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EPC CPF PHASE 2

AT BADRA OILFIELD, IRAQ

DOCUMENT DETAILS

EMPLOYER CONTRACT NO. : 090-13-BD-205-00

PROJECT : EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ

EMPLOYER : Gazprom Neft Badra B.V.

EMPLOYER JOB NO. : GB090

CONTRACTOR : Samsung Engineering Co. Ltd

CONTRACTOR JOB NO. : SG-2614

DOCUMENT NO. : GB090-2614-250-EL-SP-0015

REVISION NO. : 0 No. of pages (incl. sheet) : 39

DOCUMENT DESCRIPTION : SPECIFICATION FOR OVERHEAD LINES

0 Issued for Purchase 20/10/2014 H.J. Park M.J. Kim J.C. Byun JSK / TGK

D Issued for Bid 11/04/2014 H.J. Park M.J. Kim J.C. Byun JSK / TGK

C Re-Issued for Approval 18/07/2013 H.J. Park M.J. Kim J.C. Byun JSK / KHS

B Issued for Approval 20/05/2013 H.J. Park M.J. Kim J.C. Byun JSK / KHS
J.C. Byun /
A Issued for Review 01/04/2013 H.J. Park M.J. Kim K.H.Song
JSK
Rev Description Date Prepared Checked Approved EM / PD

Electronic Filename : GB090-2614-250-EL-SP-0015_0.docx Doc Size : A4


EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
SPECIFICATION FOR OVERHEAD LINES
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SUMMARY OF DOCUMENT REVISIONS


Date
Rev. Section Revised Revision Description
Revised
A 01/04/2013 Issued for Review Issued for Employer Review

B 20/05/2013 Issued for Approval Incorporated Employers comments


Re-Issued for
C 18/07/2013 Incorporated Employers comments
Approval
D 11/04/2014 Issued for Bid Incorporated Employers comments

0 20/10/2014 Issued for Purchase Incorporated Employers comments


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TABLE OF CONTENTS

1 SCOPE AND PURPOSE 6

2 DEFINITIONS AND ABBREVIATIONS 6

2.1 DEFINITIONS 6

2.2 ORDER OF PRECEDENCE 6

2.3 ABBREVIATIONS 7

3 REFERENCES 7

3.1 INTERNATIONAL ELECTROTECHNICAL STANDARDS IEC 7

3.2 OTHER REFERENCES 9

3.3 PROJECT SPECIFICATIONS AND PROCEDURES 10

4 DESIGN CRITERIA 10

4.1 GENERAL 10

4.2 AMBIENT CONDITIONS 11

4.3 POWER SUPPLY FEATURES 11

4.4 GENERAL CHARACTERISTICS FOR ELECTRICAL EQUIPMENT 12

4.5 SUPPORT AND STAY FOUNDATION DESIGN 14

4.6 CONNECTION OF OVERHEAD LINES 14

4.7 CONDUCTOR SPACINGS AND CLEARANCES 15

4.8 OVERHEAD LINE CLEARANCE TO OBSTACLES 15

4.9 DESIGN LIFETIME AND RELIABILITY 16

5 GENERAL DESCRIPTION 17

6 CONDUCTORS AND ACCESSORIES 18

6.1 LINE CONDUCTORS 18

6.2 JOINTS 18

6.3 EARTH CONDUCTORS 19

6.3.1 GENERAL 19

6.3.2 JOINTS AND CLAMPS 20

6.3.3 AIRCRAFT WARNING 21


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6.4 INSULATORS AND FITTINGS 21

6.4.1 CORE 21

6.4.2 HOUSING 21

6.4.3 WEATHER SHEDS 22

6.4.4 END FITTINGS 22

6.5 CLAMPS AND FITTINGS 22

7 POLES, SUPPORTS AND FOUNDATIONS 23

7.1 APPLIED LOADS 23

7.1.1 TRANSVERSE LOADS 23

7.1.2 VERTICAL LOADS 23

7.1.3 LONGITUDINAL TERMINAL LOADS 23

7.1.4 BROKEN CONDUCTOR LOADS 23

7.2 SUPPORTS 24

7.2.1 FORM OF CONSTRUCTION 24

7.2.2 TYPE OF STRUCTURE 24

7.2.3 USE OF STANDARD SUPPORTS 25

7.2.4 SPAN LENGTHS 25

7.3 STAYS 26

7.4 TOWERS OF LATTICE STEEL 27

7.4.1 GENERAL 27

7.4.2 MATERIAL 27

7.4.3 DESIGN OF SINGLE TOWER 27

7.4.4 CONSTRUCTION 28

7.4.5 NUTS AND BOLTS 28

7.4.6 ANTI-CLIMBING DEVICES, STEP BOLTS AND BIRD GUARDS 29

7.4.7 LABELLING SYSTEM FOR 33kV TOWERS 29

7.4.8 TOWER MAINTENANCE SAFETY SYSTEMS 30

8 ACCESS ROUTES & SURVEY 30


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8.1 ACCESS ROUTES 30

8.2 SURVEY AND PROFILES 30

9 ELECTRICAL EQUIPMENT 31

9.1 SWITCHES AND FUSES 31

9.1.1 TYPES OF SWITCHES AND FUSES 31

9.1.2 OPERATING MECHANISMS 33

9.1.3 ACCESSORIES 34

9.1.4 SWITCHES CONSTRUCTION 34

9.2 FAULT CURRENT INDICATOR 35

9.3 SURGE ARRESTER WITH MONITORING 35

9.3.1 SURGE ARRESTERS 35

9.3.2 SURGE COUNTERS AND LEAKAGE CURRENT METERS 36

9.4 AUTOMATIC RECLOSERS 36

9.4.1 OPERATING MECHANISM 36

9.4.2 CONSTRUCTION 37

9.4.3 CONTROL CABINET 37

10 INSPECTION AND TESTING 37

10.1 GENERAL 37

10.2 FABRICATION AND QUALITY CONTROL PLAN AND INSPECTIONS 38

10.3 TEST PROCEDURE 38

11 TAGGING AND IDENTIFICATION 38

12 DOCUMENTATION REQUIREMENTS 39

13 PACKING AND SHIPPING REQUIREMENTS 39

14 SPARE PARTS 39
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1 SCOPE AND PURPOSE


The purpose of this document is to lay down the principal rules to be followed in the
design (incl. all the required calculations like sag & tension, sizing of over head line
conductors etc.), supply, erection, testing and commissioning of the OVERHEAD LINES
including all associated equipment and route survey.

It is not apply for jobsite temporary installations.

2 DEFINITIONS AND ABBREVIATIONS


2.1 DEFINITIONS

Throughout this Document the following definitions shall apply:

Employer : Gazprom Neft Badra B.V.


Contractor : Samsung Engineering Co. Ltd
Project : EPC CPF PHASE 2 AT BADRA OILFIELD, IRAQ
Vendor : Any vendor or supplier engaged by Contractor
PMC : Project Management Consultant for Employer

2.2 ORDER OF PRECEDENCE

In the event of apparent technical conflict occurring in applying this specification and
reference documents, the following order of precedence shall apply:

Iraq Laws and Regulations


Purchase Order (Note 3)
Data sheets and Drawings
This document
Other specifications and standards referenced in this document (Note 2)

Note 1.
All electrical equipment and material must be approved by the recognized international
certifying authorities of the country of origin and by the Iraq authorities.

Note 2.
Any exceptions to and deviations from this specification and any other referenced
documents shall not be implemented without written approval by Contractor / Employer.
For cases where requirements of Contractor project specification is superior/exceed
requirements set forth in codes and standards, the former shall be considered as
mandatory requirements for this project.

Note 3.
No technical specification shall be defined herein which conflicts or alters the Contractors
Project specification.
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2.3 ABBREVIATIONS

The following abbreviations are used in this document:

AC Alternating Current
ACSR Aluminum Conductor, Steel Reinforced
ASCE American Society of Civil Engineers
CPF Central Processing Facility
ECR Electric Glass Corrosion Resistant
EMC Electro Magnetic Compatibility
EMCS Electrical Monitoring and Control System
HSE Health, safety and environment
HV High Voltage (phase-to-phase voltage between 35 kV and 230 kV)
HTV High Temperature Vulcanized
IEC International Electro technical Commission
ISO International Standard Organization
MV Medium Voltage (phase-to-phase voltage between 1 kV and 35 kV)
OHL Overhead Line
OPGW Optical Fiber Ground Wire
RMS Root Mean Square
THD Total Harmonic Distortion
UBC Uniform Building Code
ZnO Zinc Oxide

3 REFERENCES
3.1 INTERNATIONAL ELECTROTECHNICAL STANDARDS IEC

Generally the latest revision of each IEC Standard will be applied.

