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Appendix V

CEYLON ELECTRICITY BOARD

TECHNICAL SPECIFICATION
FOR

MANUFACTURE AND DELIVERY OF TOWERS, STUBS AND ACCESSORIES FOR 132kV DOUBLE CIRCUIT TRANSMISSION LINE of 8 km FROM HAKMANA TO BELIATTA

APPENDIX A CEB Approved LIST OF DESIGN DRAWING (Towers, Stubs and Other accessories) APPENDIX B CEB Approved DESIGN DRAWING (Towers, Stubs and Other accessories) in a SEPARATE VOLUME APPENDIX C Load Tree used for design OF Towers APPENDIX DTypical Load Test Data APPENDIX E - SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS to be submitted by the Bidder APPENDIX F - SCHEDULE OF COMMERCIAL PARTICULARS to be submitted by the Bidder

eylon Electricity Board, No 50, Sir Chittampalam A. Gardiner Mawatha, Colombo 02 Sri Lanak

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CEYLON ELECTRICITY BOARD TECHNICAL SPECIFICATION 132kV TOWERS

INDEX CLAUSE NO TITLE PAGE NO.

1 SCOPE 2 GENERAL 3 APPLICABLE STANDARDS 4 FORMS OF CONSTRUCTION 5 LOADINGS AND TEMPERATURES 6 DESIGN SPANS 7 TYPES OF SUPPORTS 8 CONDUCTOR AND EARTHWIRE SPACING AND CLEARANCE 9 SUPPORT DESIGN DATA 10 CLEARANCE TO GROUND, ETC. 11 ASSUMED NORMAL WORKING LOADING 12 BROKEN WIRE CONDITIONS 13 FACTOR OF SAFETY OF TOWERS 14 CONSTRUCTION OF TOWERS 15 ANTI-CLIMBING GUARDS AND CLIMBING STEPS 16 DANGER, NUMBER AND PHASE PLATES AND COLOUR CODES 17 SUPPORT STRUCTURE EARTHING SPIKES 18 WORKMANSHIP 19 ERECTION MARKS 20 CASTING, WELDING and GALVANISING 21 BOLTS, NUTS AND WASHERS 22 QUALITY ASSURANCE 23 TYPE TEST CERTIFICATE 24 PACKING 25 INSPECTION AND TESTING

2 2 2 3 4 4 5 5 6 6 7 9 9 10 10 11 12 12 12 12 13 16 17 17 19

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TECHNICAL SPECIFICATIONS FOR SUPPLY AND DELIVERY OF 132 KV TRANSMISSION LINE TOWERS 1. SCOPE This Specification covers the fabrication, galvanizing, testing, supply and delivery of Steel Towers complete with stubs, Nuts & Bolts, Spaces, washers and accessories required for construction of 132kV Double Circuit Zebra Conductor Overhead Transmission Line from Hakmana to Beliatta of 8km in length conforming to the design described below and drawings furnished in Appendix B and in Bill of quantities. 2. GENERAL The design specification and CEB approved designs for 132kV transmission line towers for proposed project are given in this document. However providing the design of towers by purchaser shall not, prejudice the right of the purchaser to reject any or all of towers if it does not comply with the technical specification at the time of inspection & testing. In case defects or shortcomings are noted in the drawings provided by purchaser, the supplier shall suggest the purchaser the necessary corrections/rectification required to provide the specified performance of towers. Only after obtaining the approval for the changes (if any) from the purchaser, the supplier shall commence the manufacture. The design conditions used for the design of towers are given in the preceding sections of this document. The tower design provided by the purchaser is a property of the purchaser and shall not be used for any other purpose with or without any modifications. Supplier shall supply towers with the required body extensions (-3m, 0, 3m, 6m, 9m and 12m) as indicated in the price schedule complying with the design drawings provided in Appendix B

