Cat 65/Cu & cont 107/Cu, WP
112.2 kgf/sq.m at 35 deg. C and with 28 kgf/sq.mat
4deg. C without EW & with RC
Employment schedule of bracket tubes regulated
pressure Conventional OHE (Cd Catenary & Cu
Contact wire 1000 kgf tension each)
Dated 29.Jan 2015
Drawing
Series
Numbe
r
3
4
ETI/OHE/G
00111
Sh.1
ETI/OHE/G
00112
ETI/OHE/G
00131
RF/33/G
00141
Sh.3
00144
Sh.3
00202
ETI/OHE/G
ETI/OHE/G
Mod.
No.
5
B
C
C
-
ETI/OHE/G
00153
Sh.1
E
ETI/OHE/G
00153
E
ETI/OHE/G
00153
Sh.3
E
ETI/OHE/G
00153
Sh.4
D
ETI/OHE/G
00154
D
ETI/OHE/G
00158
Sh.1
(for
wind
pressur
e
75kgf/s
q.m)
Page 411 of 429
RVNL
ETI/OHE/G
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
ETI/OHE/G
Sh.2
(for
wind
pressur
e 112.5
kgf/sq.m
Sh.3 (for
wind
pressure
150
kgf/sqm.
Dropper schedule for – uninsulated, overlap spans
Dropper schedule for insulated overlap spans
Dropper schedule for conventional regulated OHE
with Zero presag (1400/1400)
Adjustment chart of Regulating equipment 3-pulley
type 3:1 ratio
Schematic arrangement of regulated OHE
Schematic arrangement of un-insulated overlap (3&4
span overlaps)
Schematic arrangement of insulated overlap
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
00169
00170
00177
A
A
A
ETI/OHE/G
00195
A
ETI/OHE/G
ETI/OHE/G
A
A
Termination arrangement of OHE with 3 pulley type
regulating equipment (3:1 ratio)
General distribution of droppers.
Out line of pantograph (broad gauge and metre
gauge).
General formation of single track embankments and
cutting (broad gauge).
General formation of double track in embankments
and cutting (broad gauge)
General formation of multiple tracks (1675 mm
gauge)
Standard anchor arrangement
Anchor arrangement with dwarf mast.
Schedule of anchor block for BG track.
ETI/OHE/G
02101
02121
Sh-4
02131
Sh.3
01212
ETI/OHE/G
RE/33/G
0101
00181
A
A
RE/33/G
A
E
B
D
ETI/OHE/G
01101
Sh.1
01102
Sh.1
01103
Sh.1
01401
01402
01403
Sh. 1
01403
Sh 2
01403
Sh.3
01505
ETI/OHE/G
01502
-
ETI/OHE/G
01601
Double guy rod arrangement with anchor block for
BG track.
Schedule of anchor block for BG track (black cotton
soil)
Standard guide tube arrangement on a mast and
structures.
Trapezoidal counter weight arrangement on OHE
structures.
Arrangement of 3 kV & 25 kV pedestal insulator
supports on OHE masts and portals.
Dated 29.Jan 2015
ETI/OHE/G
RE/33/G
RE/33/G
RE/33/G
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
B
A
A
C
B
-
Page 412 of 429
RVNL
35
36.
37.
38
39
40
41
42
43
44
45.
46
Standard arrangements for mounting of number
plate on OHE structures
Schematic arrangement of regulated overhead
equipment.
Typical arrangements of OHE on cantilever masts for
double track section
Typical arrangement for fixing of bracket assembly
on 9.5 m mast and structure to set raising of tracks
(in future)
Mast on platforms (1676mm gauge).
Details of bracket arrangement on tangent and
curved tracks
Details of bracket arrangement for OHE (High
speed).
Single bracket assembly on structures and dropped
arms.
Box type cantilever Arrangement.
Arrangement at anti-creep.
Standard cantilever arrangement for boom anchor
anti-creep location.
Schematic arrangement of uninsulated over lap
(type-1) 3&4 span overlaps.
Schematic arrangement of insulated overlap.
ETI/OHE/G
01701
A
ETI/OHE/G
02101
A
ETI/OHE/G
2102
ETI/OHE/G
02102
Sh.1
ETI/OHE/G
RE/33/G
02104
Sh.2
02106
Sh.1
02106
Sh.3
02107
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
02108
02111
02113
A
A
ETI/OHE/G
F
A
-
ETI/OHE/G
ETI/OHE/G
General arrangement of regulated OHE at turn-outs
(overlap &crossed type).
General arrangement of regulated OHE at cross over
(overlap &crossed type)
Arrangement of neutral section
ETI/OHE/G
02121
sh.1
02131
sh.1
02141
ETI/OHE/G
02151
ETI/OHE/G
51
Arrangement of neutral section assembly (PTFE
Type)at SWS.
ETI/OHE/G
02161
Sh.1 of
2
02162
52
Arrangement of short neutral section.
ETI/OHE/G
53
Schematic arrangement of unregulated overhead
equipment.
Standard termination of OHE (regulated & un
regulated)
General arrangement of unregulated OHE at turnouts
(crossed & overlap type).
General arrangement of unregulated OHE cross overs
and diamond crossings (overlap and crossed type).
General arrangement of unregulated OHE at diamond
crossing
General arrangement of pull off
General arrangement of head span
In span jumper connection between catenary &
contact wire.
