11kv Steel Line Materials Vol 2 Tech Specs

THE KENYA POWER AND LIGHTING COMPANY LIMITED

KENYA ELECTRICITY EXPANSION PROJECT

DISTRIBUTION REINFORCEMENT AND UPGRADE

TECHNICAL SPECIFICATIONS For

Procurement of Various 66kV, 33kV & 11kV Line Construction Materials

ICB No: KPLC1/6E/2/A13

(IDA- Credit)

VOLUME II

April 2011

Part 2 Employers Requirements

Part 1 Bidding Procedures

Part 3 Conditions of Contract and Contract Forms

2 Kenya Power and Lighting Co Ltd Section VI Schedule of Requirements Kenya Electricity Expansion Project Technical Specifications

2 Contract XIII April 2011 KPLC

Contents SECTION I – GENERAL SPECIFICATIONS1 GENERAL SPECIFICATIONS ...................................................... 3

1 GENERAL SPECIFICATIONS ..................................................................................................................................... 4 1.1 SCOPE OF WORKS: ................................................................................................................................................. 4 1.2 DESCRIPTION OF THE PROJECT .......................................................................................................................... 4 1.3 STANDARDS ............................................................................................................................................................ 4 1.4 UNIT OF MEASUREMENT AND LANGUAGE ..................................................................................................... 4 1.5 SERVICE CONDITIONS .......................................................................................................................................... 4 1.6 WORKING STRESS AND EQUIPMENT/APPARATUS DESIGN .................................................................... 6 1.7 BASIC REQUIREMENTS FOR ELECTRICAL EQUIPMENT ............................................................................... 9 1.8 MATERIALS AND WORKMANSHIP ..................................................................................................................... 9 1.9 PROTECTION, CLEANING AND PAINTING ....................................................................................................... 12 1.10 PACKING .............................................................................................................................................................. 13 1.11 DELIVERY ............................................................................................................................................................ 14 1.12 PROGRAMME AND PROGRESS ........................................................................................................................ 14 1.13 EQUIPMENT TESTING AT PLACE OF MANUFACTURE ............................................................................... 14 1.14 PHOTOGRAPHS ................................................................................................................................................... 15

SECTION II - TECHNICAL SPECIFICATIONS ........................................................................................................ 16

2 TECHNICAL SPECIFICATIONS FOR LINE CONSTRUCTION MATERIALS ........................................... 17 2.1 SPECIFICATION FOR OVERHEAD LINES FITTINGS ....................................................................................... 17 2.2 SPECIFICATION FOR GALVANISED STEELWORKS FOR OVERHEAD LINES. ......................................... 21 2.3 SPECIFICATION FOR CONCRETE POLE FITTINGS ......................................................................................... 27

3. GUARANTEED TECHNICAL PARTICULARS. ................................................................................................... 45 3.1 PREAMBLE .......................................................................................................................................................... 45



Section I – General Specifications



1 GENERAL SPECIFICATIONS 1.1 SCOPE OF WORKS: The contract covers design, supplying and testing before shipment, painting, packing for transport, insuring, shipping, delivering to the port of Kenya, landing, customs clearing, transporting from the port to KPLC stores all materials referred to as VARIOUS LINE CONSTRUCTION MATERIALS FOR 66kV, 33kV & 11kV LINES generally described below. Subsequent paragraphs will give detailed descriptions and requirements as to the plant specified

herein. 66kV, 33kV and 11kV underground cables and overhead lines

• Line support structures and associated materials • Conductors support accessories • Line hardware materials and fittings

1.2 DESCRIPTION OF THE PROJECT

As described under vol.1 Section VII 1.4 preamble.

1.3 STANDARDS

Ratings, characteristics, tests and test procedures, etc. for the electrical equipment encompassed by this Specification shall comply with the provisions and requirements of the standards of the International Electro-technical Commission (IEC), and or KPLC operational standards unless otherwise expressly stated in Particular Technical Specifications. Where the IEC standards do not fully cover all provisions and requirements for the design, construction, testing, etc. and for equipment and components that are not covered by IEC Recommendations recognized national standards shall be applied.

The latest revision or edition in effect at the time of Bid Invitation shall apply. Where references are given to numbers in the old numbering scheme from IEC it shall be taken as to be the equivalent number in the new five-digit number scheme. The Bidder shall specifically state the Precise Standard, complete with identification number, to which the various equipment and materials are manufactured. The Bid Documents do not contain a full list of standards to be used, as they are only referred to where useful for clarification of the text.

1.4 UNIT OF MEASUREMENT AND LANGUAGE In all correspondence, in all technical schedules and on all drawings prepared by the

Contractor, the metric units of measurement shall be used. On drawings or printed pamphlets where other units have been used, the equivalent metric measurements shall be added. All documents, correspondence, drawings, reports, schedules instructions, and nameplate readings of the equipment shall be in the language stated in the Bid Data sheet.

1.5 SERVICE CONDITIONS

From the geographical condition, the project area is categorized into the tropical climate zone. In choosing materials their finishes, due regard shall be given to the humid tropical conditions under which the plant shall be called upon to work. The contractor shall submit



details of his usual practice which have proven satisfactory and which he recommends for application to the parts of the work, which may be affected by tropical conditions. The materials and finishes used shall be approved by the Employer. All switchgear and control cubicles shall also be rodent and vermin proof.

1.5.1 Environment a) Unless otherwise specifically stated in Particular Technical Specifications or Scope of

Works, any equipment, component and assembly shall be designed for the following service conditions:

Parameter Max Min Ambient air temperature Outdoor +40°C -1°C Indoor +40°C -1°C 24 hour average maximum +30°C -1°C Ambient temperature for cables in the ground +40 °C -1°C Relative humidity 90%

Height above sea level 1800m EMC Class (IEC 61000) Industrial environments Seismic coefficient 1.5 Wind pressure on project area of conductors and cylindrical objects

400 N/m²

Maximum wind pressure on steel members on 1.5 times projected area

820 N/m²

Rainfall conditions Average 800-1700 mm/year Maximum 160mm in 24 hrs Annual mean isokeraunic level Max 180 thunderstorm days Pollution (IEC 60815) Heavy :class II

Wherever any of these maximum or 24 hour average temperatures exceed the normal service condition temperatures of the IEC Recommendations for the relevant equipment, or of such other standard which is approved to be applied, the permissible temperature rises of the IEC Recommendations or the standard shall be reduced by the same amount as the difference between the above figures and the normal service condition temperatures. The Contractor shall guarantee these reduced temperature rises. All air cooled equipment shall be cooled with convection (i.e. without fans) provided other cooling methods are not explicitly allowed for in the specifications.