3. APPLICABLE STANDARDS
The towers, equipment and components supplied shall be in accordance with the standards specified below or later editions and or amendments thereof. At the bidding stage, the standards to which the equipment are manufactured and to which the materials conform must be clearly stated if they are different from standards specified. Items or works offered comply to any other internationally recognized standards or specifications may be accepted provided that they are not less rigid and English version of standards are provided. ANSI/ASCE 10-97 - Design of latticed steel transmission structures. BS EN ISO 1461 - Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods. BS 4464:1969 - Specification for spring washers for general engineering and automobile purposes. Metric series - Packaging code
2

BS 1133
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BS 4190:2001 BS 4872

- ISO metric black hexagon bolts, screws and nuts. Specification - Specification for approval testing of welders when welding procedure approval is not required. Fusion welding of steel - ISO General purpose metric screw threadsGeneral Plan. - ISO general purpose metric screw threads Selected sizes for screws, bolts and nuts - Design Criteria of overhead transmission lines - Loading tests on overhead line structures - Structural Steels - plates, wide flats, bars, sections and profiles - Hot rolled Structural Steel Sections equal and unequal leg angles. - Plain washers for metric bolts, screws and nuts for general purposes -- General plan - Mechanical properties of fasteners. Part 1-Bolts, Screws and studs - Mechanical properties of fasteners - Part 2: Nuts with specified proof load values - Coarse thread - ISO general-purpose metric screw threads - Tolerances for Fasteners - Hexagon Bolts for high strength structural bolting with large width across flats. - Hot rolled structural steel plates tolerances on dimensions and shape

DIN ISO 261 DIN ISO 262 IEC 60826 IEC 60652 ISO 630 ISO 657-5 ISO 887 ISO 898-1 ISO 898-2 ISO 965 ISO 4759 ISO 7411 ISO 7452

4. FORMS OF CONSTRUCTION Double circuit towers shall be arranged for single Zebra (61/3.18) conductors in vertical formation and One overhead 7/3.25mm galvanized steel earth wire and one OPGW above the conductors. They shall be of self-supporting broad based lattice steel construction.

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5. LOADINGS AND TEMPERATURES

Assumed Wind Loading Wind Pressure on Conductors and Earthwire Wind Pressure on Insulators Wind Pressure on lattice staff support Assumed Temperatures of Conductors & Earthwire Minimum Temperature Everyday Temperature Maximum Temperature, ACSR
0

Unit N/m N/m N/m

2

Value 970
2

1170
2

1640

Unit Value
0

C C

7 32 75

6. DESIGN SPANS The design of all tower structures are for the following basic, wind and weight spans

Basic Span (m) Wind Span (m) All Towers Normal working Broken Wire Weight Span (m) Suspension Towers Normal working Broken Wire

300

360 270 Maximum 600 450

Weight Span (m) Tension Towers Normal working Broken Wire Terminal Towers Normal working Broken wire

Maximum Minimum 900 675 450 300 -300 -200

The term spans for broken wire condition, i.e. the span under broken conductor or earth wire assuming conductors intact are subjected to normal loading.
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The term basic span shall mean the horizontal distance between the centers of adjacent supports on level ground from which height of normal supports is derived with the specified conductor clearances to ground in still air at maximum temperature. The term wind span shall mean half the sum of adjacent horizontal spans lengths supported on any one tower. The term weight span shall mean the equivalent length of the weight of conductor supported at any one tower at minimum temperature in still air. At suspension positions the minimum weight of conductor, inclusive of weights where used, is not to be less than 25%, of the total weight of conductor in the two adjacent spans. In steeply sloping country where the gradient between adjacent supports o exceeds 15 to the horizontal, special consideration shall be given to the vertical loading on towers. 7. TYPES OF SUPPORTS The standard types of towers are designated as follows:Double Circuits 1) Suspension 2) 0 3) 10 4) 30
o

tower
o

Standard Type TDL TD1 TD3 TD6 TDT

- 10
o o

and section tower

o o

- 30 - 60

Angle tower Angle tower

5) Terminal

tower

Towers shall be provided with body extension of -3m, +3m, +6m, +9m and +12m and each type designation will carry the construction type (e.g.TDL+3 etc.). Leg extensions of +1m, +2m, +3m, +4m and +6m shall be provided where necessary and the cost of leg extensions shall be excluded from the price of normal tower or tower with body extensions. The stub and cleat shall be supplied as requested in schedule of prices.