IEC 60038 IEC Standard Voltages


IEC 60050 International Electrotechnical Vocabulary (Note 1)
IEC 60060 High-Voltage Test Techniques (Note 1)
IEC 60068 Environmental testing (Note 1)
IEC 60071 Insulation Co-ordination(Note 1)
Basic and safety principles for man-machine interface, marking
IEC 60073 and identification - Coding principles for indication devices and
actuators
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IEC 60079 Explosive atmospheres


IEC 60085 Electrical Insulation - Thermal Evaluation and Designation
IEC 60099 Surge Arresters (Note 1)
Aluminum-magnesium-silicon alloy wire for overhead line
IEC 60104
conductors
IEC 60120 Dimensions of ball and socket couplings of string insulator units
Tests on indoor and outdoor post insulators of ceramic material or
IEC 60168
glass for systems with nominal voltages greater than 1000 V
IEC 60183 Guide to Selection of High-Voltage Cables
High Voltage Switches Part 1: Switches for rated voltages above 1
IEC 60265-1
kV and less than 52 kV
Characteristic of indoor and outdoor post insulators for systems
IEC 60273
with nominal voltages greater than 1000 V
IEC 60282 High Voltage Fuses (Note 1)
IEC 60287 Electric Cables- Calculation of current rating (Note 1)
Insulators for overhead lines with a nominal voltage above 1000 V
IEC 60305 - Ceramic or glass insulator units for a.c. systems - Characteristics
of insulator units of the cap and pin type
IEC 60364 Low voltage electrical installations (Note 1)
Locking devices for ball and socket couplings of string insulator
IEC 60372
units - Dimensions and tests
Insulators for overhead lines with a nominal voltage above 1000 V
IEC 60383
(Note 1)
Insulators for overhead lines with a nominal voltage above 1 000 V
IEC 60433 - Ceramic insulators for AC systems - Characteristics of insulator
units of the long rod type
Basic and safety principles for man-machine interface, marking
IEC 60445 and identification - Identification of equipment terminals, conductor
terminations and conductors
IEC 60471 Dimensions of clevis and tongue couplings of string insulator units
Power cables with extruded insulation and their accessories for
rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) -
IEC 60502 2
Part 2: Cables f. rated voltages from 6 kV (Um=7,2 kV) up to 30 kV
(Um=36 kV)
Power cables with extruded insulation and their accessories for
rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) -
IEC 60502 4
Part 4: Test requirements on accessories for cables with rated
voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)
IEC 60529 Degrees of protection provided by enclosures (IP Code)
Thermal-mechanical performance test and mechanical
IEC 60575
performance test on string insulator units
IEC 60617
Graphical symbols for diagrams parts 2 to 11 of IEC 60617
-DB 12M
IEC 60652 Loading tests on overhead line structures
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IEC 60720 Characteristics of line post insulators


Residual strength of string insulator units of glass or ceramic
IEC/TR 60797 material for overhead lines after mechanical damage of the
dielectric
Common test methods for insulating and sheathing materials of
IEC 60811
electric cables
Selection and dimensioning of high-voltage insulators intended for
IEC/TS 60815
use in polluted conditions
IEC 60826 Design criteria of overhead transmission lines
IEC 60889 Hard-drawn aluminum wire for overhead line conductors
Short-circuit temperature limits of electric cables with rated
IEC 60986
voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)
IEC 61000 Electromagnetic compatibility (EMC) (Note 1)
IEC 61089 Round wire concentric lay overhead electrical stranded conductors
Insulators for overhead lines - Composite suspension and tension
IEC 61109 insulators for a.c. systems with a nominal voltage greater than 1
000 V - Definitions, test methods and acceptance criteria
IEC 61200 Electrical installation guide (Note 1)
Overhead lines - Characteristics of greases for aluminum,
IEC/TS 61394
aluminum alloy and steel bare conductors
IEC 61284 Overhead lines - Requirements and tests for fittings
IEC 61773 Overhead lines - Testing of foundations for structures
Insulators for overhead lines - Composite line post insulators for
IEC 61952 A.C. systems with a nominal voltage greater than 1 000 V -
Definitions, test methods and acceptance criteria
IEC 62004 Thermal-resistant aluminum alloy wire for overhead line conductor
Overhead electrical conductors - Formed wire, concentric lay,
IEC 62219
stranded conductors
IEC 62271 High-voltage switchgear and control gear (Note 1)
IEC 62305 Protection against lightning (Note 1)
Concentric lay stranded overhead electrical conductors containing
IEC 62420
one or more gap(s)

Note (1) Referred codes and standards consist of more than one part. The latest revision
of each part will be applied.

3.2 OTHER REFERENCES

Overhead electrical lines exceeding AC 45 kV - Part 1: General


N 50341
requirements - Common specifications
Overhead Electrical Lines exceeding AC 1 kV up to and
EN 50423-1
including AC 45 kV - Part 1: General Requirements
ASCE 52 Guide for Design of Steel Transmission Tower (Handbook 52)
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3.3 PROJECT SPECIFICATIONS AND PROCEDURES

Particular reference is made to the following project documents and specifications:

GB090-2614-250-EL-RP-0001 Power System Study Report


GB090-2614-250-PI-GA-0001 General Plot Plan, CPF Unit and Flare Unit
GB090-2614-250-EL-SL-0002 Key Single Line Diagram - Overall
GB090-2614-250-EL-DB-0001 Design Basis for Electrical
Design Basis for Earthing and Lightning
GB090-2614-250-EL-DB-0005
Protection System
Engineering Specification for Site Preparation
GB090-2614-250-CV-SP-0004
and Fencing
GB090-2614-250-EL-SP-0013 Specification for Electrical Cables
GB090-2614-250-EL-SP-0002 Specification for HV Switchgears (33kV GIS)
GB090-2614-250-CV-DB-0001 Design Basis for Civil Work
Engineering Specification for Structural Steel
GB090-2614-250-CS-SP-0001
Works
GB090-2614-250-EL-GA-3000 Main Cable Route Plan (Overall & Key Plan)
GB090-2614-250-PR-DB-0001 Design Basis for Process
GB090-2614-250-PI-SP-0005 Painting Specification and Color Shades
GB090-2614-250-EL-DS-0015 Data sheet for OHL Electrical Equipment
0
GB090-2614-299-CV-SP-0001 Engineering Specification for Topographical
Survey of 33kV Overhead Line
GB090-4500153869-CV-K25-
0001 Site Survey Report
GB090-4500153869-CV-K25-
0002 Soil Investigation Report
GB090-4500153869-EL-C19-
0001 OHL Routing Layouts
GB090-4500153869-EL-C04-
OHL Profile Drawing
0001

4 DESIGN CRITERIA
4.1 GENERAL

Electrical power supply via overhead lines shall be provided for the connection from CPF
to Badra City for power requirement of min. 12.5 MW for a total length of approx. 15 km (It
will be updated after site survey by Contractor) which include 10.0MW for Badra City and
2.5MW for Camp.

It is essential that the overhead line, survey and the recommended route meet the
governmental rules, regulations and the authorizing agencies requirement. Vendor shall
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contact all necessary agencies to obtain permits after notification to Contractor and
Employer.

All vendor documentation, design, etc. shall be approved by Employer.

4.2 AMBIENT CONDITIONS

The overhead line shall be suitable for outdoor installation with typical atmosphere of gas
storage plant (dusty, marine and corrosive). Additionally all equipment shall be
tropicalised and UV resistant.

The design of electrical system will comply with the following environmental conditions

(a) Min. design temperature for outdoor installations : - 5 C


(b) Max. design temperature for outdoor installations : +55 C
(c) Min. design temperature for indoor installations : + 5 C
(d) Max. design temperature for indoor installations : +40 C
(e) Max. Relative humidity at +20 C : 81% max at 20 C
(f) Max wind velocity : 31.9 m / s
(g) Altitude : 66 m a. S.L.
(h) Atmosphere : Marine dusty & corrosive
(i) Seismic conditions
- Seismic zone 3 (Acc. to UBC)
- Importance Factor: Ip= 1.25,
- Factor for non Building Factor as per table 16-P UBC
- Soil Factor Type SC
All equipment shall be designed heavy duty and for continuous operation to work at -5 C
up to + 55 C. The system will be in continuous operation during the varying atmospheric
and climatic conditions occurring at all seasons. The Vendor shall ensure that all
equipment supplied and installed is selected to suit these conditions.

4.3 POWER SUPPLY FEATURES

Overhead lines including all components will be suitable for continuous operation at the
above ambient conditions with the following combined conditions of voltage and
frequency without exceeding the over-temperature limits.

Voltage Frequency
+/- 10% +/- 5%

The total harmonic distortion (THD) of the supply network voltage will not exceed 5%.

The relevant system voltage is 33 kV, 3 phases, with neutral resistance earthed. The fault
level at the source 33 kV is according to as calculation in Power System Study Report for
short circuit (Doc. No. GB090-2614-250-EL-RP-0001).
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4.4 GENERAL CHARACTERISTICS FOR ELECTRICAL EQUIPMENT

(a) Electrical arrangement of the overhead lines including protection and connection at
the different locations shall be as shown on the general single line diagram and
main cable routing drawing based on the general plot plan.