47
48
49
50
54
55
56
57
58
59
60
Dated 29.Jan 2015
ETI/OHE/G
A
A
C
D
C
-
ETI/OHE/G
02161
Sh.2 of
2
03101
ETI/OHE/G
03121
E
ETI/OHE/G
03151
-
ETI/OHE/G
03152
Sh.1
03152
Sh.2
03301
03201
05101
-
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
-
A
-
Page 413 of 429
RVNL
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
Continuity jumper connection at uninsulated overlap
Arrangement of anti-theft jumper
Connection at turn outs
Potential equalizer connection at insulated overlap
and neutral section
Connections at diamond crossing.
General arrangement of connections to OHE by
copper cross feeder (150).
General arrangement of connections at switching
station on double track section by copper cross
feeder (150).
General arrangement of connections at switching
station on multiple track section by copper cross
feeder (150).
Suspension of 25 kV feeder (spider on OHE masts.
Termination of feeder, return conductor & return
feeder (copper & aluminium)
Arrangement of suspension of double spider 25 kV
feeder and return feeder between substation and
feeding station
Assembly of section insulators
General arrangement of earth wire on OHE mast.
General arrangement of earth wire on OHE mast
Arrangement of transverse bonds
Connection of return conductor to track
Suspension arrangement of aluminium return
conductor (spider) on traction Structures.
Suspension of return conductor (spider) from boom
of structures (with clevis type disc insulators)
Connections between OHE and aluminium return
conductor at booster stations
Mounting of 25 kV Isolators on OHE structures
(General arrangement )
Details of small part steel work for supporting 25 kV
Isolator on new TCC boom
Connection from isolator to OHE
Characteristics of conductors/bus-bar for 25 kV Ac
traction
Arrangement of mounting 25 kV/240 , 10 KVA LT
supply transformer.
Employment Schedule for Cantilever Mast regulated
OHE Cat 65 Cu Cad, 107 /Cu WP 75 kG/sq.m
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
05102
05107
05103
05104
C
A
B
-
ETI/OHE/G
ETI/OHE/G
05106
05121
Sh.1
05122
Sh.1
A
C
ETI/OHE/G
05123
Sh.1
C
ETI/OHE/G
RE/33/G
05143
05145
Sh.1
05152
B
A
C
RE/33/G
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
05181
05201
05201-1
05251
05306
05307
C
A
A
F
B
ETI/OHE/G
05312
A
ETI/OHE/G
05413
B
ETI/OHE/G
A
ETI/OHE/G
ETI/OHE/G
05513
Sh.1
05513
Sh.2
05516
05600
A
A
ETI/OHE/G
05522
A
ETI/C
ETI/C
0702(OHE
only)
(Sh.1)
OHE+EW.
(Sh. 2)
OHE+RC),
Sh.3)
OHE+EW/
RC,Sh.4
0704
ETI/C
0708
A
ETI/OHE/G
RE/33/G
ETI/OHE/G
ETI/C
ETI/C
ETI/C
86
87
Employment Schedule for Tramway type regulated
OHE (WP 75 kgf/sqm) without Ex. & without RC.
Employment Schedule for 8” x 8” x 35lbs FBB (9.5 M.
long) WP 112.5 kgf/sq.m Cat. 65/Cu & Cont. 107/Cu.
Dated 29.Jan 2015
C
A
A
A
A
A
Page 414 of 429
RVNL
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
104A
105
106
107
108
Employment Schedule for OHE mast overlap central
location with 3.0 m implantation. Cat. 65/Cu & Cont.
107/Cu.WP 75 kgf/sqm
Employment schedule for OHE mast overlap center
location with 3.0M implantation, Cat. 65/Cu & cont.
107/Cu. WP 112.5 kgf/sq.m
Employment schedule for 9.5 m long OHE mast
overlap center location with 3.0M implantation, Cat.
65/Cu & cont. 107/Cu. WP 75 kgf/sq.m
Employment schedule for 9.5 m long 200x200x44.9
kg mast Cat. 65/Cu & cont. 107/Cu. WP 112.5
kgf/sq.m
Employment schedule for OHE mast overlap anchor
107/Cu. WP 75 kgf/sq.m
Employment schedule 0721 for regulated
OHE
mast(9.5 m) wind pressure 75kgf sq.m for composite
OHE(1000+1000) kgf tension
ETI/C
0709
A
ETI/C
0710
A
ETI/C
0711
A
ETI/C
0712
A
ETI/C
0713
A
ETI/C
0714
A
ETI/C
0715
A
ETI/C
0716
A
ETI/C
-
Employment schedule for regulated OHE mast (9.5m)
wind pressure 75 kgf/sqm. For composite OHE with
extra setting distance overlap anchor location.
Employment Schedule for regulated OHE mast (9.5m
) wind pressure 75 kgf/sqm for composite OHE with
extra setting distance. Overlap centre location.
Employment Schedule for regulated OHE mast (9.5m
) wind pressure 75 kgf/sqm for composite OHE with
extra setting distance. Overlap inter location.
Employment schedule for pre-stressed concrete mast
(PC 42) 9.5 long. For conventional OHE, Normal
Location (WP 150, 112.5 and 75 kgf/sqm.07253
Standard portal (NO, PRG & Double FBF type)
Special BSF portal for 5 tracks (general C
arrangement)
Protective screen at foot-over bridge and road overbridge.