8. CONDUCTOR AND EARTHWIRE SPACING AND CLEARANCE Conductors and earth wire/OPGW for each circuit of double circuit towers are arranged in vertical formation. The clearances from conductor, arcing-horns, jumper loops and all live metal to the tower steelwork shall be not less than those specified in Table 1 of clause 9-support design data ; under still air conditions and at assumed maximum swing conditions. Where uplift occurs at tension tower positions the minimum clearance between any arcing horn and jumper loop or phase immediately above it shall not be less than the minimum still air clearance from live to earth metal stated as Table 1 of clause 9.

Conductor and earth wire/OPGW tensions are so selected that the sag of the steel earth wire/OPGW at mid span, everyday tension, basic span is less than the sag of the line conductor by 1.5m for 132 kV lines.

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The vertical spacing between earth wires and top phase conductors at supports o to top phase shall be at least 4m and earth wire shade angles shall be 0 o to middle and bottom phases. conductors and not more than 5 9. SUPPORT DESIGN DATA Table 1; Clearances to Tower Parts 132 Minimum clearance from live metal to earthed metal for suspension towers :(a) (b) From still air to 10 From 10
o o o

kV

swing of insulator

mm mm

1650 1550

to 40 swing of insulator

Minimum clearance from live metal to earthed metal at tension towers:(a) (b) (c) Jumper loops from still air to 10 Jumper loops from 10
o o o

swing

mm mm mm

1650 1550 1650

to 40 swing

Minimum plan clearance from arc horn tip to tower steelwork

Assumed maximum transverse swing from vertical of:(a) (b) Jumper loops Jumper suspension insulator strings at tension towers deg deg 40 20
o o

Minimum separation between phases in down leads Maximum ratio of unsupported length of steel compression members to their least radius of gyration (L/R) :Main members in the cross arm in compression and legs Bracing carrying computed Stresses Redundant Bracing loaded in tension only

mm

2500

120 200 250 350

10. CLEARANCE TO GROUND, ETC. The clearance between the line conductors and the ground in still air under the maximum specified temperature, final tension are not less than the figure stated in Table 2 below. An additional clearance of 0.3m have been allowed to survey and sagging errors and have been considered in the calculation of tower heights. The clearance under all specified conditions between any part of any fences, walls, buildings or other structures on which a man may stand, or against which a ladder may be placed, and the nearest line conductor are specified in Table 2 below.

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Table 2; Clearances to Ground and Earthed Objects Clearance for 132 kV Minimum Clearance from Conductor: To Ground Metal Clad or Roofed Buildings, or other Buildings or Structures upon which a man may stand To earthed cradle Guard Wires To Electric power Line Wires (Line to Earth) To be added to the above Clearance to Allow for Survey and sagging error Minimum horizontal spacing between outermost conductor of adjacent power line in still air Spacing between P + T Line and cradle guard M 0.3 M 15.3 M M 4.1 6.7

4 3.7

1.8

11. ASSUMED NORMAL WORKING LOADING The assumed maximum simultaneous working loading on towers are as follows(A) Suspension Towers (TDL) (i) Vertical loading - the weights of the insulators and all other fittings and the actual dead weight of specified span lengths of line and earth conductors. at right angles to (ii) Transverse loading - a wind pressure of 970N/m the lines on the whole projected areas of the conductors, earth wires, 2 on 1.5 times and insulators. In addition a wind pressure of 1640 N/m the projected area of the members of one face of the tower. (B) Angle Towers (TD3 & TD6) Maximum vertical and transverse loading as described plus the transverse horizontal components of the maximum conductor and earth wire tensions stated in Clause 6 resolved for the maximum angle of deviation concerned. Where cross arms are not pointed in the plan at the outer ends, the design shall allow for the entire vertical loading to be applied to a single outer corner of each cross arm. The Tenderer shall indicate the variation of maximum wind spans available with the angle of deviation for the towers under this condition and also indicate the maximum minus weight span (i.e. upward force).
2