(b) Design of the distribution, installed loads and short circuit levels shall determine the
characteristics of the electrical equipment. The line conductors including all fixing
components shall be rated to withstand the short circuit currents stated in the
Contractor data sheets with peak make and RMS break values compliant with the
IEC publications.

(c) All electrical components and equipment operation shall be consistent with these
characteristics including :

Dielectric strength,
Electrodynamic stresses,
Circuit breaker peak make, RMS break and DC offset capability.

(d) The electrical components of overhead lines (e.g. switches, reclosers, circuit
breakers, earthing switches etc.) shall have been tested at the required operating
and short circuit duty in accordance with IEC 62271 and other relevant IEC
standards. This requirement applies to switching devices both in their service and
earthing position.

DISCONNECTION SWITCH
TYPE VACCUM TYPE, OUTDOOR USE
INSTALLATION POLE OR TOWER MOUNTED
RATED VOLTAGE 33kV
MAX VOLTAGE 36kV
RATED FREQUENCY 50 Hz
RATED CURRENT MIN. 400A
SHORT CIRCUIT CURRENT MIN. 25kA
BASIC IMPULSE WITH STAND
VOLTAGE LEVEL (BIL) 175kV
DEGREE OF PROTECTION IP 55

AUTO RECLOSER
TYPE VACUUM TYPE, OUTDOOR USE
INSTALLATION POLE OR TOWER MOUNTED
SWITCHING MODULE, CONTROL
CUBICLE, CONTROL CABLE, VOLTAGE
COMPONENT
TRANSFORMER, MOUNTING FRAME, etc.

INSULATION MEDIA INSIDE


EPOXY SOLID INSULATION
TANK
ARC CONTROL METHOD VACUUM WITH AXIAL MAGNETIC FIELD
MINIMUM ALLOWABLE DUTY
0
CYCLE AT RATED SHORT- O-0.1s-CO-1s-CO-1s-CO-60
CIRCUIT
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DEGREE OF PROTECTION IP 55
RATED VOLTAGE 33kV
MAX VOLTAGE 36kV
RATED FREQUENCY 50 Hz
RATED CURRENT MIN. 400A
SHORT CIRCUIT CURRENT MIN. 25kA
BASIC IMPULSE WITH STAND
175kV
VOLTAGE LEVEL (BIL)

SURGE ARRESTER
TYPE OUTDOOR USE
RATED VOLTAGE 33kV
MAX VOLTAGE 36kV
RATED DISCHARGE
10kA
CURRENT
SHORT CIRCUIT CURRENT MIN. 20kA
DEGREE OF PROTECTION IP 55

CONTROL CABINET
MICROPROCESSOR BASED
CONTROLLER TYPE
CONTROLLER
DIRECTIONAL OVER-CURRENT, EARTH
PROTECTION RELAY FAULT AND SENSITIVE EARTH FAULT
RELAY, AUTO RECLOSING RELAY
1. RECLOSER OPEN/CLOSE
2. AUTOMATIC RECLOSING FUNCTION
ON/OFF
3. BATTERY AND UPS STATUS AND
CONTROL AND MONITORING
COMMUNICATIONS 4. CHANGING PROTECTION SETTINGS
5. ENABLING / DISABLING PROTECTION
FUNCTION
6. ACTIVE TROUP CHANGING
7. REMOTE MODE / LOCAL MODE
1. SWITCH POSITION OPEN / CLOSED
2. BATTERY VOLTAGE
3. PERCENTAGE OF BATTERY CAPACITY
4. UPS MONITORING 0
5. EXTERNAL LOAD ON/OFF
6. PROTECTION STATUS AND ACTIVE
GROUP NUMBER
7. PHASE AND EARTH CURRENTS
MONITORING AND INDICATION 8. PHASE AND LINE VOLTAGE
9. PHASE SEQUENCE
10. MODE (LOCAL / REMOTE)
11. FAULT INDICATION, TYPE AND
MAGNITUDE OF FAULT
12. DATA AND TIME
13. MALFUNCTIONS
14. WARNINGS
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METERING UNIT, EVENT LOG AND DEMAND LOGGER, RTU (REMOTE


0
TERMINAL UNIT)
DEGREE OF PROTECTION IP 55

(e) The Blocking and metering device shall be equipped to cut-off power when power
consumption of Badra city is over 10MW. (without cut-off at EMPLOYER camp)

(f) The ratings for components to build the overhead lines shall be as specified in the
Contractor data sheets.

(g) Data sheets for all OHL package electrical equipment shall be provided by
Contractor for Employer review.

(h) Short circuit rating and other parameters shall be updated as per data sheets for
equipment

4.5 SUPPORT AND STAY FOUNDATION DESIGN

The foundations shall normally be of the simple-earth type employing kicking blocks or
foundation baulks as necessary.

In excavating foundations for supports with foundation baulks and for stay and anchor
baulks, the holes shall be undercut so that the baulks have solid and undisturbed earth on
their principal bearing surface wherever possible.

The supports shall be placed in the ground to the planting depths dictated by foundation
design.

All foundations shall be designed to withstand uplift, settlement, overturning and sliding
when subjected to the specified conditions of loading. Allowance shall be made in
foundation design for hydrostatic pressure, effects of seasonal rain, drying out, cyclic
loading and wind induced vibration. The Contractor will be required to confirm the
foundation design parameters by undertaking a representative sample of soil
investigations. Pole foundation have to be designed, erected and tested according to IEC
61773.

4.6 CONNECTION OF OVERHEAD LINES

The following cable connections shall be used to connect the overhead lines to the
electrical tie in points at the various locations:

Power feeding cables from 33 kV switchgears to overhead lines and from overhead
lines to downstream consumers.

Optic Fiber cables from splice box to downstream system.

These cable connections are included from Vendors scope of supply. All required material
and supports for installation and fixing of these items to overhead lines poles / towers are
part of Vendors scope.
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4.7 CONDUCTOR SPACINGS AND CLEARANCES

The specified clearance between line conductors and support steelwork shall be obtained
on the assumption that the conductor may leave the support point at any angle to the
horizontal between 0 and 10 downwards for suspension supports and between 15
upwards and 15 downwards for tension supports where uplift is specified, all angles
measured in the plane containing the conductor.

The earth conductor shall be located to provide a minimum shielding angle to the phase
conductors of 30 at the structure. In addition, the earth conductor shall be erected so its
sag is 20 less than that of the conductor at everyday temperature, still air.

It shall be assumed for design purposes, that jumper loops will swing transversely. The
minimum clearance to steelwork has to be calculated according to related conductor
specification.

The minimum clearance between line conductors and ground or other objects shall be as
specified as follows and in tables below (chapter 4.8). These clearances shall be obtained
under conditions corresponding to the 60 C, still-air sag of the line conductors and with
any angle of swing of the conductors from the vertical between zero and 35 , with the
assumption (for simplicity) that the aforementioned sag is always applicable:

Situation: Minimum Clearance

Normal ground and minor road crossing or track, road level 7m

Where an overhead line erected under this agreement crosses an asphalt road or
designated rig crossing, the overhead line shall be routed underground. For asphalt roads
ducts shall be employed.

Where obstructions of other types are met, the clearances shall be approved.

4.8 OVERHEAD LINE CLEARANCE TO OBSTACLES

With phase conductor at 85 C in still air or deflected to any angle up to 40 from the
vertical, the following minimum clearance to obstacles shall be obtained :

Vertical Clearances:

Normal Ground 7m

Minor Roads, Traces 7.5m

Clearance to Pipeline 13.5m

Major Roads, Public Roads 15m

Rig Crossing Roads 30m

Buildings, Poles Structure and Walls etc upon which a man 4.6m
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may stand a ladder

Crossing over HV/MV lines 3.5m

Crossing over telephone lines 3.5m

Any point on a support of the lower line on which a person can stand 3.6m

Horizontal Clearances:

From tower structure to nearest conductor of any power line running parallel 25m

Main roads and canals 30m

Secondary roads 20m

Communication circuits 20m

From Oil/Gas/Water Pipeline running parallel from not more than 2 km 100m

From Oil/Gas/Water Pipeline running parallel from more than 2 km 250m

From any area classified as hazardous 30m

From plantation fence 25m

From any other oil installation fence 100m

From oil wells 150m


From Oil/Gas/Water injection wells 100m

No structure will be positioned so that any excavation or erection work will be closer than
30 m to a pipeline.

Right way shall be minimum 15m either side from OHL. 0

The effect of electromagnetic field (EMF) from overhead line shall be considered to design
of cathodic protection system for buried pipeline. AC mitigation calculation and facility
shall be provided by pipeline Contractor.

4.9 DESIGN LIFETIME AND RELIABILITY

The design, selection of equipment and material for the overhead lines and its installation
shall ensure the highest achievable levels of plant reliability and availability in compliance
with the relevant codes, standards and requirements as per project specification, Process
Basis of Design (Doc. No. GB090-2614-250-EL-RP-0001).