Chart for portal foundation
Details of foundation in hard rock for portals
Muff for OHE structures
Structures muff for sand core foundations
9.5 m standard traction mast (fabricated ‘K’ series)
Remote Control Cubicle at switching station,
foundation, RCC slab Building plan & steel door.
ETI/C
0721
(OHE
only)(S
h.1)
0722
ETI/C
0723
-
ETI/C
0724
-
ETI/C
0725
A
ETI/C
ETI/C
C
ETI/C
0064
0026
sh1
0068
H
ETI/C
ETI/C
ETI/C
ETI/C
ETI/C
ETI/C
0005/68
0080
0007/68
0012/69
0018-2
0067
A
E
E
D
B
Dated 29.Jan 2015
-
Page 415 of 429
RVNL
109
109A
109B
109C
110
9.5 m standard traction mast fabricated with batten
plates ‘B’ series)
9.5 m long standard traction mast (fabricated with
batten plate)- “TM” series.
9.5 m long standard traction mast ( fabricated with
batten plate)- “ TM” series( Weight scheduled).
10.85 m long standard traction mast ( fabricated with
batten plate)- “ B” series.
ETI/C
0071
E
ETI/C
0078
Sh. I
0078
Sh. 2
00001/0
8/0
-
0059
C
ETI/C
0060
D
ETI/C
ETI/C
0032
0185
B
B
ETI/C
ETI/C
ETI/C
ETI/C
0030
0031
0180
0036
F
D
C
E
ETI/C
ETI/C
ETI/C
ETI/C
ETI/C
ETI/C
E
C
C
C
C
E
ETI/C
0042
0181
0182
0183
0184
0186
sh.1
0186
sh.2
0043
ETI/C
0044
A
ETI/C
ETI/C
D
K
ETI/C
TI/DRG/CI
V/BMAST/RDS
O
ETI/C
126
127
Details of OHE foundation in soft rock (bearing
capacity 45,000 kgf/sq. m)
Details of OHE foundation in Hard rock (bearing
capacity 90,000 kgf/sq. m)
Details of foundation for fencing upright
Employment schedule for switching and booster
station main masts
Drilling schedule for S-3 mast (length 11.4m)
Drilling Schedule for 8” x 6” x 35 lbs. RSJ mast 8.0 m
long for booster transformer station Type S-4.
Drilling schedule for S-5 mast (114 m long)
Drilling schedule for S-6 mast (length 12.4 m)
Drilling schedule for S -7 mast (length 12.4 m long)
General arrangement & details of fencing panels &
gate for switching station
Details of fencing upright and anti-climbing device for
switching station
S-100 fabricated mast for mounting LT supply
transformer and drop out fuse switch at switching
station.
S-101 details of mast for supporting isolator inside
switching station
Details of anchor beam on SP, SSP, & FP
Details of small part steel for switching station
128
Details of bracing for switching &BT masts.
ETI/C
129
Details of small parts steel of out rigger for switching
stations and booster transformer stations.
Details of small parts steel for booster transformer
stations.
Details of pre-cast cable trench for switching station
Standard ’R’ type portal rod laced general
arrangement
Standard ’G’ type portal special upright and end
piece.
Short bored pile foundation for traction mast
(permissible BM & volume)
Chart for portal foundations in dry black cotton soil
safe bearing capacity 16500 kg/sqm.
ETI/C
0033
0034
Sh.1
0034
sh.2
0037
ETI/C
0040
E
ETI/C
ETI/C
E
C
ETI/C
0038
0011/69
Sh.1
0066
ETI/C
0062
B
ETI/C
0063
C
110A
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
130
131
132
133
134
135
Dated 29.Jan 2015
ETI/C
E
B
B
C
C
Page 416 of 429
RVNL
135A
136
Details of foundation for 132 kV traction substation
structures.
Dwarf mast foundation on wet & dry black cotton soil
137
138
139
140
Typical design of new pure gravity foundation.
Typical design of side gravity foundation.
Rock Anchor for BG Track.
Bracket fitting for PSC Masts capacity 4200 kgm.
RE/ALD/OH
E/SK/C
ETI/SK/C
ETI/SK/C
ETI/SK/C
ETI/SK/C
141
SPS details for earth wire clamp on PSC mast.
ETI/SK/C
142
Special arrangement of OHE under overline structure
143
Earthing and bonding of PSC mast.
144
Typical Earthing arrangement in spun D PSC mast
with 18mm dia rod.
ETI/OHE/S
K
ETI/OHE/S
K
ETI/OHE/S
K
145
Arrnagement of antitheft jumper at overlap
146
147
148
149
Catenary dropper assembly
Parallel clamp (20/20)
Standard guide Tube assembly.
Standard anti-wind clamp
150
151
152
Multiple cantilever cross arm assembly
Anchor fitting Assembly on rolled sections
Anchor fitting Assembly on ‘K’ series TCC mast and P
type portal upright .
Anchor assembly on ‘N’ and ‘O’ type portal spans.
Structure bonds
Earthing station
Earth Electrode
Longitudinal rail bond
Short super mast assembly
Long super mast assembly
Bracket attachment assembly on portal upright
(NORPG& BFB type )
Super mast assembly on portals
Medium super mast assembly
Compensating plate
Suspension clamp
Double suspension clamp
Double suspension lock plate.
Catenary splice(65)
Typical location & schematic connection diagram for a
three interruptor switching station.