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(C) Section and 10

Angle Tower (TD1)

The loading for these towers are for any one of the following four conditions, which shall in all cases include for transverse loading as applied to straight line supports:o o (i) 0 - 10 Angle. As for angle tower loading. (ii) Section Loading. Nil angle of deviation Weight span 1220m. Unbalanced longitudinal loading of 15% maximum working tension for all conductor and earth wire points. (iii) Uplift Loading. As for condition (ii) but weight span to be minus 600m, (i.e. upward force). (iv)Heavy suspension tower in special positions the tower strength capacity derived from loading (i) and (ii) may be utilized in positions of extra long wind and weight spans, using double suspension insulator sets. The tower shall be so arranged that electrical clearances are maintained either tension insulators or with double suspension insulators, in accordance with Clause 9. (D) Terminal Towers (TDT) Loading for terminal towers are the vertical and transverse loading as described in Section (A) of this clause, using the design spans for tension towers, together with full maximum longitudinal conductor and earth wire tensions as given in the clause 6 together with a plan o angle of entry of up to 45 on the line side. In addition the terminal towers shall be designed to accommodate slack span conductors to o o -90 to the tower the sub-station gantry at any angle of exit from 0 and from the horizontal to the vertical plane. All terminal towers shall also be designed for up to 4 slack span earth wires (2 per arm) to connect to the substation earth masts. Slack Span Tension per Wire Conductors Earth wires 6660 4500 N N

Where necessary auxiliary conductor and earth wire cross arms can shall be used, for a large angle of deviation into the substation. Auxiliary conductor and earth wire cross arms shall be designed to carry the slack span tensions mentioned above, together with the relevant weights of insulators, etc. (E) Eccentric loading Eccentric loads in vertical direction caused by one circuit conductors strung on double circuit towers were considered in the design of all types of double circuit towers. For terminal towers, torsion loads caused by the unbalanced longitudinal working tension due to one circuit conductors and earth wire strung were considered.

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12. BROKEN WIRE CONDITIONS Suspension structures have been designed for the reduced vertical and transverse loading derived for Clause 6 plus the unbalanced longitudinal force at maximum working tension due to the breakage of one conductor or one earth wire. In the case of a conductor breakage the pull on a suspension tower may be assumed to be reduced to 70% of the specified maximum working tension. This reduction has not been assumed in the case of an earth wire breakage. The Tenderer shall indicate the maximum minus weight spans (i.e. upward force) available for the healthy (unbroken) span under this condition. Tension Towers are designed for vertical & transverse loading plus the full unbalanced longitudinal forces at maximum working tension due to the simultaneous breakage of two adjacent conductors on the same side of the tower or of one earth wire and a conductor. Calculation of stresses in angle tower members under broken wire loading shall be made for the worst conditions of loading of that particular member for the range of loading for which the tower may be employed. For TD1 towers, the design shall take account of the possibility that the unbalanced tensions referred to in Clause 11.c. ii & iii may act either in the same direction as broken wire forces, or in the opposite direction, applying increased torsion moments to the tower body.

13. FACTOR OF SAFETY OF TOWERS Each type of straight line tower have been designed so that no failure or permanent distortion shall occur when tested with applied forces equivalent to twice the maximum simultaneous working loading specified in Clause 11. Each type of angle and terminal or special tower have been designed so that no failure or permanent distortion shall occur when tested with applied forces equivalent to 2.5 times the maximum simultaneous working loading specified in Clause 11. All towers also has been designed so that no failure or permanent distortion occurs when tested with applied forces equivalent to 1.25 times the maximum simultaneous working loading resulting from the assumed breakage of conductor (s) specified in Clause 12. All cross arms have been designed so that no failure or permanent distortion shall occur when tested with applied forces equivalent to 2.0 times for each types of straight line towers and 2.5 times for each type of angle towers under the broken wire condition specified in Clause 12. The minimum factors of safety guaranteed for the towers are given below.

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