All components shall be of a well tested and proven industrial design which ensures
maximum safety to personnel, maximum service reliability and economic operation for an
operational life time of at least 25 years. Even under extreme conditions of major short
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circuit there shall be no danger to persons in the vicinity of the assembly.

The Vendor has to take care that the components are selected considering easy
maintenance, simple and quick diagnosis and long maintenance intervals.

All components shall be designed for continuous duty at rated load and under the given
climatic conditions. Standard industrial high performance systems and components of
proven manufacturer standard shall be used only. Components of same kind and type
shall be selected for equivalent functions. The interchangeability must be guaranteed.

5 GENERAL DESCRIPTION
The main arrangement for overhead lines with the main components is shown in figure 1.

(1) Earthing and Lightning


Protection Conductor
(2) Line Conductor
(3) Stay pole
(4) Suspension pole
(5) Crossarm
(6) Insulator
(7) Span length 0
7

Figure 1: General Components of Overhead Line

The overhead lines shall be designed for redundant 33kV, 3-phase power transmission
lines starting from CPF, Main Substation. The line wire shall be designed according to IEC
61089 (round wire concentric lay overhead conductors).

The feed in will be realized by HV underground power cable coming from the disconnect
switch installed last tower or pole located near battery limit of CPF. The connection
between the last tower or pole and the 33kV switchgear shall be adequately sized XLPE
insulated cable for aboveground & underground installation.

The overhead line towers are constructed from single prefabricated poles. All towers will
be supported by stay wires. Each tower will be equipped with long crossarms including
earth wire holder preassembled. At crossarms the isolator chains will be installed as
tension or suspension.

The position of each tower or pole shall be fixed in such way, that its center of gravity is
situated above the center of the foundation block. Pole or tower foundations have to be
designed, erected and tested according IEC 61773 (Overhead lines - Testing of
foundations for structures).
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The overhead lines are connected to the earthing system on the first tower and the last
tower at each location. The other towers or poles are connected to the earthing system
over the earthing wire installed on the top of the towers or poles. And all towers or poles
are to be earthed by dedicated earthing rods and branch point is also to be earthed.

For installation of wires the general rule is to fix the wire on one end and pull to the
required sag level according to environmental condition. The required sag levels shall be
in accordance with to calculate stress data. The wire sag depends on wire temperature
and wire specification data.

Power sytem study (short circuit, load flow, motor starting, etc.) and transient stability
study including OHL shall be done by ETAP. But special design (sag and tension
calculation, etc.) for only OHL shall be done by dedicated software (PLS CADD)

6 CONDUCTORS AND ACCESSORIES


6.1 LINE CONDUCTORS

The line conductors shall consist of Aluminum Conductor, Steel Reinforced, (ACSR) of the
cross section and having the characteristics stated in the data sheets. The conductors
shall comply in all respects with the requirements of IEC 61089 or other equivalent
international standard. The steel core wires shall be performed so that they remain inert
when the conductor is cut. The steel core shall be covered with approved grease.

The standing of each layer of the conductor shall be as close and even as possible. The
outermost layer shall be right-handed.

The aluminum shall be of the highest purity commercially obtainable and the Contractor
shall submit certificates of analysis giving the percentage and nature of any impurities in
the metal of which wires are made. Precautions shall be taken during manufacture,
storage and erection of ACSR conductors to prevent the possibility of contamination by
copper or other materials which may adversely affect the aluminum.

The line conductors shall be supplied on drums which allow the conductors to run out
smoothly and in lengths as long as can be conveniently handled and erected. Drums
shall be marked with type, size and length of conductor on the drum and also with an
arrow to show the correct direction of rotation for rolling.

The preservative shall not react with aluminum, plus barrel and sides of drums shall be
covered with a waterproof paper, or equivalent, so as to ensure no damage to the
conductors.

6.2 JOINTS

Joints for connecting line conductors shall be of approved types. Tension joints for ACSR
conductors shall be of the compression type. The design of the joint shall make it
impossible to position the steel sleeve incorrectly. The electrical conductivity and current-
carrying capacity of each joint shall not be less than those of the line conductor. Tension
joints shall not permit slipping of or cause damage to, or failure of, the complete line
conductor, or any part thereof, at a load less than 95 percent of the ultimate strength of
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the line conductor.

All joints shall consist of as few parts as possible and there shall be no danger of relative
movement between individual layers of the conductor during assembly. All caps or nuts
shall, unless otherwise approved, be locked in an approved manner so that normal
adjustment, or removal, of the caps for inspection shall not adversely affect either the
locking device itself, or any part of the fitting to which it is attached. Non-tension joints
shall not permit any slip or damage of the jumper connection at a load of less than 25 % of
the ultimate strength of the conductor, and shall be designed so that no loosening of the
jumper connections can occur in service.

The possibility of improper and faulty assembly / erection shall be minimized by the design
of the joints and their relevant special tools for assembly. Erection tools and methods are
subject to approval and no alteration shall be made without written approval of the
Employer.

Where mating surfaces and jumper terminals are to be compressed onto the conductor or
bolted together, they are to be protected by the application, of a strippable plastic coating
or other approved means.

Following the installation of compression joints, the electrical resistance of all joints shall
be measured by means of approved micro ohm meter equipment in accordance with the
Test requirements. The values of resistance measured shall be recorded on a schedule
which shall be submitted to the Employer as part of the final records.

Where down-lead connections to substation equipment require aluminum-to-copper


connectors, the aluminum fittings shall be of the compression type and exposed contact
between copper and aluminum shall be prevented by watertight insulating washers.

Where electrical connections employing dissimilar materials are to be made, suitable


precautions shall be taken to ensure electrolytic action does not occur between the mating
surfaces.

6.3 EARTH CONDUCTORS

6.3.1 GENERAL

The earth conductors shall consist of stranded, galvanized steel wire, imbedded optic
fibers (OPGW), of the cross section and having the characteristics stated in the relevant
data sheets.

The earth conductor shall comply with international standard and be tested in accordance
with IEC 61089 insofar as it applies to steel wire. The individual wires shall be performed
so that they remain inert when the conductor is cut.

The individual wires shall be galvanized in accordance with the specification. The wires
shall be of uniform section, smooth and free from surface imperfections. The diameters of
the wires shall not vary more than 2 % from the figures stated in the data sheet.

The stranding of each layer of the conductor shall be as close and even as possible. The
outermost layer shall be right-handed.
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There shall be no joints in individual wires in a drum length.

The provisions of the Specification in relation to line conductors, to line conductor drums
and to the use of line conductor repair sleeves shall also apply to the earth conductors.

6.3.2 JOINTS AND CLAMPS

Joints and tension clamps for earth conductors shall comply with the specified mechanical
requirements for line conductor joints and clamps.

The compression type tension clamp is used at all the tension towers to hold earth wire.
The assembly is connected to hole in horizontal strain plates of the tower body. The
jumper terminal attachment plate is welded with dead. The jumper terminal is fixed with
attachment plate by means of bolts & nuts. The compression tube and jumper tube give
adequate area of support without any slip to the earth wire under normal working tension
and vibration conditions.

Reference drawing for tension clamp

Joints are used for jointing earth wire. These are made of mild steel rods such that it does
not crack or fail during compression. It shall be easily compressible with 100 ton hydraulic
compressor.

Reference drawing for compression joint


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6.3.3 AIRCRAFT WARNING

Line sections located in height restricted areas, or otherwise defined by Employer shall be
provided with visual aids for denoting obstacles to the Convention on International Civil
Aviation. The aids may comprise one, two or all three measures detailed hereunder.

(a) Red/White Painting

Where specified, towers shall be painted in red/white bands/boxes. For technical


details reference is made to the job specification "Painting Procedure / Specification
(Doc. No. GB090-2614-250-CN-PP-0010).

(b) Aircraft Warning Spheres

Where specified air traffic warning spheres shall be provided on the earthwire /
OPGW.

The system shall comprise white spheres, alternating with red ones. The distance of the
first sphere to the tower shall be max. 15 m. The warning spheres shall be located on the
earthwire in equal spacing. White spheres shall be alternated with red spheres, providing
maximum contrast.

One mass damper shall be installed on both side of sphere.

The maximum installation distance between individual spheres shall be governed by the
sphere diameter:

The warning spheres shall be of anodized Aluminum with a diameter of at least 600 mm.
Paint shall be applied by stove-enameling, for better durability. Spheres shall consist of
two individual halves for easy installation. The fixing clamps of the spheres shall match
the preformed armour rods to be supplied for each sphere, to be mounted between
sphere and earthwire/OPGW.

6.4 INSULATORS AND FITTINGS

Insulator sets shall be composite insulator type and shall consist of a core, housing sheath
weather sheds and metal end fittings.