Typical general arrangement of a three interruptor
switching station
Typical location plan & general arrangement forsectioning & paralleling station
RE/33/P
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
ETI/PSI
153
154
155
155A
156
157
158
159
160
161
162
163
164
165
166
167
168
169
Dated 29.Jan 2015
ETI/C
ETI/OHE/S
K
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
0209
C
02
-
131
142
208
214
sh.2
214
Sh.2 of
2
529
A
A
A
537Sh.1
of 2
537
Sh.1 of
2
566
A
D
A
D
B
EC
L
RE/33/P
ETI/OHE/P
ETI/OHE/P
1190
1550
5060-2
25501/2
3224
3230
3240
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
ETI/C/P
ETI/OHE/P
ETI/OHE/P
3250
7000
7020
7021
7030
7020
8010
8030
D
E
B
A
F
B
G
B
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
8050
8060
51911/2
1160
1170
1172
1090
003
C
C
D
ETI/PSI
004
F
ETI/PSI
005
F
H
C
D
J
K
C
C
Page 417 of 429
RVNL
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
Typical location plan and arrangement for a feeding
station
Typical general arrangement at a booster transformer
stn. (with 4 cross feeder) type III
Typical general arrangement of 280 KVA Booster
booster transformer stn. (with 4 cross feeder) type III
Typical general arrangement at a booster transformer
stn. (without cross feeder) type I
Typical number plate for auxiliary transformer
Typical fencing and anti-climbing arrangement at
switching station
Typical earthing layout of sub-sectioning and
paralleling station
Typical earthing layout of a sectioning and paralleling
station.
Typical earthing layout of a feeding station
Earthing details for interruptor LT supply transformer
25 kV lightnig arrestors PT type- I ( S-100 masts, S101 mast, fencing upright and main mast)
Typical earthing layout at a booster transformer
stations (without cross feeder ) for Type-I and II
Typical cable run layout of a sub-sectioning &
paralleling station.
Typical cable run layout of a sectioning & paralleling
station
Typical cable run layout of a feeding station
Typical earthing layout of a booster transformer
station (with 4 cross feeder for type III, IV and V)
Typical drawing for a terminal board
36 mm Aluminium Bus terminal
36 mm Aluminium Bus splices
36 mm Aluminium Bus Tee connector
36 mm Aluminium Tee terminal
36 /15 Tap connector
36 mm Aluminium flexible bus splice
36 mm Aluminium bus splice cum tee connector
Typical number plate for interruptor and double pole
isolator
Typical number plate for potential transformer Type-I
Typical number plate for booster transformer
Standard plan Remote Control cubicle at a switching
station
Typical details of pressed steel door, window and
ventilator
Bolted base connection for portals located in drains.
Details of base plate for mast on drains in station
yards.
(B) LIST OF STANDARD DRAWINGS FOR TRAMWAY
Span and stagger chart for Tramway type OHE
(regulated)
Dated 29.Jan 2015
ETI/PSI
E
ETI/PSI
013
B
ETI/PSI
018
A
ETI/PSI
011
C
7525
104
E
ETI/PSI
201
B
ETI/PSI
202
B
ETI/PSI
ETI/PSI
203
204
B
C
ETI/PSI
211-1
A
ETI/PSI
301
C
ETI/PSI
302
C
ETI/PSI
ETI/PSI
303
212
B
B
ETI/PSI
ETI/PSI/P
ETI/PSI/P
ETI/PSI/P
ETI/PSI/P
ETI/PSI/P
ETI/PSI/P
ETI/PSI/P
ETI/PSI/P
501
6480
6490
6500
6510
6520
6550
6560
7520
C
C
B
C
D
B
B
B
B
ETI/PSI/P
ETI/PSI/P
RE/Civil/BS
-11/95
RE/Civil/S115/95
ETI/C
ETI/C
7521
7522
B
B
-
ETI/PSI/P
ETI/PSI
R1
0010
0002
C
A
TYPE OHE (REGULATED)
ETI/OHE/G
04201
-
Page 418 of 429
RVNL
201
Drilling schedule of OHE mast 8.5m & 9 m long RSJ)
and BFB respectively.
ETI/OHE/G
202
Schematic arrangement of (regulated) tramway type
OHE
Arrangement of bracket assembly for Tramway Type
OHE (Regulated)
Arrangement for anti-creep for Tramway Type OHE (
Regulated)
Arrangement of anti-creep for Tramway OHE
(regulated alternative arrangement )
Arrangement of section Insulator for Tramway Type
OHE (regulated)
Small parts steel for supporting section insulator
assembly for regulated tramway type OHE.
General arrangement of turnouts for Tramway type
OHE ( regulated)
Adjustment chart for Tramway type OHE (regulated)
Bridle wire clamp (6 mm)
Large suspension clamp 20 mm (with armour rod)
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
ETI/OHE/G
04204
B
ETI/OHE/G
04205
B
ETI/OHE/G
04206
B
ETI/OHE/G
04207
Sh.1
04207
Sh.2
04208
B
ETI/OHE/G
ETI/OHE/G
ETI/OHE/G
ETI/OHE/P
ETI/OHE/P
C
B
B
ETI/OHE/P
ETI/OHE/P
04209
1070-1
1580
Sh-2
2380
2540-1
C
-
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
2550-3
5090-3
5090-6
E
F
B
B
-
Hook bracket
BFB steady arm assembly for Tramway OHE
(Regulated)
Anti wind clamp for tramway OHE (regulated)
Counterweight assembly (light)
Counter weight assembly with pulley type regulating
equipment (3:1 ratio)
Employment schedule for tramway type regulated
OHE without RC and EW(WP 112.5 kgf/sqm)
Protective screen at FOB/ROBs.
i) standard plan –height gauge for level crossing( for
clear span upto 7.3m) details of structure &
foundation.