1.5.2 Acoustics, Noise measurement The equipment shall as far as possible not generate undue vibrations or bothersome noise. Provided nothing else is specified the following requirements shall not be exceeded:

Area of equipment location Maximum noise level dB(A) Machine hall, workshop etc. (one meter from the machine)

85

Office, control room, day room etc 55



Emergency diesel generator (7 meter from engine room)

85

1.5.3 Tropicalization

a) All equipment must be designed for operations in the severe tropic climate conditions and fully comply with climatic aging tests as per IEC 60932-class 2.

b) In choosing materials and their finishes, due regard shall be given to the humid tropical

conditions under which the plant will be called upon to work. Where it is not specifically called for, the contractor shall submit details of his usual practice which have proven satisfactory and which he recommends for application to the parts of the work, which may be affected by tropical conditions. The materials and finishes used shall be approved by the Employer. All switchgear and control cubicles shall also be rodent and vermin proof. Enhanced description.

i. Metals: Iron and Steel are generally to be painted or galvanized as appropriate. Indoor parts may alternatively have chromium or copper-nickel plates or other approved protective finish. Small iron and steel parts (other than rustless steel) of all instruments and electrical equipment, the cores of electromagnets and the metal parts of relays and mechanisms shall be treated in an appropriate manner to prevent rusting.

ii. Screws, Nuts, Springs, Etc.

The use of Iron and steels shall be avoided in instruments and electrical relays wherever possible. Steel screws shall be zinc, cadmium or chromium plated or where plating is not possible owing to tolerance limitations, shall be of corrosion resisting steel. Instrument screws (except those forming part of a magnetic circuit) shall be of brass or bronze. Springs shall be of non-rusting material, e.g., phosphor-bronze or nickel silver, as far as possible.

iii. Rubbers:

Neoprene and similar synthetic compounds, not subject to deterioration due to the climatic conditions, shall be used for gaskets, sealing rings, diaphragms, etc.

TROPICALIZATION TO BE IN COMPLIANCE WITH CLIMATE GRAPH NO. 8 OF THE IEC 721-2-1, TEST B: DRY HEAT IEC 68-2-2 TEST Bd; DAMP HEAT, CYCLIC IEC 68-2-30.

1.6 WORKING STRESS AND EQUIPMENT/APPARATUS DESIGN

1.6.1 General

a) The design, dimensions and materials of all parts shall be such that they will not suffer damage under the most adverse conditions nor result in deflections and vibrations, which might adversely affect the operation of the equipment. Mechanisms shall be constructed to avoid sticking due to rust or corrosion.

b) The equipment and apparatus shall be designed and manufactured in the best and most

substantial and workmanlike manner with materials best suited to their respective purpose and generally in accordance with up-to-date recognized standards of good practice.



c) All parts which will or might have to be dismantled for the purpose of serving or replacement shall be assembled with anti-corrosive fasteners. The type, material and size of all fasteners shall be selected to safely withstand the maximum superimposed direct, alternating, kinetic and all loads induced by workmen when installing or removing the fasteners during the life of the equipment.

d) The equipment shall be designed to cope with 0.15G acceleration of seismology on the

centres of gravity.

e) All equipment shall be designed to minimize the risk of fire and consequential damage, to prevent ingress of vermin, dust and dirt, and accidental contact with electrically energized or moving parts. The plant shall be capable of continuous operation with minimum attention and maintenance in the exceptionally severe conditions likely to be obtained in a tropical climate.

f) Upon request by the Employer complete information regarding the design assumptions,

loading and operating conditions, deflections and unit stresses used in the design shall be provided by the supplier.

g) The Contractor shall be deemed to have examined the specification and drawings herewith,

and unless stated specifically to the contrary in the schedule of proposed conditions and /or deviations from the specification to have concurred with the design and layout of the applicable project features as being sufficient to insure reliability and safety in operation, freedom from undue stresses, adequate drainage and other essentials for a satisfactory working plant.

1.6.2 Strength and quality

a) All steel castings and weldings shall be stress-relieved by heat treatment before machining, and castings shall be stress-relieved again after repair by welding.

b) Liberal factors of safety shall be used throughout, especially in the design of all parts subject

to alternating stresses or shocks. 1.6.3 Design data High and medium voltage plant and equipment

The rating and design criteria for the HV and MV plant and equipment shall be as follows:

Item Parameters SYSTEM VOLTAGE 66 kV 33 kV 11 kV 1 System 50 Hz, 3 phase 2 Neutral point earthing Solid earthed 3 Nominal voltage of networks 66 kV 33 kV 11 kV 4 Highest system voltage as defined by

IEC-60038 72.5 kV 36 kV 12 kV

5 Short circuit and earth fault current, symmetrical r.m.s. value (min breaking current) not less than

25 kA 25 kA 25 kA

6 Thermal short-circuit current, 3 second not less than

25kA 25 kA 25kA

7 Dynamic peak current (min making 63 kA 63 kA 63 kA



Item Parameters SYSTEM VOLTAGE 66 kV 33 kV 11 kV

current)not less than 8 Rated current of busbars and bus

coupler if not given in Scope of Works, for each individual substation

1250 A 1250 A 1250 A

9 Minimum rated current of isolating switches and circuit breakers if not given in Scope of Works

800 A 800 A 630 A

10 Insulation level according IEC 60071: 10a Switching surge withstand voltage Phase-to-earth N/A N/A N/A N/A Longitudinal impulse component of

combined test N/A N/A N/A

10b Lightning impulse withstand voltage (1.2/50 m/s kVpeak) at 1000m a.s.l

325 kV 170 kV 75 kV

10c Test voltage at power frequency 1 min dry and wet. To earth and between phases at 1000m a.s.l