6.4.1 CORE

The core shall be a glass fiber reinforced rod. It is preferable that the glass fibers shall be
resistant against acid attacks (ECR, Electric Glass Corrosion Resistant) in order to
prevent stress corrosion of the rod. Also, the glass fiber rod shall be resistant against
hydrolysis under service conditions.

6.4.2 HOUSING

The core shall be covered by housing in order to provide resistance against environmental
influences, UV radiation, external pollution and humidity. The housing shall be made of
high temperature silicone rubber material.
The required total creepage distance shall be achieved by assembling the respective
number of moulded sheds.
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The housing shall be designed in such a way that the end fittings are not covered with
housing material in order to avoid electrical punctures of the housing.

6.4.3 WEATHER SHEDS

The sheds shall be made of high temperature silicone rubber material. The sheds shall
have uniform diameters or alternate shads and shall provide an open aerodynamic profile.
The shed profiles shall be designed as per IEC 60815.

6.4.4 END FITTINGS

The End fittings shall be of hot dip galvanized forged steel or malleable cast iron. The gap
between fittings and housing shall be sealed by an elastometer with permanent elasticity.
The sealing shall stick permanently to the surface of the metal cap as well as to the
housing.

6.5 CLAMPS AND FITTINGS

The conductor clamps and insulator fittings shall be suitable for single-suspension
insulator strings and single conductors. Single tension insulator sets are to be provided for
tension supports and single sets for downlead connections to substations. The tension
insulators shall be provided with a single attachment at the support crossarm.

Suspension and tension conductor clamps shall be as light as possible. All clamps shall
be designed to avoid any possibility of deforming the stranded conductor and separating
the individual strands.
Line and earth conductor suspension clamps shall be free to pivot in the vertical plane
above a horizontal axis passing through and transverse to the centre line of the conductor.
Suspension clamps shall permit the complete conductor to slip at approximately twice the
still-air tension at the temperature extremes in an environment section outline, but shall be
mechanically clamped in an approved manner.

All conductor grooves and bell-mouths in ferrous clamps shall, after galvanizing, be
smooth and free from waves, ridges or other irregularities.

Ferrous suspension clamps for conductors with outer aluminum strands shall be provided
with soft, pure aluminum liners to protect the conductor.

Tension clamps shall be of the compression type and shall comply in all respects with the
provision of the Specification for line conductor joints where applicable, to either the
tension or non-tension components.

Fittings made of steel or malleable iron shall be galvanized. The mechanical strength of
the fittings shall be verified by Contractor and the minimum failure load of each fitting
shall be stated on final design drawings.

A safety factor of all fittings, when supporting the maximum working load, shall be
foreseen.

All bolt threads shall be greased before erection. All bolts and nuts shall be locked in an
approved manner.
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7 POLES, SUPPORTS AND FOUNDATIONS


7.1 APPLIED LOADS

The assumed maximum simultaneous working loads on the supports based on the
appropriate angles of deviations and span lengths and with the particulars calculated by
the Contractor shall be as follows:

7.1.1 TRANSVERSE LOADS

(a) The normal transverse load shall be the wind pressure acting horizontally at right
angles to the lines on the whole projected area of all conductors (phase and earth
wires), under maximum line tensions, together with the wind pressure on the
projected area of the poles and structural steelwork. Necessary data for above
calculations shall be provided by the Contractor.

The full wind span shall be taken regardless of the angle of line deviation.

(b) Wind at 45 the same wind as in (a), but with wind acting at 45 to the line. For wind
at 45, the length of the conductor shall be taken as the projected length at right
angles to the wind direction.

7.1.2 VERTICAL LOADS

(a) Normal :
For normal load conditions, the mass of the line and earth insulators, the mass of
the insulators, insulator fittings, earth conductor fittings, spacers, dampers and
ancillary apparatus where applicable. It shall be assumed that the normal loads will
include the actual total mass of the specified weight span of the line and earth
conductors.

(b) Minimum :
For the minimum load condition, the mass of line and earth conductors shall be zero.
For conditions of uplift, a net total uplift equivalent to the mass of the length of line
and earth conductors shall be as specified.

7.1.3 LONGITUDINAL TERMINAL LOADS

(a) Normal Terminal

The longitudinal components of the maximum line and earth conductor tensions as
stated on the data sheets.

(b) Section

One third of the maximum working conductor tensions as stated on the data sheets.

7.1.4 BROKEN CONDUCTOR LOADS

The applied load when a conductor breaks.


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7.2 SUPPORTS

7.2.1 FORM OF CONSTRUCTION

Supports shall be of steel or concrete pole construction, single or H pole configuration as


required, normally stayed at angle, section and terminal positions only.

The supports shall be arranged for single-circuit, three-phase working and they shall be
designed to carry the line conductors with the necessary insulator sets, earth conductor,
stays and all ancillaries and fittings.

The line conductors shall be arranged in delta or horizontal formation with a single
overrunning earth conductor.

The position of the earth conductor with respect to the line conductors shall be defined as
per special calculation which is to be performed by Contractor and as per international
standards.

The method of attachment of the earth conductor to the poles shall be by means of
clamps at intermediate poles and by means of tension compression fittings at section,
angle and terminal poles.

At Contractor specified positions, the supports shall be designed to carry, in an approved


manner, additional equipment such as cables and their terminations, isolators, fuses,
earth switch, arrester or other accessories as may be required.

Crossarms shall be of steel and shall conform to the design and typical dimensions to be
defined after OHL vendor selection. Crossarms shall comply with international standards
and shall be not less than 6 mm thick.

7.2.2 TYPE OF STRUCTURE

The structure nomenclature shall normally be defined by the pole top steelwork which
shall be the following standard types:

ANGLE OF TYPE OF
POSITION OF USE
DEVIATION [] INSULATOR
Intermediate, straight line 0 to 2 Suspension
Light angle / section 0 to 30 Tension
Medium angle 30 to 60 Tension
Heavy angle 60 to 90 Tension
Line terminal for road crossing 0 Tension
Line terminal with isolator and earth switch 0 Tension
Terminal tap off (single cable feed) with isolator,
0 Tension
fuse switch and earth switch
Terminal tap off (two cable feeds) with isolator,
0 Tension
fuse switch and earth switches
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In-line tap off (single cable feed) with isolator, fuse


0 Tension
switch and earth switch
In-line tap off (two cable feeds) with isolators, fuse
0 Tension
switches and earth switches

In-line isolator with isolator and earth switch 0 Tension

Tee off(single) (tee-off line 15 perpendicular to


0 Tension
main line)

All structure types with overhead line-to-cable interfaces shall be equipped with surge
arresters.

7.2.3 USE OF STANDARD SUPPORTS

The standard types of structures shall be designed for use as specified in the following
clause on span lengths.

Where a transmission line route makes any deviation not exceeding 2 degrees, a single
support with suspension insulators shall normally be used.

Where the transmission line route makes a deviation of up to 30 degrees, a single support
with tension insulators shall normally be used.

Where the transmission line route makes a deviation in excess of 30 degrees, an H pole
support with tension insulators shall normally be used.

Terminal, section, isolator tap-off and tee off supports shall normally be H pole
configuration.

Isolators, switch fuses and fuses shall be erected on H pole type supports.

To supply the well-head locations from the adjacent main line transmission lines shall be
constructed by tee off connections via an H pole or a combined H and lay-pole
arrangement which will be introduced into the new lines.

7.2.4 SPAN LENGTHS

The expression span length shall be taken to mean the horizontal distance between the
center lines of adjacent supports.

The standard span length shall be as calculated by the Contractor depending on material
and cross section of conductors and shall be the span length on which all standard
supports, assuming level ground, shall be based.

All standard supports used with corresponding specified maximum angles of deviation,
and straight line supports used at straight line positions, shall however, be designed so
that where the ground contours are favourable, the sum of the two adjacent spans may
total 2.15 times the standard span length. No single span shall normally exceed 1.6 times
the standard span length, except on special supports. Where straight line supports are
used at other than straight positions, the sum of the two adjacent spans shall be reduced
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in an approved manner.

Where the ground contours are favourable, all supports, except straight line supports,
may be used at straight lines or at relatively small angles of deviation positions with the
sum of the two adjacent spans exceeding the limitation.

The term wind span is defined as half the sum of adjacent span lengths on any one
support.

The term weight span is defined as the weight of an equivalent length of conductor or
earth wire at any support at any temperature between the specified minimum and
maximum.

The standard span shall be based on the capability of the pole supports both to be
supplied new or from stores and on the following.

The design wind and weight spans shall be as follows:

Normal Working Load

(a) Standard Span : To be calculated by Contractor

(b) Wind Span : 1.1 x Standard

(c) Max. Weight Span : 2 x Standard

(d) Min. Weight Span


- Suspension insulators : Zero
- Tension insulators : -1 x Standard

7.3 STAYS

Stays shall comprise stranded galvanized steel stay wire. The steel guy wires shall be
performed so that they remain inert and do not move relative to each other when the guy
is cut. The individual stay wire shall have a breaking stress not less than 1,000 N/mm2.