ETI/C
0705
A
ETI/C
TI/DRG/CI
V/HGAUGE
/RDSO
0068
00001/0
5/0
H
-
ii) standard plan –height gauge for level crossing(for
clear span above 7.3m upto 12.2 m) details of
structure & foundation.
TI/DRG/CI
V/HGAUGE
/RDSO
00002/0
5/0
-
(iii) Span length 7.3m for Class-II to IV roads and
TVU<1 Lakh
CORE dwg
No:RE/CIV
IL/S1
38-04
(Mod
R1)
(iv) Span length 7.3mto 10.0 m for Class-II to IV
roads and TVU<1 Lakh
CORE dwg
NoRE/CIVIL/S-
(V) standard plan –height gauge for level crossing
( for clear span 7.3m to 10m) details of structure &
foundation
220
C
C
ETI/OHE/G
04202
Sh.1
Sh.2
04203
Anchor
arrangement
with
conventional and High rise OHE
Dated 29.Jan 2015
dwarf
mast
for
TI/DRG/CI
V/HGAUGE
/RDSO
ETI/OHE/H
R/G
140/000
8 (ModR1)
00001/1
4/0
01402
-
Page 419 of 429
RVNL
221
Employment
schedule of bracket tube regulated
conventional OHE (Cd-Cu catenary and Cu contact
wire (1000 kgf tension each ) for wind pressure 150
kgf/ sq. m at 10 deg. C
Employment schedule of bracket tubes unregulated
unconventional OHE (Cd.CU-catenary) and CUcontact wire.
Standard arrangement of supporting cantilevers on
the boom of portals and TTC (to avoid Bird’s nesting)
Volume charts and equivalent chart of foundation
(side bearing, side gravity & WBC)
ETI/OHE/G
00158
Sh-3
-
ETI/OHE/G
00159
Sheet 3
0076
-
236
Volume chart and equivalent chart of foundations(NG
type)
TI/CIV/FN
D/RDSO
237
Volume and equivalent chart of foundations for dry
black cotton soil only (NBC type)
TI/CIV/FN
D/RDSO
238
Volume chart & equivalent chart of new pure gravity
foundations (500 mm exposed)
TI/CIV/FN
D/RDSO
239
Volume & equivalent chart of foundations for dry
black cotton soil only (8000 kg/sq. m) NBC type 2.5
m depth
Volume charts and equivalent chart of foundations
(side bearing, side gravity &WBC)
TI/CIV/FN
D/RDSO
222
234
235
240
241
Volume
charts
and
foundations(NG type)
242
Volume and equivalent chart of foundations for Dry
black cotton soil (NBC type) for 16500 &11000 kgf/
sq m, 3.0 m depth
Volume chart and equivalent chart of new pure
gravity foundations (500 mm exposed).
243
244
245
246
247
248
249
250
equivalent
chart
of
Volume and equivalent chart of foundations for Dry
black cotton soil only (8000 kg/ sq m) NBC type 2.5
depth
Employment schedule for OHE mast (9.5 m) for wind
pressure 150 kgf/ sq m copper OHE
pressure 150 kgf/ sq m copper OHE & EW
pressure 150 kgf/ sq m copper OHE &RC
pressure 150 kgf/ sq m copper OHE,RC&EW
pressure 150 kgf/ sq m copper OHE, with higher
implantation overlap anchor location
pressure 150 kgf/ sq m copper OHE with higher
implantation overlap inter location
Dated 29.Jan 2015
ETI/C
TI/CIV/FN
D/RDSO
ETI/C
00001/1
2/0
sheet-1
00001/
12/0
sheet -2
00001/
12/0
sheet -3
00001/
12/0
sheet -4
00001/
12/0
sheet -5
00001/
04/0
sheet-1
00001/
04/0
sheet-2
00001/
04/0
sheet-3
00001/0
4/0
sheet-4
00001/0
4/0
sheet-5
0726
Sheet 1
0726
Sheet-2
0726
Sheet-3
0726
Sheet-4
0727
ETI/C
0728
TI/DRG/CI
V/FND/RD
SO
TI/DRG/CI
V/FND/RD
SO
TI/DRG/CI
V/FND/RD
SO
TI/DRG/CI
V/FND/RD
SO
TI/DRG/CI
V/FND/RD
SO
ETI/C
ETI/C
ETI/C
ETI/C
C
-
-
-
-
-
-
Page 420 of 429
RVNL
251
252
Employment schedule for tramway type regulated
OHE WP 150 kgf/ sq m without RC &EW
Raised register arm clamps
253
254
255
256
257
258
Contact wire parallel clamp(Part small)
Parallel clamp Part (150/105-150)
Steady Arm hook BFB (forged)
259
Tabular stay sleeve (forged)
260
Register Arm Eye piece 25 mm (Forged)
261
Mast fittings for hook insulator ( forged)
262
Modified BFB steady arm assembly with 25 mm drop
bracket ( ID-2306)
263
Terminal clamp (15 mm) –compression type
264
Terminal clamps( 19mm) compression type
265