140 kV 70 kV 28 kV

11 For the design and erection of the conductors in the switchyard the following minimum distances shall be observed

11a Phase to earth [mm] 700 500 500 11b Phase to phase [mm] 790 435 250 11c Busbars phase to phase [mm] 1250 11e Height to live parts above ground [mm] 3500 2900 2900 11f Height to live parts above ground at

transformer transport routes [mm] 5000

12g Lowest part of insulators above ground [mm]

2 500

12 Maximum temperature rise of conductors above ambient temperature (40 ºC)

40 ºC

13 Maximum wind pressure on conductors and cylindrical objects

400 N/m2

14 Maximum wind pressure on flat surfaces

820 N/m2

15 Minimum nominal creepage distance as defined in IEC 60815, Table II

25 mm/kV (inland area) 31 mm/kV (in coast and industrial area)

Note 1) Ref IEC 60038) Note 2) For all current carrying parts the permissible short circuit duration shall be at least 1 second. Indoor equipment shall be arch tested in accordance with IEC 60298 amendment 2. The dynamic or momentary short circuit current on which the equipment design shall be based shall be computed by multiplying the r.m.s. value of the symmetrical short circuit current by the factor 1.8 x 2 .



Note 3) Ref IEC 60071) All High and Medium Voltage equipment shall be designed for installation at 2200 m above sea level. IEC 60071 shall apply with the specified correction factor for the altitude above sea level. 1.7 BASIC REQUIREMENTS FOR ELECTRICAL EQUIPMENT

All materials supplied under this Contract shall be new and of the best quality and of the class most suitable for working under the conditions specified. They shall withstand the variations of temperature and atmospheric conditions arising under working conditions without distortion deterioration or undue stresses in any parts and also without affecting the suitability of the various parts of the Works for which they were designed. The Plant shall be designed for a lifetime of 40 years. Equipment with a shorter life cycle shall be identified and so arranged that they are easy to replace.

1.7.1 Corona and radio interference

a) Switchgear shall be electrically designed to avoid local corona formation and discharge likely to cause radio interference.

b) The design of all line conductor fittings, insulator fittings, etc. shall avoid sharp corners or

projections which would produce high electrical stress in normal operation.

c) The design of adjacent metal parts and melting surfaces shall be such as to prevent corrosion of the contact surfaces and to maintain good electrical contact under service conditions.

d) Particular care shall be taken during manufacture of conductors and fittings and during

subsequent handling to insure smooth surface free from abrasion. 1.7.2 Insulators and fittings

a) All porcelain insulators and bushings for outdoor equipment shall be brown glazed. The resin insulators for indoor equipment may be of the inherent colour of the resin. All fittings shall be malleable iron hot-dipped galvanized alloy.

b) All the insulators and bushings shall have impressed thereon, before firing the glaze, the

name, initial or trade mark of the manufacturer, the year of manufacture and the mechanical strength.

1.8 MATERIALS AND WORKMANSHIP 1.8.1 General

a) Materials shall be new; the best quality of their respective kinds and such as is usual and suitable for work of like character. All materials shall comply with the latest issues of the specified standard unless otherwise specified or permitted by the Employer.



b) Workmanship shall be of the highest class throughout to ensure reliable and vibrations free Operations. The design, dimensions and materials of all parts shall be such that the stresses to which they may be subjected shall not cause distortion, undue wear, or damage under the most severe conditions encountered in service.

c) All parts shall conform to the dimensions shown on and shall be built in accordance with

approved specifications. All joints, datum surfaces and meeting components shall be machined. All machined finished shall be shown on the drawings. All screw, bolts, studs and nuts and threads for pipe shall conform to the latest standards of the International Organization for Standardization covering these components and shall all conform to the standards for metric sizes. The supplier shall never incorporate any standards or size system by his own account, regardless of that accepted and incorporated in this Contract.

d) All materials and works that have cracks, flaws or other defects or inferior workmanship will

be rejected by the Employer. All defective materials shall be promptly removed from the site by the supplier.

1.8.2 Standard Specifications The design, materials, manufacture, testing, inspection and performance shall, unless

otherwise specified in the Special requirements of these Specifications, conform to the authorized standards of the International Electro technical Commission (IEC) or equivalent national standards in additional to KPLC Operational procedures. The supplier shall include a statement of the standards, intended to be used.

1.8.3 Assembly Necessary items of equipment shall be assembled in the factory prior to shipment and routine

tests shall be performed by the contractor as may be required to demonstrate to the satisfaction of the Employer the adequacy of equipment and its component parts. All tests should simulate normal operating conditions as closely as possible. All dismantled parts shall be properly match marked and doweled to ensure correct assembly in the field.

1.8.4 Casting

a) Casting shall be true to pattern, of workmanlike finish and of uniform quality and condition, free from blowholes, porosity, hard spots, shrinkage defects, cracks or other injurious defects, shall be satisfactorily cleaned for their intended purpose.

b) Major defect on castings shall not be repaired, plugged, or welded without permission of

the Employer. Such permission will be given only when the defects are small and do not adversely affect the Strength, use or merchantability of the castings. The Employer shall give the distinction between major and minor defects. Excessive segregation of impurities or alloys at critical points in a casting will be a cause for its rejection. The largest fillets compatible with the design shall be incorporated wherever a change in section occurs. All castings shall be stress-relieved before machining and again after repair by welding.

c) Plates to be joined by welding shall be accurately cut to size and rolled by pressure to the

proper curvature, which shall be continuous from the edges. Flattening in the curvature along the edges with correction by blows will not be allowed. The dimensions and shape



of the edges to be jointed shall be such as to allow thorough fusion and complete penetration, and the edges of plates shall be properly formed to accommodate the various welding conditions.