The provisions of the Specification, in relation to conductor drums, shall also apply to
stranded stay wire.

The attachment of the stays to the supports shall be made in an approved manner.

All stays shall be equipped with stay insulators with the characteristics as given in the
relevant data sheets. The stay insulators shall be positioned so that they are lower in
elevation than any bare live metal on the support.

The angle between the stays and pole shall not be less than 30. Stay rods, stay blocks
and stay foundations shall be of Employer approved dimensions and types. Stay rods
shall be fabricated in galvanized steel.
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7.4 TOWERS OF LATTICE STEEL

7.4.1 GENERAL

Single circuit tower structures shall be of the self-supporting lattice type steel frame.

The members of the latticed structures shall be of hot rolled steel angle sections. All tower
material shall be factory made and entirely galvanized by the hot-dip process.
The general outlines and main data will be shown in vendors documents and drawings.

7.4.2 MATERIAL

Material for the steel towers shall be of the type and grade most suitable for the
application intended and shall conform to the latest applicable standard, specifications
and recommended practices of the industry. Cold-formed steel angles, flat bars and rods
shall not be used for tower members.

Mild steel and/or high strength steel shall be used for the fabrication of towers. The
requirements as described in job specification of supply "Engineering Specification for
Structural Steel Works (Doc. No. GB090-2614-250-CS-SP-0001) shall be fulfilled.

The quality of steel to be used shall correspond according to EN 10025 (latest Version).

7.4.3 DESIGN OF SINGLE TOWER

The design document of each single type of tower shall include the following:

Design criteria with grade of steel and minimum size for tower members and
connections and with maximum allowable slenderness ratio for tower members

Calculation of the maximum wind pressure on the overhead line components

Sag and tension calculation for the required range of spans along with data sheets
of conductors and ground-wire, including all installed accessories and fittings.
Tensions shall be calculated using change-of-state equation with governing (starting)
loading conditions and tension limitations as specified in data sheets. Loading
condition with quartering wind shall be included in calculation as well. Sags shall be
calculated using catenary formula.

Loading tables and loading trees prepared for the maximum external forces and for
the maximum tension in conductor and earthwire as per sag and tension calculation

Calculation of the maximum swing angle of insulator strings, jumper loops, jumper
strings and complete conductor catenary span

Calculation of the conductor clearance at mid-span in still air conditions

Calculation of the member-wise wind load and self-weight of tower, including


redundant members
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Member design tables including member with size, length, gross area and radius of
gyration, compression and tension member forces, compression curve number,
number and size of bolts, bearing and shear stress, safety factors, including
equations for calculation of slenderness ratio as per relevant standard etc.

Design of redundant members including buckling and bending criteria

Foundation loads in global direction for each leg extension

Stub angles shall be at least 2 mm thicker than attached steel leg angle and shall be
fitted with cleats. The stub angle shall be completely galvanized and shear
connectors shall be designed to transfer entire axial and shear force. Cleat
connections shall be checked for shear and moment forces

The unit stresses in members and connections for the structural design calculation, based
on the design loading and design unbalanced loading (broken wire conditions) multiplied
by a safety factor. Connections shall be designed for the same member forces and
according to the above mentioned standards. The towers shall be designed with an
overload capacity (factor of safety). The factor of safety shall be as per civil design basis.
No damage or permanent distortion of any members, bolts, connections of fittings or
elongation of bolt holes shall be permitted for these design conditions.

7.4.4 CONSTRUCTION

The towers shall be of standard construction and shall be designed to reduce the number
of different parts to a minimum, thus facilitating transport and erection. No member shall
be of angles with dimensions less than 45 x 45 x 5 mm. The minimum thickness for legs
and compression members in cross arms and in earthwire peaks shall be 6 mm. Gusset
plates shall not be less than 6 mm thick.

The diameter of bolt holes for all types of towers shall not be more than 1.5 mm larger
than the nominal diameter of the bolt. All members of the towers shall be connected by
bolts. Connections of members shall be designed to avoid eccentricity as much as
possible.

All members, except redundant members, carrying computed stress shall be connected
with at least two bolts.

7.4.5 NUTS AND BOLTS

Bolts shall have hexagonal heads and nuts, with metric thread (coarse). In general, bolts
for the connection of tower members shall not be less than 16 mm in diameter.

All nuts shall be secured by use of helical spring lock washers in connection with flat
washers.

All nuts and bolts shall be hot dip galvanized. Threads before galvanizing shall be coarse
threads. There shall be no excess of galvanizing at the root of the thread and nuts shall
turn easily on the completed bolts without excessive looseness. Nut threads shall be
tapped after galvanizing so as to produce a finger-free fit on the galvanizing.
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The length of bolts and the length of thread shall be such that bearing is upon the shank
and not upon the threads. When in position all bolts or screwed rods shall project through
the corresponding nut, but such projection shall not exceed 8 mm or less than 3 threads.

7.4.6 ANTI-CLIMBING DEVICES, STEP BOLTS AND BIRD GUARDS

Each tower shall be fitted with an anti-climbing device to prevent unauthorized persons
from climbing the tower. The anti- climbing device shall be of either a spike type or a
barbed wire type of stainless steel and shall be fixed at a height of approx. 3 m above the
foundation. It shall provide suitable gates adjacent to the step bolt legs to be locked with
padlocks.

For double circuit type towers step bolts shall be provided on two diagonally opposite
tower legs. They shall begin directly above the foundation and continue to the tower top.
They shall be spaced at a distance of 333 mm from center to center, distributed strictly
alternating on the outer sides of the leg angles. The spacing distance of all step bolts shall
be equal on the entire tower.

Tower members positioned above insulator strings/solar panels (if applicable) shall be
fitted with stainless steel needle strips, effectively preventing birds from sitting in these
locations. The strips shall extend sufficiently, horizontally beyond the protected location
and be applied to all surfaces a bird can sit on.

7.4.7 LABELLING SYSTEM FOR 33kV TOWERS

Identification labels shall be installed on all types of tower and positioned so as to be


readable when approaching the pole/tower from the most common line of approach.

The identification plates required for each circuit on each tower should be as follow:

1 Danger Plate
1 Tower Number Plate
1 Circuit Plate
2 Phase Plates

All plates stipulated in the above table should be accumulated and supported properly at
one aluminum plate or enameled iron plate of 3 mm thickness min. using the stainless
screws.

The identification labels are to be attached beside the anti climbing device and leg of the
tower in a prominent position so as to be easily read.

They must be positioned high enough on the tower so they are out of reach where there is
a risk of vandalism.

For tower type the character holder & the individual characters (tags) are designed to be
min. of 1 mm thickness. The height of the letter (tag) for 33 kV tower shall not be less than
80 mm.

The danger plates should be fabricated in the same way of slide in character of the
individual character holder plate, the background should be red color of an engineering
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reflective sheet.

The holders can be screwed in position or strapped using approved stainless steel cable
ties of band-It straps. It is important that the top and bottom of each end of the holder is
tightly crimped to ensure that the characters are securely held in place and not easily
removed by vandals.

Airborne observation plate should be provided for towers on each tension and every tenth
suspension tower; the tower number shall be cut from the aluminum, with a letter height of
min. 700 mm. The plate background shall be yellow phosphorous Diamond / engineering
reflective sheet. The plates shall be installed either on the top cross-arm or on the earth
peak in a position that is easily recognizable from the air.

For all types of towers two numbers of the phase plates should be provided and installed
on each circuit one phase plate allocated down of the first cross arm and the other
allocated two meter from the stub angle.

7.4.8 TOWER MAINTENANCE SAFETY SYSTEMS

The Bidder/Contractor shall be responsible for the complete supply and installation of a
system to facilitate operator safety during line maintenance. The system should be
designed so that it provides clear indication by means of flags of which circuit has been
made safe to work-on and which is live, and constant reminder to operators by means of a
wristlet in circuit identification colors of which circuit they should be working on.

8 ACCESS ROUTES & SURVEY


8.1 ACCESS ROUTES

Subject to the requirements of landowners and their tenants, way leaves and access
facilities (but not necessarily the actual transport routes and access tracks themselves)
will be provided by the Employer to enable the Contractor to carry out the erection of the
lines. The Employer will, however, permit the Contractor to use access routes and tracks
as may exist.

8.2 SURVEY AND PROFILES

At an early stage of the Agreement, the Contractor shall mobilize on site to evaluate the
line route shown in the drawings or sketches. The Contractor shall establish the optimum
location of the line route considering minimal disturbance to landowners and property and
ease of future line maintenance by the Employer.