Feeder splice ( 150)
266
Feeder splice sleeve
267
Feeder joint socket left
268
19 mm bus terminal clamp ( compression type)
269
Parallel clamp ( dia 20 mm/ 18.75mm)
270
18mm single clevis assembly modified
271
Signals at neutral sections
Dated 29.Jan 2015
ETI/C
ETI/OHE/P
/1360-1
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
ETI/OHE/P
TI/DRG/OH
E/FTGFE/R
DSO
TI/DRG/OH
E/FTGFE/R
DSO
TI/DRG/OH
E/FTGFE/R
DSO
TI/DRG/OH
E/FTGFE/R
DSO
TI/DRG/OH
E/FTGFE/R
DSO
TI/DRG/OH
E/FTGNF/R
DSO
TI/DRG/OH
E/FTGNF/R
DSO
TI/DRG/OH
E/FTGNF/R
DSO
TI/DRG/OH
E/FTGNF/R
DSO
TI/DRG/OH
E/FTGNF/R
DSO
TI/DRG/OH
E/FTGNF/R
DSO
TI/DRG/OH
E/FTGNF/R
DSO
TI/DRG/OH
E/FTGFE/R
DSO
TI/DRG/OHE
/NS/RDSO
0706
A
E
1040-3
1041-2
1050-3
1051-2
1530-1
00003/
0 0/0
B
D
A
C
C
00004/
03/0
00002/
00/0
00005/
04/0
00006/
05/0
00001/
02/1
00002/
02/1
00003/
03/0
00004/
03/0
00005/
03/0
00006/
03/0
00006/
03/0
00001/
00/0
00001
/00/01
Page 421 of 429
RVNL
272
Schedule anchor block for BG track
273
Double guy rod arrangement with anchor block for
BG track.
274
Schedule of anchor block for BG track black cotton
soil
275
Guy rod dia 25 mm
Dated 29.Jan 2015
TI/DRG/OH
E/GUYROD
/RDSO
TI/DRG/OH
E/GUYROD
/RDSO
TI/DRG/OH
E/GUYROD
/RDSO
TI/DRG/OH
E/GUYROD
/RDSO
00001/
07/0
00002
/07/0
00003/
07/0
00004/
07/0
Page 422 of 429
RVNL
(C)LIST OF STANDARD RDSO’s SPECIFICATIONS FOR OHE
Sl.
No.
DESCRIPTION
SPECIFICATION NO.
LAST
REV.
1.
Technical Specification for annealed stranded
copper conductors for jumper wire for Electric
Traction
ETI/OHE/3(2/94) with
A&C slip No.1of (4/95)
2.
Specification for Copper bus bar.
RE/30/OHE/5 (11/60)
3.
Specification for Steel tubes.
4.
Specification for Hot dip zinc galvanization of steel
masts ( Rolled & fabricated). Tubes and fittings
used on 25 kV ac OH
ETI/OHE/13(4/84)
with A&C slip No. 1of
(5/86),2 of (4/90) & 3
of (4/90)
3
5.
Specification for Stainless steel wire ropes.
TI/SPC/OHE/WR/1060
with A&C slip No 1 of
(11/06) & 2 of (05/07)
2
ETI/OHE/11 (5/89)
1
-
OR
ETI/OHE/14(9/94)
with A&C slip No.1 of
9/95,2 of
1/97,3(8/99)4
of(12/99) & 5 of
(10/2001).
6.
Specification for solid core porcelain insulators for
25 kV ac 50 Hz single phase overhead traction
lines.
TI/SPC/OHE/INS/0070
(04/2007)
OR
ETI/OHE/15(9/91)
with A&C slip No.1
(5/99), No..2 of
(2/2000) and 3 of
(2/2000).
-
7.
Specification for 25 kV ac single pole and double
pole isolators for Railway Electrification.
ETI/OHE/16(1/94)
with A&C slip No.1 of
(06/2000) & 2 of
(3/2004)
2
Dated 29.Jan 2015
Page 423 of 429
RVNL
8.
Specification for steel and stainless steel bolts,
nuts .
9.
Aluminum alloy section and tubes for 25 kV
Traction Overhead Equipment.
ETI/OHE/21(9/74)
10.
Specification for Dynamometers.
RE/OHE/22(9/61)
-
11.
Specification for Light weight Section insulator
assembly.
TI/SPC/OHE/LWTSI/0060(
08/06)
-
12.
Specification for Enameled steel plates.
ETI/OHE/33(8/85)
-
13.
Specification for retro-reflective structure Number
plates.
ETI/OHE/33A(12/97) with
A&C slip 1 to 8
8
14.
Performances specification for modular cantilever
assembly.
TI/ SPC/OHE/MCS/080
-
15.
Specification for Galvanized steel wire rope.
A&C Slip No.1 of (5/98)
1
16.
Specification for Hard drawn copper catenary.
ETI/OHE/37(12/73)
-
17.
Technical specification for hard drawn grooved
contact wire for electric traction (jointed/welded
contact wire).
ETI/OHE/42(6/97)
-
18.
Specification for three pulley type regulating
equipment with modified Pulley group (3:1 Ratio)
TI/SPC/OHE/ATD/0060
with A&C slip 1 to 3
3
19.
Technical specification for exothermic welding
connection for bonding, earthing/drinding
TI/SPC/OHE/Exothrmbond/
0100(04/10)
-
20.