1.8.5 Forging

a) The ingots from which the forgings are made shall be cast in metal moulds. The workmanship shall be first-class in every respect and the forgings shall be free from all defects affecting their strength and durability, including seams, pipes, flaws, cracks, scales, fins, porosity, hard spots, excessive non-metallic inclusions and segregations.

b) The largest fillets compatible with the design shall be incorporated wherever a change in

section occurs. All finished surfaces of forgings shall be smooth and free from tool marks.

c) The forging shall be clearly stamped with the heat number in such locations to be readily

observed when the forging is assembled in a completed unit. 1.8.6 Welding

a) Wherever welding is specified or permitted, a welding process, including stress relieve treatment as required if necessary, conforming to an appropriate and widely recognized professional standard shall be used.

b) Plates to be joined by welding shall be accurately cut to size and rolled by pressure to the

proper curvature, which shall be continuous from the edge. Flattening in the curvature along the edges with correction by blows will not be allowed. The dimensions and shape of the edges to be jointed shall be such as to allow through fusion and complete penetration, and the edges of plates shall be properly formed to accommodate the various welding conditions.

c) The surfaces of the plates adjacent to the edges to be welded shall be thoroughly cleaned

of all rust, grease and scale to bright metal. All important welding shall be stress-relieved by heat treatment before machining.

1.8.7 Galvanizing

a) Unless specifically mentioned to the contrary, iron and steel shall be galvanized in the factory after fabrication. The zinc coating shall be uniform, clean, smooth and as free from spangle as possible. Galvanizing shall be applied by the hot dip process for all parts other than steel wires. All steel wires shall be galvanized by a recognized trade standard.

b) The minimum quantities of zinc coating shall be 350 gram/sq. metre for bolts and nuts

and 550 gram/sq. Metre for all other parts except steel wires, unless otherwise specified in the Contract Documents. The uniformity of zinc coating, tested by dipping surface shall be exposed until the surface has been dipped four times for bolts and nuts, and six times for all parts.



c) The preparation for galvanizing and the galvanizing itself shall not distort or adversely affect the mechanical properties of the materials.

d) Special treatment during galvanizing to prevent the formation of “White rust” during

shipment or storage is required. The Bidder shall state in his Tender the treatment to be used.

1.8.8 Colour standard

The final colour of each item shall be as described under each item. 1.8.9 Nameplate

a) To facilitate operation and maintenance it is very important that all equipment e.g., Outdoor/indoor Switchgear, valves, instruments, switches, pipeline, etc., shall be clearly identified by nameplates showing the function and proper use of each item. Such identification shall be in English and must be intelligently and carefully designed to minimize errors and to avoid maloperation in operation or maintenance.

b) The nameplates shall be permanently legible, clearly worded, weather proof when outdoors

and securely mounted in conspicuous and logical locations.

c) A table showing materials, dimensions, location, mounting and wording shall be submitted to the Employer for approval.

1.9 PROTECTION, CLEANING AND PAINTING

1.9.1 Embedded steelwork

All parts to ultimately be buried in concrete shall be cleaned and protected before leaving the manufacturer’s plant by cement wash or other approved method. Before being installed they shall be thoroughly desiccated and cleared of all rust and adherent matter, or be treated according to a method approved by the Employer. Such cleaning or treatment shall not detrimentally affect the strength or final operation and function of the equipment.

1.9.2 Steel exposed to atmosphere

a) All machined parts or bearing surfaces shall be cleaned and protected from corrosion before leaving the manufacturer’s plant by the application of an approved rust preventive coating, or a peelable plastic film. Where the latter is impracticable, such parts shall be heavily covered with high melting point grease.

b) All parts, other than machined parts, which will be exposed after erection shall be

thoroughly cleaned and galvanized or given with two coats of best quality approved primer and one coat of best quality approved finish paint before leaving the manufacturer’s plant. All outside panel surfaces shall be primed, filed where necessary, and given not less than two coats of synthetic undercoat. The finishing coat for the outdoor and indoor installations shall be gloss paint.



c) All steel surfaces, which are in permanent contact with oil, shall be given three coats of approved oil resistant.

d) No painting or protection is required for finished or unfinished stainless steel

parts.

e) The final colour of all equipments, frames for meters and relays, and switch handle shall be as described under each particular item.

f) The humid and tropical conditions shall be taken into account on selection of the

paints and painting procedure. 1.10 PACKING

a) Each item shall be packed properly or protected for shipment from the place of manufacture to the site.

b) Each crate of package shall contain a packing list in a waterproof envelope and a copy

in triplicate shall be forwarded to the Employer prior to dispatch. All items of material shall be clearly marked for easy identification against the packing list.

c) All cases, packages, etc, shall be clearly marked on the outside to indicate the total

weight, to show where the weight is bearing and the correct position of the slings and shall bear an identification mark relating them to the appropriate shipping documents.

d) Cases, which cannot be marked as above, shall have metal tags with the necessary

marking on them. The metal tags shall be securely attached to the package with strong steel wire or equivalent.

e) Long pieces of steel angles shall be packed in bundles and properly tied together by

an approved method and care taken to ensure that they are robust and not of excessive length and weight for handling in transit.

f) Short pieces of steel angles and steel plates shall be bolted or wired together through

holes and packed in stout timber cases.

g) Bolts, nuts, washers and fillers shall be bagged in sealed vinyl and packed in steel cans. The cans shall bear the contents and be crated together.

h) Packing together of components of dissimilar metals shall not be acceptable.

i) Conductors and overhead earth wire shall be packed on drums stoutly constructed of

good quality wood. Drums shall be securely battened around the perimeter to give maximum protection to the conductor and the earth wire and correct direction of rolling indicated with an arrow in a manner not easily removable.

j) The first layer of conductors or earth wire on drums shall be secured to the hub in

manner avoiding damage to subsequent layers.

k) All drums shall be protected from deterioration on site by termite or fungus attack by an approved impregnation treatment at the works before dispatch.



l) The Employer shall reserve the right to inspect and approve the equipment and the

packing before the items are dispatched. The supplier shall be entirely responsible for ensuring that the packing is suitable for transit and such inspection will not relieve the supplier from responsibility for any loss or damage due to faulty packing.