The Contractor shall be responsible for the complete survey of the transmission lines. The
survey shall include all necessary clearing and the setting out of the bearing for each
section of line, the measuring and leveling and production of all necessary plans, profiles,
route maps and pole schedules; the location of pole positions on the profiles in
accordance with the Specification and all necessary setting out for construction, all to the
approval of the Employer. All surveying measurements, both linear and vertical, made on
the line route shall be closed on standard reference points, or, where such points are not
available, the measurements shall be closed by alternative reciprocal measurements, the
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degree of closing error to be approved by the Employer unless otherwise approved


supports will not be located on top of sand dunes.

The Contractor shall be responsible for checking the minimum weight condition on
suspension insulators under all temperature conditions without wind. The mass of
conductors carried by any suspension insulator set shall not be less than 25 % of the total
mass of the corresponding line conductors included in the two adjacent spans. Similarly,
the mass of conductors carried on any pole shall not exceed the mass of conductors
equivalent to the specified weight spans.

The Contractor shall be responsible for any alterations to the Works which may be
required in order to comply with these requirements or to give the specified minimum
clearances acc. to chapter 4.7.

9 ELECTRICAL EQUIPMENT
9.1 SWITCHES AND FUSES

9.1.1 TYPES OF SWITCHES AND FUSES

(a) Line Isolation Switch

Isolators shall comply with the requirements of IEC 62271 and IEC 60265 and shall
be rated for 33 kV, 50 Hz. The continuous rating and a fault current of shall be as
calculated in short circuit calculation and load summary, data shall be as stated in
the data sheets.

The switch shall be of the triple pole, gang-operated, rocking type, spring assisted,
manually-operated, preferably having hinged blades and front connections and shall
be capable of breaking full load current. The isolators shall be capable of making the
system fault current specified in the data sheets, without damage to the equipment
or danger to the operator.

(b) Isolator with Earth Switch

The equipment shall comprise a 33 kV line isolator integral with an earth switch and
shall be suitable for pole-mounted operation.

The line isolation switches shall be fitted with approved type three-phase earthing
switches to be located on either the tip, or the bottom contact terminals of the switch
as specified on the data sheets.

The earth switch shall be of triple-pole construction, spring-assisted, manually-


operated and fully rated for the system fault rating. The earth switch shall form an
integral part of the main switch. Two independent earthing pads with connectors
suitable for the specified size of the earth conductor shall be provided at one end of
the switch. The main switch and the earth switch shall be mechanically interlocked
so that it will not be possible to close the earth switch when the main switch is
closed or vice versa. The rated peak short circuit current and the rated short time
current of the earthing switch shall be as stated on the data sheets.
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(c) Switch Fuse

Switch fuses shall comply with the requirements of IEC 62271 and IEC 60265, the
technical requirements listed on the data sheets and fuses shall meet the
interrupting current requirements of IEC 60282.

The design and mounting shall be constructed so as to permit easy operation from
ground level using an operating rod, i.e.; an operating eye shall be provided on the
fuse tube designed for use with a hook stick.

The fuse holder of a switch fuse shall be dimensionally compatible with a universal
fuse link of corresponding rating.

The main assembly may be mounted on a two-insulator base arrangement, the top
and bottom contact sub-assemblies and mounting fitting shall be fitted into the
composite-type insulators, the upper fixed contacts shall positively latch.

Insulators shall be of composite- type; they shall meet the electrical and mechanical
characteristics of IEC and provide minimum creepage.

The assembly shall be designed so that the tube can be closed without using undue
care even when the closing force is applied at an angle. The fuse tube shall be
capable of accepting IEC fuse links.

The toggle mechanism shall provide locking action to protect the fuse link from
shock. A spring-assisted flipper shall assist arc interruption by withdrawal of the fuse
tail.

The fuse tube cap shall preferably be of the non-expendable type and an arc
shortening rod, if provided, shall be attached to the fuse tube cap.

(d) Isolator with Switch Fuse

The equipment shall be comprised of a combined 33(36) kV line isolator and switch
fuse suitable for pole-mounted outdoor operation. The fuse switch arrangement shall
be mounted on the same phase base below the line isolator and shall be comprised
of three single-pole-type switch fuses.

(e) High-Voltage Fuse Links

High-voltage fuse links shall be general purpose, powder filled, fault-limiting fuses
and shall comply with the requirements of IEC 60282, shall be suitable for use with
fuse isolators to be provided and shall be rated and characterized, as to be suitable
for selective operations with the fuse links presently in use on the system.

All current-carrying parts of the fuse links shall be nonferrous materials, with the
main requirements being resistance to atmospheric corrosion. Each fuse link shall
be permanently marked with the following information: SUPPLIER, identifying mark,
current rating, and type designation (e.g. K or T).

The fuse ratings shall be advised by the Vendor following protection coordination
study, exercise performed by the Contractor during detail design.
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9.1.2 OPERATING MECHANISMS

The switches along with their interlocked, earth switches shall be complete with
gang/manually- operated switch opening and spring-assisted push button triggered
closing operating mechanisms. The mechanism drive and linkage of the isolator shall
allow the operating handle to be mounted about 1.25m above the ground and shall be
designed to minimize wear and permit some degree of misalignment of the structure. It
shall be as simple as possible, being comprised of a minimum of bearing and wearing
parts. Shaft and pin bearings shall be of self-lubricating or dry type and shall permit easy
manual operation by one person, even following long periods of non-operation.

The mechanism shall provide simultaneous isolation of all three phases and arranged for
up-ON operation.

The closing mechanism shall be a spring-assisted manual-device designed so that the


speed of operation is independent of the operator. The mechanism shall be of robust
construction and shall be carefully fitted to ensure a quick, smooth, simple and effective
operation. The time of operation shall be as fast as possible. The mechanism design
shall be suitable for operation under the severe site service and climatic conditions
specified herein.

The operating mechanisms shall be of substantial construction using such materials as


may be necessary to prevent sticking due to rust or corrosion.

The ganged, switching mechanism shall be provided with sufficient adjustment to allow for
final alignment of the switch blades for simultaneous operation. Adjustable stops shall be
provided to prevent over travel in either direction.

It shall not be possible after final adjustment has been made, for any part of the
mechanism to be displaced at any point in the travel to allow improper functioning of the
switch when the switch is opened or closed at any speed. The overall design of the
mechanism shall reduce mechanical shock to a minimum and shall prevent its inadvertent
operation due to fault current stresses, vibrations, or other causes. The mechanisms shall
be self-locking in both the open and closed position and shall be of a type that shall
operate all three phases simultaneously.

The operating mechanism shall be suitable for manual-off operation by means of the
operating handle positioned, as specified, above on the overhead line structure and push-
button triggered ON operation after the spring is charged using operating handle.

The operating mechanism and operating handle shall be complete with all supporting
accessories, all brackets, angles, guides or guide bearings or other members as may be
required for attaching the operating mechanism and operating handles to the pole
structures specified herein. All required bearings shall be weather protected by means of
covers. The lubrication requirements shall be as specified.

The connecting assembly between the mechanism of the switches and their operating
down rods shall be robust and strong with a positive mechanical connection between
linkages to provide adequate gripping force in order to prevent slipping between the
mechanisms during the operation of the switches.
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9.1.3 ACCESSORIES

(a) Counter Balance Springs

These shall be provided, as necessary, for counter balancing the switches to prevent
impact at the end of travel both on opening and closing of the switch/earth switch. The
springs shall be of non-rusting alloy.

(b) Earthing Pads

Each pole of the switch shall be provided with two earthing pads of non-corroding material
at opposite ends, brazed to the supporting base. Flexible copper earth connectors shall be
provided for connecting operating handles of switches/earth switches to the earthing
system.

(c) Position Indicator

A mechanical-position indicating device shall be provided for each switch/earth switch.

(d) Padlocks

The operating mechanism of each switch and the earth switch shall be provided with
facilities for locking the switch in the OPEN or CLOSED position. The facilities include
those for the spring charging handle and the closing push button.

(e) Name Plate

A weatherproof and corrosion-proof name plate shall be provided on the switches, the
earthing switches and the operating devices. The name plates shall conform to IEC
standards.

(f) Live Line/Earthing Clamp Support

In order to carry out live line maintenance, supports to receive a live line clamp and an
earthing clamp shall be provided adjacent to bottom terminal of line isolation switches and
when equipped at the bottom terminals of the fuses.

Necessary extension of the terminals shall be provided in order to enable support of the
clamps as described above. The extension shall be at least 150 mm long and shall have
16 mm diameter hole to suit the dimension of the cable lug to which the connection shall
be made.

9.1.4 SWITCHES CONSTRUCTION

Switches along with interlocked earth switches, where these are fitted, shall be complete
with all parts that are necessary or essential for the safe and efficient operation under all
site and climatic conditions.

All contacts shall be designed to give permanent current carrying capacity at rated current
after exposure to the environment for 25 years. These contacts shall be heavily silver clad
on each side of each interface. Embossed surfaces with wiping action are preferred.
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Live metal parts shall be of non-rusting and non-corroding type. Current carrying parts
shall be of hard- drawn high conductivity electro-tinned copper or copper alloy. The
terminals of the equipment shall be capable of connecting the overhead conductors and
underground cables without risk of corrosion. Arcing horns or alternative protective
devices shall be fitted to protect contacts from erosion.