Technical specification for Fittings for 25 kV ac
OHE
A&C Slip No 1 of (3/97)
and CORE's A&C slip No. 2
of (4/2000), 3 of (08/01) 4
of (03/2002) & 5 of
(10/2010).
5
21.
Technical Specification for cadmium copper
conductors for overhead Railway traction.
ETI/OHE/50(6/97) with A &
C Slip No 1 to 3
3
Dated 29.Jan 2015
TI/SPC/OHE/Fasteners/
0120
OR
A&C slip latest.
-
-
Page 424 of 429
RVNL
22.
Technical Specification for 37/2.25mm Hard
Drawn Stranded copper conductor
TI/SPC/OHE/HDCSCF/003
0(06/03)
-
23.
Specification for Discharge/earthing pole
assembly for 25 kV ac traction.
ETI/OHE/51(9/87)
1
24.
Specification for interlocks for ac traction
switchgears.
ETI/OHE/52(10/84)
-
25.
Principles for OHE layout plans and sectioning
diagrams for 25 kV ac traction.
A&C slip no.1 of (6/88), 2 of
(6/88), 3 of (6/90), 4 of
(8/92) & 5 of (11/2006)
5
26
Specification for 19/2.79 mm all aluminum alloy.
Stranded
A&C slip No. 1 of (11/89)
&2 of (10/92)
2
27
Specification for Bimetallic (aluminium-copper)
strip.
ETI/OHE/55(4/90)
-
28
Technical specification for 4 wheeler overhead
equipment inspection car 1676 mm gauge
TI/SPC/OHE/4WDHTW/00
70 (06/07)
-
29
Specification for hand operated lifting and
swiveling platform.
ETI/OHE/58/1(1/95)
-
30
Technical specification for 8 wheeler OHE
inspection car 1676 mm gauge
TI/SPC/OHE/8WDEIC/0090
(2/09)
1
31
Specification for Short Neutral Section Assembly
(phase Break)
TI/SPC/OHE/SNS/0000 of
(2/2000)
-
32
Specification for solid core cylindrical post
insulators for systems with nominal voltages of
220 kV, 132 kV, 110 kV & 66 kV
ETI/OHE 64(10/88)
1
33
Specification for continuous cast copper wire rods.
C Slip No 1 to 3
3
34
Technical Specification for hard drawn grooved
contact wire for electric traction draw3n out of
continuous cast copper (CCC) wire rods.
C Slip No 1,3,4 & 5
4
35
Gearless hand operated pulling and lifting
machines (TIRFOR)
TI/SPC/OHE/TOOLPL/0990
1
Dated 29.Jan 2015
Page 425 of 429
RVNL
36
Galvanised steel stranded wire (GSSW) for
Anchoring of Traction Mast
TI/SPC/OHE/GSSW/0090
(10/2009)
-
37
Rachet lever Hoist ( Pull-lifts)
TI/SPC/OHE/TOOLPL/1990
-
38
Specification for Insulated Cadmium Copper
Catenary 19/2.1 mm Dia meter for provision under
over line structures in the 25 kV ac Electric
traction
TI/SPC/OHE/INSCAT/0000
(04/00) with A & C Slip No 1
-
39
Technical specification for infrared imaging
system for handheld application.
TI/SPC/OHE/TIPS/0010(03
/01)
-
40
Technical specification for infrared imaging
system for stationary Installation.
/05) Rev. 1
-
41
Specification for Loco mounted analysis system
/03)
-
42
Technical specification for galvanized steel
stranded wire for traction bonds for 25 kV ac
Electric traction system
TI/SPC/OHE/GALSTB/004
0(09/04)
1
43
Technical specification for Silicone composite
insulators for 25 kV ac 50 Hz single phase
overhead traction lines.
TI/SPC/OHE/INSCOM/107
0(01/07)
-
44
Specification for Retro-Reflective structure
number plate on FRP base
TI/SPC/OHE/FRPNP/0060
-
45
Technical specification for on Board Equipment for
line scanning for thickness of contact wire used in
25 kV ac traction.
TI/SPC/OHE/CW/WEAR/00
80(02/80)
-
46
Technical specification for Gas Auto tensioning
device.
TI/SPC/OHE/GATD/0080(9
/08)
-
47
Specification for Testing load testing Machine 25
kV Poprcelain & Composite insulator before
installation.
TI/SPC/OHE/INSTEST/009
0(02/09)
-
48
Specification for Solid core Porcelain cylindrical
Post Insulators with nominal Voltage of 66 kV, 110
kV, 132 kV & 220 kV
TI/SPC/OHE/POST/0100(0
1/10)
-
49
Technical specification for propelled Auger vehicle
for digging of foundations of over-head lines
TI/SPC/OHE/AUGER/0090(
02/09)
-
Dated 29.Jan 2015
Page 426 of 429
RVNL
50
Technical specification for propelled road Rail
vehicle for maintenance of over-head lines.
TI/SPC/OHE/RRV/
0090(05/09)
-
51
Technical specification for self propelled mast
Erection machine vehicle for running on
(1676)mm) Routes of Indian railways.
TI/SPC/OHE/MEMV/
0090(03/09)
-
52
Technical specification for galvanized steel
stranded wire for traction mast
TI/SPC/OHE/GSSW/0090(
10/2009)
-
53
Technical specification for roof mounted infrared
thermal imaging system for on live line scanning
of ac OHE system.