(a) Consignee: NAME OF SUPPLIER (b) Name of Project: SUPPLY OF VARIOUS 66KV, 33KV & 11KV LINES

CONSTRUCTION MATERIALS (c) Contract No.: KPLC1/6E/2/A13 (d) Port of destination: KPLC, NAIROBI SOUTH STORES (e) Item Number, if applicable,

Package number in sequence, and quantity per package: ……………………………………………….

(f) Description of Contents: ………………………………………………

Net and gross weight, cubic measure: ………………………………… The shipping mark is finally subject to the Employer’s approval.

1.11 DELIVERY

a) The Supplier shall deliver all materials supplied under the Contract to the site in adequate time for its according to the Schedule.

b) Each delivery notification shall include a complete shipping list of the contents of each

package to be delivered and shall indicate the anticipated date of delivery and the serial number for each component to be used for identification and evidence of the insurance cost arranged for it.

1.12 PROGRAMME AND PROGRESS

a) Within 21 days after the date of signing the contract agreement, the Contractor shall prepare his detailed program in a Software form covering the design, manufacture and delivery of the Works, in sufficient detail to define the various sections of the Works. A Soft and hard copy shall be submitted to the Employer for approval.

b) Upon approval of the programme by the Employer, it should thereafter be referred to as

the approved detailed Construction Program and shall become a part of the Contract.

c) Regular Monthly progress reports shall be provided by the supplier, indicating the actual state of progress of all items during the course of manufacture in the form given by the Employer.

1.13 EQUIPMENT TESTING AT PLACE OF MANUFACTURE

a) The manufacturers shall be responsible for performing or for having performed all the required tests specified under the specification for all the equipment. Bidders shall confirm



the manufacturer’s capabilities in this regard when submitting tenders. Any limitations shall be clearly specified.

b) Tender documents shall be accompanied by copies of Type test and Routine test reports &

certificates for similar rated equipment for the purpose of tender evaluation. Type test reports & certificates shall be certified by the National Standards and Testing Authority (NSTA) of the country of origin. Where a body other than NSTA is used to certify the type-test reports, a copy of the certificate of accreditation shall be attached. Current contact information of the testing and certification authority shall be provided.

c) Upon completion of the manufacturing process, routine tests shall be carried out as per the

respective standards of each equipment and the results endorsed by the NSTA of the country of manufacture.

d) The Contractor shall arrange for the Employer’s staff members to witness tests of major items

of equipment in the manufacturer’s plant as follows: (1) As per schedule 3 in Vol 1

e) The equipment mentioned above shall be subjected to inspection by two KPLC Engineers or

her representative at place of manufacture for 5 days per equipment and all routine tests and other tests specified under each specification carried out in their presence. KPLC representatives shall approve shipment of the equipment if they are satisfied that the requirements of the specification are fully met. The supplier shall quote separately as in Vol 1 for these inspections. The full cost of the visit, including air tickets, manufacturer’s local transportation and accommodation shall be borne by the contractor.

1.14 PHOTOGRAPHS The Contractor shall keep photographic records of the progress of each phase of the work. The determination of each particular phase shall be agreed upon between the contractor and the employer after contract signing and as work progresses. Upon completion of the work, the Contractor shall submit three sets of colour photographs or a CD with explanatory description adequately edited in book form to the Employer’s satisfaction.



Section II - Technical Specifications



2 TECHNICAL SPECIFICATIONS FOR LINE CONSTRUCTION

MATERIALS 2.1 SPECIFICATION FOR OVERHEAD LINES FITTINGS

2.1.1 SCOPE

a) This specification is for overhead line fittings for use on overhead power lines operating at voltages up to and including 66 kV (66000 volts) a.c. b) This specification covers the following overhead line fittings:-

• Conductor terminations. • Joints (Non-tension joints). • Suspension clamps. • Connectors

Particular requirements for each type of fittings as may be relevant for a specific requisition are given in clause 4.3.

2.1.2 REFERENCES

The following documents were referred to during the preparation of this specification and may be referred to. In case of conflict, the provision of this specification shall take precedence. Unless otherwise specified, the latest revision, edition and amendments shall apply.

• BS 729: Hot dip galvanized coating on iron and steel articles.

• BS 3288: Insulator and conductor fittings for overhead power lines. o Part 1: Performance and general requirements. o Part 2: Dimensions.

• ESI 43-92: Conductor termination’s, joints and insulator binds for

overhead up to and including 132 kV. 2.1.3 TERMS AND DEFINITIONS For the purpose of this specification, the definitions in the reference standards shall

apply. 2.1.4 SERVICE CONDITIONS

As stated in clause 1.5 2.1.5 MATERIAL AND CONSTRUCTION



2.1.5.1 The fittings shall be free from defects which would be likely to cause them to be unsatisfactory in service. 2.1.5.2 All parts of fittings shall be either inherently resistant to atmospheric corrosion, both during storage and in service. 2.1.5.3 All ferrous metal parts except those made of stainless steel shall be protected by hot dip galvanizing as per the requirement of BS 729. 2.1.5.4 The threads of nuts and tapped holes shall be cut after galvanizing and shall be well oiled or greased. All other threads shall be formed before galvanizing.

2.1.6 PARTICULAR REQUIREMENTS

a) Conductor Termination’s. Ball ended hook, Socket clevis and Socket tongue 2.1.6.1 Ball ended hook, Socket clevis and Socket tongue shall be suitable for use on

Aluminium conductor steel-reinforced (ACSR) of outer diameter between 7.00 mm and 18.2 mm (25 sq. mm and 150 sq. mm) and standard disc insulator of ball and socket type with the ball pin diameter of 16 mm.

2.1.6.2 Ball ended hook, socket clevis and socket tongue shall be of malleable iron or ductile iron, hot dip galvanised to BS 729.

Tension clamp 2.1.6.3 Tension clamp shall be bolted type and shall be suitable for use on aluminium

conductor steel-reinforced (ACRS) of outer diameter between 7.00 mm and 18.2 mm (25 sq. mm and 150 sq. mm).