The equipment shall be mounted on the pole structure with all equipment fixed to a
composite-steel frame. All iron and steel parts shall be galvanized. An equipment
earthing lug and screw shall be provided in an accessible position.

Isolators, earth switch and fuse switches and their supporting structures shall be erected
as directed by the Vendor. Isolators shall be used at the start of the main and branch lines,
as required.

9.2 FAULT CURRENT INDICATOR

As specified in the data sheets, Fault-current passage indicators shall be installed on the
33 kV overhead-line networks as instructed by the Employer. The indicators will generally
be installed at the commencement of the main feeders and at positions on the main
feeders on the remote side of spur tee-offs.

Fault-current indicators shall have sensitivity to both earth and phase-to-phase faults as
given in the data sheets. The indicators shall be sensitive to permanent faults and
insensitive to in-rush currents and transient faults.

Indication of the passage of fault current shall be by means of a mechanical flag indicator.
After a fault and on reclosing the breaker, the indicator shall reset with the voltage
available. If the fault persists, the indicator shall re-trip.

The indicator shall be capable of satisfactory operation under all climatic conditions
existing at site. Fault current indicators shall be fitted to each phase conductor of three-
phase lines.

Units using batteries shall incorporate a low-battery-level test facility. There shall also be
means of testing units both in-site and off-site. Where additional test equipment is
required, this test shall be included at the rate of one test equipment to every 10 complete
installations.

9.3 SURGE ARRESTER WITH MONITORING

9.3.1 SURGE ARRESTERS

Arresters shall be of the metal oxide, gapless type enclosed in HTV-Silicon (high
temperature vulcanized) rubber housing moulded directly on the ZnO resistors. The
design of equipment shall be in accordance with the requirements of the IEC 60099 and
any additional requirements of this specification.

The surge arresters shall be designed to facilitate inspection, cleaning and repairs, and for
operation where continuity of supply is the first consideration. They shall be designed to
ensure satisfactory operation under the atmospheric conditions prevailing at the site and
under sudden variation of voltage as may be met with under working conditions on the
system.
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Surge arresters are to be erected at 33 kV structures to protect the components of the


complete MV distribution system and to increase the reliability of the power supply system.

Surge arresters shall also be provided at the cable termination structures near by the
transformer.

The surge arresters shall be suitable for pole mounting and each unit shall be supplied
complete with a mounting bracket suitable for attachment to a steel cross arm.

Each arrester shall be identified by a rating plate in accordance with IEC requirements. In
addition, identification marks shall be provided on each separately-housed unit of a multi-
unit arrester so that the units can be replaced in correct position in the event these are
being dismantled.

9.3.2 SURGE COUNTERS AND LEAKAGE CURRENT METERS

Surge counters shall be provided and shall be operated by the discharge current passed
by the surge arrester. Surge counters shall be of the electromechanical type and designed
for continuous service.

Internal parts shall be unaffected by atmospheric conditions at site; they shall be


contained in a weatherproof housing conforming to IP 55 of IEC 60529 and shall be
designed to allow the recording device to be read without exposing the internal parts to
the atmosphere.

The surge counter shall be connected in the main earth lead from the arrester in such a
manner that the direction of the earth lead is not changed or its surge impedance
materially altered. The connecting conductor shall be supplied with the arrester and shall
be of a type that does not require sealing ends. A bolted link shall be provided so that the
surge counter may be short circuited and removed without taking the arrester out of
service.

Leakage current meters shall be supplied as an integral part of the surge counter and
shall be designed for continuous service. The value of leakage current beyond which the
operation is abnormal shall be clearly marked in red on the meter.

9.4 AUTOMATIC RECLOSERS

9.4.1 OPERATING MECHANISM

The auto recloser shall be provided with multi shot auto-reclosing mechanism able to
undertake upto to 4 trip and autoreclose operations in one cycle

Recloser lockout link and operation counter shall be provided on the recloser tank.
Provision of operation counter in the recloser control, as has been specified under control
cabinet, shall also supplied.

The control mechanism shall be suitable for mounting at the auto recloser supporting
structure, and below the auto recloser in a weatherproof, dust-proof, vermin-proof housing.
The necessary brackets and fittings for this purpose shall be provided. Mounting drawings
shall be provided.
The degree of protection shall be min. IP55 as per IEC 60529.
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The number of recloser operations to the first maintenance as well as the number of
operations between successive maintenance (I.e. the recloser duty cycle) shall be
indicated in datasheet. 0

9.4.2 CONSTRUCTION

The auto reclosers shall be out-door type, designed for three phase operation and suitable
for pole or tower mounting.

The auto reclosers shall be supplied complete with supporting / mounting brackets,
operating mechanism and control cabinet.

The recloser tank shall have a mechanical status indicator for both the open and the
closed position. The status indication shall be visible from the ground.

All current carrying parts shall be made of electrolytic high conductivity copper with the
contacts silver-plated.

Manually operated levers to enable manual trip and close of source-side interrupter
switches during power outages shall be provided.

9.4.3 CONTROL CABINET

Control cubicle is a microprocessor based controller that provided a direction over-current,


earth fault and sensitive earth fault relay, auto reclosing relay, instantaneous metering,
event log, demand logger and RTU (Remote Terminal Unit) for remote control in a single
package.

Detail functionality for protection and measuring of control cabinet shall comply with para.
4.4 (d) in this specification.

The cubicle is constructed out of powder coated, zinc anodized mild steel for a long,
maintenance free lifetime.

Communication protocol shall be used as IEC 67850.

Aux. power supply shall be 24V DC provided by a charger/battery which is built in control
cabinet. The battery for control box shall be rechargeable. The charger circuit shall be
capable of accepting input from a single-phase distribution transformer (230Vac, 50Hz).
Battery shall have back-up time of min 4 hours.

Control of reclosers shall be possible remotely through EMCS. Measuring data shall be
available in EMCS (kW, kVAR, kVA, etc). Those control and measuring signal shall be
transmitted to EMCS from control cabinet of recloser via fiber optic cable.

10 INSPECTION AND TESTING


10.1 GENERAL

Factory inspection and pre-commissioning activities will take place as defined below. It is
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the responsibility of the Contractor that all equipment shall be checked for compliance to
this specification and associated documents and for quality, safety and operability.

10.2 FABRICATION AND QUALITY CONTROL PLAN AND INSPECTIONS

(a) Inspection and testing activities shall be defined by the Vendor on the Fabrication
and quality control plan based on the minimum requirements established on
Contractors Inspection and Test Plan.

(b) During the manufacturing period, all equipment could be subject to inspection by
Employer and / or Contractors inspectors or by others appointed by Contractor or
by the Employer. Accessory material could be subject to inspection too.

(c) Vendor shall allow the free access of inspectors to the workshop, shall give all
information required and shall make available all copies of internal orders to other
sub-vendors.

(d) Vendor has to hold all documentation, operating manuals, drawings, etc. ready for
review during the factory inspection. It is the Contractor's responsibility to verify
that the documentation strictly complies with the actual equipment supplied and
this specification.

10.3 TEST PROCEDURE

(a) The tests shall be carried out in Vendors workshop at his care and expense.

(b) Even in case Contractor waives to witness the tests the Vendor shall draw up the
certificate of the tests carried out containing a full report and all the results and the
measures of the tests.

(c) The tests shall be carried out in accordance with the requirements of IEC codes
and of the Inspection and Test Plan, which shall be sent to Employer and
0
Contractor for approval.

(d) Upon successful completion of the inspection a Final Release Certificate will be
issued by Contractor.

11 TAGGING AND IDENTIFICATION


Major components shall have the following identifying information on a permanently
fastened nameplate:

Identification Number
Electrical Rating Data
Manufacturers Name, Model, and Serial Number
Manufacturers Internal Job Reference Number
Main technical data of all equipments
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12 DOCUMENTATION REQUIREMENTS
Vendor shall deliver all required documentation as specified in part 2 of the scope of
supply being part of the material requisition. All documentation shall be in English. 0

13 PACKING AND SHIPPING REQUIREMENTS


Adequate protection shall be provided to prevent mechanical damage and atmospheric
corrosion in transit and at the job-site.

Equipment and materials shall be protected to withstand extended period of storage at the
job-site for a minimum period of 12 months. Equipment shall be protected to safeguard
against all adverse environments, such as: humidity, moisture, rain, dust, dirt, sand, mud.

Finally all packing and shipping requirements will be specified in a separate Project
Procedure for Transport Marking, Packing, Custom Clearance & Shipping, being part of
the inquiry / purchase documents.

14 SPARE PARTS
The Vendor shall provide and list the following:

Spares for installation supervision and start-up / commissioning


Spares for 3 (three) years operation
Recommended list of capital and insurance spare parts
Recommended list of operational spares for 5 (five) years
Special tools