TI/SPC/OHE/ITIC/0100(02/
2010)
-
54
Technical Specification for self-propelled
intelligent OHE parameter recording cum
Inspection Car (Dhanwantari)
TI/SPC/OHE/8WDEITC/00
12(07/2012)
-
55
Technical specification for self propelled wiring
train for paying of contact & catenry wire of over
head lines on BG ( 1676 mm )
TI/SPC/OHE/WIRING/0090
(02/2013)
-
56
Technical specification for 8-Wheeler Diesel
Electric Tower Wagon (Under Slung)
TI/SPC/OHE/8WDETC/009
0 (02/2009 )
1
57
Technical Specification for spun prestressed
cement concrete (PSC) OHE traction mast.
ETI/ C/2(8/94)
-
58
Indian Railway standard specification for spraying
zinc coating on the OHE mast.
ETI/C/3(5/83)
-
59
Draft Indian Railway Standard specification for
cold roll formed mast for Railway electrification.
ETI/C/4(8/90)
-
60
Specification for Flo-Coat Tube.
ETI/C/5(5/88)
1
61
Corrosion Resistant Paint System for outdoor
structures of Traction Distribution and traction
rolling stock.
TI/SPC/CIV/POR/0080(08/
2008)
-
------------------------------------------------------------------------------------------------------------------------------------------
Dated 29.Jan 2015
Page 427 of 429
Dated 29.Jan 2015
RVNL
Page 428 of 429
RVNL
CHAPTER: B-21
Miscellaneous instructions
21.1
RAILWAY BOARD/RDSO INSTRUCTIONS TO BE FOLLOWED IN RAILWAY
ELECTRIFICATION WORKS (REF. RB letter D.O. NO. 2013/RE/161/9FTS-74851 DATED
09.04.2013).
Sr.
General Deficiencies in RE Works
Rly. Board/RDSO Guidelines
No.
1.
Availability of 120 mts distance between Railway Board’s letter BNo. 2010/l3c(G)/
stop signal and central line of insulated 148/5 dated 11.6.12 para 30.2 ACTM vol.
overlap/ section insulators.
II part.II
2.
Comprehensive
policy
regarding Railway
Board
letter
No.
insulators for 25 kV ac traction on IRs ( 2002/Elec.(G)/161/21 Vol. II Pt. dated
vandal/ Pollution prone area)- regarding 04.07.12
use of composite insulators
3.
Trimming/ cutting of trees in electrified Railway Board letter No. 2008/Elect.
sections
(G)/161/8 Pt. dated 05.09.12.
4.
To avoid provision of splice in large span Railway
Board
letter
No.
2008/
wires.
Elec.(G)/161/8 Pt. Vol. II Pt. dated
26.09.12.
5.
Insulated catenary to be provided under TI/MI/0036(09/99) Rev. 0
all ROBs/FOBs
6.
Provision of pipe on hex-Tie rod at cross TI/MI/0035(09/01) Rev. 1.
overs and short tension length ATDs.
7.
Testing of 25 kV porcelain and composite TI/MI/0042(12/2008) Rev.0
insulators before installation.
8.
Modified protection scheme to be ETI/C/0068(07/09) Rev. H
provided at all FOB/ROB.
9.
Increasing data transfer speed of TI/IN/002(02/10) Rev.0
traction scada system from 600/1200 or latest
bps to minimum 9600 bps
TI/SPS/RCC/SCADA/0130 04/2014
10
Provision of long cross type G – jumpers As per RDSO Drg.
on parallel run side instead of cross
over/turnout site.
11.
Separate DJ close boards for MEMU/EMU
Required for MEMU/EMU operation
12.
Ensuring projection of RT at pull of i.e. RDSO Drg. No. ETI/OHE/G/02106 Rev.C
negative stagger location to be beyond
the vertical plane of contact wire.
13.
Fixing arrangement for mast anchor RDSO
Drg.
No.
fitting for anti falling device for three TI/DRG/OHE/ATD/RDSO/0000/05/0
pulley modified ATD
14.
Caternary wire in place of GI wire at ACC RDSO
Drg.
No.
locations in polluted area.
TI/DRG/OHE/GENL/RDSO/000001/12/0
Rev.0 ref. ETI/OHE/G/02111 Rev.A dated
23.10.2012.
15.
Gap between mast fitting for hook Drg. No. RE/33/G/000141
insulators and top of the mast
16.
Measurement of contact resistance and As per ACTM para 20908 Vo. II, Part I and
opening/closing time of CBs/BMs during OEM’s this is to be done in the
commissioning of TSS/switching posts.
preconditioning test.
17.
Provision of double eye distance rod.
TI/MI/00008 Rev. 0
18.
Soft copy of LOP, Power supply diagrams For better accessibility and reproductivity.
and other relevant drawings in Auto CAD software.
Dated 29.Jan 2015
Page 429 of 429

Revised RVNL`s Standard Technical Specification for material and

Transcription

Similar documents

Geohex Brochure

PDF Lot View

KEMPEGOWDA INSTITUTE OF MEDICAL SCIENCES

` A S H B O R O U G H `

yaggy colby - Olmsted County

Recommended Billing Codes for the Anatomotor Table For Cervical

Krawler T/A KX - Suburban Tire

Pay Application #4 - the Public Building Commission of Chicago

View - Brooksville

Limo-Van Tour of the H-ana Coast Plus Lana`i