2.1.6.4The clamp body and keeper piece shall be of high strength and heat treated cast

aluminium alloy. 2.1.6.5 The clamp cotter bolts, and U-bolts shall be galvanised steel and the pin shall

be stainless steel. 2.1.6.6 The clamp shall have slip strength of not less than 85% of the rated ultimate

strength of conductor it is intended for use with. b) Joints (Non-tension) Parallel groove clamp (PG Clamp) 2.1.6.7 Parallel groove clamp (PG Clamp) shall be suitable for use on aluminium

conductor steel-reinforced and all aluminium conductors of outer diameter in the range of 7.00 mm to 18.2 mm for ACSR conductors and 9.0 mm to 13.2 mm for AAC conductors (25 sq. mm and 150 sq. mm).

The groove of the PG clamp shall correctly fit the conductor it is intended for use with. It shall have adequate cross sectional area and length. The PG clamp shall be of electrolytic, high strength, corrosion resistant aluminium alloy.



c) Suspension Clamps 2.1.6.8 Suspension clamps shall be suitable for use on aluminium conductor steel-

reinforced (ACSR) of up to 18.2 mm diameter (150 sq. mm) and shall be of the following types.

Clevis ended hook type and pivoted type (similarly known as envelope type and trunnion type respectively). The clamp body and keeper piece shall be of high strength, heat-treated cast aluminium alloy. The clamp cotter bolts, hangers, brackets and U-bolts shall be of galvanised steel and the cotter pin shall be of stainless steel. Angle suspension clamp type (similarly known as side opening type). The clamp shall be suitable for use on turning angles from 10 to 120 degrees. The clamp body and keeper shall be of malleable iron or ductile iron, hot dip galvanised to BS 729. The clamp cotter bolts and bolt shall be galvanised steel and the cotter pin shall be stainless steel. d) Connectors 2.1.6.9 The connectors shall be suitable for use on stranded bare conductors and shall

correctly fit the conductor it is intended for use. 2.1.6.10 The connector shall have adequate cross sectional area and dimensions and

shall have current carrying capacity at least equal to the capacity of the conductor it is intended for.

• Aluminium connectors

• Aluminium connectors (line taps) shall be suitable for connecting stranded

aluminium conductors

• The connector shall be manufactured from electrolytic, high strength aluminium.

• Copper connectors

• Copper connectors shall be suitable for connecting stranded copper

conductors.

• Bi-metal connectors

o Bi-metal connectors shall be suitable for connecting stranded aluminium conductors to stranded copper conductors.

o The bi-metal connector shall be designed to provide an effective corrosion barrier between the dissimilar metals (aluminium and copper).



2.1.7 TESTS

The fittings shall be tested as per BS 3288. APPENDIX TABLE I: TERMINATION’S (TENSION JOINTS)

DESCRIPTION NORMAL BASIC APPLICATION Ball ended hook to BS 3288 Ref. 15/81

Termination of conductors above 50 sq. mm and up to 100 sq. mm

Socket tongue to BS 3288 Ref. 15/81

Termination of conductors up to 50 sq. mm

Socket tongue to BS 3288 Ref.15/35

Termination of conductors above 50 sq. mm and up to 100 sq. mm

Ball clevis For section pole construction for conductors of up to 50 sq. mm

Socket clevis For vertical flying angle and section pole construction

Terminating clamp 3 – U bolt

For terminating ACSR conductors of up to 100 sq. mm

Terminating clamp 4-U bolt

For terminating ACSR conductors above 100 sq. mm

TABLE II: NON - TENSION JOINTS

DESCRIPTION NORMAL BASIC APPLICATION P.G. Clamp (2 bolted)

For 25 sq. mm ACSR conductor

P.G. Clamp (3 bolted)

For 75 sq. mm ACSR conductor

P.G. Clamp (4 bolted) For 150 sq. mm ACSR conductor TABLE III: SUSPENSION CLAMPS

DESCRIPTION NORMAL BASIC APPLICATION Clevis ended hook type suspension clamp (envelop type)

For 33kV suspension type construction

Pivoted type suspension clamp (Trunnion Type)

For 33kV suspension type construction

Angle type suspension clamp (Side opening type)

For vertical flying angle construction

TABLE IV: CONNECTORS

DESCRIPTION NORMAL BASIC APPLICATION Aluminium connectors Line tap For 50 sq. mm AAC conductor



Line tap For 100 sq. mm AAC conductor Copper connectors Copper service line tap For 25 sq. mm Copper conductor Copper service line tap For 50 sq. mm Copper conductor Bi-metal connectors Bi-metal Connector line tap For conductor size 50 sq. mm Bi-metal Connector line tap For conductor size 100 sq. mm

2.2 SPECIFICATION FOR GALVANISED STEELWORKS FOR OVERHEAD LINES.

2.2.1 SCOPE

2.2.1.1This specification is for galvanised mild steelworks for overhead lines and pole mounted transformers. 2.2.1.2 This specification is for the following steelworks.

(i) steel cross arms of different configurations for use on wood poles. (ii) supporting steelworks for ancillary equipment. (iii) steelworks for supporting and terminating HV and MV/LV overhead lines and services.

2.2.2 REFERENCES

The following documents were referred to during the preparation of this specification and unless specified, the latest revision, edition and amendments shall apply.

In case of conflict, the provision of this specification shall take precedence.

• BS 4 Structural steel sections

• BS 729 Specification for hot dip galvanised coating on iron and steel articles

• BS 4360 Specification for weldable structural steel

• BS 5135 Specification for arc welding of carbon and carbon manganese steels

• ESI 43 - 95 Steelworks for overhead lines 2.2.3 TERMS AND DEFINITIONS For the purpose of this specification, the definitions in the reference standards shall

apply. 2.2.4 SERVICE CONDITIONS



As stated in clause 1.5

2.2.5 MATERIALS

a) Structural steel used, shall be grade 43A as specified in the BS 4360: 1972 “Specification for weldable structural steel”. b) The tensile strength and yield stress of the steel shall be not less than 430/510 N/sq. mm and 255 N/sq. mm respectively.

Angle sections shall be as per BS 4848 Channel sections shall be as per BS 4

c) Welding Welding where specified, shall be by metal-arc welding and shall be as per BS 5135:1974 After welding and before galvanising, welds shall be thoroughly cleared to remove

slag and spatter, preferably by sand blasting. 2.2.6 MATERIALS (CONSTRUCTION AND FABRICATION)

2.2.6.1 All materials before and after fabrication shall be straight and free from twists. 2.2.6.2All dimensions specified shall be subject to the following tolerances, unless stated.

(i) Dimensions up to and including 50 mm - (1 mm) (ii) Dimensions greater than 50 mm - (2 mm).

2.2.6.3Erection clearance for cleated ends of members connecting steel to steel shall not be greater than 2mm at each end. 2.2.6.4Bolt holes shall not be more than 2mm greater than the diameter of the bolt for bolts up to 24mm diameter. 2.2.6.5Cutting may be by shearing, cropping, sawing or machine flare cutting. Sheared or cropped edge shall be dressed to a neat finish and be free from distortion where parts are to be in metal contact. 2.2.6.6All holes shall be drilled in one operation and burrs shall be removed. Holes shall not be formed by a gas cutting process. All matching holes for bolts shall register with each other so that a gauge 2mm less in diameter than the diameter of the bolt shall pass freely through the assembled members in a direction at right angle to such members. 2.2.6.7All components shall be thoroughly galvanised by hot dip method after fabrication and shall comply with the requirement of BS 729:1991.



2.2.6.8Bending of flat straps shall be carried out cold. 2.2.7 TESTS

2.2.7.1 The tensile strength, yield strength, elongation and bending tests shall be done in accordance with the requirement of BS 4360. 2.2.7.2 Tests on galvanising shall be carried on the finished steel in accordance with the requirement of BS 729.

APPENDIX LIST OF STEELWORKS

ITEM KPLC CODE

FUNCTION

181201 D - Iron (LV Insulator Bracket) 188104 Shackle strap 188115 11 kV tie strap (flat) 188111 11 kV tie strap (angle) 188108 33 kV tie strap 188107 11 kV terminal strap 188109 33 kV terminal strap Earth stock 182911 11kV steel cross arm (1620 X 70 X 70) 186914 11 kV steel cross arm – Terminal (1620 X 125 X 76) 186914 33 kV steel cross arm – Terminal (2400 X 100 X 75) 186925 Fuse/Taplin Isolator cross member (2290 X 100 X 50)

(Channel for all transformers - 4” X 2” X 1/4”)

186921 Steady Insulator cross member (2290 X 100 X 50) (Channel for up to 200 kVA - 4” X 2” X 1/4”)

186922 Steady Insulator cross member (2290 X 125 X 64) (Channel for 300 kVA - 5” X 2 1/2” X 1/4”)

186923 Transformer Platform (4” X 2” X 1/4”)

(Up to 200 kVA)

186924 Transformer Platform (5” X 2 1/2 X 1/4”) 186924 Transformer Mounting Bracket (2 1/2” X 2 1/2” X 1/4”)

(For transformer platform - Code 86924)



FIGURE 3A. 11KV FLAT TIE STRAP (590mm X 40mm X 6mm)

FIGURE 4. 33KV TIE STRAP (860mm x 50mm x 50mm X 6mm - MS angle)



FIGURE 5. 11KV TERMINAL STRAP (250mm X 75mm X 10mm - MS flat)

FIGURE 6. 33KV TERMINAL STRAP (500mm X 76mm X 10mm - MS flat)



FIGURE 7. D – IRON (LV Insulator Bracket) -332mm X 40mm X 6mm Galvanised steel flat



11kv Steel crossarm

2.3 SPECIFICATION FOR CONCRETE POLE FITTINGS 2.3.1 SCOPE

This specification is for galvanized mild steelworks for overhead lines and pole-mounted transformers.

This specification is for the following steelworks.

(i) Steel cross arms of different configurations for use on concrete poles. (ii) Supporting steelworks for ancillary equipment.



(iii) Steelworks for supporting and terminating HV and MV/LV overhead lines and services.

2.3.2 REFERENCES

The following documents were referred to during the preparation of this specification and unless specified, the latest revision, edition and amendments shall apply. In case of conflict, the provision of this specification shall take precedence.

• BS 4 Structural steel sections

• ISO 1461 Specification for hot dip galvanised coating on iron and steel articles

• BS 4360 Specification for weldable structural steel

• BS 5135 Specification for arc welding of carbon and carbon manganese steels

• ESI 43 - 95 Steelworks for overhead lines

2.3.3 SERVICE CONDITIONS

As stated in clause 1.5 2.3.4 MATERIALS

Structural steel used, shall be grade 43A as specified in the BS 4360: 1972 “Specification for weld able structural steel”. The tensile strength and yield stress of the steel shall be not less than 430/510 N/sq. mm and 255 N/sq. mm respectively.

Angle sections shall be as per BS 4848

Channel sections shall be as per BS 4 Welding

• Welding where specified, shall be by metal-arc welding and shall be as

per BS 5135:1974

• After welding and before galvanizing, welds shall be thoroughly cleared to remove slag and spatter, preferably by sand blasting.

2.35 CONSTRUCTION - FABRICATION

2.3.5.1 All materials before and after fabrication shall be straight and free from twists. The material shall be free from blisters, scale and other defects. 2.3.5.2 All dimensions specified shall be subject to the following tolerances, unless stated.



(i) Dimensions up to and including 50 mm - (1 mm)

(ii) Dimensions greater than 50 mm - (2 mm).

2.3.5.3 Erection clearance for cleated ends of members connecting steel to steel shall not be greater than 2mm at each end. 2.3.5.4 Bolt holes shall not be more than 2mm greater than the diameter of the bolt for bolts up to 24mm diameter. 2.3.5.5 Cutting may be by shearing, cropping, sawing or machine flare cutting. Sheared or cropped edge shall be dressed to a neat finish and be free from distortion where parts are to be in metal contact. 2.3.5.6 All holes shall be drilled in one operation and burrs shall be removed. Holes shall not be formed by a gas cutting process. All matching holes for bolts shall register with each other so that a gauge 2mm less in diameter than the diameter of the bolt shall pass freely through the assembled members in a direction at right angle to such members. 2.3.5.7 All components shall be thoroughly galvanised by hot dip method after fabrication and shall comply with the requirement of ISO 1461. 2.3.5.8 Bending of flat straps shall be carried out cold.

2.3.6 PACKING

Each assembly and package of items associated with this specification shall be suitably marked with reference to KPLC Code. Where an item includes a number of components to form a complete assembly, all component parts shall be included in one composite package, which shall be firmly strapped or bound together.

2.3.7 TESTS AND INSPECTION Refer to clause 1.16

The manufacturer shall be responsible for performing or for having performed all the required tests in this specification. Bidders shall confirm the manufacturer’s capabilities in this regard when submitting tenders. Any limitations shall be clearly specified. The tensile strength, yield strength, elongation and bending tests shall be done in accordance with the requirement of BS 4360. Tests on galvanizing shall be carried on the finished steel in accordance with the requirement of ISO 1461. Copies of test reports (for similar items) issued by the relevant National Testing Authority confirming compliance of the steel structures on offer with the specifications shall be submitted with the tender for the purpose of technical evaluation

2.3.8 TECHNICAL DOCUMENTATION



Design and fabrication drawings including material details of the items to be supplied shall be submitted to KPLC for approval before manufacture. Tenders with substantial deviation but offering superior materials shall be accompanied by detailed descriptive manuals, drawings and certified test reports for the purpose of technical evaluation. A detailed list & contact addresses of previous customers shall be submitted with the tender. List of workshop tools and equipment shall also be submitted for reference.

FIG. 1. D – IRON (LV Insulator Bracket): KPLC CODE 181201; (332mm X 40mm X 6mm Galvanised steel flat)



FIG. 2. SHACKLE STRAP (LV Extension Strap): KPLC CODE 188104; (180mm X 40mm X 6mm mild steel flat)

FIG. 3: 11KV CROSSARM: KPLC CODE 186808; (L1770mm X 70mm X 70 x 9.5mm MS Angle)



FIG. 4: 11KV CROSSARM TENSION PLATE: KPLC CODE 186807, (445mm X 65mm X 6mm – MS)

FIG. 5: U-BOLT AND NUT: KPLC CODE 188108 (M20 X 700mm)



FIG. 6: 11KV CROSSARM; H-SECTION: KPLC CODE… (2500mm X 70mm X 70mm X 9.5mm MS

ANGLE)

FIG. 7: CONNECTING BAR FOR H-SECTION: KPLC CODE………. (541mm X 75mm X 6mm Mild Steel Flat)



FIG. 8: 33KV STEEL CROSSARM, H-SECTION/ LIGHT ANGLE KPLC CODE 188109, (2500mm X 100mm X 75 X 9.5 mm Mild Steel Angle)

FIG. 9: 33KV STEEL CROSSARM – INTERMEDIATE (2500X100X75X9.5MM);



FIG. 10: 33KV STEEL CROSSARM; TERMINAL (2500X125X75X9.5MM);

FIG. 11: DISTANCE PIECE KPLC CODE…….(235mm x 1 inch Pipe)



36 36

3636

FIG. 12: LV CLAMP (BRACKET) KPLC CODE: 186800; (1225MMX50MMX50MMX6MM)

FIG. 13; (M16X750MM) U-BOLT AND NUT FOR LV BRACKET; KPLC CODE: 186801



FIG. 14: (465MMX50MMX6MM), TENSION PLATE FOR LV BRACKET, KPLC CODE: 186802

360

20

10 C

LEA

RA

NC

E

FIG. 15: (470MMX75MMX6MM); STEEL CLIPS FOR STAY WIRE; KPLC

CODE: 186803



233 233

113120113

R113

R100

4444

120 120

FIG. 16: (2600MMX125MMX64MMX6MM) ; STEADY BAR U-CHANNEL; KPLC CODE: 186812

120120

2615

41

R104

44mm SLOTED HOLE

154 93

5043

40 X 4.5 THK PLT X50 LG1 / 22Ø HOLE

40

50

FIG. 17: TENSION PLATE FOR UPPER- STEADY BAR (435MMX65MMX6MM); KPLC CODE: 186815; WASHER (SQ. 50MMX40MMX4.5MM),



130 130

4444

130103 130

FIG. 18: (2600MMX125MMX64MMX6MM); STEADY BAR U-CHANNEL; KPLC CODE: 186812

70

408

170

130

260

R120

53 50

103154

44mm SLOTED HOLE

115

164

38

1523

130130

170

70

FIG. 19: U-BOLT (M20 X 750MM); KPLC CODE 186813, TENSION PLATE FOR MID- STEADY BAR (465MMX65MMX6MM); KPLC CODE: 186816;



R 147R 134

VA

RR

IES

300

FIG. 20: DETAILS OF TRANSFORMER PLATFORM ASSEMBLY

1915

34

R13

6

44mm SLOTED HOLE

154 123

5073

FIG. 21: (490MMX65MMX6MM) TENSION PLATE FOR TRANSFORMER PLATFORM: KPLC CODE: 186817



FIG. 22. LV FUSE BAR, KPLC CODE 186809, (U2600X100MMX50MMX6MM)

190

7070

45019

0

150

300

R140

FIG. 23: U-BOLT & NUT FOR FUSE BAR, KPLC CODE: 186810; (M20X850MM)



FIG. 24. 11KV TERMINAL CROSSARM, KPLC CODE 186805, (1626MMX125MMX75MMX9.5MM MS ANGLE)

FIG. 25: FITTING STRAP (173MMX75MMX10MM)



FIG. 26. POLE BRACKET (350X70X70X9.5MM MS ANGLE);



Part 3: Technical Schedules



3. GUARANTEED TECHNICAL PARTICULARS. 3.1 PREAMBLE 3.1.1 All documentation necessary to evaluate whether the equipment offered is in accordance with this Specification shall be submitted with the Bid. 3.1.2 Guaranteed Technical Particulars shall be provided and signed by the Manufacturer and submitted together with copies of the manufacturer’s catalogues, brochures, drawings, copies of type test reports, customers sales records, customer reference letters and details of production capacity and manufacturing experience in the manufacture of each item bid for tender evaluation, all in English language Note: This schedule does not in any way substitute for detailed information required elsewhere in the specification.